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INDUSTRIAL TRAINING REPORT
INSTITUT KEMAHIRAN BELIA NEGARA TEMERLOH
KAMPUNG BONGSU
28500 LANCHANG
PAHANG DARUL MAKMUR
MUHAMMAD AMZAR BIN MOHD KAMAL
MH 10018
FACULTY OF MECHANICAL ENGINEERING
UNIVERSITI MALAYSIA PAHANG
01 JULY 2013 – 06 SEPTEMBER 2013
ACKNOWLEDGEMENTS
First of all thanks to God who give me strength and health upon finishing this
training. Lots of thanks to both my parent for their support morally and financially, I
love you both. Special thanks for my faculty supervisor, Mr. Idris Bin Mat Sahat for
his guidance upon finishing this final report. Thanks also to my fellow friends who
give support and exchange ideas upon improving my skill and improve my learning.
Thank a lot to Mr. Azmi Bin Saad, Director of Institut Kemahiran Belia Negara
Temerloh (IKBNT) who given opportunity for me to do my industrial training here.
Thank also for CHIP ( Cawangan Hubungan Industri & Promosi ) of IKBNT for
their cooperation during this period of training. My personal thanks to Mr. Mohd
Hizbullah Bin Ibrahim, head of Jabatan Teknologi Kejuruteraan Automotif
Penyelenggaraan for his guidance and cooperation upon me finishing this training.
Thanks a lot for my first industrial supervisor, Mr. Tanoon A/L Eh Boon, who
currently teaching at Institut Latihan Perindustrian Miri, and my second industrial
supervisor, Mr. Ahmad Farhan Hakim Bin Azmi for their cooperation, guidance and
advise during my training. Special thanks to my master teacher there, En. Mohd
Fazdil Bin Sharani, for teaching me and give me new experience. My fellow
colleague there, Mr. Mohd Yusdi Bin Mohd Zaki, Mr. Azizul Bin Anwar and Mr.
Mohd Abd Karim Bin Muhd Nor, I really and humbly thanks for yours cooperation,
ideas, treatment, and support. Last but not least, all the staff of IKBN Temerloh,
thanks for cooperation and guidance upon me while I am in training there.
i
ABSTRACT
This report summarize all the experience and knowledge gain during my industrial
training. My training is conducted in Institut Kemahiran Belia Negara Temerloh. In
this report, I will briefly explain the experience that related to mechanical
engineering and focusing upon automotive technology. This report will contain
company profile, company activity, my activity during industrial training, figures,
conclusion, and lastly recommendations.
ii
TABLE OF CONTENTS
Page
ACKNOWLEDGEMENTS i
ABSTRACT ii
TABLE OF CONTENTS iii
LIST OF FIGURES vi
CHAPTER 1 COMPANY PROFILE
1.1 Introduction 1
1.2 Company Background 2
1.3 Company Organization 4
1.4 Training Schedule 5
CHAPTER 2 COMPANY ACTIVITIES
2.1 Introduction 6
2.2 Relation to Mechanical Engineering 6
2.3 Conclusion 7
CHAPTER 3 STUDENT SELF ACTIVITY
3.1 Introduction 8
3.2 Activities
3.2.1 Teaching 8
3.2.2 Learning 10
3.2.3 Management 11
iii
3.2.4 Module Writing 12
3.2.5 Vehicle Servicing 13
3.3 Weekly Diary
3.3.1 Week 1 14
3.3.2 Week 2 15
3.3.3 Week 3 16
3.3.4 Week 4 17
3.3.5 Week 5 18
3.3.6 Week 6 18
3.3.7 Week 7 19
3.3.8 Week 8 20
3.3.9 Week 9 21
3.3.10 Week 10 22
3.4 Job Analysis 23
CHAPTER 4 CONCLUSION
4.1 Introduction 27
4.2 Conclusion 27
iv
CHAPTER 5 RECOMMENDATIONS
5.1 Introduction 29
5.2 Recommendations
5.2.1 Improve the knowledge of instructor 29
5.2.2 Implies uses of English language 30
5.2.3 Implementation of safety procedure 30
5.2.4 Establish maintenance and asset handling department 31
REFERENCES 32
APPENDICES 33
A Surat Lantikan Program Pemantapan Asas Matematik
IKBN Temerloh
B Modul Program Pemantapan Asas Matematik
IKBN Temerloh
C Senarai pelajar yang ditugaskan
D Kertas Penerangan Pengecas Turbo
E Senarai Aset Bengkel 2
F Minit Mesyuarat Bengkel 2
G Pictures during industrial attachment
v
LIST OF FIGURES
Figures No. Title Page
1 Location map of IKBN Temerloh 3
2 Organizational chart of IKBN Temerloh 4
3 Training schedule for trainee 5
4 Meeting for Program Pemantapan Asas Matematik 9
IKBN Temerloh
5 Briefing for 5S and Safety for new intake student 9
6 Practical class on transmission system 10
7 Petrol Engine Dyno machine checked by worker
from Newera Sdn. Bhd. 11
8 Toyota Corolla KE70 rear brake service 13
9 Jamuan Raya IKBN Temerloh preparation 21
10 Student presentation for diesel injector 22
vi
CHAPTER 1
COMPANY PROFILE
1.1 INTRODUCTION
Institut Kemahiran Belia Negara was a government agency under
Ministry of Youth and Sports. It was introduced in 1964 under the name of
Pusat Latihan Belia. The purpose of IKBN is to provide opportunities for
skills training in various areas for school leavers, provide exposure to
entrepreneurship in the field of skills acquired and lastly to provide leadership
programs, spiritual, and statehood for shaping youth identity.[3]
1.2 COMPANY BACKGROUND
IKBN Temerloh has capacitance of 900 student for seven program
offered. In average 100 students will register on one session. With its
abundance of tools and equipment provided to student, it is suitable for
certificates and diploma student. The proggrames offered here get its
certifications from Malaysian Qualification Agency (MQA) and Jabatan
Pembangunan Kemahiran (JPK). There are two institute involved in
curriculum development for IKBN Temerloh. These institute are, one
Universiti Tun Hussein Onn situated in Johor, and the second one is Georgian
College, Canada.[2]
1
The three main core for courses here were;
1. Foundry Technology
2. Automotive Technology
3. Packaging Technology
IKBN Temerloh is directed by its director Mr. Azmi B Saad. The operational
date started on 1st June 2006 With Mr. Azmi B Saad as its director and helped
by 4 officers. The first student intake was on July 2008 with 240 students in
eight field of expertise.[2]
Its vision is “ To become the best institute in providing skills training for
youth to realize national development requirement.” [2]
The mission of IKBN Temerloh is “ to produce as many youths as possible,
who are skillful, disciplined individuals, patriotic, visionary and honorable in
order to fulfill the labor force requirements parallel with the national
development policy.”[2]
The objectives of IKBN Temerloh were;[2]
• To train school leavers youths with technical skills in Foundry
(Mechanical), Automotive and Packaging fields to fulfill national
industrial demand or to involve in entrepreneur field.
• To produce workforce among youths who are noble, disciplined,
competitive cultured and knowledgeable suitable with their role as
national development agent.
2
The location of IKBN Temerloh is shown on map below.
Figure 1: Location map of IKBN Temerloh
3
1.3 COMPANY ORGANIZATION
Figure 2: Organizational chart of IKBN Temerloh
4
1.4 TRAINING SCHEDULE
Below is the training schedule proposed by Mr. Tanoon A/L Eh Boon.
Figure 3: Training schedule for trainee
5
CHAPTER 2
COMPANY ACTIVITIES
2.1 INTRODUCTION
In this chapter, I will explain IKBN Temerloh activities that relate to
Mechanical Engineering. IKBN Temerloh for me is directly involve in all
field that was core in mechanical engineering. As we know, mechanical is
about mathematics and the study of phenomenon. So in IKBN Temerloh, we
here teach student the application and theory of Mechanical Engineering to
student.
2.2 RELATION TO MECHANICAL ENGINEERING
Learning facilities we can say is the most place that applied the
knowledge of one fields. In example we can see that universities around the
world is teaching all the knowledge required for their student in ones field.
That include IKBN Temerloh.
In IKBN Temerloh, student were offered certificates and diplomas in three
main fields mentioned earlier. Focusing on my training department that is
Jabatan Teknologi Kejuruteraan Automotif (Penyelenggaraan), here we
teach student the maintenance of vehicle part. Here we teach them theory and
give them hands on experience. Interestingly it can give them quick skill.
6
The program offered at my department is Diploma of Engineering
Technology In Automotive (Maintenance) (MQA/FA0834) and second is
Certificate of Engineering Technology In Automotive
(Maintenance)(MQA/FA0435). Upon learning, student were needed to
complete up modules before they graduate. Theses module were core to their
courses.[2]
The learning module were;
• Engineering drawing and CAD
• Automotive Electrical & Electronics
• Machining
• Welding & Thermal Cutting.
• Braking & Steering System
• Comfort System
• Engine Management System
• Industrial Maintenance
• Workshop Management
• Handover Procedure
From the module, most of the title were related for mechanical engineering.
We can see that application of mechanical engineering is directly applied to
them.
Taken one example, Comfort System module. The module will explaining the
driver and passenger comfort, including audio system. The main of this
module were suspension. The suspension is explained in detail and the theory
behind it. The student were also expose newest comfort system to ensure that
they were updated for industry later.
2.3 CONCLUSION
In conclusion, the activities here most related in all mechanical
engineering fields. This include all the learning module offered at the
institute.
7
CHAPTER 3
STUDENT SELF ACTIVITY
3.1 INTRODUCTION
In this chapter, the activities joined during industrial attachment will be
briefly described.
3.2 ACTIVITIES
3.2.1 Teaching
One of the job involved for me is to replace and conduct class if being asked
by instructor of my department. In example on the second week I have been
given task to give briefing on 5S concept applied in IKBN Temerloh.
We can say teaching is the best ways to applied what we had known and learn
what we did not know yet. The best way is to communicate with student.
From there we can learn new things and improve our soft skill. For me is
quite a challenge where we need to make people who did not understand to
understand.
On the third week, i had been appointed to be mentor (tutor) for Program
Pemantapan Asas Matematik IKBN Temerloh (See Appendix A). By this
appointment, I need to finish up nine module on basic mathematics (See
8
Appendix B). from there i have been given 10 student where i need to focus
on.
During my industrial attachment also, i have been helping my master teacher,
Mr. Mohd Fazdil Sharani to conduct his class where he is unavailable due to
meeting. He ask me to kept eye on his student, giving them quizzes and
assignment. I also helped in practical classes.
Figure 4: Meeting for Program Pemantapan Asas Matematik IKBN
Temerloh
Figure 5: Briefing for 5S and Safety for new intake student
9
Figure 6: Practical class on transmission system
3.2.2 Learning
During my stay here, i had involved direct in class conducted
by instructor here whether its theory or class. From this involvement i
had learn a lot application of theory i learned in my faculty and direct
application toward automotive technology here.
In example class on diesel engine. It been taught by my master
teacher, Mr. Mohd Fazdil Sharani. From this class, i have learned
principle of diesel engine. In theory, diesel engine is a compression
ignition (CI) engine. It uses compression of hot air to ignite the fuel
that sprayed to by the injector. The mechanism that control this type
of ignition is called fuel pump and it is connected with the crank-shaft
using timing belt or chain. It is also connected with the cam-shaft.
The device that control the firing order and amount of fuel is called
governor. The governor using mechanical or vacuum to controls its
system or using both.
Here also i learned on how to use Arc Weld by one of my colleague.
He taught me the basic on how to use Arc Weld to weld and its
precautions. He also taught on how to use flame cutter to cut metal.
10
3.2.3 Management
During my stay also, my main job is to involve in Bengkel 2
management. Here i had been given task to complete asset listing.
Asset listing is important because our department had the most
expensive and most teaching aid (See Appendix E). Doing asset
listing let me know what function of certain item. Most of the
teaching aids here were not available in FKM i think. So that lets me
know what item and its function. Apart from that, i need to brief about
asset finding in meeting (See Appendix F). Apart from that I also need
to supervise any maintenance done from appointed contractor.
In overall, engineer is an executive position that need management
skills a lots compare to practical skill. Here i can learn and sharpen
my management skills. In conclusion, this is really a good exposure
and experiences for me.
Figure 7: Petrol Engine Dyno machine checked by worker from
Newera Sdn. Bhd.
11
3.2.4 Module Writing
Another project for me is to write module on Turbochargers and
Superchargers. this module will consist of explanation paper, working paper
and sample question.
My job is to compile and revise the explanation paper. The new compiled and
revised paper will need me to research a lot about turbochargers system. This
include the theory upon it. From my research, turbochargers system consist of
fluid mechanics and heat transfer application for its component.
Turbochargers is one of the initiatives to improve efficiency of the engine. It
reduce the fuel consumption. It is also one of the device that can increase
engine performance. Turbocharging is one of the interesting topic to discuss
about.
From module making, it’s really challenging because, module making need
us to have sufficient knowledge upon the topic. (See Appendix D)
12
3.2.5 Vehicle Servicing
The most doing activities is doing vehicle servicing. That is because
Bengkel 2 is services workshop. Most of the staff here send their car for basic
maintenance such as changing engine oil, changing brake pad, air-
conditioning services and others.
For me, i am directly join when there is vehicle to service. In my workplace,
most of the cars come for quick service that is changing oils, refill air-
conditioners gas and else. There are also some major servicing that
consuming time. Example of it were major servicing of air-conditioning
system, replacing engine gasket and full braking service.
In servicing, the main is to known the problem. From that, we can know,
what parts that causing the problem. In overall, i learn lots in servicing
vehicle major and minor.
Figure 8: Toyota Corolla KE70 rear brake service
13
3.3 WEEKLY DIARY
3.3.1 Week 1
This report is written to conclude all the activities during my
first week during my industry attachment. For my industry
attachment, I had been placed in Institut Kemahiran Belia Negara
Temerloh (IKBNT) which is situated in Lanchang, Temerloh, Pahang.
On 1st July 2013, I had come to report myself to the administration
department of IKBNT. There I had met two others industrial
attachments from UMP. Then we had meeting with the director of
IKBNT. He advised us to gain knowledge and experiences during the
industrial attachment. From there we had been taken by Mr. Zulkifli,
head of industry relationship department to our respective supervisor.
For me I had been placed under Mr. Tanoon A/L Eh Boon. He is the
head of Bengkel 2, which is an automotive maintenance and
technology workshop. This workshop focused on how to do
maintenance and what technology behind vehicle. On 2nd July, I had
a meeting with Mr. Hizbullah, the head of automotive department. He
suggests me to put a study upon my FYP related study topic during
my internship. There he also asks me to be in a good relation with
other staff during my internship. I had been placed under Mr. Tanoon
supervision. That evening, I had meeting with Mr. Tanoon discussing
upon possible project that I will be conducting. The main project is for
me to do some restructure of the workshop layout. That afternoon, I
had been watching an air-conditioner full maintenance of Perodua
Kelisa, and involve during the process. On that day also, I have met
Mr. Saifuddin Airel, to discuss about allowance payment. On 3rd 4th
and 5th of July, I have been given task to supervise upon maintenance
of workshop simulation instrument, which are hydraulic simulation
work bench and pneumatic simulation work bench. On 3rd of July
also, I have been ask to help one of the staff to key-in student marks
as the semester is about to begin. That all report for the first week
activities during my internship program. For the first week I can say
that I have used my knowledge upon industrial engineering subject.
14
3.3.2 Week 2
On 8 July 2013, Monday, I had been given a task to compile
two module. The first module is about Turbochargers and
Superchargers. The second module is about Automotive
Transmission. On that day also we have been scheduled to met
auditors from the Ministry of Youths and Sports. But unfortunately
they did not come on that day. So I continues my study upon modules
that I need to compile. The module need me to explain on how its
work, and the step needed to services the item and also some
questions. Here they called it WIM (Working Instructor Module).
On 9 July, the first semester student had come to our workshop. This
is like their faculty for all their study time. There I had been asked to
supervise student on cleaning the lab. The main job is to swept the
floor and arrange all the ABM (Alat Bantu Mengajar). In the evening,
we had to brief the student upon the system of the workshop. On 10
July, I had been asked to do some lecture upon student on 5S system
implied on IKBNT. I also brief them about the safety precaution on
the lab. Here I had been helped by my colleagues to brief the student.
There I can see their eagerness to learn.
On 10 of July, the auditor from, ministry had come. They asked us to
do some item searching and had been given a week to finish it. At
noon we had meeting on how to tackle this problem. There we had
been asked to do some asset tagging from the files and catalogue
provided to us.
On 11 July, I had been searching for asset under my responsibility.
There I can see the application of Industrial Engineering course. On
12 July, we had another meeting, the main agenda is for us to do some
asset relocation to help us upon facing the same problem again.
15
3.3.3 Week 3
On the third week, the focus on this week is to finish up the
audit on aset. Here me and my colleagues have been given few files
(Kew.Pa) that relate to inventory and aset on this workshop.
We need to do through check upon the aset. The totals amount involve
here is millions, so we have to be really strict upon checking the aset.
On the finding, we notice that several aset is not clearly tagged and its
cause some difficulties to us.
Some of the aset also have not been listed on the catalogue from the
suppliers. This cause some complication due to we need to retagged
the item. On 17 of July, we had meeting with head of workshop. Here
I brief them on what had I done during the period provided. They all
satisfies of what I do upon the aset finding. Here the head of
workshop divide the job, and I had been reassign to focus on
packaged aset. During the meeting I had been also in charge of listing
the minute of the meetings. On 18 July, I continue to do my job as
soon I finished the minutes of meeting report.
On Friday, I do the usual job to finish up the aset until the meeting
upon Mentor-Mentee program. This program is about improving
student skill upon basic meeting. I had been appointed as mentor to 10
students. This program scheduled to start upon week 4 of my stay here
16
3.3.4 Week 4
On the fourth week, our workshop are to expect the arrival of
the auditors from the ministry. On the third week also I have been
conducting my mathematics class.
On Monday ( 22 July), my colleagues and I have to do overtime due
to the trouble upon finding aset. As they are need to teach in the day,
we do the aset finding at the night. In the evening, some student have
asked me to helped them upon their final project. Their final project is
about a cleaning device specialised to do the cleaning of ceiling fan
and blade type window. Their focus is to reduce risk of cleaning
worker as their need to climb up a stair to do their work.
The next day, the auditors from the ministry have come. I had to brief
them upon the aset that are located in the workshop. They are satisfied
with the condition of our workshop aset and all going well. In the
evening, I had done some teaching upon mathematics subject. Here I
found out the student were good in mathematics but they were weak
on English language. As the subject taught in English, they have
difficulties upon understanding the subject and problem statement.
There were some who did really understand the mathematic. And I
have to make them see the mathematic is easy. It is quite a difficult
task and it is a good experiences.
On Wednesday, I continue my tutor upon mathematics, there were ten
student in my class and it is quite manageable. The next day, I helped
one of my colleague to helped him upon teaching diesel engine. The
subject is about the application, theory and how to service main part
of diesel engine.
That all the work that I had been done on the fourth week, as Friday
was public holiday.
17
3.3.5 Week 5
On the fifth week of my industrial attachment. The main job is
to finish up the module that has been assigned. On Monday, I had
done some asset checking for the others workshop.
On Tuesday, I had involved in servicing a Proton Saga BLM upon
changing its brake pad. The brake pad need to be changed as it
already wears. The car gear knob had lot of free play and I have been
taught how to diagnose the problem. It is caused by damaged bushing.
While the engine running, there is a noise at the gearbox section.
Further diagnosis tells that the clutch bearing had been damaged. The
next step is to replace the bearing.
On Wednesday and Thursday, I had been focused to finish upon
module assigned, it really time consuming progress as we need to
have the real thing to complete the module. I and my colleagues wait
for training engine to arrive as we need to open it to make our work
easier.
On Friday, I had fever, and I went to the clinic, doctor there give me
full day leave. The fever is caused by bacterial infection and
dehydration.
3.3.6 Week 6
On this week, we at IKBN Temerloh is on holidays due to
Hari Raya Aidilfitri. Most of the staff here, having leave from 5th to
9th August 2013.
18
3.3.7 Week 7
On week 7, the first day of the week is Monday and I started
my work as usual. There are not so much happen on that day as staff
still on vacation. Furthermore the student is still on holidays. On this
day I continues module development as usual. In the evening I helped
to replace air condition radiator for Nissan Grand Livina 1.6 MT. the
radiator need to be replaced as it is leaking. The leaking is caused by
dent in chassis that caused puncture to the radiator. The cause of the
dent is probably caused by loose rock on road.
On Tuesday, I continues my work upon module development. The
module need several touches and several editing. Furthermore I need
to make the module easy to understand.
On Wednesday, I have done a turbocharger overhaul. I have been
helped by one of the instructor there, En. Jupili, he told me on how to
open and do the overhaul of the turbo charger component.
On Thursday, I joined En. Fazdil classes on how to remove gearbox
from the engine bay. The car model involve in this process is Proton
Iswara 1.3 1999,with automatic transmission.
On Friday, I joined class conducted by En. Fazdil upon servicing
diesel injector. Here I learn on how to remove an injector from the
engine assembly, the precaution upon removing. Then we need to
dissemble the injector. It consist of 7 part. The part need cleaning and
reassemble. After that we need to check the injector. The pressure for
injector to operate is around 10 to 20 bar. If it exceed the specified
pressure, the injector need to be cleaned.
19
3.3.8 Week 8
On Monday, I helped upon changing rear brake assembly of
Toyota Corolla KE70 1970 model. It is an old car. The part that need
replacing is the brake shoes, hydraulic piston. The other work is
involve in engine gasket replacing. The engine involve is Mitsubishi
4G15 engine fitted on Proton Wira. The original gasket, was wear an
caused water to enter cylinder 1 and 2, this caused lost of compression
as the cylinder is considered dead (malfunction) due to no
compression happen. the effect of this problem is lost of power, harsh
noise and vibration due to only two cylinder working.
On Tuesday, all my day were used to marking student mathematics
module. On Wednesday, I had done motorcycle chassis welding that
is helped by Mr. Razi. The problem of the chassis is that shearing
stress occurs at the joining of the plate. That caused the plate to shear.
The cause of the shear is load and vibration due to road conditions.
On Thursday, I helped Mr. Fazdil Bin Sharani conducting class on
removing gearbox from two different system. One is front wheel drive
vehicle, the other is rear wheel drive vehicle. I also learned on
welding techniques using ARC weld from Mr. Razi. On Friday, I had
done some pattern searching to help my colleague upon investment
casting technique.
20
3.3.9 Week 9
On 9th week, there were not so much things happen. the focus
upon this week is to finish up asset listing and doing several
management work. I had continues my role as mentor to guide
student. Upon teaching, i been able to finish up two module. On
Wednesday, I got a call from FKM supervisor say that he will be
coming on next week. Since that call I need to prepare for his visiting.
On Thursday and Friday, I involved in IKBN Temerloh Hari Raya
feast. It is a direct order from the Director for staff to be involved in
preparing meals and delicacies for student and themselves. on these
two days i had learn to make ‘ketupat’ from coconut leaves and
cooking.
Figure 9: Jamuan Raya IKBN Temerloh preparation
21
3.3.10 Week 10
On Monday, FKM supervisors had come to do his evaluation. Before
his evaluation I had to set up the presentation room helped by Mr.
Ahmad Farhan. On Tuesday, my colleague and I done some aset
listing again to ensure we finish our work. We also look up for several
car servicing there. During these last few days, i had been focusing
upon finishing my work to be pass up to my department. On Friday, i
had been asked by Mr. Mohd Fazdil to accompany him to give
opinion upon student presentation. Today, i helped to coach them by
given comment and yet makes them to improve their self-confidence.
Figure 10: Student presentation for diesel injector
22
3.4 JOB ANALYSIS
On 2nd week of my industrial training I have been given task upon
compiling module about turbocharger and automotive transmission. On this
week also, there been scheduled auditors visit from the ministry office. The
audit is mainly focused upon checking the tools and items that been placed
here.
2nd week is mainly about management, there I have been given firsthand
experience of teaching, it is not the same as giving presentation, and the
feeling is completely different.
This week I study the turbocharger system. It is a system to increase the
intake air. Car using turbocharger gain increase in horse power torque and
give better fuel economy. The theories apply to turbocharger system is
mainly fluid dynamicity where we can see application of turbo-machinery.
On 3rd week, all my work is focused upon aset finding and retagging. My
colleague and i need to ensure the asset were there and in good condition. In
theory, asset tagging were important as we need to have record on what we
were dealing with. As engineer, asset management were important because
we have record of what we are spending. Due to the recorded asset, we can
save our spending.
On forth week, the main focus is still on asset tagging as the ministry auditors
supposed to come. In this week, i had to manage time as the due date for the
audit is around the corner. Apart from that, I helped some student to do their
group final project, i helped them to understand the concept of their final
project as they seem to have difficulties. The project that their doing consist
of simple lever system where the load is squeeze between the blade. This is
similar to lever system used in scissor or pliers. Upon mathematics, the topic
that i taught on this first meeting was percentage, the question consist of
simple and basic percentage problem. Lastly, i helped my colleague upon
teaching diesel engine where this class is about servicing diesel engine and it
concept of operation. Diesel engine use Diesel as its fuel. It was invented by
Rudolf Diesel. Diesel engine is a compression ignition engine where fuel are
23
injected to compressed air. This result an explosion in the cylinder that drive
the piston downward. Movement of piston is connected to crankshaft then to
the flywheel and lastly transmission system (applicable to land vehicle).
Application of diesel is vast especially in generating electricity, shipping and
heavy industry or machinery. Diesel engine give higher fuel efficiency
compare to petrol engine. Because of its produce low end torque ( maximum
torque at low engine speed) it is most suitable in hauling heavy object. Newer
diesel engine use turbochargers to improve its efficiency and power. This
result in much ‘greener’ as the fuel consumption is decreased for the same
amount of power needed compare to old technology. The turbocharger also
improve its engine performance in high altitude where the atmospheric
pressure is less.
The main focus of fifth week is to finish up module. On Tuesday, one of the
staff car needed to change the front brake pad, I supervised the process. In
servicing brake system, the first step is to known the problem, the main
problem is less effective braking. The first is to check the brake fluid. If its
decreased, do top up it with the same type of fluid (DOT 3 or DOT 4 or
follow manufacturer recommendations). Next is to check whether there are
leaking or not. If there are leaking replace the leak hose or tighten the nut
involved. After replacing, we needed to remove air that are in the brake line.
This called ‘bleeding’ process. This process can be done manually or used a
bleeder. Upon changing brake pad, the main issue is that there are noise from
the wheel. That is caused by weary brake pad or damaged brake pad. The first
step is to remove the wheel of the car. There we can see brake assembly. Next
is to remove the brake calipers from the disc-brake. The brake pads is
assemble at the brake caliper. Remove it then change a new one. Be ensure to
tighten the bolt and nuts because vibration of the cars can cause it’s to loosen
thus result in malfunction brake system. Malfunction brake system cam cost
life if luck run out.
Apart from that, i noticed that the gear lever have a lot of free play (Manual
Gearbox) . It is caused by weary gear level bushing. The solution of this
problem is to replace the bushing. In addition i have been taught on how to
recognize damaged clutch bearing. Damaged clutch bearing will make some
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knocking noise if clutch pedal were pressed. To change it, gearbox assembly
needed to be completely removed from the engine and engine bay.
On seventh week, i had done some major servicing upon turbo charger unit.
The problem of the turbo unit is that the turbo charger were leaking and kind
of stuck when we need to turn it. So the main cause is that the oil seal were
broken. Broken oil seal can cause exhaust gas to enter the shaft housing.
When this happen, oil will be vaporized due to extreme heat. That cause it to
form a gum like substance. The substance make the turbine shaft harder to
rotate. That cause less efficient turbo unit. As the turbo unit is not directly
connected to the engine system, it will not cause harm to the engine but it will
cost reduce in engine performance. The problem can directly be detected
when there is reduce in performance or leaking from the turbo charging unit
or decrease in engine oil volume.
The turbo charger must be open in these precautions, first do not hammer it
cause it will break the unit. Turbo charger unit is made up of cast iron. It is
hard but brittle. Second is to remember the arrangement of the parts. Any
disarrangement of the part will cause unfit or leaking. The first is to ensure
that we have turbochargers service kit. This kit will consist of oil floating
bearing, oil seal, turbine and shaft. First is to aligned the turbo. This is to
make sure that all the components were in align position. Any misalignment
of the component will cause vibrations and un-balanced turn. Due to high
speed of the turbine when it turn, the turbo charger may explode if it
misaligned. That also will cause the leaking and damaged oil floating bearing.
After removing all the parts consist of the unit, we must ensure to clean the
housing of the turbine and compressor. This to remove any excess engine oil
or soot. Then we replace the part with the turbochargers service kit. After
that, we need to balanced the turbine using special machine. This machine
will balance the rotation of turbine and compressor to avoid any vibration that
can cause harm to the turbocharger unit.
In servicing diesel injector, we need to ensure that the place are clean and
dust free. That is because any tiny dust will cause the injector to malfunction.
That is because there were blockage upon it. The injector are sensitive device
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and crucial part to maintain performance of an diesel engine. Diesel engine is
a compression ignition engine that in theory, need compression of hot air and
sprayed fuel react to form explosion and thus push the piston down. This thus
drive the engine.
An injector need cleaning due to dirty fuel, leaking and less in performance.
Premature explosion that will cause engine knocking also is might be one of
the reason that injector is malfunction. The injector that involve in this class
were taken from Mitsubishi’s diesel engine. The system use in this engine is
direct injection diesel engine. That mean that fuel is injected to the cylinder
when piston is in TDC condition. The firing order is set up by the governor.
After cleaning the injector, we test the injector first. The test is using injector
tester tools. The injector is attached to the tester and fuel is pump. While
pumping the fuel, the gauge is observed to ensure spraying pressure is in
manufacturer specifications range. The common operating pressure for
injector is in 10 to 20 bar range. There are several things that need to be
observed, first is there is leaking at the injector. If there are leaking, the nut
must be tighten to specified tight using torque wrench. Second are the injector
working at specified pressure. If the injectors not working in specified
pressure, let say above, that mean we need to clean it again. And if its lower
than specified that mean injector need to be replaced. And lastly, if the
injector working, if it not working, that mean the injector need to disassemble
and reassemble again. This is due to wrong assembly of injector components.
(Please see Appendix G for more picture)
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CHAPTER 4
CONCLUSION
4.1 INTRODUCTION
This chapter will conclude all the experiences gathered during
industrial attachment.
4.2 CONCLUSION
As conclusion, my training here really makes me realize that I need to
work hard to secure my future. As we know, in this era, we need to strive and
be bold in order to find job.
Knowledge and experience really have effect upon employment in future.
Knowledge upon what happen in present and past do makes differences. In
order to be selected amongst the best, we had to be knowledgeable. Apart
from that, experiences gained proven to be a good teacher to teach us how to
improve ourselves.
Even thought I undergoes training in government sector, but working here
make me realize there is not so much different with private sector as most of
the staff here comes from private sector.
In addition, during my stay, i also learned that having good alliance with
people can make us in ease as the working condition is much pleasant.
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In conclusion, during my training here i had gain lots of experience upon my
field of study. In my training also, i gain lot of knowledge on how to deal
with people as my job scope in future also will involve in dealing with
people. Lastly, i have achieved my main objective upon industrial training
that is to gain knowledge and experience upon automotive engineering. This
is achieved as I get to know lots about basic automotive technology that helps
people moves and drive the world.
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CHAPTER 5
RECOMMENDATIONS
5.1 INTRODUCTION
During my industrial attachment, i found that several things needed to
be improve of. This chapter will story about recommendation i found will be
suitable upon improving IKBN Temerloh in general.
5.2 RECOMMENDATIONS
5.2.1 Improve the knowledge of instructor
During my training there, i noticed that most of the staff there
did not used all the teachings aids provided. That is because there is
no one know how to use it. This result in waste of money as most of
the teachings aids cost tens of thousands. The solutions of which can
be used is to provide training course. To save the cost of the training,
we should do the training in the IKBN only and hire someone from
the suppliers to train them. This thus involved the contributions of the
suppliers to provide enough training.
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5.2.2 Implies uses of English language
One of the issue for the students here is that they were not
really well in usage of English. The cause of its they were afraid of
being laughed at when they speaks English. One of the proposed
solution is to implies the used of English in the teaching. It is hard,
but try it for one day per week. This will boost their confident level.
Another one is to conduct an English camp for them. This will help
them upon improving English usage. Maybe the second one is a bit
costly, but in term of quality and increase in student values, it is
reasonable.
5.2.3 Implementation of safety procedure
The conducted safety procedure were not strict enough here.
We can say that improving the safety procedure is really in need. First
of all is to avoid liability needed to be incurred. The second one is to
reduce risk upon worker and mostly student. We can see student
hangs around the workshop without consideration upon their safety.
To minimize the risk, student should be told and clearly advise not to
hang out around the car model or play with the teaching aids without
supervision. They should sit and hang around allocated area that will
be labeled with signage. Lastly signage reminding them that some part
is prohibited area without presence of instructor. These were my
recommendations:
1. Signage showing on what type of injuries could occurs.
2. Student were not allowed to be in working area without
supervision.
3. Student were required to tidy up their working place to
avoid sharp item of hazardous materials laying around.
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5.2.4 Establish maintenance and asset handling department
For overall in huge facility asset management department is
needed. That will including IKBN Temerloh also. That is because,
most of the asset were not checked or maintained periodically. From
my observation, the asset and teachings aid, were not periodically
checked. Its only be maintained by supplier if there were report of
malfunction machines. That will cost spending as repairing an item
will cost times and money. This will increase IKBN Temerloh
spending due to repairing cost. In conclusion, maintenance and asset
department is needed to reduce cost upon repairing. The spending of
the department might be costly for the first six month due to tools and
department set up, but in long term, it can cut cost up to 30% in long
term.
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REFERENCES
[1] Industrial Training Format July-September, 2013, Faculty of Mechanical
Engineering, Universiti Malaysia Pahang
[2] IKBN Temerloh ’s Website Main Page, retrieved on 1st September 2013 from
www.ikbnt.gov.my
[3] Ministry of Youth and Sports Main Portal, retrieved on 30th August 2013
from www.kbs.gov.my
[4] Toyota Corolla, Wikipedia, retrieved on 13th September 2013 from
en.wikipedia.org/wiki/Toyota_Corolla
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APPENDICES
A Surat Lantikan Program Pemantapan Asas Matematik
IKBN Temerloh
B Modul Program Pemantapan Asas Matematik
IKBN Temerloh
C Senarai pelajar yang ditugaskan
D Kertas Penerangan Pengecas Turbo
E Senarai Aset Bengkel 2
F Minit Mesyuarat Bengkel 2
G Pictures during industrial attachment
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