OUALI Victor

2nd year – Group

Student’s Supervisor : Mr Fadi SULAIMAN

Host firm’s adress :

DELPHI DIESEL SYSTEMS

Courteney Road Hoat Way

GILLINGHAM KENT ME 8 ORU – UNITED-KINGDOM

Sciences and Technics for Engineer

FIRST YEAR WORK EXPERIENCE REPORT

A first professional experience in United-Kingdom

From 18/06/2012 to 13/07/2012

A FIRST PROFESSIONAL

EXPERIENCE IN UNITED-KINGDOM

Student training conducted from June 18th to July 13th 2012 in Delphi Diesel Systems Ltd, under the responsibility of Mr Fadi Sulaiman.

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THANKS

First, I would like to thank Delphi Diesel Systems who welcomed me during four weeks on its premises and helped me to understand most of the aspects of the industry world.

A great thank to Mr Fadi Sulaiman and all the engineers of the validation team in the engineering department for their availability, their forbearance and their interest in my studies. I also want to thank them for all the knowledge that I acquiered about engineers work, and professional skills requiered by engineer profession.

I also want to thank the Human Resources department which helped me with all the administrative formalities and procedures necessary to my good integration in the enterprise.

Then, I would like to say thank you to all the people who made my work placement such a pleasant stay, to the trainees of various nationalities and the English staff with whom I exchanged a lot and shared good moments.

Finally, I thank my school manager and every workers from the training offce that made that whole experience possible.

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SUMMARY

THANKS.......................................................................................................................... PAGE 2

INTRODUCTION............................................................................................................ PAGE 4

COMPANY PRESENTATION......................................................................................... PAGE 5

PERSONAL OBJECTIVES............................................................................................. PAGE 8

INTERVIEW.................................................................................................................. PAGE 15

CONCLUSION.............................................................................................................. PAGE 17

DOCUMENTATION...................................................................................................... PAGE 24

BACK COVER AND KEYWORDS............................................................................... PAGE 26

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INTRODUCTION

As part of my frst year of studying at the INSA, I had the opportunity to immerse myself in the world of work for four weeks. Since I chose the International section in my engineering school, I wanted an internship focused on an abroad engineering formation, to guide me in my future international career choices.

Going in England to acquire experience in a global industrial company was my main purpose but it has not been the only important aspect of my journey. discovering the world of work and the interactions between people who come from many different countries has also been an important aspect of that training. This also was what motivated me to have this abroad experience in the frst place.

I heard about Delphi Diesel Systems Ltd in United-Kingdom through my father who currently work as engineer for them. I decided to try and contact one of the team for an internship and sent my cover letter and my CV to Mr Sulaiman. My application was accepted and I integrated the Validation Team of the Gillingham Delphi site on the 18th of June, 2012.

Under the direction of Mr Fadi Sulaiman, manager of the validation team, I worked at Delphi for four weeks. I discovered many technical aspects on the fuel injection pumps, and many things about the automobile industry in general. I also met a lot of engineers during my training. They literally are from all over the world, and it was fascinating taking with them about different topics such as studies, the world of work, the world economic situation and much more.

What motivated me in this internship was having a glimpse of the world of work in a global company, seeing and meeting engineers in their different work environments. Doing technical tasks as well as challenging my english talking skills has been fundamental and gratifying to me. That was also the occasion to learn more about English way of life and United-kingdom economy. It all was very interesting considering that I plan to go back in UK in few years for an abroad semester or for my PFE.

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COMPANY PRESENTATION

PRESENTATION AND HISTORICAL

Delphi Diesel Systems Ltd (D.D.S) is a limited and private company division of Delphi Automotive Systems Ltd (D.A.S), which is a worldwide vehicle components manufacturer. It provides electrical and electronic, powertrain, safety and thermal technology solutions to the global automotive and commercial vehicle markets. The global company operates through four segments:

1. Electrical / Electronic Architecture

2. Powertrain Systems

3. Electronics and Safety

4. Thermal Systems

The D.D.S history is linked with the history of D.A.S, which activities are very diverse and varied across the world. My training took place in the Gillingham site which has a complex history, due to many merge between different companies.

Gillingham site was founded by C.A.V Ltd in 1970. CAV Ltd produced diesel fuel injection equipment for diesel engine manufacturers worldwide and electrical equipment for commercial and military vehicles.

In 1974 the company's name became Lucas C.A.V. In 1979 the site became property of Lucas Diesel Systems Ltd. Lucas Diesel Systems Ltd came from Lucas Industries Plc (Public limited company) which was a famous British manufacturer of components for the motor and aerospace industry. In 2000 the site has been acquiered by Delphi Automotive Systems Ltd, a USA based automotive parts and systems manufacturer. The name was changed to Delphi Diesel Systems Ltd and the business became a major part of the Delphi Powertrain Systems division.

REGISTERED OFFICE ADDRESS (EUROPE)

Delphi Powertrain Systems

Customer Technology Centre

Avenue de Luxembourg

L-4940 Bascharage

Grand Duchy Luxembourg

TRAINING ADDRESS

Delphi Diesel Systems

Courteney Road Hoat Way

Gillingham, Kent ME 8 ORU – United-Kingdom

Tel: +44 (0)1634 234 422 / Fax: +44 (0)1634 374 725

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DELPHI AUTOMOTIVE SYSTEMS OVERVIEW

Delphi Automotive Systems Ltd is one of the world leaders supplier of electronics and technologies for automotive, commercial vehicle and other market segments. It operates major technical centres, manufacturing sites and customer support facilities in thirty countries. Delphi delivers real-world innovations that make products smarter and safer as well as more powerful and effcient. The company is employing more than 101 000 employees in 30 countries.

DELPHI AUTOMOTIVE SYSTEMS STRUCTURE

1. Consumer Products

2. Manufacturer Products

3. Aftermarket & Dealer Products

ORGANIZATION OF PRODUCT LINES

1. Controls & Security (Body Security, Mechatronics, and Displays)

2. Electrical/Electronic Architecture (Electrical/Electronic Distribution Systems, Connection Systems, and Electrical Centers)

3. Entertainment & Communications (Audio, Navigation, and Telematics)

4. Powertrain (Diesel and Gasoline Engine Management Systems)

5. Safety (Occupant Protection and Safety Electronics)

6. Thermal (Climate Control & Powertrain Cooling)

DELPHI DIESEL SYSTEMS ACTIVITIES

Delphi Diesel Systems, Ltd which correspond to the Powertrain segment of D.A.S provides systems integration of full end-to-end Gasoline and Diesel engine management systems including Fuel Injection Systems, Ignition Systems, Air and Fuel Management, Electronics, Sensors and Actuators, Valve Train Systems, Fuel Handling Systems, Evaporative Emissions Systems and Transmission Management Systems.

The company supplies diesel components and systems and provides rail kits, actuator kits, diagnostic tools, electronic unit injector, electronic unit pump, diesel flters, nozzles and

injectors, rotary pumps and parts. The company also offers servicing packages for diesel fuel injection systems ftted to cars, light commercial vans, trucks, and tractors, as well as other agricultural, industrial, and marine applications. The main competitors of Delphi are Bosh, Continental, Denso and Stanadyne.

On the Gillingham site where I was located, manufacturing facility are specialized in rotary direct injection pumps and common rail systems. It employs over a 1000 workers.

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DELPHI MARKET OVERVIEW

➢ Market Segments by engine size

Small Engine Applications (10 – 60 Horse power)

Pass Car LD Commercial (50 – 350 Hp) *

US Light Truck (80 – 250 Hp) *

Medium Duty On and Off Highway (40 – 350 Hp) *

Heavy Duty Segment (215 – 600 Hp)

* Type of pumps manufactured by Delphi Diesel Systems

CUSTOMERS

Delphi Diesel Systems customers are worldwide automakers such as PSA Peugeot, Citroën, Caterpillar, VW, Hyundaï, or Toyota.

DELPHI BUSINESS LOCATION ON A GLOBAL SCALE

(see annexes 1 & 2)

England – Gillingham, Kent / Park Royal, London / Sudbury, Suffolk / Stonehouse, Gloucestershire.

Romania – Iasi. Turkey – Izmir. Singapore.

Korea – Seoul, Changwon and Busan.

Mexico – Saltillo. China – Shangaï.

Spain – Sant Cugat and Barcelona.

France – Blois and La Rochelle.

India – Mannure and Chennai.

United States – Michigan.

Brazil – São Paulo.

CERTIFICATIONS

In 2009, Delphi was awarded the Carbon Trust Standard to reward the signifcant actions taken by the company's operations in UK to reduce its total carbon footprint. The Carbon Trust Standard is a UK Government certifcation that acknowledge achievements in carbon management and reduction. Delphi was the frst automotive company to obtain this standard.

Delphi UK has earned the TS 16949 quality certifcation and the ISO14001 environmental certifcation.

As far as Calibration is concerned: The UKAS: U-K Accreditation Service approved test houses to undertake calibration to their declared accuracies traced back to the True Value.

EXTERNAL COMMUNICATION

Regarding external communication, Delphi has its own website that you can visit at this address:

HTTP://www.delphi.com/

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PERSONAL OBJECTIVES

INTRODUCTION TO DELPHI

When I arrived at the Delphi Diesel Systems site of Gillingham on June 18th, I was greeted by Mrs Koshy Litty and Mr Sathish Panguluru, engineers from the Validation Team, since my manager Fadi Sulaiman was not present that day.

First, they showed me every security aspects that I needed to respect and to remember in order to have a good training in their premises. They also gave me my personal protective equipment that I had to wear in the Technical Centre and in the Prototype Factory and every risky areas. It featured security shoes, protection glasses and blouses. Ear protections were given to me later in order to work in very noisy areas.

After this short yet necessary introduction, they showed me my desk in the big open-space where Validation Team operates. After this short moment, Mr Panguluru showed me pumps parts I had to be familiar with. Understanding the pump structure and design as well as knowing the different parts was my frst task as trainee. Without it I could not be able to do anything.

Then he explained to me what the activities of the Gillingham site were and gave me my frst opportunity to meet workers and discover a frst validation pump aspect in the Prototype Factory; place where I spent a lot of time during my frst two weeks of training in D.D.S.

DFP3.X PRODUCTS OVERVIEW

Pumps can have one, two or three hydraulic heads. Everything depends on the customer's requirements and the CO2 emission standard implementation.

The DFP3.X is a project number. There are different pump models within a project. All the pumps of a project share almost the same specifcations. Adaptations and variation within a project are made according to client requirements.

I choose to describe you pumps from the DFP3.X project frst because studying them through many tests and documents was one of the main task of my training. But also because the understanding of pumps and their components was the frst thing I had to do before any other operation. It actually was the most important thing to learn before I could do any other work on validation.

➢ Common DFP3 Components

External View (see Annex 3) / Internal View (see annex 4)

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THE PROTOTYPE FACTORY

I've been shown the Prototype Factory by Mr Angus Andi. This factory area is used to manufacture parts of pumps which are still in development. This is only for prototype pumps: these parts are made for Validation tests within the Validation Process, and constitute an important stage just after the “PLAN & DESIGN” process, which is part of the general DPDP (Delphi Product Development Process) which I am going to explain brieMy:

A Customer request implies the starting of the Delphi Product Development Process (DPDP); This Process is organized in four stages:

1. PLAN & DESIGN

2. DESIGN VALIDATION

3. PROCESS VALIDATION

4. PRODUCTION & CONTINUOUS IMPROVEMENT

DPDP organization implies a lot of different meetings and reviews between Production, Design and Validation teams too. But I am not allowed to explain exactly what are they, due to the Confdential Agreement signed to protect the Delphi Diesel Systems business integrity.

The Prototype Factory is organized into four distinct areas:

1. An area holding the machines which product development pumps parts.

2. A sterile and air conditioned room named “Clean Room” containing all the measuring instruments needed to validate the parts produced, but also everything that workers need in order to assemble the prototype pumps. This is where I often worked and observed during my frst two weeks.

3. An area used for the cleaning of parts produced by machines in the frst area. It consists of two different kind of specifc bins (aluminium and iron) used depending on the material of the parts undergoing the cleaning are made of. Two other specifc bins are used for development parts too (stage before the development of a complete prototype).

4. A metrology area, which is used to calibrate every measuring instrument.

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MY MISSIONS IN THE PROTOTYPE FACTORY

I did and saw a lot of different tasks in the Prototype Factory. I also met workers who were very patient and proud to explain to me what their daily work consisted in. Here is what I did with them in the Prototype Factory:

1. I assembled core components such as drive shaft and hydraulic head components (tappet, plunger and tappet spring) into the housing.

2. I assembled the front plate with the housing.

3. I assembled pump hydraulic heads.

All those task took place in the Clean Room. It was a prerogative thing for everyone who wanted to go into the “Clean Room” to wear a special equipment. In order to respect this rule, the Clean Room had a lock-chamber, where workers had to wear a complete equipment, which consisted in surgical gloves, blouse, hair protection and sole protections. Once properly equipped people were allowed into the room, to effectuate their daily mission.

➢ The front plate assembling process

1. Implementation of the drive shaft and the rider within the housing.

2. Implementation of joints (greased beforehand)

3. Implementation of the front plate

4. Screw tightening of the front plate

➢ The hydraulic pump assembling heads process

1. Implementation of the frst head components (tappet, plunger, tapper spring)

2. Screw tightening of the frst head

3. Measuring the clamping force and the angle

4. Implementation of the second head components (tappet, plunger, tapper spring)

5. Screw tightening of the frst head

6. Measuring the clamping force and the angle

Tools enable us to maintain the pumps isostatically on a metal work surface while workers perform various operations. Every tightening and measures were made by the Technician with an electronic machine. This machine was calibrated with standard values, linked with the four stapes. For each step a program was established on the machine. Technicians had to selected each program before each step. An excel fle was used to input all the measures. This fle is the most important fle produced in the Clean Room: it is done to help the production traceability. It lists every different pumps according to their serial number and associated measures. The fle enables the monitoring of the quality of calibration and metrology of manufactured parts.

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➢ Noteworthy elements in the Prototype Factory

◦ Ramish who mounts pumps in the Clean Room, has been working for Delphi since he was

18, which means he worked for 35 years at Delphi! He said to me that this work is tiring and repetitive due to pumps which are unwieldy. Fortunately tools helps them in their daily work.

◦ All new engineers had to come and see his work to understand and appreciate problems

of design and construction.

◦ To validate the prototype of the housing produced by the Prototype Factory, workers need

to validate over 500 measures that must match the design plan! Weight, appearance, diameter, surface condition, temperature and pressure are some of the tested criteria.

THE VALIDATION PROCESS

* Validation Package Approval

The Design Failure Mode Effect Analysis (DFMEA) is a prerogative document in the Validation Process. It contains everything about what, why and how the pump systems could fail. It lists everything that could happen (in terms of failure) to the pump: it is a "prediction" built by the Design Team.

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Collect CustomerRequirements

Plan & Design Tests

Order Prototype & Assemble Pumps

Characterise Pump Pre-test &Raise Test Requests

Endurance Test Post Test Pump Characterisation Pump Strip down Documents *

Validation PlanningReview DFMEA

Concern ManagementProcessEndurance Test

SchedulingFail Concern

From the Design to the Production, there are four stapes of Validation divided in four levels on four different samples (A, B, C and D).

◦ A & B in the Prototype Validation (frst test and running tests)

◦ C in the Factory (to start the Production Process at a huge scale)

◦ D Production (following of the Production)

THE INDUCTION PROGRAM

In addition to my work as a trainee, I had to follow an induction program. This program was offered to all newcomers in the frm. It allows each new worker to discover the functioning and the organization of the workplace through the visit of the different sites and information meetings about administrative operation, safety and calibration.

➢ My Induction Program

◦ Week 1

• Monday, 25 th JUNE 2012

➔ 8h30 – 11h00 / Corporate Induction

➔ 13h00 – 14h00 / Company Introduction

• Tuesday, 26 th JUNE 2012

➔ 09h30 – 10h30 / Technical Centre Tour

• Wednesday, 27 th JUNE 2012

➔ 09h00 – 10h00 / Manufacturing Tour

➔ 14h00 – 15h00 / Meeting with department administrator

• Friday, 29 th JUNE 2012

➔ 10h30 – 11h30 / Communications Meeting

◦ Week 2

• Wednesday, 4 th JULY 2012

➔ 14h00 – 15h00 / Quality and PDP Process

• Thursday, 5 th JULY 2012

➔ 09h00 – 10h00 / Finance

➔ 13h00 – 13h30 / Calibration

I discovered The Technical Centre during my frst week of induction. I was shown the Centre with other new workers and trainees. Even though duration of our contracts and our situation in the frm were very different. It was very interesting for me to notice that every people starting work for Delphi Diesel Systems were treated equally during the induction program.

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THE TECHNICAL CENTRE

I spent my time in the Technical Centre with Lee, a technician, who taught me numerous things about pumps tests. He is an expert about the Hartridge test rigs. He showed me the most needed tests in order to validate pumps from the A sample.

After machining and assembly in the Prototype Factory, each pump is tested in the Technical Centre before being dispatched to the customer. The frst test to be carried out after assembly is a bubble test. It involves passing air at 2 bar though the pump whilst immersed in an oil bath. The test ensures that all seals are tight and there are no leaks from the housing and connectors. Should there be a leak, the pump would be sent back to assembly (Clean Room in the Prototype Factory) to fx the problem. I did not do this test myself but a worker from the Technical Centre showed it to me.

On completion of the bubble test, the pump is mounted on a Hartridge test rig to be run through a range of operating conditions. The Hartridge rig provides a rotary drive and fuel supply to the pump, with inlet conditions being set by the operator. I shadowed Lee who was in charge of those operations.

➢ The Inlet Metering Valve Test (IMV Test)

We start the rig test with a mounted pump. Once the pump reaches 800 RPM and 370 bar, we stop it and monitor the rail pressure during 3 minutes time. Within that duration the rail pressure must stay above 160 bars. If it goes below the test fails.

➢ The Pump Test (with the IMV off)

There are two possibilities for the drive shaft rotation: Clockwise and Anti-Clockwise (it depends on the customer's requests). For this test, we make the pump pressure vary from 0 to 2000 bar and the drive shaft rotation from 0 to 4000 RPM. We start the rotation on slow speed. We then pick up the pace and make both characteristics vary. We fnally check the Fuel Delivery using 7 couple values randomly picked from the readings.

During all the test, datas are kept and analysed by computers. Computers are connected to captors placed into the rig test and the pump.

We need to wait and to monitor the test program from the beginning to the end and to insure that everything is working well. This kind of test is long to organize because we have to wait for the good room temperature to start it.

As a consequence, the Technical Centre has 4 rooms test in order to realize these tests and some more. In each room contains six test rigs, each of them is monitored by a technician. Then, if all goes well, there must be 32 test programs running at the same time in this Technical Centre part.

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➢ The mapping pumps process

From all the tasks that I had to do in the Technical Centre this process was one of my favourite! To realize it, we need to dismount pumps from test rigs after all those long tests, and we need to recover and clean each parts of the pump. Then we take pictures of the surfaces and parts which could have some problems. This test is made to ensure that parts of the pump did not sustain any damage during endurance tests.

It takes place in a Clean Room at 19°C in the Technical Centre. The room has 3 tool boxes, 2 metal tables, 1 computer and a light table. This equipment helps technicians to take pictures for the different pump mapping works that they have to do:

◦ Selection of the metal plate in which the pump could be engaged. The pump is sighting to

the plate. Then the plate is sighting to a metallic arm which is situated under the metal tables. The plate keeps the pump immobile during the dismounting operation due to the arm which can't move.

◦ Dismounting of the pump with appropriate tools. We need to pay attention not to damage

the pump during this operation.

◦ We put aside small parts which could easily be lost.

◦ Once the whole pump is disassembled it is often dirty due to full engine oil. That's why

we need to clean it. To do it, we put all pump parts on a metallic cleaning table outside the Clean Room. We take an aerosol of LPS, an electrical contact cleaner ultra degreaser, and spray it on pump parts.

◦ After this frst step we need to quickly dry the parts. For this we use the compressed-air

pistol which is next to the cleaning table. We need to be careful not to send the small parts Mying away. We also have to pay attention to the risk of the fuel projections on face or body parts.

◦ When the cleaning and the drying is done we need to classify the parts. For that we gather

the parts of pumps that go together. For example, all hydraulic head parts are gathered together.

◦ We fnish the mapping operation in the Technical Centre, taking pictures of each

important part of the surfaces on the light table.

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INTERVIEW

The interview was for me the occasion to learn more about my manager and Delphi Diesel Systems organization, but also about engineers goals in Validation Team and more basically, about engineers' work. I decided to ask my questions to Mr Sulaiman not only because he was the manager of my training but also because he was in charge of the organization and running of the Validation Team of the Gillingham site. I learnt a lot of things during and after this moment that's why I would like to thank him once again.

INTERVIEW OF MR SULAIMAN

1. What and where did you study?

I studied Aerospace at the University of London. Indeed, I was fond of Automotive and Mechanical Systems, but my teacher said to me that Automotive was dying in UK. He advised me to go in the Aerospacial department, because Aerospacial industry was growing at that time. So because I was really certain of what I wanted, I studied Aerospace in order to have a job in Automotive industry (80% of engineers who work in Aerospacial frm are Mechanical engineers). And that is what happened. I made my teacher wrong, and I realized my professional wishes!

2. Which work experience did you have since you are graduate from London University?

I had a job in Ford during 4 years and half, and after this work experience, I moved to Delphi Diesel Systems in 2006.

3. What are your missions and responsibilities in Delphi Diesel Systems?

I have two goals: First provide robust pumps. Second give the most warranty that our pumps will not fail to the main customers.

4. Which qualities do you think an engineer needs?

To my mind, an engineer needs to be: CONFIDENT DYNAMIC COMMUNICANT ORGANIZED and he needs to UNDERSTAND PHYSIC and be FLEXIBLE

5. In these qualities that you require, which gave you dif3culties?

To be organized and Mexible all the time is really diffcult, because it depends of periods. When there is a lot of things to do, to plan and to execute, sometimes, these two aspects of my work are more diffcult to consider.

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6. What do you think about the capacity to communicate that each engineer need to have in work?

It is one of the most important qualities! It is used all the time. For example the meetings: you are sitting with different people to explain projects, or what is wrong or good, which goals, what we need to change, or to improve etc. And communication is also UP and DOWN: it is the same if you need to talk with people in production or to your chief engineer: you need to speak clearly, with no doubts and seriously. And don't forget that any worker deserve respect, whatever their degree of responsibility.

7. Which languages do you speak?

I speak ENGLISH and ARABIC Muently, and I have some basics in GERMAN and FRENCH language.

8. How many times a month do you travel?

I travel one time a month, sometimes more, and often in France, Romania and Spain, in our production and development sites. Sometimes in customers' head offce too.

9. Why in customers' head of3ce?

The communication with customers, the “interface” is made by the Technical Project Lead (T.P.L). But it happens that they need me to explain topics about Validation to customers. I also have meetings with them about processes, robustness of products, new products, and I always have to insure that everybody understand goals and missions and that everything is working in the good way.

10. What do you think about the current Automotive industry in UK?

This industry is dying in UK: but globally it is never gonna be dead. In Europe, the problem is that we need to stay competitive against China, USA, Asia (India) and South America (Brazil). Once we do not know how to surpass them anymore the automotive industry in Europe will be ended.

11. And what about oil reserves which are not unlimited?

About this aspect: we need to develop other concepts, other technical issues, like electrical batteries, but this solution is not the perfect solution. For me, in 20 years, the Automotive will die, and it will be due to the high cost of development processes as well as the high cost of raw materials, due to their increasing demand and rarefaction.

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CONCLUSION

ASTONISHMENT REPORT

This work experience was a very rewarding moment for me. I discovered many world work aspects that I did not suspected before.

First, I was surprise by the diversity of workers in Delphi Diesel Systems. My frst day gave me an impression that I could defne as an anthill. There were so many workers from many different countries! It was perfect for me because it gave me a lot of possibilities during my training to talk with other people and to learn more about the many skills that I did not know. Every day I met different persons and thanks to that I discovered little parts of a D.D.S side. I also had some exchanges about English way of life and its social codes, but also about other countries. It really did confrm me that engineers need to be communicant, open-minded and sometimes patient with their work environment.

The language barrier was a bit of a challenge to me, particularly during the two frst weeks. I was incredibly surprise by my capacity to understand things. The frst times I talked with people I often ended up lost. Everything was going very fast, and I was seriously obliged to be focused on everything. By the end of days, I was exhausted, but not only because I was discovering the world of work, but also because I needed to talk in English all the time. But in the end I am very proud I did it. Obviously because my English level has improved a lot but also because I was alone in a foreign country. Which meant changing habits about food, drink, timetable or weather!

About technical skills the language barrier got in the way once again. I had to learn all the vocabulary and technical aspects of my observation and task very quickly. It was a true challenge for me and I am very happy I have been supported by the Validation Team engineers. Even though they were sometimes very busy, they were always here for me when I was asking something about my mission or needed their help to understand a special tests aspect.

Validation work was supposed to be my principal mission. But I did not know beforehand in what it consisted. So when I realized how far Validation work was from my expectation when I came to Gillingham I was pleasantly surprised. Indeed, I believed that Validation work was a work in which I was supposed to do always the same tasks. But it actually was a very rich and varied work. And I know exactly now why I was believing something like that. I did not know how pumps and rotary systems were made and what were customer requests. After one month of training in Validation, I can not do the same mistake: this work is incredibly precise and is a fundamental in car making process. It necessitates a huge knowledge and expertise by real tests and essays. This is the most diffcult work that I ever seen before. Validation team has to be effcient every days to respect D.D.S business plans and customer requests on quality. And I still feel humble in front of this kind of technological and human success.

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CONNECTION WITH MY PROFESSIONAL PROJECT

This work experience was an amazing and impressive moment for me. It gave me most things that I was expecting such as: knowledges about engineering world work, integration in a worldwide company and an immersion in a foreign culture that led to an improvement of my English level. But more than that: I still was hesitating between different engineering department school. This dilemma that would condition the rest of my studies was bugging me before I came to my training. But thanks to knowledge and experiences acquired during my training period, I realized that my problem was not so much about this choice in itself, but more about what I really want to do later. In which feld do I want to evolve professionally.

And I thought about it. I am very interested in chemical skills since I am young. And basically, I was coming to INSA school in order to go to Civil engineering course. These two points have been a motivation for a long time and they still are fundamental in my reMexion about professional orientation. I know exactly what I do not want to do. For the rest, I prefer to have the choice, to stay open-minded about any possibilities. This training also helped with two other points. First to remember that I need to fnd a department school connected with one of the two motors identifed above. Then that I need to be more Mexible, and more open-minded about professional possibilities or department. And I think that it is the best to remember about this experience.

One could think about why I did not defnitely settled for “Civil” department. The thing is that after this immersion in the professional world of work I am pondering. It would be easier for me if I was not so curious. I am more motivated than ever, and very impatient to give my best to win the right to become engineer and to keep traveling around the world. Discovering the “Materials” section of Delphi Diesel Systems reminded me how I still am crazy about chemistry or materials skills. That's why I currently just can not say what department I will choose between “Civil” and “Materials and Nanotechnology”. I am looking forward to the informations that will com from the pre-specialization course that I'll choose. So I know exactly what I am supposed to do to be successful. I know it is going to be diffcult but I know where I stand and I could not be more motivated. I am very close to doing the most important choice of my studies. And I am ready to take responsibility for this choice. Responsibility also is a value that I developed during this training.

Foreign experience truly changed me: I have seen and experienced a new way of life, new points of view. Those elements helped me to be more open-minded. This whole experience made me grateful and humble. After one year of preparation and expectations about the “student training period” it was defnitely matching my expectations. This training gave me inspiration and a confdence that I did not suspect to have. These qualities and sentiments are very important to me to live up to my professional and personal goals in life. They represent the motivation and energy that I need to have if I really want to be successful.

Finally the last important thing that I have to remember about this professional immersion is to fully take in my work environment materially and humanly. Almost every engineers that I met said it to me. Before I came to Delphi Diesel Systems, I did not have a precise idea of what an ideal workplace should be. I also learnt what my limits were and stay open for solutions to overcome them. Though technical place is mostly interesting I think management position is far more challenging and motivational to me. I hope I can pursue that goal after my engineering grade. Yet I am still at the beginning of my studies and I know that in the coming years I will evolve and get a more relevant and accurate point of view on my professional project.

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PROFESSIONAL OBJECTIVE

After two-years intensive engineering program, I will look for « Civil » or « Materials and Nanotechnology » department integration. It is why in short term I want to have some experiences in these different industries.

HIGHER EDUCATION AND DIPLOMAS

(2012-2013) Second student year in the International Stream of the National Institute of Applied Science (INSA) of Rennes (35)

(2008-2011) Student in the Camille Claudel's Secondary School of Blois (41)

(2004-2008) Student in the Joseph Crocheton's Middle School of Onzain (41)

DIPLOMAS

French Diplomas English equivalence

(Juin 2011)

Baccalauréat Scientifique, option Physique-Chimie, Mention

BIEN à Blois (41)

(Actuellement)

Prépare le Diplôme d'Ingénieur INSA

(June 2011)

Scientific British A-levels, with a Physic and Chemical

Specialization, in Blois (41) (with honors)

(Currently)

In preparation for the INSA Engineering Degree

WORK EXPERIENCE

• English Internship (from 18/06/2012 to 13/07/2012)

Currently my most meaningful Work and Life experience in Delphi Diesel Systems (Courteney Road Hoat Way, GILLINGHAM KENT ME 8 ORU - UNITED-KINGDOM) in pumps validation engineering team supervised by

Mr Fadi SULAIMAN (fadi.sulaiman@delphi.com)

• Summer Job (from 26/07/2012 to 13/08/2011)

Served as Commercial Assistant within a French Agency Bank of Credit Agricole (11 rue de la Justice, 41150 ONZAIN - FRANCE) Features : home offce, data entry, telephone, archiving.

SPECIAL SKILLS

Informatic Skills

Patentee Computers and the Internet. Regular LibreOffce, Word, Excel, Power Point and Internet. Scheme and Java programming (beginner). CATIA – Dassault Systems (Computer Aided Three dimensional Interactive

Application)

Spoken Language

FRENCH (mother tongue) - ENGLISH (Auent) - SPANISH (Auent) - JAPANESE (basic)

MISCELLANEOUS

Regularly practices jogging cycling and pool. Was part of an athletics club for 8 years. Practiced dance Hip-hop for 2 years. Followed the teachings of music theory and violin in a music school for 9 years.

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CV MR OUALI VICTOR

Résidence Les Glenan, Studio 25

20 avenue des Buttes de Coësmes

CS 70839

35708 RENNES cedex

Tél : +330647731915

E-mail : victor.ouali@hotmail.fr

Born the 2nd of February in 1993

Nationality : FRENCH

Driving License

ANNEXES TABLE

ANNEX 1........................................................................................................................ PAGE 21

ANNEX 2........................................................................................................................ PAGE 21

ANNEX 3........................................................................................................................ PAGE 22

ANNEX 4........................................................................................................................ PAGE 23

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21

Annex 1

Annex 2

22

Annex 3

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Annex 4

DOCUMENTATION

CONFIDENTIALITY AGREEMENT

“On behalf of the University, we agree to commit to Delphi Diesel Systems that we will respect the confdentiality of the information we receive from Delphi during the placement of Victor Ouali.

This confdentiality agreement will include but not be exclusive to any technical documentation and/or fnancial information within Victor's reports.

In addition, no confdential information received before, during or after the placement period shall be shared with a third party and the same information shall be protected such that the written report will be kept locked and secure. The report and parts of it will only be publicised if written approval is received from Delphi Diesel Systems Ltd.

The confdentiality agreement is not valid for information that:

1) Can be demonstrated as known prior to entering this agreement.

2) The contractual partner can legally obtain from a third party without a confdentiality agreement.

3) Is public or is made public without breach of the commitments that are detailed in this agreement.

4) Can be demonstrated as worked out by the contractual partner through independent research.

In the case of notice of any inventions made by the contractual partner connected to products related to Delphi, all intellectual property rights will be remain the property of Delphi Diesel Systems.“

SOURCES

➢ Intranet of the Gillingham centre. All pages concerning organisations and certifcations. [On

line]. http://www.deimos.ukgil.europe.delhpiauto.net/ (saw during my training from June 18th to July 13th).

➢ One of the Delphi Diesel Systems' website. Pages concerning information and general

organisation. [On line] http://apollo.delphiauto.com/ (saw during my training from June 18th to July 13th).

➢ Delphi Automotive Systems website. Pages concerning location and powertrain systems. [On

line]. http://delphi.com/ (saw during my training from June 18th to July 13th).

➢ Wikipedia. Page concerning historic of Delphi. [On line]

http://en.wikipedia.org/wiki/Lucas_Industries (saw the August 5th 2012)

➢ I also used confdential documents from my training: the "Customer Program".pdf and the

"DFP Induction Pack".pdf

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BACK COVER AND KEYWORDS

I conducted my student training from June 18th to July 13th 2012 in Delphi Diesel Systems Ltd, which is a worldwide vehicle components manufacturer situated in United-kingdom.

Under the responsibility of Mr Fadi Sulaiman, I worked on rotary pumps, and precisely on their Validation process. I also discovered the world of work with different workers, mainly engineers and technicians from the Validation team.

My main missions had to do with testing pumps with technicians in the Technical Centre, and working in the Prototype Factory. I also worked with engineers on different issues about Validation of the rotary pumps. All that while overcoming the challenge of the language barrier.

I have always wanted to have an abroad experience, and this training in a foreign country was the best I could hope for. I am really grateful and proud to people who enabled this unforgettable experience possible.

➢ To describe my training period, I chose these fve key-words:

Discovery—Open-mindedness—Validation—Automotive—Fundamental

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