Report Intern Final PDF

 

Table of Contents 1.Introduction ............................................ .................................................................. ............................................ ............................................. ....................... 1 1.1 History ......................................... ............................................................... ............................................ ............................................. ........................... .... 1 1.2 Structural of main activity ................................. ....................................................... ............................................. ........................... .... 2 1.3 Objectives ........................................ .............................................................. ............................................ ............................................. ....................... 3 1.4 Scope of training ............................................ ................................................................... ............................................. ............................. ....... 4 1.5 Process ........................................................ .............................................................................. ............................................. .................................. ........... 5 2.Industrial Environment.................................. Environment........................................................ ............................................. ...................................... ............... 8 2.1 Adaptation Adapta tion and an d adjustment adjus tment to t o the industry .......................................... ......................................................... ............... 8 2.2 Practice of o f occupational occupatio nal safety and an d health environment ............................... .................................. ... 10 3.Industrial Experience ............................................ ................................................................... ............................................. ........................... ..... 12 3.1 Maintenance Day ......................... ............................................... ............................................. ............................................. ........................ .. 12 3.2 Welding ........................................... ................................................................. ............................................ ........................................... ..................... 13 3.3 Auto-Mechanic work .......................... ................................................. .............................................. ....................................... ................ 14 3.4 Service and repair gearbox and pump .............................................. .............................................................. ................ 15 4.Industrial Projects............................... Projects..................................................... ............................................ ............................................. ......................... .. 16 4.1 Fabricating Fabricatin g Machine Shaft for Fire Hydrant Pump .......................................... .......................................... 16 4.2 Welding leaked parts on Softener So ftener Tank in Boiler Room ................................. ................................. 19 5.Summary ............................................ .................................................................. ............................................ ............................................. ......................... .. 21 6.References .......................................... ................................................................ ............................................ ............................................. ......................... .. 22 7.Appendix ............................................ .................................................................. ............................................ ............................................. ......................... .. 23

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1.Introduction 1.1 History

Robin Resources (Malaysia) Sdn. Bhd. is established in 1994 with an initial investment of US$ 50million. It is wholly owned by Akij Group of Bangladesh in its 57 acres site in Mentakab. The main machine use is Dieffenbacher Continuous Press and can produce a design capacity of 2.6 meters x 28 meters of Medium Density Fibreboard (MDF). The machine can produce 400m3 per day but after certain improvement modifications and with an efficient and dedicated workforce, Robin Resources has managed to increase the capacity up to an average of 650 m 3 per day.

Basically, all raw material are sources locally from strictly legal establishments. The raw materials are plantation species rubber wood, acacia wood and timber wood such as wodd slabs, wood off-cuts and peeler cores as its raw material for producing MDF. At 2004, Robin Resources decided to invest in Robina Plantation Sdn. Bhd. This idea mainly to ensure sustainability in wood supply. The company itself will manage and harvest 15,000 acres of Acacia plantation which is located about 25 km from the factory.

Robin Resources’ production capacity has grown from 100,000 m3 in the 1996

to surpass the designed capacity of 135,000 m3 by 1999 and continued to grow up to a maximum of 195,000 in 2010.

In line with the increased output. Robin Resources

also improved the quality and the variety of its products to offer more choices to the market.

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1.2 Structural of main activity

The main product of Robin Resources is Medium Density Fibreboard (MDF)  by using rubber wood as its raw material. The main application of MDF board is  bedroom set, doors, partitions and dining table. They also have their own specification on the products.

Figure 1 MDF surface specification 

Figure 2 Overview of Robin Resources

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1.3 Objectives  Objectives 

The main objectives of Industrial Training (MEC698) are : 1)

To expose students to actual working culture and industrial practice.

2)

To motivate students to practice the right working attitudes and  professionalism to increase in crease their employability employabilit y potential.

3)

To allow students to extend their theoretical knowledge into practice.

4)

To facilitate students to potential employers.

5)

To expose students to potential employers.

6)

To encourage students to apply theory and practical knowledge.

7)

To enhance the ability to improve student creativity skills and sharing ideas with others.

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1.4 Scope of training  training  During the training period, Madam Chiau transfer me to join the maintenance team. Mr Loranze prepared the training schedule for me. From there I learn from the technicians and engineers. Basically, I will follow the training schedule and will be supervised by Mr Fauzi. The training schedule are as follows:

From

To

Training Description

10 July

23 July

Lathe, milling, drilling and shaping

24 July

6 Aug

Welding and cutting

7 Aug

20 Aug

Auto-mechanic work

21- Aug

1 Sept

Service and repair gearbox, hydraulic cylinder, pneumatic and pump

2 Sept

7 Sept

Fabricate and installing pipe

8 Sept

15 Sept

Factory process and paper works

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Remarks

 

1.5 Process  Process  MDF Production Process In a nutshell, wood is crushed into chips, refined into fibre, mixed with glue and wax and compressed under a high temperature hot press. This in turn cures the glue which then binds the fibre together to become raw MDF. This raw MDF is then conditioned, sanded, cut and packed before it is ready for sale.

Figure 3 Raw material

Wood Preparation

The bark in the rubber wood branches are debarked in order to ensure quality and also remove the latex which is commonly found on the bark of the wood.

The debarked branches are chipped together with the other wood materials and the chips goes through a chip screening process. Strong magnets in the screening  process remove metals which may be found in the wood while oversized chips are separated and sent for re-chipping to ensure that only optimal and uniformed sized chips are used to maintain consistency in quality.

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The wood chips will then be steamed in a digester di gester where paraffin wax is added for a smoother surface and to give it a better water repellency property. Finally, the waxed and steamed wood chips will refined into fibre, where resin is added. The fibre is then dried to a required moisture content level before undergoing a shifting process where only high quality fibre that meets the correct specification will be allowed to be transferred to the Mat Former. MDF Production

At the Mat Former, the fibre will be laid out in the correct height and density  before passing through a Metal Detector and a Density Scanner before reaching the Hot Press for pressing. If either the Metal Detector or the Density Scanner detect any  problems within the Pre-Press Mat, the conveyor belt will drop to purge and reject the  problematic fibre mat and prevent it from reaching the Hot Pr Press. ess.

At the Hot Press, the fibre mat will be compressed while undergoing a continuous press and the high temperature in the Hot Press will cure the resin, activating it to bind the fibre together. This compressed and resin cured fibre will come out of the out-feed as raw board.

Figure 4 Dieffenbacher Continuous PressMachine

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The raw board will then be cut into master panel sizes before it is sent to the Star Cooler for about an hour for the board to cool down naturally. The master panels will then been stacked and further conditioning for an additional 3 to 5 days

Figure 5 Cooling Process

Finishing End

After conditioning, the master panel will be sent for sanding where the surface is sanded to ensure a uniform smoothness while the thickness of the board will be calibrated during this sanding process.The sanded board will then be cut to size,  packed and sent to the warehouse where it will be arranged for dispatch out of the factory.

Quality Assurance

Throughout, the entire production process from the receipt of the incoming incomin g raw materials to the finished packed board, stringent quality checks are monitored in every section of the entire process.

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2.Industrial Environment 2.1 Adaptation and adjustment to the industry   Throughout my training period, Mr Mohd Fauzi Bin Jamari will be my supervisor and monitor my projects. He is the senior supervisor for maintenance department. The industrial training was at workshop of Robin Resources and the working hour is from 8.00 am until 5.00 pm. All the workers including the internship students will be provide a locker. The company also provide canteen coupon worth RM200 per month only for internship students. Every early morning, Mr Fauzi will distribute the projects among the technicians. Since this company is quite big, so there are always something need to be done. Usually, the operator will report the maintenance team if their machines have  problems a day before. befo re. So, Mr Fauzi will easily easil y coordinate his team and get the jobs job s done in time.

Figure 6 Example of distribution of work by Mr Fauzi

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Figure 7 Mr Fauzi and me

 

During my training period, I can see the workers were very dedicated to their  projects. We are required to use Fingerprint Scanner as proof of our attendance and our break time. Mr Ten Kian Fah, who is the Engineering Manager of the company also monitor and take part in our projects. I can see their teamwork during the maintenance day. The exchange of ideas and knowledge are very obvious among them.

Figure 8 Example of teamwork shown by the employees and employer From right Mr. Chua (owner), Mr Kuldeep Singh (Production Manager) and technicians

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environment   2.2 Practice of occupational safety and health environment  The practice of occupational safety and health is excellent. All the workers wearing personal protective equipment (PPE) such as safety boots, gloves and masks during the working period. Furthermore, Mr Mas who is the safety officer has created Permit to Work (PTW) form which will be filled by the workers if they need to do a maintenance job in a confined space. This form is important to notify the operator and the safety of the workers. The safety signs also equipped around the factory. The safety of machines also a priority for Robin Resources (M) Sdn Bhd. They equipped with closed-circuit television (CCTV) at vital parts of the factory. The main objectives of these CCTV cameras are to identify and detect any unusual behaviour of the machines. These CCTV cameras are being monitored by the operators. For example, if a log is stuck during the screening process, the operator will stop and call the technicians to fix them.

Figure 9 Mr Awang monitored the machines at Green End Department

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Mr Mas also remind that internship students to be very careful during the training period because we do not cover by SOCSO: Employment Injury Insurance Scheme. So, any incident happen will be students’ s tudents’ responsible. If we do not know how

to use a certain tools or machine, do not proceed and ask the technician. For example, Mr Halim ask me to cut the mild steel rod into four parts by using Bandsaw Column Machine. Since I am not familiar with the machine, I ask him to teach me on how to use it.

Figure 10 Bandsaw Column Machine

As we can see, all the machines in the workshop will be provided with Standard Operating Procedure (SOP) and all the workers must follow it to ensure their safety. It also provided the names of experienced operator who knows the machine well. These operators also responsible on the maintenance of the machine such as changing the cutting tool or chain to lengthen its tool life.

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3.Industrial Experience  During my training period, I had been assigned into many engineers and technicians. From my experience, the workers are very kind and always offered themselves to share knowledge with me. Most of the workers have hav e more than ten years of working experience. So, basically they know almost every machine in the factory. Every month, every departments will have their own maintenance day according to necessity.

3.1 Maintenance Day  A day before maintenance day, da y, Mr Loranze and Mr Fauzi will sort out the tasks evenly among the technicians. There are three important lines lin es in this factory which are Hot-Press Line, Sanding Line and Cut to Size (CTS). As a internship student, I also involve the tasks throughout my training period. The main objectives are to make sure that the machine in normal state and to detect any unusual behaviour.

Figure 11 Example of distribution of works among the workers

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3.2 Welding  This is one of my favourites during my training. Mr Safwan and Mr Yong are the technicians that taught me welding skills and knowledge. Basically, the most common type of welding rod are stainless steel and mild steel. Each one of them have their own purpose. For example, stainless steel welding rod is use when it used in heavy duty parts such as the bucket or excavator. This part is used to hold bunch of logs at vecoplant line.

Figure 12 Example use of mild steel welding rod

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Figure 13 Bucket of Excavator

 

3.3 Auto-Mechanic work   The maintenance team have its own auto-mechanic technicians which means their jobs only on maintaining the vehicles used by the factory such forklifts, excavator and tractor. During my training, there are two important forklifts which are the 16 tonne forklift. These forklifts are used to transfer the fibreboard from diagonal saw to sanding line and cut to size line. There is a time when the engine of the forklift is overheated. So, technicians and I need to dissemble the top cover of the forklift. We were able to identify that the shaft in the crankshaft have been broken. This taught me that even a small thing can have a big affect on the vehicle.

Figure 14 Technician initiate monthly

Figure 15 Dissemble parts of

maintenance of forklift

16 tonne forklift

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3.4 Service and repair gearbox and pump  pump   I also involved in servicing and repairing rep airing gearbox and pump. In order to redu reduce ce cost, the company very encourage the technicians to always check critical parts of the machines such as gearboxs and pumps. Maintaining the gearbox is not hard as long we know how to assemble the parts. Firstly, we dissemble the parts and get rid of old lubricant oil. Then, we begin cleaning the internal parts. We use diesel, water and dry  by using dry compressed air. Next, we check the internal parts such as sprocket or shaft whether there is a crack. Instead of replacing replacin g the gearbox, we only need to change the sprocket.

Figure 16 Sprocket and Shaft

Figure 17 Internal parts of a gearbox

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4.Industrial Projects During the industrial training, I have been given some projects by Mr Fauzi. These projects will help them to test my skills and engineering knowledge. Management of time and the quality of product is the key factor of these projects. Mr Fauzi also assigned some technicians to assist me throughout the projects.

4.1 Fabricating Machine Shaft for Fire Hydrant Pump 

Date: 19 July 2018 Tools and machine used: Lathe Machine, micrometre screw gauge, callipers, sand  paper

In this project, I need to replace the old shaft since there was a crack occur in the shaft. Mr, Weinss will monitor my project as he is a certified lathe machine operator. Mostly, this project take place in the workshop and use the lathe machine. The specifications had been given to me in the form of old shaft. So, my first job is to take the measurements and sketch the shaft to make it easier for me to understand the details of the shaft.

Figure 18 A simple sketch of shaft by me

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From the sketch, the length of the shaft is 350 mm but we need to use a longer steel rod. The remaining length will be easier for the chuck of the lathe machine to hold. Before I start to install the rod in the chuck, I need to identify which parts is critical. This process is important because there will be ball bearing to install in the shaft.

Figure 19 Installation of steel rod

Figure 20 Cutting process takes place

The required diameter is 50mm but we need to make it tight fit with the bearing. bearin g. So we need to obtain around 50.02mm. In order to achieve that, calliper is not enough so we use micrometre screw gauge but how is the method? The lathe machine only can achieve around 0.05mm. Here come the trick, Mr Weinss asked me to use sand  paper. While the rod is rotating, we apply some force on the surface of the shaft by using sand paper. We need to check diameter frequently. If the bearing is loose, the shaft is rejected. After that, I need to fabricate the thread at the end of the shaft. I ask Mr Weinss on how to read the thread chart that display on the lathe machine. The required thread is 14 per inch, so we set the speed A and B to 40 and 35. After the setting, the lathe machine will move automatically. I only need to set the start point and end point.

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Figure 21 Threading Chart

Figure 22 A micrometre screw gauge

Figure 23 Fabricated shaft

After the threading process finished, Mr Weinss checked the shaft and he approved. He told me to keep the shaft in the store as spare parts.

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4.2 Welding leaked parts on Softener Tank in Boiler Room

Date: 7 August 2018 Tools and machine used: Welding Set, Stainless Steel welding rod, Bandsaw machine For the next project, Mr Fauzi asked me to join Mr Safwan and Mr Kana to check the softener tank in Boiler room. The operator complaining that maybe the tank is leaked. So, the first step is to stop the usage of the tank. Then, we identify the leaked parts.

Figure 24 Softener Tank

Figure 25 Leaked parts

After that, we cut some steel from the workshop to cover the leaked parts. The steel must cover all the leaked parts so that we can weld the steel on the softener tank. We also bring the welding set by using trolley and stainless steel welding rod.

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In this part, Mr Safwan brief me on how to weld efficiently. Since the place is quite dark, we install a fluorescent lamp. After the welding session completed, we  paint the softener tank with a new colour to cover the worked parts. p arts.  

Figure 26 Welding process

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5.Summary As a summary, there are many things that I have learned during my industrial training at Robin Resources (M) Sdn Bhd. The technicians technici ans and engineers are willingly to help and share out their knowledge to internship students. studen ts. I can say that I have make a good relationship with them as I make a small farewell celebration before I sign out. Generally, I have learnt on how to use the tools correctly and efficiently. I am more familiar with the tools and machines then before. As a future mechanical engineer, the industrial training Ihelp me to expose myself to the engineering world. With this experience, student can acquire the knowledge and cultivate the talent or skill that has been practiced during the training to become a knowledge before working later. I have learnt how to work under  pressure, communicate through thr ough team members and finish tthe he job perfectly. As a conclusion, the training undertaken by each student is an effective measure to create a generation of educated, self-confident and future later.

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6.References 1.

http://www.robinmdf.com/   http://www.robinmdf.com/

2.

https://www.dieffenbacher.de/en/ https://www.dieffenbacher.de/en/  

3.

http://www.robinmdf.com/direct-print-specifications  http://www.robinmdf.com/direct-print-specifications 

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7.

Appendix

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