3.4.1 Oil Trap Water Separator.
Firstly, this project given by my supervisor for the trainee as there was visit by HQ Audit. This project is mainly about environmental problem and how the trainee need to came up with solution.
Problem Statement:
The oil trap in the drainage didn’t properly function as it needs to trap the oil flow from the workshop. This is because the existing oil trap is lower than water flow which cause sand in oil trap cannot trap the oil. Thus, the drainage would be clogged oil.
Solution:
As this was only a simple task, we came up with solution that the oil trap needs to be build higher than water flow.
31 Installation steps:
Figure 3.19 Insert Grill The grill is installed in order to hold the mat and sand.
32
Sand is put into the drainage to trap the oil
Figure 3.21 Insert Mat
Green mat function as to prevent the sand from flowing out
3.4.2 Workshop layout renovation
This task was given to trainees as there was visit by HQ Audit. The workshop of Light and Vehicle Unit need to be renovates to make sure that vehicles, tools, oil drum and others are neatly arranged. I was assigned to sketch the workshop layout and came with new idea for new arrangement. The new layout was drawn by using software Catia by one of our teammates.
33
Figure 3.22 Workshop Layout
Main Office (Pejabat Utama)
o For technician and assistant engineer.
Heavy Machinery Main Control Room (Bilik Kawalan Jentera) o For workers to observe works in workshop.
Vehicle Service (Tempat Servis Kenderaan) o Space for repairing and services.
Stor
o Install used battery and oil.
Worktable (Meja Kerja)
o Space to keep tools and machine.
Toilet (Tandas)
o For worker uses
Walkway (Laluan Pejalan Kaki)
34 3.4.3 Oil drum storage
Problem statement: There is no specific space for oil drum storage in workshop. Oil drums are kept scattered at the workshop and it could cause danger for the worker. With this, trainees were given task to build (proposal) for oil drum storage.
This project is mainly on environmental working condition. Its objective is to improve working environment, avoid hazard at work like explosion and easy installation of oil drum. Advantages of oil drum storage;
Easy arrangement.
o Oil drum will be neatly arranged if there is storage to keep it. Usually, these drums will be labelled and storing it by label will make work easy.
Improve safety at working place.
o If there is oil spill, it will hazardous for workers as it could cause accidents. Thus, by keeping oil drum in storage and guard it well, it will reduce accidents. Design of oil drum storage by using Inventor AutoDesk
35
Figure 3.24 Front view
36
Figure 3.26 Side view (3D)
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Figure 3.28 Back view
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Figure 3.30 Back view (3D)
Figure 3.31 Side view
Oil Storage and Layout of workshop using Delmia software.
By using the Delmia software, we have designed the possible layout involving the oil trap building and nearest building involved. From all the view that we have chosen, we can see workers gathering the oil barrels to the oil storage building.
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Oil Storage Workers picking up oil Barrel
Workshop building
Figure 3.32 Top View
40 Workshop Building
Figure 3.33 Side view
Oil Trap Building
Figure 3.34 Zoomed view
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42 3.5 SUMMARY OF DAILY ACTIVITIES
Week Details
1
Introduction session with the administration.
Briefing about the rules and history of this company. Also briefing about laws and safety regulations and equipment’s need to be wear during work.
Go to office to settle about thumbprint and send feedback letter from factory to Industrial Training Unit.
Supervisor shown us certain places in the company. Brought overall look workshop.
Description of duties by Mr. Zainuddin Bin Daud and tour around the work area and to recognize and learn the components in engine.
First assigned unit is Heavy Machinery Unit. For this unit, I have watched demonstration for final drive.
The technician gave details explanation on how final drive works and factors of why gear need to be change.
Problem: The sun gear wear. So, it need to be change to avoid accident and ensure the vehicle run smoothly.
Figure 3.36 Gear 27 th J u n e 2 0 1 6 – 30 th J u n e 2 0 1 6
43 2
Learn about the components of the engine.
Besides that, technician shows us the demonstration of overhauled engine in light vehicle.
Innovation project of oil trap water separator.
The purpose was to find the problem and we need to improve it.
The solution was we need to increase the level of oil trap in the drainage so that it will trap the water when the water flows through it.
3
In third week, I have been assigned to Light Vehicle Unit and was introduced to Head unit, Mohd Fadhli Bin Mohamad.
I have been assigned to do the layout for control unit. We measure the parameter of the room and design it using software.
Besides, we’re in progress do the oil trap water separation project.
Other than that, we have been given a detail explanation on factors of underpowered engine.
The factors are mainly because of piston ring wear and valve’s leak.
If the piston ring wears, it needs to be change.
Then, factors of valve leak are because it is not properly closed which can cause scratch on valve and there will be oxygen out.
3 th Ju ly – 5 th J u ly 20 16 11 th J u ly 2 0 1 6 – 14 th J u ly 2 0 1 6
44 4
Cleaning workshop.
Self-study on final drive, automatic gearbox and engine overhaul.
Given a mini project which was workshop layout innovation.
We are needed to change and improved the old layout of heavy machinery and vehicle unit.
The layout was drawn by using Catia software.
I have been assigned to sketch the old layout of heavy machinery and vehicle unit.
Figure 3.37 Workshop Layout
5
During this week, I have been assigned to Vehicle Test Line (VTL) unit.
Briefing by Mr Anuar in Vehicle Testing Line Unit (VTL).
He shows around the workshop and gave details explanation on each test of the car.
Demonstration on smoke tester. The smoke tester purpose is to detect the pollution of smoke emitted from the vehicle.
If the results of the test is higher than 50, the car will be issued by environmental department.
We have been given new mini project which is oil drum storage by supervisor.
The purpose of this project is to change the oil drum in the
17 th J u ly 2 0 16 – 21 th J u ly 2 01 6 24 th J u ly 2 0 1 6 – 2 8 th Ju ly 2 0 1 6
45
storage, easy to keep the oil drum and to ensure the safety of the workers.
6
Inspection on vehicle like Toyota Hilux, Nissan Urvan, Toyota Fortuner 2.5G
Only Nissan Nevara passed all test during the inspection while other vehicle had failed.
The vehicle failed the test if it didn’t pass the range or limit that had been assigned.
As for the Nissan Urvan, it didn’t pass the test because the result of front brake is less than 50%.
While for Toyota Hilux, it didn’t pass the test because the result of rear brake is less than 50%
Vehicle that didn’t pass the test will be send to the service center for services
7
At 7th week, I have been assigned to Building Maintenance Unit.
Briefing given by Mr Azi Izwan and he gave me task to be completed within a week.
Task was mainly about air conditioning system, organizational chart in Jabatan Kerja Raya and function of each department in JKR.
During this week, I have been prepared for Industrial Training presentation as there would be lecturer visit.
- Log book
- Slide Presentation - Report
I did self-study on fire fighting system and installation of ceiling cassette split type air conditioner (E series) Acson.
31 st J u ly 2 01 6 – 4 th Au gu st 2 01 6 7 th Au gu st 2 0 1 6 – 11 th Au gu st 2 0 1 6
46 8
Mr Zulfadli brought us to Air Cond Workshop unit. He gave us briefing and details about this unit.
Besides, he introduced us to the staff of this unit.
Clean the workshop and arrange tools.
Did self-study on installation of wall mounted split type air conditioner.
Wall mounted split type air conditioner usually used in hotels, houses and small room.
Other than that, I have been given task by my supervisor to managed files for Audit visit from main branch.
During this week, we have meeting with our supervisor to discuss for new project about innovation.
We need to come up with new idea to innovate any tools in workshop.
Divided into three groups. 9
I have been assigned to Project Unit and Mr Zamri gave briefing about this unit.
He introduced me to staffs of this unit.
Given task to study about fire fighting system
Wet riser system
Dry riser system
Hose reel system
Meeting with supervisor and other trainee.
We were given quizzes and task.
14 th Au gu st 2 01 6 – 18 th Au gu st 2 01 6 21 st Au gu st 2 0 1 6 – 25 th Au gu st 2 0 1 6
47 10
Study on do’s and do not’s in installation of mechanical system in air conditioning system.
Final meeting with our supervisor to discuss about our final project.
Each group need to present their ideas.
1st group: circuit breaker to avoid electrical waste
2nd group: smart toolbox and air-conditioning filter.
3rd group: oil jet and tool dispenser.
After discussion, my group idea which was 3rd group chosen.
Oil jet function as to keep oil from spill onto the floor during repairing the vehicle. We created this oil jet as automatic hydraulic and can be control by remote.
Figure 3.38 Oil Jet (Sketch)
For tool dispenser, it acts like washing machine but for tools. It is easy for technician to use tools.
28 th Au gu st 2 01 6 – 1 st Sep tem b er 2 01 6
48 CHAPTER 4