Industrial Training Report

FKM ‫ ׀‬UITM ‫ ׀‬INDUSTRIAL TRAINING REPORT

INDUSTRIAL TRAINING REPORT

NEW HORIZON RESOURCES (M) SDN BHD LOT 8014A JALAN BUKIT CHERAKAH KAMPUNG BARU SUBANG 40150 SHAH ALAM

MUHAMAD FADZRUL FAIZ BIN ASHEMI 2017806298

Faculty of Mechanical Engineering UNIVERSITI TEKNOLOGI MARA

OCTOBER 2019 1

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ACKNOWLEDGEMENT First of all, I would like to thank Pn. Noraliza Ghazali for accepting me New Horizon Resources Sdn Bhd, which is a great company for interns to experience the maintenance and fabricating industry for mechanical engineering. Next, I would like to thank my supervisor En. Arafin Bin Moharam for being generous in guiding me throughout the industrial training by sharing his knowledge and inviting me to site visits which opened my eyes to the aviation world. My special thanks to En. Khalid Bin Adam for all the knowledge sharing sessions he held just for us interns for almost 2 hours every week. Last but not least, I would like to thank everyone New Horizon Resources for their kindness and for the knowledge they share.

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ABSTRACT Students from the Faculty of Mechanical Engineering in UiTM are required to undergo a 10 week industrial training programme as part of the bachelor programme which is in between 2 semesters, specifically in between the 6th and 7th semester in my condition. I attended the first day of my industrial training on 8th July 2019 and was assigned under En. Khalid Bin Adam by the head of department of Ground Support Equipment (GSE) department. This report aims to show the internship process that I went through with New Horizon Resources Sdn Bhd. Throughout this 10 week period which will include industrial environment such as adaptations to safety in a workplace, industrial experience such as site visits and knowledge gained from supervisor, technician and staff that I met throughout this industrial training. This report will also include some information about New Horizon Resources Sdn Bhd regarding its history and activities that it has involved in.

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TABLE OF CONTENTS INTRODUCTION ................................................................................................................................ 6 History .............................................................................................................................................. 6 Organization Chart ......................................................................................................................... 7 Structural of Main Activity ............................................................................................................ 8 Objective of Practical Training ...................................................................................................... 8 Scope of Training ............................................................................................................................ 9 INDUSTRIAL ENVIROMENT ........................................................................................................ 10 Adaption and Adjustment To The Industry ................................................................................. 6 Practice Of Occupational Safety & Health Enviroment .............................................................. 6 INDUSTRIAL EXPERIENCE.......................................................................................................... 10 Metal Work Fabrication ............................................................................................................... 10 Ground Support Equipment ........................................................................................................ 11 INDUSTRIAL PROJECTS ............................................................................................................... 19 Relation Between The Tasks to The Mechanical Engineering Course ..................................... 19 Integrating The Theoretical Knowledge With Practical Works ............................................... 19 Project ............................................................................................................................................ 20 SUMMARY ........................................................................................................................................ 22 Discussion & Conclusion .............................................................................................................. 22 Recommendations ......................................................................................................................... 22 APPENDIX ......................................................................................................................................... 23

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LIST OF FIGURE

Figure 1 : NHR Logo ................................................................................................... 6 Figure 2: Wearing PPE during works ........................................................................ 12 Figure 3: Welding main pillar to upper & lower part……………………………….13 Figure 4: Setup 90º angle each corner ........................................................................ 13 Figure 5 : Welding bones to main pillar .................................................................... 13 Figure 6: Grinding process to make smoothing surface............................................. 14 Figure 7: Painting process .......................................................................................... 14 Figure 8: Fabricate & repairing the awning of rooftop .............................................. 15 Figure 9 : Axle Jack…………………………………………………………………16 Figure 10: Tripod Jack ............................................................................................... 16 Figure 11: Performing Load Test……………………………………………………17 Figure 12: HyCat Software………………………………………………………….17 Figure 13: Maximum Load ........................................................................................ 17 Figure 14: Remove Cylinder Jack...............................................................................18 Figure 15: Lift Up by Forklift…...... .......................................................................... 18 Figure 16: Cylinder Jack Complete Services ............................................................. 18 Figure 17: Pneumatic/ Hydraulic Diagram………………………………………….19 Figure 18: Hydraulic Circuit ...................................................................................... 19 Figure 19: Coating the steel bar ................................................................................. 20 Figure 20: Portable Canopy ....................................................................................... 21 Figure 21: Malabar Axle Jack……………………………………………………….23 Figure 22: Hydro Axle Jack ....................................................................................... 23 Figure 23: TronAir Tripod Jack……………………………………………………..23 Figure 24: TronAir Axle Jack .................................................................................... 23 Figure 25: Storage Cage ............................................................................................. 24 Figure 26: Portable Canopy ....................................................................................... 24

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INTRODUCTION

Figure 1 : NHR Logo

History New Horizon Resources Sdn Bhd (NHR) was incorporated in Shah Alam on 1st April 2010. The principal activities of NHR are Services, Support, Maintenance and Trading in Aviation Field. They are one of the vendors in automotive and mechanical for airport ground operation and engineering sectors. They provide a high quality machining trade services for aviation/MRO and engineering in Malaysia. At NHR, they selectively pick their staff based on knowledge, capabilities and are of the highest discipline. They trained their staff to be ultimate solution provider that will cater even of the highest echelon challenges in their field. They develop, produce and supply quality products and superior services to satisfy the needs of aircraft maintenance engineering sector. NHR’s mission is to provide consistent high quality products and services at competitive prices to earn satisfied, repeated client. They also provide on time critical judgments and solution to their client’s problem and needs. Second is to be the first and leading one stop center for aircraft and ground support part fabrication and repair.

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Organization Chart

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Structural of Main Activity 

Vehicles maintenance (car ,van, lorry, TD20, TD25, etc)



Aircraft jacks/tow bars load test



Aircraft Machining and Sheet Metal Repair



Aircraft Non-Structural Welding



Metal work fabrication (dolly, trolley, etc)

Objective of Practical Training

Industrial training is one of the requirements for the award of degree of Bachelor of Engineering (Hons) Mechanical, known as EM220, by the Faculty of Mechanical Engineering, Universiti Teknologi MARA (UiTM). The objectives of the programme are: i.

To expose students to actual working culture and industrial practice

ii.

To allow students to extend their theoretical knowledge into practice

iii.

To motivate students to practice the right working attitudes and professionalism to increase their employability potential

iv.

To facilitate students to potential employers

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Scope of Training In New Horizon Resources Sdn Bhd (NHR), I have been training into two department which is Ground Support Equipment (GSE) and Metal Work Fabrication. It is a department under project division responsible for the project management of mechanical including services, maintenance, repairing, painting and fabricating. Throughout the 10 week industrial training programme, I managed my training 5 weeks with GSE and other 5 weeks with fabrication. These experiences has indeed opened my eyes to the aviation or aircraft and fabrication industry in Malaysia and how the Malaysian economy benefited from this industry. Listed below are the scopes I was exposed to which are related to mechanical engineering under Ground Support Equipment and fabrication: 1. 2.

Managing mechanical tools. Repairing and maintenance aircraft jacks.

3.

Welding & grinding metal bars.

4.

Painting & coating.

Exposures are given on the above scope in the form of reading material provided by the department, reviewing drawings and knowledge sharing session in the office and on-site knowledge sharing.

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INDUSTRIAL ENVIROMENT Adaption & adjustment to the industry Adapting with the working environment in New Horizon Resources Sdn Bhd as an intern is easy going because I was treated and welcomed by everyone in the company in a very positive way. Despite having a lack in knowledge in the aircraft and fabrication industry, all the staff in GSE and fabricating department were all very generous for sharing all their knowledge and past working experience. Besides that, I adjusted well to the working hours in the company. Working on GSE department starts at 9.00am in the morning and ends at 5.30pm while working on fabrication department starts 10.00am ends at 6.00pm in the evening for 5 days a week, Monday to Friday. Throughout the 5 working days, I will usually start the day by checking my notifications in the WhatsApp group for any invitations to site visits or any task and end the day by writing all of activities I had done on the day on my daily logbook. Working’ schedule on fabrication department: TIME 10:00 am – 1:00 pm

1:00 pm – 2:00 pm 2:00 pm – 6:00 pm

TASK •

Safety talks

•

Fabricate

•

Welding & grinding

•

Perform tasks given by supervisor

Lunch break •

Continue fabricate

•

Learning about drawings

•

Daily log book written

Table 1: Schedule on Fabrication Department

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Working’ schedule on GSE department: TIME 9:00 am – 1:00 pm

1:00 pm – 2:00 pm 2:00 pm – 5:30 pm

TASK •

Safety talks

•

Learning about aircraft jacks

•

Reading manual aircraft jacks

•

Site visit or inspection

Lunch break •

Maintenance or services jacks

•

Repairing

•

Site visit or inspection

•

Daily log book written

Table 2 : Schedule on GSE Department

Practice of Occupational safety and health environment New Horizon Resources Sdn Bhd has serious concern on safety, therefore I was instructed by the company to apply for the rule of safety during working. Aside from abiding to the law regarding safety, everyone who enters NHR workshop are required to equip themselves with a proper Personal Protection Equipment (PPE). PPE is equipment that will protect the user against health or safety risks at work. It can include items such as: 

Safety helmets



Gloves



Eye protection



Safety footwear

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Eye protection

Gloves

Safety footwear Figure 2: Wearing PPE during works

INDUSTRIAL EXPERIENCE I.

Metal Work Fabrication (5 weeks)

Fabricating a Storage Cage (12 units) Storage cage are customer request from Pos Malaysia. They have request about 12 unit storage cage from NHR Sdn Bhd for loading their stuff. I have been train by staff under fabricate department in order to build storage cage. The size of storage cage is about (7*3.5*4 feet). Here, I applied all the skill of mechanical process such as grinding, cutting, welding and painting in order to make storage cage. There are a few step or procedure that I have learned to make a storage cage. I.

Cutting the square tubing bar (1.25*1.25 inches) with the length of 7 feet to use as the main pillar, 4 feet and 3.5 feet for upper and lower part.

II.

Start by building the upper part which is make it square by using the welding and the angle of corner should be 45 degree to assemble each tubing bar.

III.

Using the same step in order to build the lower part.

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IV.

Attach the 4 main pillar (7 feet) to join the upper and lower base every each corner with angle of 90 degree by using welding.

Figure 3: Welding main pillar to upper & lower part

V.

Figure 4: Setup 90º angle each corner

Attach square aluminum plate (4*3.5 feet) at the lower part as the base by using a welding (MIG).

VI.

Cutting square tubing bar (1*1 inches) to make a bones and joining it by using a welding.

Bones

Figure 5 : Welding bones to main pillar

VII.

Assemble the steel’s net around the body of the cage by using welding. Weld it spot every edge of the square tubing bar to make it fixed.

VIII.

Welding 4 units of roller at the bottom every corner to make a movement of the storage cage.

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IX.

For the finishing process, grinding all the welding parts to remove and clean the unwanted material and make a smoothing surface.

Figure 6: Grinding process to make smoothing surface

X.

The storage cage need to wash with the chemical substances in order to remove dust and rusty things.

XI.

Continue with painting the storage cage with grey’s color by using a spray gun. The combination paints should be 75% of paint’s color and 25% of thinner. Mixing both paint and thinner until it ready to spray. Mask must be wear to avoid color dust get into our mouth and nose.

Figure 7: Painting process

XII.

Let the storage cage dry and it considered done. The customer will come and pick up their storage cage. 14

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Maintenance, Fabricating & Repairing Customer” Lorry Parts The first customer’s lorry is from FGV Company. They brought it to NHR for fabricate and repairing for some a few parts of the lorry have been broken or damaged that need to be repair and fixed such as wall, rooftop and inside parts of the lorry. For the metal wall, we replaced the damage wall with the new one which is we fabricate it by using aluminum plate as it easy to bent and formed. In order to join the metal and aluminum plate, we spot it by using the rivet. Before performing the process of the rivet, a hole needed to be made by using the drilling machine. Once the hole is made, we use rivet to join metal part and the aluminum plate. From this, I learn on how to use mechanical tools properly and always be careful to avoid any injury. Second lorry we were received from Courier Company which is has minor problem with the rooftop. The awning of the rooftop also have a minor problem which is breakdown due to clash with a sign’s bus stop. For this task I was given by other staff to complete the fabricating and repairing. For the rooftop, I have to remove out the damaged plywood and replace with the new one. Since they use rivet to attach it to the metal, I have to remove out the rivet with drill on it. In order to replace it with new one, I have to take a correct dimension by using measuring tape and cutting by grinding tools. Then, attach the new plywood with the sheet metal by using the rivet. After finished the process rivet, the plywood have to paint with the white color mixed with the thinner. Next we move to fabricate and repairing the awning of the rooftop. This part I have to replace the damage awning with the aluminum sheet because it easy to bent. Remove the original damage part with drill on the rivet and get a new one and attach it again by using the rivet.

Figure 8: Fabricate & repairing the awning of rooftop

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II.

Ground Support Equipment (5 weeks)

Over Ground Support Equipment I have been assist by Manirag a/l Munusamy. He’s position as mechanic under this department. He had more than 42 years of experience in handling aircraft GSE and transport equipment for customers like Malaysia Airline Berhad, Druk Air (Bhutan), Air Asia, and RMAF. He was previously employed by Malaysia Airlines Berhad for 32 years. Attended a lot of technical training locally and internationally in all types of GSE. There were many thing that I have learn from him during 5 weeks about aircraft jacks, tow bar and load test. Maintenance, Service Aircraft Jacks & Load Test 1. Axle Jack & Tripod Jack Tronair axle & tripod jack recommends performing preventive maintenance which should include a 90-day routine inspection and 12-month load test. These axle jacks & tripod jacks were arrived from MAS AIRLINES due to some jacks had some problem such as cylinder leaking, broken seal and the jack cannot lift up. These jacks are placed directly on or under aircraft landing gear. Here I learned how to service all the problem from the mechanic aircraft jacks.

Figure 9 : Axle Jack

Figure 10: Tripod Jack

Basically, these jack have 2 stages and 3 stages cylinder jack to lift up. In order to service, these jack have to disassemble by part by using mechanical tools. Working on these jacks, worker must be careful while disassemble the jacks to avoid any accident that might be broken the some part of the jacks. All the part must be washed with the diesel or petrol to prevent it from rusty and dust. After we make maintenance and service on these jacks, the last part to be make is load test. Load test is part which is to 16

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ensure that jacks whether it can lift up the cylinder to reach their maximum load or not. Procedure performing load test: 1. Connect the load cell to the module that already connected to a laptop. 2. Open HyCat software and go to setting to put maximum the trigger level according to the jack maximum load. 3. Key in the data such as examiner name, model number, serial number and unit number. 4. Start the load test by lifting the jack up to 100% of its maximum load capacity. Load indication will show on laptop screen. 5. After reaching 100% of its load capacity, start the cycles test for 10 minutes. 6. After 10 minutes, stop cycle and check whether the jack pass or fail the requirement. 7. Save and load test is complete. 8. All the document load test must be reported to the customer as a proof of load test on that jacks.

Figure 11: Performing Load Test

Figure 12: HyCat Software

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Figure 13: Maximum Load

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Site Visit Throughout the internship period, I was given the opportunity to join for site visit with the supervisor and mechanic to hangar KLIA (MAS Airline). The purpose of the site visit is we are going to checking the aircraft jacks that have some problem which is the jacks cannot lift up. The jack cannot lift up because of some component stuck and broken. We have to remove out the cylinder jack by using the hammer and forklift and carry out into the workshop for service and maintenance. For the service. We have to disassemble by part and wash with the diesel to move out the rusty thing.

Figure 14: Remove Cylinder Jack

Figure 15: Lift Up by Forklift

Figure 16: Cylinder Jack Complete Services

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INDUSTRIAL PROJECTS Relation between the tasks to the mechanical engineering course Metal Work Fabrication department specializes on making storage cage and other fabrication. While GSE department focus on maintenance, service and repairing the aircraft jacks. All these are related to Mechanical Engineering as it involves workshop practice. It’s expose on me how to use mechanical tools properly. From this, I gain to make storage cage by my own self. Regarding this. I also learn some knowledge from the staff about skill and how to practice it time working. Integrating the theoretical knowledge with practical works I have applied my theoretical knowledge from Fluid Mechanics to understand the how does jacks system working. It involve pneumatic and hydraulic system on the aircraft jacks. The staff give me the manual all of the jacks and teach me to understand more about system hydraulic and pneumatic works on that jack. From my point of view, assignments given by lecturers are very useful because these assignments portrait the real world application on how to use the knowledge we gained in the classroom.

Figure 17: Pneumatic/ Hydraulic Diagram

Figure 18: Hydraulic Circuit

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Project

Fabricate Portable Canopy Portable Canopy is the one of the project that I have been involve during my internship at NHR Sdn Bhd. All the design have be conduct by previous staff which is En Nizammudin Bin Mohd Hashim. All the material and measurement of the hollow steel bar have been cut before I got intern at NHR. Material: Hollow Steel Bar Quantity & Measurement: 11 feet for front (2 units), 9 feet for back (2 units), 6 m (rectangle’s design) for rooftop (2 units), 4.3 m (rectangle’s design) for rooftop (3 units) Process of fabricate portable canopy: i

Before start building portable canopy, all the hollow steel bar must be coating with antirust to prevent it from rusty.

Figure 19: Coating the steel bar

ii Install 9 feet hollow steel bar both sides for the front to the 6 m steel bar by using bolt and nut. iii Install 11 feet hollow steel bar both sides for the back to the 6 m steel bar by using bolt and nut. iv After that, install 3 unit of 4.3 m steel bar in the middle as rooftop between 9 feet and 11 feet steel bar by using the welding. v

Install support with 0.5 m steel for every angle by using the welding.

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vi Install 4 unit of stopper wheel for every bottom of 9 feet and 11 feet hollow steel bar for a movement of the canopy by using the welding. vii Install 4 units of 24 feet hollow steel bar for the bones of the rooftop to place and support the zinc. viii Install the zinc for the rooftop every layer by using rivet to connect the zinc with the bones. ix 30 units of zinc with length (10*2 inches) needed to complete the portable canopy. x

Build the awning from 4 inches length of the zinc and welding 3 unit of steel bar for the support zinc with angle 45 degree.

xi Install the zinc for the awning with the same process which is drilling and rivet. xii Finally, the portable canopy have been fabricate after 2 weeks we start build it.

Figure 20: Portable Canopy

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SUMMARY Discussion & Conclusion

Students from the Faculty of Mechanical Engineering in UiTM are required to undergo a 10 week industrial training programed as part of the bachelor programed which intends to expose students to the real working environment and improving employability upon graduation. I have been exposed to the fabrication and ground support equipment industry throughout the industrial training period and I now can relate it with my theoretical knowledge that I learned in the faculty during my bachelor programed. I would say that the theoretical knowledge I learned in Fluid Mechanics is applied in the real industry in terms of the maintenance, service and repairing the aircraft jacks. In addition, I realize that in order to be a successful engineer, I need to continue learning, acquire more technical knowledge and develop various technical skills. Last but not least, I have learned to communicate with different types of people in both lower and upper grades. This is when we work on site, we're going to meet different types of people. NHR staff tell us that either we like it or not we need to adapt these environments. From this, as I work, I can become more open-minded and become self-confident in the future. In a nutshell, even though it was only 10 weeks and it is very short time to learn and gain skills, the industrial training was achieved. I learned a lot of new mechanical and aviation-related work. Last but not least, this training has improved my punctuality and attitude discipline. Recommendations

My 10 week industrial training with NHR Sdn Bhd has been excellent because of the knowledge I gained from the all staff in the department who were willing to share their working experience and knowledge to interns. I would recommend students especially mechanical engineering students to join NHR Sdn Bhd for their internship programed, specifically Ground Support Equipment (GSE) department for those who are interested in exposing themselves to the aircraft and aviation sectors. 22

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APPENDIX TYPES OF AIRCRAFT JACKS

Figure 21: Malabar Axle Jack

Figure 22: Hydro Axle Jack

Figure 23: TronAir Tripod Jack

Figure 24: TronAir Axle Jack

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STORAGE CAGE

Figure 25: Storage Cage

PORTABLE CANOPY

Figure 26: Portable Canopy

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