Industrial Training Report

FKM ‫ ׀‬UITM ‫ ׀‬INDUSTRIAL TRAINING REPORT
INDUSTRIAL TRAINING REPORT
NEW HORIZON RESOURCES (M) SDN BHD

LOT 8014A JALAN BUKIT CHERAKAH KAMPUNG
BARU SUBANG 40150 SHAH ALAM
MUHAMAD FADZRUL FAIZ BIN ASHEMI
2017806298
Faculty of Mechanical Engineering
UNIVERSITI TEKNOLOGI MARA
OCTOBER 2019
1
ACKNOWLEDGEMENT
First of all, I would like to thank Pn. Noraliza Ghazali for accepting me New Horizon
Resources Sdn Bhd, which is a great company for interns to experience the mainte-
nance and fabricating industry for mechanical engineering. Next, I would like to thank
my supervisor En. Arafin Bin Moharam for being generous in guiding me throughout
the industrial training by sharing his knowledge and inviting me to site visits which
opened my eyes to the aviation world. My special thanks to En. Khalid Bin Adam for
all the knowledge sharing sessions he held just for us interns for almost 2 hours every
week. Last but not least, I would like to thank everyone New Horizon Resources for
their kindness and for the knowledge they share.
2
ABSTRACT
Students from the Faculty of Mechanical Engineering in UiTM are required to undergo
a 10 week industrial training programme as part of the bachelor programme which is
in between 2 semesters, specifically in between the 6th and 7th semester in my condition.
I attended the first day of my industrial training on 8th July 2019 and was assigned
under En. Khalid Bin Adam by the head of department of Ground Support Equipment
(GSE) department. This report aims to show the internship process that I went through
with New Horizon Resources Sdn Bhd. Throughout this 10 week period which will
include industrial environment such as adaptations to safety in a workplace, industrial
experience such as site visits and knowledge gained from supervisor, technician and
staff that I met throughout this industrial training. This report will also include some
information about New Horizon Resources Sdn Bhd regarding its history and activities
that it has involved in.
3
TABLE OF CONTENTS
INTRODUCTION ................................................................................................................................ 6
History .............................................................................................................................................. 6
Organization Chart ......................................................................................................................... 7
Structural of Main Activity ............................................................................................................ 8
Objective of Practical Training ...................................................................................................... 8
Scope of Training ............................................................................................................................ 9
INDUSTRIAL ENVIROMENT ........................................................................................................ 10
Adaption and Adjustment To The Industry ................................................................................. 6
Practice Of Occupational Safety & Health Enviroment .............................................................. 6
INDUSTRIAL EXPERIENCE.......................................................................................................... 10
Metal Work Fabrication ............................................................................................................... 10
Ground Support Equipment ........................................................................................................ 11
INDUSTRIAL PROJECTS ............................................................................................................... 19
Relation Between The Tasks to The Mechanical Engineering Course ..................................... 19
Integrating The Theoretical Knowledge With Practical Works ............................................... 19
Project ............................................................................................................................................ 20
SUMMARY ........................................................................................................................................ 22
Discussion & Conclusion .............................................................................................................. 22
Recommendations ......................................................................................................................... 22
APPENDIX ......................................................................................................................................... 23
4
LIST OF FIGURE
Figure 1 : NHR Logo ................................................................................................... 6

Figure 2: Wearing PPE during works ........................................................................ 12
Figure 3: Welding main pillar to upper & lower part……………………………….13
Figure 4: Setup 90º angle each corner ........................................................................ 13
Figure 5 : Welding bones to main pillar .................................................................... 13
Figure 6: Grinding process to make smoothing surface............................................. 14
Figure 7: Painting process .......................................................................................... 14
Figure 8: Fabricate & repairing the awning of rooftop .............................................. 15
Figure 9 : Axle Jack…………………………………………………………………16
Figure 10: Tripod Jack ............................................................................................... 16
Figure 11: Performing Load Test……………………………………………………17
Figure 12: HyCat Software………………………………………………………….17
Figure 13: Maximum Load ........................................................................................ 17
Figure 14: Remove Cylinder Jack...............................................................................18
Figure 15: Lift Up by Forklift…...... .......................................................................... 18
Figure 16: Cylinder Jack Complete Services ............................................................. 18
Figure 17: Pneumatic/ Hydraulic Diagram………………………………………….19
Figure 18: Hydraulic Circuit ...................................................................................... 19
Figure 19: Coating the steel bar ................................................................................. 20
Figure 20: Portable Canopy ....................................................................................... 21
Figure 21: Malabar Axle Jack……………………………………………………….23
Figure 22: Hydro Axle Jack ....................................................................................... 23
Figure 23: TronAir Tripod Jack……………………………………………………..23
Figure 24: TronAir Axle Jack .................................................................................... 23
Figure 25: Storage Cage ............................................................................................. 24
Figure 26: Portable Canopy ....................................................................................... 24
5
INTRODUCTION
Figure 1 : NHR Logo
History
New Horizon Resources Sdn Bhd (NHR) was incorporated in Shah Alam on 1st April
2010. The principal activities of NHR are Services, Support, Maintenance and Trading
in Aviation Field. They are one of the vendors in automotive and mechanical for airport
ground operation and engineering sectors. They provide a high quality machining trade
services for aviation/MRO and engineering in Malaysia.
At NHR, they selectively pick their staff based on knowledge, capabilities and are of
the highest discipline. They trained their staff to be ultimate solution provider that will
cater even of the highest echelon challenges in their field. They develop, produce and
supply quality products and superior services to satisfy the needs of aircraft mainte-
nance engineering sector.
NHR’s mission is to provide consistent high quality products and services at competi-
tive prices to earn satisfied, repeated client. They also provide on time critical judg-
ments and solution to their client’s problem and needs. Second is to be the first and
leading one stop center for aircraft and ground support part fabrication and repair.
6
Organization Chart
7
Structural of Main Activity
 Vehicles maintenance (car ,van, lorry, TD20, TD25, etc)

 Aircraft jacks/tow bars load test
 Aircraft Machining and Sheet Metal Repair
 Aircraft Non-Structural Welding
 Metal work fabrication (dolly, trolley, etc)
Objective of Practical Training
Industrial training is one of the requirements for the award of degree of Bachelor of
Engineering (Hons) Mechanical, known as EM220, by the Faculty of Mechanical En-

gineering, Universiti Teknologi MARA (UiTM). The objectives of the programme are:
i. To expose students to actual working culture and industrial practice
ii. To allow students to extend their theoretical knowledge into practice
iii. To motivate students to practice the right working attitudes and profes-
sionalism to increase their employability potential
iv. To facilitate students to potential employers
8
Scope of Training
In New Horizon Resources Sdn Bhd (NHR), I have been training into two department
which is Ground Support Equipment (GSE) and Metal Work Fabrication. It is a de-
partment under project division responsible for the project management of mechanical
including services, maintenance, repairing, painting and fabricating. Throughout the
10 week industrial training programme, I managed my training 5 weeks with GSE and
other 5 weeks with fabrication. These experiences has indeed opened my eyes to the
aviation or aircraft and fabrication industry in Malaysia and how the Malaysian econ-
omy benefited from this industry.
Listed below are the scopes I was exposed to which are related to mechanical engi-
neering under Ground Support Equipment and fabrication:
1. Managing mechanical tools.

2. Repairing and maintenance aircraft jacks.
3. Welding & grinding metal bars.
4. Painting & coating.
Exposures are given on the above scope in the form of reading material provided by
the department, reviewing drawings and knowledge sharing session in the office and
on-site knowledge sharing.
9
INDUSTRIAL ENVIROMENT
Adaption & adjustment to the industry
Adapting with the working environment in New Horizon Resources Sdn Bhd as an
intern is easy going because I was treated and welcomed by everyone in the company
in a very positive way. Despite having a lack in knowledge in the aircraft and fabrica-
tion industry, all the staff in GSE and fabricating department were all very generous
for sharing all their knowledge and past working experience. Besides that, I adjusted
well to the working hours in the company. Working on GSE department starts at
9.00am in the morning and ends at 5.30pm while working on fabrication department
starts 10.00am ends at 6.00pm in the evening for 5 days a week, Monday to Friday.
Throughout the 5 working days, I will usually start the day by checking my notifica-
tions in the WhatsApp group for any invitations to site visits or any task and end the
day by writing all of activities I had done on the day on my daily logbook.
Working’ schedule on fabrication department:
TIME TASK
10:00 am – 1:00 pm • Safety talks
• Fabricate
• Welding & grinding
• Perform tasks given by supervisor
1:00 pm – 2:00 pm Lunch break
2:00 pm – 6:00 pm • Continue fabricate
• Learning about drawings
• Daily log book written
Table 1: Schedule on Fabrication Department
10
Working’ schedule on GSE department:
TIME TASK
9:00 am – 1:00 pm • Safety talks
• Learning about aircraft jacks
• Reading manual aircraft jacks
• Site visit or inspection
1:00 pm – 2:00 pm Lunch break
2:00 pm – 5:30 pm • Maintenance or services jacks
• Repairing
• Site visit or inspection
• Daily log book written
Table 2 : Schedule on GSE Department
Practice of Occupational safety and health environment
New Horizon Resources Sdn Bhd has serious concern on safety, therefore I was in-
structed by the company to apply for the rule of safety during working. Aside from
abiding to the law regarding safety, everyone who enters NHR workshop are required
to equip themselves with a proper Personal Protection Equipment (PPE).
PPE is equipment that will protect the user against health or safety risks at work. It can
include items such as:
 Safety helmets
 Gloves
 Eye protection
 Safety footwear
11
Eye protection
Gloves
Safety foot-
wear
Figure 2: Wearing PPE during works
INDUSTRIAL EXPERIENCE
I. Metal Work Fabrication (5 weeks)
Fabricating a Storage Cage (12 units)
Storage cage are customer request from Pos Malaysia. They have request about 12 unit
storage cage from NHR Sdn Bhd for loading their stuff. I have been train by staff under
fabricate department in order to build storage cage. The size of storage cage is about
(7*3.5*4 feet). Here, I applied all the skill of mechanical process such as grinding,
cutting, welding and painting in order to make storage cage. There are a few step or
procedure that I have learned to make a storage cage.
I. Cutting the square tubing bar (1.25*1.25 inches) with the length of 7 feet to
use as the main pillar, 4 feet and 3.5 feet for upper and lower part.
II. Start by building the upper part which is make it square by using the welding
and the angle of corner should be 45 degree to assemble each tubing bar.
III. Using the same step in order to build the lower part.
12
IV. Attach the 4 main pillar (7 feet) to join the upper and lower base every each
corner with angle of 90 degree by using welding.
Figure 3: Welding main pillar to upper & lower part Figure 4: Setup 90º angle each corner
V. Attach square aluminum plate (4*3.5 feet) at the lower part as the base by using
a welding (MIG).
VI. Cutting square tubing bar (1*1 inches) to make a bones and joining it by using
a welding.
Bones
Figure 5 : Welding bones to main pillar
VII. Assemble the steel’s net around the body of the cage by using welding. Weld
it spot every edge of the square tubing bar to make it fixed.
VIII. Welding 4 units of roller at the bottom every corner to make a movement of
the storage cage.
13
IX. For the finishing process, grinding all the welding parts to remove and clean
the unwanted material and make a smoothing surface.
Figure 6: Grinding process to make smoothing surface
X. The storage cage need to wash with the chemical substances in order to remove
dust and rusty things.
XI. Continue with painting the storage cage with grey’s color by using a spray gun.
The combination paints should be 75% of paint’s color and 25% of thinner.
Mixing both paint and thinner until it ready to spray. Mask must be wear to
avoid color dust get into our mouth and nose.
Figure 7: Painting process
XII. Let the storage cage dry and it considered done. The customer will come and
pick up their storage cage.
14
Maintenance, Fabricating & Repairing Customer” Lorry Parts
The first customer’s lorry is from FGV Company. They brought it to NHR for fabricate
and repairing for some a few parts of the lorry have been broken or damaged that need
to be repair and fixed such as wall, rooftop and inside parts of the lorry. For the metal
wall, we replaced the damage wall with the new one which is we fabricate it by using
aluminum plate as it easy to bent and formed. In order to join the metal and aluminum
plate, we spot it by using the rivet. Before performing the process of the rivet, a hole
needed to be made by using the drilling machine. Once the hole is made, we use rivet
to join metal part and the aluminum plate. From this, I learn on how to use mechanical
tools properly and always be careful to avoid any injury.
Second lorry we were received from Courier Company which is has minor problem
with the rooftop. The awning of the rooftop also have a minor problem which is break-
down due to clash with a sign’s bus stop. For this task I was given by other staff to
complete the fabricating and repairing. For the rooftop, I have to remove out the dam-
aged plywood and replace with the new one. Since they use rivet to attach it to the
metal, I have to remove out the rivet with drill on it. In order to replace it with new
one, I have to take a correct dimension by using measuring tape and cutting by grinding
tools. Then, attach the new plywood with the sheet metal by using the rivet. After
finished the process rivet, the plywood have to paint with the white color mixed with
the thinner. Next we move to fabricate and repairing the awning of the rooftop. This
part I have to replace the damage awning with the aluminum sheet because it easy to
bent. Remove the original damage part with drill on the rivet and get a new one and
attach it again by using the rivet.
Figure 8: Fabricate & repairing the awning of rooftop
15
II. Ground Support Equipment (5 weeks)
Over Ground Support Equipment I have been assist by Manirag a/l Munusamy. He’s
position as mechanic under this department. He had more than 42 years of experience
in handling aircraft GSE and transport equipment for customers like Malaysia Airline
Berhad, Druk Air (Bhutan), Air Asia, and RMAF. He was previously employed by
Malaysia Airlines Berhad for 32 years. Attended a lot of technical training locally and
internationally in all types of GSE. There were many thing that I have learn from him
during 5 weeks about aircraft jacks, tow bar and load test.
Maintenance, Service Aircraft Jacks & Load Test
1. Axle Jack & Tripod Jack
Tronair axle & tripod jack recommends performing preventive maintenance which
should include a 90-day routine inspection and 12-month load test. These axle jacks
& tripod jacks were arrived from MAS AIRLINES due to some jacks had some
problem such as cylinder leaking, broken seal and the jack cannot lift up. These jacks
are placed directly on or under aircraft landing gear. Here I learned how to service all
the problem from the mechanic aircraft jacks.
Figure 9 : Axle Jack Figure 10: Tripod Jack
Basically, these jack have 2 stages and 3 stages cylinder jack to lift up. In order to
service, these jack have to disassemble by part by using mechanical tools. Working on
these jacks, worker must be careful while disassemble the jacks to avoid any accident
that might be broken the some part of the jacks. All the part must be washed with the
diesel or petrol to prevent it from rusty and dust. After we make maintenance and
service on these jacks, the last part to be make is load test. Load test is part which is to
16
ensure that jacks whether it can lift up the cylinder to reach their maximum load or
not.
Procedure performing load test:
1. Connect the load cell to the module that already connected to a laptop.
2. Open HyCat software and go to setting to put maximum the trigger level ac-
cording to the jack maximum load.
3. Key in the data such as examiner name, model number, serial number and unit
number.
4. Start the load test by lifting the jack up to 100% of its maximum load capacity.
Load indication will show on laptop screen.
5. After reaching 100% of its load capacity, start the cycles test for 10 minutes.
6. After 10 minutes, stop cycle and check whether the jack pass or fail the re-
quirement.
7. Save and load test is complete.
8. All the document load test must be reported to the customer as a proof of load
test on that jacks.
Figure 11: Performing Load Test Figure 12: HyCat Software Figure 13: Maximum Load
17
Site Visit
Throughout the internship period, I was given the opportunity to join for site visit with
the supervisor and mechanic to hangar KLIA (MAS Airline). The purpose of the site
visit is we are going to checking the aircraft jacks that have some problem which is
the jacks cannot lift up. The jack cannot lift up because of some component stuck and
broken. We have to remove out the cylinder jack by using the hammer and forklift and
carry out into the workshop for service and maintenance. For the service. We have to
disassemble by part and wash with the diesel to move out the rusty thing.
Figure 14: Remove Cylinder Jack Figure 15: Lift Up by Forklift
Figure 16: Cylinder Jack Complete Services
18
INDUSTRIAL PROJECTS
Relation between the tasks to the mechanical engineering course
Metal Work Fabrication department specializes on making storage cage and other fab-
rication. While GSE department focus on maintenance, service and repairing the air-
craft jacks. All these are related to Mechanical Engineering as it involves workshop
practice. It’s expose on me how to use mechanical tools properly. From this, I gain to
make storage cage by my own self. Regarding this. I also learn some knowledge from
the staff about skill and how to practice it time working.
Integrating the theoretical knowledge with practical works
I have applied my theoretical knowledge from Fluid Mechanics to understand the how
does jacks system working. It involve pneumatic and hydraulic system on the aircraft
jacks. The staff give me the manual all of the jacks and teach me to understand more
about system hydraulic and pneumatic works on that jack. From my point of view,
assignments given by lecturers are very useful because these assignments portrait the
real world application on how to use the knowledge we gained in the classroom.
Figure 17: Pneumatic/ Hydraulic Diagram Figure 18: Hydraulic Circuit
19
Project
Fabricate Portable Canopy
Portable Canopy is the one of the project that I have been involve during my internship
at NHR Sdn Bhd. All the design have be conduct by previous staff which is En Ni-
zammudin Bin Mohd Hashim. All the material and measurement of the hollow steel
bar have been cut before I got intern at NHR.
Material: Hollow Steel Bar
Quantity & Measurement:
11 feet for front (2 units), 9 feet for back (2 units), 6 m (rectangle’s design) for rooftop
(2 units), 4.3 m (rectangle’s design) for rooftop (3 units)
Process of fabricate portable canopy:
i Before start building portable canopy, all the hollow steel bar must be coating
with antirust to prevent it from rusty.
Figure 19: Coating the steel bar
ii Install 9 feet hollow steel bar both sides for the front to the 6 m steel bar by
using bolt and nut.
iii Install 11 feet hollow steel bar both sides for the back to the 6 m steel bar by
using bolt and nut.
iv After that, install 3 unit of 4.3 m steel bar in the middle as rooftop between 9
feet and 11 feet steel bar by using the welding.
v Install support with 0.5 m steel for every angle by using the welding.
20
vi Install 4 unit of stopper wheel for every bottom of 9 feet and 11 feet hollow
steel bar for a movement of the canopy by using the welding.
vii Install 4 units of 24 feet hollow steel bar for the bones of the rooftop to place
and support the zinc.
viii Install the zinc for the rooftop every layer by using rivet to connect the zinc
with the bones.
ix 30 units of zinc with length (10*2 inches) needed to complete the portable can-
opy.
x Build the awning from 4 inches length of the zinc and welding 3 unit of steel
bar for the support zinc with angle 45 degree.
xi Install the zinc for the awning with the same process which is drilling and rivet.
xii Finally, the portable canopy have been fabricate after 2 weeks we start build it.
Figure 20: Portable Canopy
21
SUMMARY
Discussion & Conclusion
Students from the Faculty of Mechanical Engineering in UiTM are required to undergo
a 10 week industrial training programed as part of the bachelor programed which in-
tends to expose students to the real working environment and improving employability
upon graduation. I have been exposed to the fabrication and ground support equipment
industry throughout the industrial training period and I now can relate it with my the-
oretical knowledge that I learned in the faculty during my bachelor programed. I would
say that the theoretical knowledge I learned in Fluid Mechanics is applied in the real
industry in terms of the maintenance, service and repairing the aircraft jacks.
In addition, I realize that in order to be a successful engineer, I need to continue learn-

ing, acquire more technical knowledge and develop various technical skills. Last but
not least, I have learned to communicate with different types of people in both lower
and upper grades. This is when we work on site, we're going to meet different types of
people. NHR staff tell us that either we like it or not we need to adapt these environ-
ments. From this, as I work, I can become more open-minded and become self-confi-
dent in the future.
In a nutshell, even though it was only 10 weeks and it is very short time to learn and
gain skills, the industrial training was achieved. I learned a lot of new mechanical and
aviation-related work. Last but not least, this training has improved my punctuality
and attitude discipline.
Recommendations
My 10 week industrial training with NHR Sdn Bhd has been excellent because of the
knowledge I gained from the all staff in the department who were willing to share their
working experience and knowledge to interns. I would recommend students especially
mechanical engineering students to join NHR Sdn Bhd for their internship programed,
specifically Ground Support Equipment (GSE) department for those who are interested
in exposing themselves to the aircraft and aviation sectors.
22
APPENDIX
TYPES OF AIRCRAFT JACKS
Figure 21: Malabar Axle Jack Figure 22: Hydro Axle Jack
Figure 23: TronAir Tripod Jack Figure 24: TronAir Axle Jack
23
STORAGE CAGE
Figure 25: Storage Cage
PORTABLE CANOPY
Figure 26: Portable Canopy
24

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FKM ‫ ׀‬UITM ‫ ׀‬INDUSTRIAL TRAINING REPORT

INDUSTRIAL TRAINING REPORT

NEW HORIZON RESOURCES (M) SDN BHD

MUHAMAD FADZRUL FAIZ BIN ASHEMI

Faculty of Mechanical Engineering

UNIVERSITI TEKNOLOGI MARA

Organization Chart ......................................................................................................................... 7

Structural of Main Activity ............................................................................................................ 8

Objective of Practical Training ...................................................................................................... 8

Scope of Training ............................................................................................................................ 9

INDUSTRIAL ENVIROMENT ........................................................................................................ 10

Adaption and Adjustment To The Industry ................................................................................. 6

Practice Of Occupational Safety & Health Enviroment .............................................................. 6

Metal Work Fabrication ............................................................................................................... 10

Ground Support Equipment ........................................................................................................ 11

INDUSTRIAL PROJECTS ............................................................................................................... 19

Relation Between The Tasks to The Mechanical Engineering Course ..................................... 19

Integrating The Theoretical Knowledge With Practical Works ............................................... 19

Discussion & Conclusion .............................................................................................................. 22

Figure 1 : NHR Logo ................................................................................................... 6

Figure 1 : NHR Logo

Structural of Main Activity

 Vehicles maintenance (car ,van, lorry, TD20, TD25, etc)

Objective of Practical Training

Engineering (Hons) Mechanical, known as EM220, by the Faculty of Mechanical En-

i. To expose students to actual working culture and industrial practice

ii. To allow students to extend their theoretical knowledge into practice

iv. To facilitate students to potential employers

1. Managing mechanical tools.

Adaption & adjustment to the industry

Working’ schedule on fabrication department:

10:00 am – 1:00 pm • Safety talks

• Welding & grinding

• Perform tasks given by supervisor

1:00 pm – 2:00 pm Lunch break

2:00 pm – 6:00 pm • Continue fabricate

• Learning about drawings

• Daily log book written

Table 1: Schedule on Fabrication Department

Working’ schedule on GSE department:

• Learning about aircraft jacks

• Reading manual aircraft jacks

• Site visit or inspection

1:00 pm – 2:00 pm Lunch break

2:00 pm – 5:30 pm • Maintenance or services jacks

• Site visit or inspection

• Daily log book written

Table 2 : Schedule on GSE Department

Practice of Occupational safety and health environment

I. Metal Work Fabrication (5 weeks)

Fabricating a Storage Cage (12 units)

Figure 5 : Welding bones to main pillar

it spot every edge of the square tubing bar to make it fixed.

the storage cage.

the unwanted material and make a smoothing surface.