industrial report.docx

8/10/2019 industrial report.docx

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ABSTRACT

The following report describes the activities carried out during a 12 week, full-time internship at

the Engmech Sdn Bhd. The document contains information about the organization and the

responsibilities performed throughout the period of 30th June until 19th September 2014. The

objective of this report is to reflect upon the experiences collected during the internship from the

perspective of Bachelor In Engineering (Hons) Mechanical student. The first part of the report

offers an overview of the organization, followed by the industrial environment, experience and

also task and project that have been carried during the training. This report also describes in

some detail the most relevant projects carried out and their respective analysis. Finally, the

report wraps-up with a few closing remarks and conclusions from the experience

This industrial training at Engmech Sdb Bhd is the opportunity that have been taken in order to

know in depth on how work culture in real industry. I was able to learn about the tender,

quotation and how they do the business. Besides that, I have been exposed with the technical and

management department as I have to understand the project by using the theory that I have learnt

and also be able to manage manpower to finish the job in time frame. Furthermore, I was able to

learn about the production of graphite electrode which produces from carbon.


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Organization chart

1.2 Structure of Main Activity

Engmech Venture Engineering Sdn Bhd, desire long term relationship with customer for

example at SGL Carbon, they was there about 6 years to do maintenance job and general

fabrication work. They offer full technical support from our various expertise counter parts..

Some of the services are including:

1. Mechanical and Electrical Engineering Design

2.

Management and site supervision team

3. Plant maintenance and servicing

4. Dismantling and Installation of heavy equipment


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Engmech Venture Engineering Sdn Bhd is also a company dealing with trading activities for

example:

1. Authorized Distributor for Dairy products: Tube, Fittings, PHE, Pump & etc

2. Automatic Sliding door: Commercial and Industrial type.

3. Filling Machine for solutions

4. AHU, Chillers, Cooling Tower, Air Condition units

5. Polishing Stainless steel plate up to 15mm thick plate from RA 0.6 to RA 0.2 (mirror

finished). Calibrated with surface tester.

6. Servicing packaging machines

7. Refurbishment for equipment

1.3 Objective of Practical Training

The objectives of the industrial training are to expose students to actual working culture and

industrial practice. Work under pressure is one of the working cultures. It is important parts

which need to be fulfil by the engineer. Working without this culture may definitely drop the

potential and ability of an engineer.

Other than that, it is created to allow students in extending their theoretical knowledge into

practice. To explain more, as in the university students is exposed to theoretical knowledge.

Here in the industry, students can manage to relate knowledge studied in the university and use it

by doing it into practice.

Besides, the objective is to motivate students to practice the right working attitudes and

professionalism to increase their employability potential. Here students may work under the

supervision of the supervisor which will be guiding the students on how to work by following

the right ethics.

Last but not least it is to facilitate students to potential employers. Normally students which

undergo training at certain company have better chance to work with their previous employers

compare to those who are new. This is because, those students had already adapted the working

environment and had followed the training, and therefore the experience may help them to put

themselves to the vacancy position.


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1.4 Scope of Training

For this practical training, I have been assigned as an assistance engineer and responsible to

monitor site at SGL Carbon, Banting. My scope of jobs is to deal with client for the project or

maintenance job given by them. After dealing with client, the information of the project must be

informed to the engineer and site supervisor in order to let them discuss about the project. After

the project had been approved, trainee must deal with safety officer to get appropriate permit so

that workers can do jobs legally. In order to let the project run smoothly, I have responsible to

order a material and bring the material from office to site.


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2.2 Practice of Occupational Safety and Health Environment

Safety and health are the most important matters at any site in this world. At Engmech Sdn Bhd,

it is important to wear well condition Personal Protective Equipment (PPE) which include safety

helmet and safety boots while at the workshop.

The usage of safety shoe is to protect feet from hard, rough or awkward surfaces, while avoiding

any objects to crash onto the feet and lead to injuries. It is strictly advised to wear the safety

shoes for the whole time because most of the areas have dangerous machines and the surfaces

also rough and slippery such as workshop area and production process area.

Safety helmet are also compulsory to wear at workshop and site. The reasons of wearing the

safety helmet is to indicate that the person who handling forklift or crane and as a safety to avoid

impact on head which can lead to injuries.

At SGL Carbon, addition of equipment for example safety glasses, dusk mask and safety vest

need to be wear. SGL Carbon is a very dusty factory due to the production of electrode. The raw

material is in powder state which can be breath in an can affect long time term to the body.

There are also traffic flow for the forklift thus it is strictly advised to wear safety helmet and also

safety vest in order to let operator alert with surrounding.

Hand gloves are worn to protect hand from any sharp edges which may lead to injuries while

working with fabrication of product. Hand gloves also assist in handling the products

comfortably.

For workplace that is above 2 meter, it is compulsory to wear safety harness. When climbing the

ladder, there is principle which is 2 hands and 1 leg. It means by when climbing the ladder, make

sure 2 hands are holding the ladder and push 1 leg pushing the body upward. The workplace also

must be provided with life line so that


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Figure 1: Full body safety harness

Inside the tank, it strictly to wear special suit to since the hazardous atmosphere inside tank may

affect the skin. In SGL Carbon, Pitch impregnation tank is filled with chemical and the coil

inside tank is filled with thermo oil. Before entering confined space workplace, hazardous

atmosphere test must be conducted. It is to ensure the oxygen is sufficient and no harmful gases

in the tank. The tank also must be provided with blower in order to create good ventilation inside

the tank.

Figure 2: PVC chemical suit Figure 3: Hazardous atmosphere test device


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3.0 INDUSTRIAL EXPERIENCE

3.1 Decision Making Ability

During the training I have being given opportunities to make some decision that related to my

task. Although its just a minor decision, however it gives me motivation to perform the entire

task successfully. During my 12 weeks training Engmech, I have given the chance to design the

toolbox and also to manage manpower for the projects.

3.2 Interpersonal Skills

The training has improved my ability in interacting with others people such as peers and

superior. It is fun to deal with this people, especially when they were willing to help and explain

to me about thing that I didnt understand. Most of the company operators are foreign workers

and this allowed me to learn the differences between culture and its relative influence on their

perception and behavior

3.3 Teamworks Skill

Most of the time during the training, I worked with Mr Chin Chee Keong, leader of site

supervisor. He tell me what to do and also order the material used for the project to me. Some of

the task we perform it together. I was able to contribute my ideas and insights in our works.

3.4 Communication Skill

During the training, I able to improved my communication skill especially my English languages

skill both spoken and written. This is because English is the most used language in the company

for every day communication and report paperworks.

3.5 Self-Management

Getting to know what its like to work in the real industry has taught me how to conduct myself

properly in an engineering environment. I am able to improve my time management, more

punctual in work in order to finish job based on time frame. I also learned how to wear

appropriate attire to work and manage my appearance well.


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3.6 Leadership awareness

Although I dont have opportunities to lead any project or working group throughout the

training, however I am able to gain some useful leadership insight by observing how some of the

company superiors lead their subordinate. From my observation most of the company superiors

applied coherent and straight style of leadership.

3.7 Project Management

For now I only involve or assigned on a few minor project. The project I have listed below.

From this project I have learned how to organize, plan project and control the manpower.

3.8 Industrial Safety Exposures

SGL staff responsible for the obtaining of all building and operating permits. However,

contractor is responsible for the fulfilling of all requirements to allow worker to legally work on

site. Basically, trainee is responsible to help engineer to get appropriate permit that are

applicable to the type of work being perform. There are several types of permit which are:

1. Site incident prevention plan (SIPP)

Project planning which will be discuss by both side client and contractor and verify by

the safety officer. Every project which has been agreed by both side need a SIPP to

inform to safety officer in order to let worker to do the job legally at the location.

2.

Work plan

Working procedure to complete the project and potential hazards may occur due to the

working procedure. The working procedure must be discussed with the supervisor and

trainee must identify the potential hazard for each procedure and how to avoid it.

3. Hot work permit

Activities that can be source of ignition if flammable material is present for example

welding, cutting and grinding must require this permit. Usually the safety precaution to

avoid ignition is fire extinguisher and fire blanket must be ready at site.

4.

Confined space entry permit

This permit is required when the workplace is in the tank which has hazardous

atmosphere or bad ventilation. Hazardous atmosphere test must be conduct before

worker is allowed to enter the workplace.


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5. Forming - reinstall vibrator feeder at forming silo

After maintenance, the vibrator feeder must be reinstalled in order for client to run the

production. Task given was to confirm the date with maintenance staff and arrange

workers to do the job.

6. Forming - fabricate 2 units toolbox

Fabricate 2 units of toolbox according to the sample that have been given by client. Task

given was design and measure the toolbox according to the client desire.

7. Forming - fabricate and install handrail for platform at level 1

Fabricate safety handrail for platform at forming level 1. This job takes 2 days to

complete where 1 day to take measurement and fabricate and 1 day to install the

handrail.

8. Forming - improvement flash conveyor and fabricate scrapbox

This tender required Engmeh to modify the flash conveyor according to design given.

The flash conveyor added a scrapbox that can be lift by forklift to empty the scrap inside

it.

9.

Forming - install handrail at moving hopper level 5

This tender required Engmech to fabricate safety handrail for moving hopper at forming

level 6. The safety handrail is following the diameter of the moving hopper. Task given

is to get information about the dimension of moving hopper with SGL staff in order to

engineer roll the pipe according to correct diameter.

10.

Forming - install new spool piece cover at extrusion oil line mixer level 3

This tender required Engmech to install piping system for automation according to the

circuit given by SGL engineer.

11.Forming - install opening door cover at chain conveyor concrete silo

This project required engmech to make a square hole at the roof of conveyor and

fabricate opening cover for the hole. The purpose of this project is to ease the

maintenance of the conveyor

12.Forming - replace guide flatbar at C29 at forming level 9

This project required Engmech to change the guide flatbar which at the C29 conveyor

because the flatbar is damage. The task given is to discuss with system owner when and


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how long to stop the conveyor in order to work on location. The system must be proper

lockout (LOTO) to avoid any incident at the conveyor during the maintenance process.

13.Graphite - machining new graphite head for furnace 8

This tender required Engmech to machining new graphite head which used for for

furnace 8. The graphite head is create e at the Engmech workshop in Puchong.

14.Graphite - maintenance of furnace 4

This project required Engmech to dismantle and maintenance the cooling channel of

furnace no 8 at graphitization shop. The cooling channel either straightens or fabricate

back according to the condition of the cooling channel.

15.

Graphite 2 - move blower and lathe machine to graphite 2

This tender required Engmech supply labor and appropriate equipment to remove the

blower and lathe machine from the container and move these components to the

graphitization shop 2. The process of removing the components must finish before 3pm

since the container must be send back to the shipping before 3pm. 45 ton of crane was

being used to lift the component out from the container. SGL carbon supply 8 ton

forklift to move these component to the graphitization shop 2. Task given is to ensure

the tools and equipment used to move the components are complete and discuss with the

SGL engineer about the arrangement of the components.

16.Graphite -repair wind separator at DEMCO crane graphite

The the wind separator at DEMCO crane was crack. Engmech was responsible to

welding the crack in order to repair it. Task given is to get information about the

material of the wind separator in order to choose the suitable welding rod.

17.Graphite -reposition furnace 8

This tender required Engmech to shorten the current length of furnace number 8 in orderto follow the standard design of all the furnaces at the graphitization shop. There are 4

sets metallic bed and tie rod need to be modified. The short circuit side components also

need to be relocated to the new position. This is the largest and longest project at the

SGL Carbon. Task given is to follow up from the beginning until this project is finished.


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18.PI - fabricate and install spool piece

This tender required Engmech to supply and install spool piece at pitch impregnation

pipeline system.

19.PI - install valve and fabricated jacketed pipe together with insulation

Install valve at the thermo oil pipeline and insulate for safety purpose. The jacketed pipe

is fabricated to supply to the client for cooling system.

20.PI - welding coil in the pitch tank and do radiographic test (RT) for the joint

This tender required Engmech to repair the leakage at the thermo oil coil inside the pitch

tank. The coil was been repair by using argon welding. The joint need to be tested using

RT in order to ensure zero defects at the joint to avoid another leakage.


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4.2 Technical Drawing

Technical drawing is very important in real industry since it is used by engineer to ease the

visualization of all component either it visible or hidden. The engineer gave me the drawing of

furnace 8 to study the components required to be modified and also the actual length need to be

shorten. From the drawing, 4 sets of metallic bed needed to be shorten by 1050mm each. The tie

rod also must be shorten same as the length of metallic bed. The components affected by the

modification are the short circuit, cooling system, column and refractory block. All these

components need to be relocated according to the new position.

Drawing for reposition of furnace 8 can be refer appendix 1 until 3.

4.3 Scope of Jobs

The scope of jobs to has been discussed within the engineers in order to identify the components

and procedure to reposition the furnace 8.

4.3.1 Access platform

Figure 5: Access platform being remove by crane

The first components need to be dismantle is the access platform. the platform was being

removed by using overhead crane. To install it to new location, it must have good inter connect

with platform at furnace 7 and the base must be put cement grouting.


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4.3.4 Short circuit flohe set

Figure 7: Flohe set being remove by crane

Short circuit flohe set also being move by a crane to facilitate the removing process of other

component. It is then being relocated to new position according to the new length.

4.3.5 Tie rod

Figure 8: Tie rods being remove and modified

The tie rods are dismantle by using chain block. It is then being cut and modifies to shorten the

length by 1050mm. The joint must be checked with magnetic particle inspection (MPI) spray to

ensure no crack at the welded joint.


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4.3.6 Process cooling

The components which involve in process cooling are accumulator, hose, valve and all its fitting.

All this components must be removed and relocated to new position. The 6inch sch 40 pipe for

water supply also must be extended 2.1m from the previous location.

4.3.7 Metallic bed

Figure 9: Metallic bed being remove and modified

The metallic bed has been remove by crane and been modified at green area. To modified the

metallic bed it taking a long duration and use many of grinding and cutting disk as well as

oxygen cylinder and acetylene cylinder for process of cutting and grinding.


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4.3.8 Refractory (U shape and Pillar)

Figure 10: refractory block being remove by crane

The refractory which include 2 sets of U shape and 4 pillars is a very heavy component. It has

been remove by 45 ton crane. Before reinstall it to new position, the base must be hack and

install new grouting.

All the work above are the component involve to complete the project reposition furnace 8

following the same design as the other furnace at graphitization shop by shorten it 2.1m.

Basically, trainee monitors the progress of the project and inform project engineer and project

manager. Trainee also responsible to ensure the equipment and tools as well as material well

provided to smooth the progression of the project. However, apart from this project there is also

a maintenance jobs need to be done. Some of the project are urgent and have its deadline usually

due to the shutdown of plant. Therefore it is very important for me to arrange workers and keep

update the jobs to engineer and project manager so that all the projects can be done follow the

time frame. If the project did not follow the time frame, Engmech need to use profit gain from

the tender to pay worker salary. Thus the longer the duration of the project been extend, the

lower the profit gain. This knowledge already learnt from the subject Industrial Management

where profit is equal to total revenue deducts with total expenses. In order to get higher profit,

total expenses must be lower since total revenue are difficult to manipulate. By reduce working

time can minimize total expenses of a company.


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5.0 SUMMARY

5.1 Conclusion

In conclusion, the industrial training had given me a lot of new knowledge and experience as a

mechanical student and also as a person. I expect to involve more on engineering calculation

related work or task, however much of my training time were focusing more on operation and

management aspect. However this didnt affect my excitement and focus on the ongoing training

period. On the contrary I am happy to have been able to take this valuables opportunity to

explore and experience new dimension of work in industry which I never experience before.

During my placement I had the practical work experience under project engineer En Zubari

which treated me as his real assistant. I was capable to contribute my ideas and insights in his

works. At the same time, he provided me with productive and stimulating learning environment.

I try to apply what I have learned in the lecture class at UiTM to actual work setting. I also able

to get a better understanding about the production process in a SGL Carbon especially related to

Electrode production. From the task and project given by my supervisor, I able to understand

manufacturing related aspect such as scheduling, manpower planning, and material flow. This

training has exposed me to the invaluable experience that I can't gain from the lecture hall or

classroom. Lastly, the industrial training is not only the knowledge outside the classroom but it

also opens my world view wider.

5.2 Recommendation

I recommend the company to create more structured training program. I understand that the

person responsible to supervise the practical student is already busy with their work burden.

However I believe that they can spend small portion of their time to plan more comprehensive,

structured and organized training for the practical student. The supervisor in charge should list

and arrange the training task which will be performed by the trainee.

A training schedule also should be made in order to optimize the training period. In arranging

and assigning the training task, the supervisor also should try to fill the training period with task

that significant in developing the trainee knowledge, skills and experience for its future career.

industrial report.docx

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