INDUSTRIAL TRAINING REPORT

(ACSON MALAYSIA SALES & SERVICE SDN.BHD.)

STUDENT: TAN CHUN KEAT (KEM090056)

LECTURER: DR ABUL KALAM

MECHANICAL ENGINEERING DEPARTMENT

ENGINEERING FACULTY

UNIVERSITY MALAYA

Abstract

This report describes the overview of what I did and learned during my industrial

training in Acson Malaysia Sales & Service Sdn Bhd. The report is a requirement to

fulfill the internship program of Bachelor of Mechanical Engineering. The report

primarily focuses on the practical knowledge in air conditioning system, design of duct

system, project handled and responsibility, and working environment. During the

internship period, I had been assigned into products and projects department. I was

assigned with two supervisors, Mr. Chua Yean Shin and Miss See Lee Foon. They had

taught me that to apply the engineering knowledge in the work. In addition, I have the

opportunity to learn the necessary soft skills in dealing with other peoples. Through this

training, I gained valuable working experience which I can apply in the future. This

report proves that I had undergone and completed my industrial training in this

company. Also, this report serves as a reference to the future employer to evaluate my

performance and working experience gained from the industrial training.

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Acknowledgement

First of all, I would like to express my greatest gratitude to my supervisors, Mr

Chua Yean Shin and Miss See Lee Foon who are the engineers of Acson Malaysia Sales

& Service Sdn Bhd. Mr Chua serve as the project engineer and Miss See is the product

engineer. During these ten weeks of industrial training in this company, they are willing

to share their knowledge and experience, with me. Mr Chua shared more on practise and

site visit for more exposure on working engineer’s life to me. Miss See was willing to

give me the technically support on my assigned task.

Then, I would like to give my appreciation to Mr. Lee Chuan Yee, who is the

person-in-charge for internship programme. He had done a good jobs in arranging the

task and works for us.

In addition, I would like to thank Mr. Lee Nam Chuan, who is the general

manager of Acson Malaysia Company for providing chance to me for the internship .

Mr. Lee always shares his experience and knowledge in air condition industry. At the

same moment, he taught me soft skills which are needed to be equipped with before

entering the real working life.

Next, I would like to thank Dr Abul Kalam who is my supervisor from UM. He

advises us to be nice with the colleagues. Besides, he also play his part as the faculty

supervisor in this industrial training program well.

Lastly, I would like to address my sincere appreciation for all my colleagues for

their teaching, advice and also cooperation with me during my whole internship training.

. It was a meaningful environment to have my friendly colleagues during the training.

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ContentsAbstract.......................................................................................................................................... i

Acknowledgement........................................................................................................................ ii

List of Figures............................................................................................................................... iv

List of Tables................................................................................................................................. iv

CHAPTER 1: INTRODUCTION.........................................................................................................1

1.1 History of OYL and ACSON...................................................................................................1

1.2 Company Profile..................................................................................................................2

1.3 Principles, Corporate Values and Total Customer Satisfaction............................................4

1.4 Organization Structure........................................................................................................1

1.5 Industrial Training program.................................................................................................1

CHAPTER 2: INTERNSHIP PROGAMME..........................................................................................2

2.1. Main Assignment................................................................................................................2

2.2. Training..............................................................................................................................4

2.2.1. Basic Refrigerant Cycle................................................................................................4

2.2.2. Type of Air Conditioning System.................................................................................5

2.2.3. ACSON Product Range.................................................................................................6

2.2.4. Heat Load Calculation..................................................................................................7

2.2.5. Duct System Design.....................................................................................................9

2.2.6. Other Training...........................................................................................................10

2.4. Factory Visit......................................................................................................................11

2.5. Site Visit............................................................................................................................11

2.6. Soft skill Training..............................................................................................................12

CHAPTER 3: INTERNSHIP OUTCOME...........................................................................................13

3.1. Beneficial Experiences......................................................................................................13

3.2. Relevance between Work Experience and Studies...........................................................14

CHAPTER 4: CONCLUSION AND RECOMMENDATION.................................................................16

4.1. Conclusion........................................................................................................................16

4.2. Recommendations...........................................................................................................16

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REFERENCE..................................................................................................................................17

List of Figures

Figure 1: Organization Chart.........................................................................................................1Figure 2: The basic refrigeration system with R-22 flowing as shown in direction........................4Figure 3: General specifications of air conditioning system..........................................................6Figure 4: The cooling loads in a room...........................................................................................8Figure 5: Duct Calculator.............................................................................................................10

List of Tables

Table 1: Principles, Corporate Values and Total Customer Satisfaction......................................10Table 2: Weekly progress..............................................................................................................2

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CHAPTER 1: INTRODUCTION

1.1 History of OYL and ACSON

In 4 February 1974, O.Y.L Industries Sdn Bhd was incorporated in Malaysia as a

private limited company. O.Y.L. commenced its operations with the assembly of gas

cookers and GLEM gas ovens in Shah Alam. The company joint venture with Guthrie

Malaysia Holdings Berhad in year 1976 to form O.Y.L. Condair Industries Sdn Bhd.

O.Y.L. started manufacturing industrial air conditioners and refrigeration equipment.

This company was then known as Mulpha International Trading Corporation Berhad. In

year 1982, O.Y.L success to acquire ACMA Electrical Industries Sdn Bhd and became

the main distributor of refrigerator and air conditioner in Malaysia. In year 1983, O.Y.L

made a long term contracts with Mitsubishi Electric Corporation, Japan.

OYL created the ACSON brand in 1984. ACSON later achieved international

recognition. Since that, Acson had grown positively from a steady home appliances

business, selling high quality and proud Malaysian made products from stand fans to air

conditioners. Then it became a public listed company on Kuala Lumpur Stock

Exchange (KLSE). In 1990, Hume Industries had acquired O.Y.L and placed it under the

Hong Leong Group, Malaysia. In 1992, this company made an important step toward

globalization of its activities. By achieving the growth and expansion of the company, it

acquired J&K Hall of UK and US-based Company, AAF and McQuay. In September

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2006, the Daikin Industries Ltd had acquired O.Y.L. to strengthen their business

operation.

1.2 Company Profile

ACSON MALAYSIA SALES & SERVICE SDN BHD is a subsidiary of O.Y.L

Industries Bhd (formerly, a public listed company in the KLSE and a member of the

renowned Hong Leong Group, Malaysia) which was then acquired by Daikin Industries

Ltd, since September 2006. Since its incorporation in 1984, Acson has grown positively

from a steady home appliances business, selling high quality & proud Malaysian made

products from stand fans to air conditioners. Today, the company has consolidated its

business and is now specialized in the air conditioning industry.

In testimony to the high standards of product quality, ACSON products have

been awarded the CE marking for entry into European Markets. Moreover, ACSON has

penetrated and joined the competitive international scene. With that, the proclaimed

ACSON brand name is proudly transformed to ACSON INTERNATIONAL, which is a

move to reflect worldwide brand recognition.

ACSON International is a leading brand of air-conditioner, made-in-Malaysia,

exported to more than 50 countries in 5 continents with annual turnover of USD 1.4

billion. ACSON International is set to reach for greater heights. Since its inception in

1984, it has recorded many milestones in its growth and set many exemplary

benchmarks of success. All of this is due to the company’s commitment to quality,

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product development as well as dedication and professionalism of its management and

staff.

In the new millennium, ACSON Malaysia Sales & Service Sdn Bhd has

consolidated and its business strives to become a leading air-conditioners distributor

under the ACSON INTERNATIONAL label, renowned for performance and

technological innovation. In addition, it is also an industry leading service and support

provider. Their mission is to provide excellent value added service and support to

customer’s ACSON product year after year. The strong service teams which made up of

over 50 service technicians and engineers and an extensive network of Authorized

Service Dealer (ASD), are tactically situated across Malaysia.

The headquarter of ACSON Malaysia Sales & Services Sdn Bhd is located at Lot

4, Lorong 19/1A, Seksyen 19, Petaling Jaya, Selangor Darul Ehsan. I had my industrial

training for 10 weeks in this company. In headquarter engineering and management

departments are placed at the upper floor while the service department is placed on

ground floor. The first floor is used as office for the core company of Acson, which is

Daikin Industries Ltd. For information, there are seven branches of Acson in Malaysia

which locate at Penang, Kuantan, Johor Bahru , Ipoh, Melaka, Kota Bahru and Kota

Kinabalu.

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1.3 Principles, Corporate Values and Total Customer Satisfaction

In order to compete with the global competitors, ACSON Malaysia Sales &

Service Sdn Bhd always holding four principles:

- Acson are always there when you need any service and

support, as the tagline ‘We care, we share’.

- Acson Malaysia always put their valued customers at the

first place.

- Acson Malaysia is always committed to provide the highest

quality of product at all time.

- Acson Malaysia insist on using genuine part in all service we

provide, whether under or after warranty, to provide the

maximum value to our customer.

Table 1: Principles, Corporate Values and Total Customer Satisfaction

In addition, there are corporate values that contribute to the uniqueness of this

company

a) Absolute Credibility

b) Enterprising Management

c) Harmonious Personal Relations

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Every morning, there is an assembly which is attended by all the staff of

headquarter, including all other branches. During the assembly, every staff is required to

speak loudly the three corporate values as listed above. Then, they may sing the song

“Bersatu Kita Maju”. A representative may read the one of the guidelines in ‘Total

Customer Satisfaction’ (created by Acson which has total of 31 set of guidelines). The

guidelines are interpreted at the customer’s point of views on servicing, the desired

behavior as a salesperson and also the important of the quality of servicing to a

company.

Therefore, all these efforts equip them with not only continues improvement in

productivity as well as excellent customer service to gain customers confidence in

Acson’s products and services.

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1.4 Organization Structure

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Figure 1: Organization Chart

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The chart above shows the organization structure in Acson Sales & Services Sdn Bhd.

There are seven departments in this company, which are sales, marketing and planning,

project and application, service, finance and administrative, product and engineering and

part business development. However, the departments I had been placed at are product

and projects department..

1.5 Industrial Training program

This company has a well-planned schedule for trainee throughout the internship.

Each trainee is assigned to two mentors, one from the product engineer and one project

engineer. There is a long term project for each trainee with different topic. Besides, there

are several technical trainings for trainees to gain extra knowledge regarding the air

conditioning system. The trainings include heat load calculation, classification of air

conditioner and product range of ACSON Malaysia. Meanwhile, trainee also

participated in several exhibition and factory visit.

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CHAPTER 2: INTERNSHIP PROGAMME

2.1. Main Assignment

During the internship period, each of the trainees is given a project to be followed. My

project title is EZ-Series, which is the control system of ACSON products. Based on

each topic, I have been assigned to study the product system, and come out with a report

according to the outline.

Project outline

Activity WeekIntroduction of the product

What is this History of why this kind of product was developed Working principle

Week 1-2

Market survey Collecting and understanding market’s needs and

demands Current status of this product in the market Countries where it is popular Application

Week 3-4

Comparison with similar product system Advantages and disadvantages Comparison with other brands

Week 5-6

Recommendations Are the products good enough Way to improve

Week 7-8

Conclusion Week 9Report submission and project presentation Week 10

Table 2: Weekly progress

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A report and a presentation are done for this assignment. The report is about a product

from ACSON, EZ-Series. EZ-Series consist of EZ-LINZ, EZ-SOL, and EZ-LI. In this

report, the focus will be on EZ-LINZ, a centralized control system of air conditioners.

EZ-LINZ can be categorized in Building Management System. There are 5 chapters in

the report. There will be a brief introduction of Building Management System in the

Chapter 1. The working principle of the product will also be explained in the Chapter1.

Chapter 2 is about the market demand on BMS system. In this section, market survey

researches from different survey and research companies are taken as references. In

Chapter 3, the features of the product and similar products will be discussed. Chapter 4

is about the recommendation of improvement of this product. Lastly, Chapter 5 is the

conclusion.

In the last week of the internship period, a presentation has been done to the mentors.

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2.2. Training

2.2.1. Basic Refrigerant Cycle

During the first week, Mr Yeo Jian Rong, one of the project engineers, has given us

training on the basic refrigerant cycle.

Basically, the air conditioning system is defined as a system used to

simultaneously control its temperature, humidity, cleanness and distribution to meet the

requirement of the conditioned space. Air conditioners are built fundamentally on the

principal of refrigeration cycle which consist mainly the following component:

i. Evaporator Fan Coil Unit (Indoor Unit)

ii. Compressor

iii. Expansion Device Condensing Unit (Outdoor Unit)

iv. Condenser

The diagram below shows how the basic components are connected in an air

conditioning system.

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Figure 2: The basic refrigeration system with R-22 flowing as shown in direction

From this diagram, the first component is the evaporator. The evaporator is used

to cool the air in the indoor. A heat transfer occurs between the indoor air and refrigerant

passing through copper coil in the evaporator. The heat of indoor air (higher

temperature) is transfer to refrigerant (lower temperature) and carried away to

compressor.

Inside compressor, it pressurizes the vapor refrigerant to obtain high temperature

and pressure state. Then the vapor refrigerant is allowed to pass through the condenser

where a heat transfer occurs between the refrigerant (higher temperature) and outdoor air

(lower temperature). The heat carried by refrigerant is transfer to outdoor air due to

temperature difference and become in liquid form. After that, the liquid refrigerant

enters the expansion valve and expands to become a low pressure mixture of liquid and

vapor refrigerant. The cycle is then repeated again.

2.2.2. Type of Air Conditioning System

After the refrigerant cycle briefing, Mr Yeo also brief us about the type of air

conditioning system.

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Figure 3: General specifications of air conditioning system

The air conditioning has come to a new era. Nowadays, the air conditioning

system is divided into two categories according to the medium used in the system. They

are Direct Expansion (DX) and Chilled Water (CW) system. The DX system uses

refrigerant as a medium for heat transfer process to take place in indoor section while for

CW system, water is used as the medium for heat transfer process in indoor section.

Besides that, under these two groups, they are categorized into two groups

depend on the manner the medium (air or water) being cooled at condenser. They are

known as air-cooled or water-cooled DX or CW system. The air cooled DX or CW

system uses outdoor air to cool the heated medium which is passing through the

condenser. While the water-cooled DX or CW system utilizes the water to cool the

heated medium in the condenser. And, the water will carry the heat to cooling tower

which are then dissipated to surrounding.

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2.2.3. ACSON Product Range

There is a briefing on ACSON product by Mr. Lee Chuan Yee. Besides that, I also refer

to the catalogues of the products.

Acson Products are divided into seven categories which are listed as below:-

(i) Air Cooled DX System Single Split Units

(ii) Air Cooled DX System Multi Split Units

(iii) Air Cooled DX System Packaged Units

(iv) Water Cooled Units

(v) Chilled Water System Units (Air Cooled)

(vi) Complimentary products

(vii) R410A Products

2.2.4. Heat Load Calculation

There is also training on heat load calculation by the technical assistant, Mr. Muhd Nasir

bin Mhd Yusuf. The first step is to calculate the heat load of an area which is being air-

conditioned. Calculating the heat load is important in determining the suitable cooling

capacity of air conditioner to meet the requirements of user.

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Heat load is defined as the amount of heats that required to remove in order to

achieve the desired condition. Heat load is classified into two main types which are

sensible and latent heat. If a substance is heated and its temperature rises or falls as the

heat is added or removed, the increase of heat is called sensible heat. On the other hand,

the latent heat is heat which causes a change in state of a substance without change in

temperature.

In air conditioning system, cooling load is another term which has the same

meaning of heat load. In this context, the term of cooling load is used for the following

discussion. Basically, cooling load can be classified into three types which are skin load,

internal load and other load. The below figure show the three cooling loads in a room.

Figure 4: The cooling loads in a room

As show in the figure, skin loads originate from the heat sources from the outside

or external to the conditioned space such as sunlight and transmission gain through

glass, walls and roofs, transmission through glass, ceiling, partitions or floors,

infiltration and ventilation. The internal loads are produced from the sources inside the

conditioned space such as people loads, equipment loads and lighting loads. Other

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cooling loads occur from heat gains or losses associated with moving cool fluids to and

from the conditioned space. For example, heat is generated from supply air side, return

air side and outside or ventilation air along the ducting system. The total heat loads in

this room is the sum of the three cooling loads. There are two methods which are Rules

of Thumbs and DACCS-PC HKGSG software to calculate the total heat load of

conditioned space. However, due to time constraint, I am only able to learn the first

method.

Rules of Thumbs:

This method is an approximation of calculation and thus the fastest way to obtain

the heat load. The procedures of using this method are:-

1) Calculate the area which is being conditioned. The unit of area is in feet square

2) Refer the Design and Cooling Check diagram. Choose the suitable application and

Grant Total Value.

3) Multiply the Grant Total Value with the area calculated in step 1 to obtain heat load

(Btu/Hr).

4) The suitable model of air conditioner is selected based on the calculated heat load.

Usually, the cooling capacity of air conditioner must be higher than the heat load

calculated.

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2.2.5. Duct System Design

Another important aspect in air conditioning system design is the duct system design.

For information, the function of air duct is to conduct air from one point to another. This

design is introduced to determine the dimension of air duct which is used to connect the

indoor unit with outdoor unit. Duct Calculator is used to calculate the size of duct

provided the pre-determined air quantity.

Figure 5: Duct Calculator

Below are the major steps in using the duct calculator to determine the size of air duct.

1) Establish the friction rate and air quantity (in CFM unit). Usually, the friction rate is

set at 0.1 in wg/100 ft and air quantity is obtained from the result of equipment

selection process.

2) Set the air quantity opposite to friction loss. Then, obtain the velocity (in FPM unit)

opposite to air quantity.

3) Read the diameter of round duct at opposite of arrow

4) The step 3 is repeated for equivalent rectangular duct

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2.2.6. Other Training

Besides the training above, there are also other training and briefings. For example, the

technical sharing from the service department. In those sharing, some basic knowledge

is learnt such as basic wiring, starter connection etc.

2.3. Schedule of Technical Specification

The preparation of technical specification of each selected air conditioning units is

carried out before tendering a project. This procedure is important before tendering a

project because the consultant or contractor will compare the technical specification

sheets provided by various air conditioner suppliers such as ACSON, YORK and

PANASONIC. For information, there are complete technical manual provided by Acson

Company to prepare an accurate technical specification of every air conditioning unit.

Generally, the most common specifications are model no, country of manufacturer,

electrical properties, features of cooling coil, compressor, and motor, temperature of air

entering and leaving coil, dimension of indoor and outdoor unit and also operating

weight.

2.4. Factory Visit

We have a change of visiting the O.Y.L. Manufacturing Factory at Sungai Buloh. On the

visit, I am exposed to the manufacturing process line. Next to O.Y.L.M. is the O.Y.L.

R&D centre. There are four sectors in O/\.Y.L. R&D: Test Room, Sound Room,

Component Testing Lab and CADCAM Lab.

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2.5. Site Visit

During my internship period, I have change to go outside to the site with my mentor, Mr.

Chua. The purpose of going to the site is to have more understanding of the demand o

the customers, collect data of the project, giving advises to the consultants and

contractor about ACSON products or to propose ACSON products to them. For me, Mr.

Chua taking me to the site is also one of the ways to make me having more exposure for

more product information on its application. Another task for me in the site is to collect

the data and dimension of the compound.

2.6. Soft skill Training

Part of the internship program is to train our soft skill like communication skill and

presentation skill. In the program, the trainees have to present any topic in front of all

the staff of the company. For me, I group up with another trainee to present a topic on”

Yellow Pages versus Google” in the presentation, we mention about the use of yellow

pages and google search and compare them. The presentation end up with the conclusion

of downfall of the yellow pages usage due to the internet usage is more popular

nowadays.

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CHAPTER 3: INTERNSHIP OUTCOME

3.1. Beneficial Experiences

These ten weeks of industrial training at Acson Malaysia Company provide me

experiences which have significantly altered my perception of air conditioning industry.

The following are some beneficial experiences that I gained from working in this

company:-

a) This internship provides me an exposure to air conditioning industry. Through this

program, I had learnt how to design a good quality air conditioning system, select

suitable air conditioner based on requirement, engineering calculation and so forth.

In addition, I have the opportunity to learn the new engineering software such as

Duct Seizer Software and DACCS-PC HKGSG Software, which are the platform to

design the dimension of air duct and calculate the heat load in a conditioned space

respectively.

b) Apply the engineering knowledge which I had acquired back at university in air

conditioning industry. For instance, I applied the thermodynamic and heat transfer

theory in order to understand the principle working of air conditioning system.

c) Working on projects assigned allows me to have better understanding on air

conditioning industry. The mistakes appear when I carried out the project would

serve as the lesson in the future. In addition, this move allows me to listen to ideas

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and opinion of others. Then I would develop new ways to solve the problem faced

independently.

d) This internship is surrounded by network of people from different parts of world.

Therefore, I need to equipped myself with soft skills which I learnt from my

supervisor and experienced colleagues in this company.

e) Working with colleagues from different positions allows me to have an insight on

how to shape my careers towards engineering job in the near future.

3.2. Relevance between Work Experience and Studies

Several courses which I have learnt in university come into practical use during the work

experience. For example:

i. Applied Thermodynamics (KMEM2216) is widely used in this industry.

Knowledge on refrigerant cycle is also useful as it is the most basic

concept that has to clearly understand by each of the employee to

promote the air conditioning system.

ii. Heat Transfer (KMEM3119), is also the basic knowledge used in this

industry especially when studying about the heat exchanger in the air

conditioning.

iii. Engineering Drawing and CAD (KMEM1104) is another useful thing that

I have learnt in university which applicable here. During designing the air

conditioning system used in a building, AutoCAD is used. I have

widened my view on how this software is used in a real working industry.

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iv. Instrumentation and Measurement Technique (KMEM3116) is the

subjects where I learned about sensors and calibration. During the

intership period, when I went to site visit, my mentor asked me to collect

data and performed measurement. This is where the Instrumentation and

Measurement Technique that I learnt come into practical use.

v. There are a few training given by the company are relevant with the

subjects I learnt from university. For example, when they taught about

wiring for air conditioner, there are a few terms that I learnt from Power

Electric and Machine (KMEM3110). The knowledge I learnt from this

subject help me understanding the topic easier.

vi. There is a project given to each of the trainee as the task to be completed

to fulfill the requirement of internship. Thinking and communication skill

course that I have taken during my university life have enhanced my

thinking skill which is useful while doing this project.

vii. In the main assignment, I was asked to perform benchmarking for the

ACSON products with similar competitor products. SWOT analysis was

done for the product. This is another practice that I learnt from Product

Development and Design (KMEM2218)

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CHAPTER 4: CONCLUSION AND RECOMMENDATION

4.1. Conclusion

These ten weeks of internship greatly boost up my engineering knowledge of both

theoretically and practically. I have meet with quite a number of professionals whom

expertise in air conditioning system and experienced the real working life. Other than

that, the projects that have been assigned to me also improve my confidence and soft

skill level.

4.2. Recommendations

I would like to propose several recommendations to Acson Malaysia as following:

i. Trainee should be given more chance to participate in company project so that

they know what are the skills required in a real working environment.

ii. Project given should be relevant to the type company. For example in Acson

Malaysia it is a Sales and Service Company, however the project assigned is

more research based topic. This company does not have R and D department,

which is a barrier to obtain information regarding the project.

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REFERENCE

1. ACCA. 1995. Duct design for residential winter and summer air conditioning and

equipment selection. Manual D, 3rd ed. Air-Conditioning Contractors of America,

Washington, D.C.

2. Yunus A. Cengel, Heat and Mass Transfer: A Practical Approach, 3rd Edition,

McGraw-Hill, Singapore, 2006.

3. OYL Manufacturing Company Sdn Bhd. (2008). Retrieved April 10, 2010, from

http://www.oyl.com.my/OYL/profile.html

4. Acson Malaysia Sales & Service Sdn. Bhd. (2009). Retrieved April 10, 2010, from

http://www.acson.com.my/index.asp

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