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

24

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

25

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)

26

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.

27

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.

28

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.

29

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.

30

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.

31

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

32

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

33