ABSTRACT

The following report describes the activities carried out during a 12 week, full-time internship at
the Engmech Sdn Bhd. The document contains information about the organization and the
responsibilities performed throughout the period of 30th June until 19th September 2014. The
objective of this report is to reflect upon the experiences collected during the internship from the
perspective of Bachelor In Engineering (Hons) Mechanical student. The first part of the report
offers an overview of the organization, followed by the industrial environment, experience and
also task and project that have been carried during the training. This report also describes in
some detail the most relevant projects carried out and their respective analysis. Finally, the
report wraps-up with a few closing remarks and conclusions from the experience
This industrial training at Engmech Sdb Bhd is the opportunity that have been taken in order to
know in depth on how work culture in real industry. I was able to learn about the tender,
quotation and how they do the business. Besides that, I have been exposed with the technical and
management department as I have to understand the project by using the theory that I have learnt
and also be able to manage manpower to finish the job in time frame. Furthermore, I was able to
learn about the production of graphite electrode which produces from carbon.











1.0 INTRODUCTION
Engmech sdn. Bhd was formed in 29
th
June 2004 and fully incorporated in Malaysia to carry out
projects specialized in palm oil, pharmaceutical, food and beverage and general fabrication
works. Engmech is managed by a team of professionals that consists of mechanical engineers
with experience in the related industries.
Based in Puchong, Selangor, the company operated its business under 54,000square feet with
more than 200 local and foreign workforces. Its also equipped with modern facilities such as
Computer Added Design System (CAD) and modern welding and fabrication machine. These
modern facilities not only boots the production efficiency and productivity but it is also provide
the company with a competitive edge constantly designed and fabricated product meet customer
requirement.
1.1 History

Company profile
Company Name : Engmech Venture Engineering Sdn. Bhd.
Company Address : No. 2, Jalan Meranti Permai 3,
Meranti Permai Industrial Park,,
47100 Puchong, Selangor.
Phone No. : +603 - 8060 9116(DL)
Fax No. : +603 - 8060 8016(Factory)

Organization chart

1.2 Structure of Main Activity
Engmech Venture Engineering Sdn Bhd, desire long term relationship with customer for
example at SGL Carbon, they was there about 6 years to do maintenance job and general
fabrication work. They offer full technical support from our various expertise counter parts..
Some of the services are including:
1. Mechanical and Electrical Engineering Design
2. Management and site supervision team
3. Plant maintenance and servicing
4. Dismantling and Installation of heavy equipment



Engmech Venture Engineering Sdn Bhd is also a company dealing with trading activities for
example:
1. Authorized Distributor for Dairy products: Tube, Fittings, PHE, Pump & etc
2. Automatic Sliding door: Commercial and Industrial type.
3. Filling Machine for solutions
4. AHU, Chillers, Cooling Tower, Air Condition units
5. Polishing Stainless steel plate up to 15mm thick plate from RA 0.6 to RA 0.2 (mirror
finished). Calibrated with surface tester.
6. Servicing packaging machines
7. Refurbishment for equipment

1.3 Objective of Practical Training
The objectives of the industrial training are to expose students to actual working culture and
industrial practice. Work under pressure is one of the working cultures. It is important parts
which need to be fulfil by the engineer. Working without this culture may definitely drop the
potential and ability of an engineer.
Other than that, it is created to allow students in extending their theoretical knowledge into
practice. To explain more, as in the university students is exposed to theoretical knowledge.
Here in the industry, students can manage to relate knowledge studied in the university and use it
by doing it into practice.
Besides, the objective is to motivate students to practice the right working attitudes and
professionalism to increase their employability potential. Here students may work under the
supervision of the supervisor which will be guiding the students on how to work by following
the right ethics.
Last but not least it is to facilitate students to potential employers. Normally students which
undergo training at certain company have better chance to work with their previous employers
compare to those who are new. This is because, those students had already adapted the working
environment and had followed the training, and therefore the experience may help them to put
themselves to the vacancy position.

1.4 Scope of Training
For this practical training, I have been assigned as an assistance engineer and responsible to
monitor site at SGL Carbon, Banting. My scope of jobs is to deal with client for the project or
maintenance job given by them. After dealing with client, the information of the project must be
informed to the engineer and site supervisor in order to let them discuss about the project. After
the project had been approved, trainee must deal with safety officer to get appropriate permit so
that workers can do jobs legally. In order to let the project run smoothly, I have responsible to
order a material and bring the material from office to site.

















2.0 INDUSTRIAL ENVIRONMENT
This section will discuss on the industrial environments during the training. It includes the
adaptation and adjustment to the industry and the practice of occupational safety and health
environment.
2.1 Adaptation and Adjustment to the Industry
The industrial training commenced for the 30th June 2014 till 19th September 2014 about 12
weeks of training. Engmech Sdn Bhd operate follow office normal office hour which is from
Monday to Friday. The working hour of the company is from 8.00am to 5.00pm.
After 2 weeks stay at office, I have been assigned by project manager to monitor site at SGL
Carbon, Banting. I must arrive at SGL Carbon before 8.00am. Start from this week, I have to
wake up earlier since i live in Shah Alam riding a motorcycle to go to Puchong which take about
40 minutes. After arrive at the office, I used company car to go to SGL Banting. I do not have
any problem to wake up earlier thus I was able to arrive at site on time according to the office
hours.
Discipline and self-motivated are the main aspect need to be highlighted during the training, I
was able to consistency wake up before 6.00 am in order to let myself available at SGL Carbon,
Banting before 8.00 am. I am also able to vow to company and site regulations as well as
regulations prescribed by UiTM during 12 weeks of internship.
At SGL Carbon, there was senior trainee which taught me the scope of jobs needs to do here. He
guides me about a month before he finishes his internship with Engmech. Within the period, I
learnt a lot of thing in order continue his work without
Communication skill is very important aspect while being in the industry. I need to understand
the problem and also the information given by client in order to do the job correctly. I also need
to communicate with site supervisor to plan the work and arrange the manpower as well as
material at the site.



2.2 Practice of Occupational Safety and Health Environment
Safety and health are the most important matters at any site in this world. At Engmech Sdn Bhd,
it is important to wear well condition Personal Protective Equipment (PPE) which include safety
helmet and safety boots while at the workshop.
The usage of safety shoe is to protect feet from hard, rough or awkward surfaces, while avoiding
any objects to crash onto the feet and lead to injuries. It is strictly advised to wear the safety
shoes for the whole time because most of the areas have dangerous machines and the surfaces
also rough and slippery such as workshop area and production process area.
Safety helmet are also compulsory to wear at workshop and site. The reasons of wearing the
safety helmet is to indicate that the person who handling forklift or crane and as a safety to avoid
impact on head which can lead to injuries.
At SGL Carbon, addition of equipment for example safety glasses, dusk mask and safety vest
need to be wear. SGL Carbon is a very dusty factory due to the production of electrode. The raw
material is in powder state which can be breath in an can affect long time term to the body.
There are also traffic flow for the forklift thus it is strictly advised to wear safety helmet and also
safety vest in order to let operator alert with surrounding.
Hand gloves are worn to protect hand from any sharp edges which may lead to injuries while
working with fabrication of product. Hand gloves also assist in handling the products
comfortably.
For workplace that is above 2 meter, it is compulsory to wear safety harness. When climbing the
ladder, there is principle which is 2 hands and 1 leg. It means by when climbing the ladder, make
sure 2 hands are holding the ladder and push 1 leg pushing the body upward. The workplace also
must be provided with life line so that

Figure 1: Full body safety harness
Inside the tank, it strictly to wear special suit to since the hazardous atmosphere inside tank may
affect the skin. In SGL Carbon, Pitch impregnation tank is filled with chemical and the coil
inside tank is filled with thermo oil. Before entering confined space workplace, hazardous
atmosphere test must be conducted. It is to ensure the oxygen is sufficient and no harmful gases
in the tank. The tank also must be provided with blower in order to create good ventilation inside
the tank.

Figure 2: PVC chemical suit Figure 3: Hazardous atmosphere test device




3.0 INDUSTRIAL EXPERIENCE
3.1 Decision Making Ability
During the training I have being given opportunities to make some decision that related to my
task. Although its just a minor decision, however it gives me motivation to perform the entire
task successfully. During my 12 weeks training Engmech, I have given the chance to design the
toolbox and also to manage manpower for the projects.
3.2 Interpersonal Skills
The training has improved my ability in interacting with others people such as peers and
superior. It is fun to deal with this people, especially when they were willing to help and explain
to me about thing that I didnt understand. Most of the company operators are foreign workers
and this allowed me to learn the differences between culture and its relative influence on their
perception and behavior
3.3 Teamworks Skill
Most of the time during the training, I worked with Mr Chin Chee Keong, leader of site
supervisor. He tell me what to do and also order the material used for the project to me. Some of
the task we perform it together. I was able to contribute my ideas and insights in our works.
3.4 Communication Skill
During the training, I able to improved my communication skill especially my English languages
skill both spoken and written. This is because English is the most used language in the company
for every day communication and report paperworks.
3.5 Self-Management
Getting to know what its like to work in the real industry has taught me how to conduct myself
properly in an engineering environment. I am able to improve my time management, more
punctual in work in order to finish job based on time frame. I also learned how to wear
appropriate attire to work and manage my appearance well.


3.6 Leadership awareness
Although I dont have opportunities to lead any project or working group throughout the
training, however I am able to gain some useful leadership insight by observing how some of the
company superiors lead their subordinate. From my observation most of the company superiors
applied coherent and straight style of leadership.
3.7 Project Management
For now I only involve or assigned on a few minor project. The project I have listed below.
From this project I have learned how to organize, plan project and control the manpower.
3.8 Industrial Safety Exposures
SGL staff responsible for the obtaining of all building and operating permits. However,
contractor is responsible for the fulfilling of all requirements to allow worker to legally work on
site. Basically, trainee is responsible to help engineer to get appropriate permit that are
applicable to the type of work being perform. There are several types of permit which are:
1. Site incident prevention plan (SIPP)
Project planning which will be discuss by both side client and contractor and verify by
the safety officer. Every project which has been agreed by both side need a SIPP to
inform to safety officer in order to let worker to do the job legally at the location.
2. Work plan
Working procedure to complete the project and potential hazards may occur due to the
working procedure. The working procedure must be discussed with the supervisor and
trainee must identify the potential hazard for each procedure and how to avoid it.
3. Hot work permit
Activities that can be source of ignition if flammable material is present for example
welding, cutting and grinding must require this permit. Usually the safety precaution to
avoid ignition is fire extinguisher and fire blanket must be ready at site.
4. Confined space entry permit
This permit is required when the workplace is in the tank which has hazardous
atmosphere or bad ventilation. Hazardous atmosphere test must be conduct before
worker is allowed to enter the workplace.


5. Working at height permit
This permit is required when the workplace is more than 2 meter height. The worker
must wear safety harness and the workplace must be provided with life line.
6. Scaffolding permit
This permit is required when the working procedure need to use scaffolding to do the
job.
7. Weekend or night permit
This permit is to get permission to work on weekend or night in order to complete the
job before the due date.
I also involve in many maintenance and fabrication job at the site in term of managing
manpower, material and getting the information besides dealing with safety issue. The examples
of project I involve are:
1. Baking - install cooling pipe at baking furnace
This tender is required Engmech to modify the cooling pipe at the baking furnace in
order to facilitate maintenance. There are 9 furnaces and 1 furnace have 2 flexible
cooling pipe. This project only can be done when the furnace shutdown.
2. Baking - modified ramp of rebake cleaning machine
The shaft for the rebake cleaning machine was fracture due to the electrode speed
entering the machine was too fast. This tender required Engmech to lower the angle of
ramp at the rebake cleaning machine to slower the movement of electrode.
3. Baking - repair enclosure cover for inergen system together with barrier
The enclosure cover has been hit by forklift. This tender required Engmech to repair the
enclosure cover of inergen system and also barrier it with 4 inch pipes. Task given is to
get the key from security and must inform production staff before begin the job.
4. Forming - dismantle vibrator feeder
This tender required Engmech to supply labor to dismantle vibrator feeder at forming
concrete silo. This is actually a repeated job since the client needs to do maintenance for
12 concrete silos. Task given was to discuss with production staff when to start this job.
Trainer also needs to inform production staff before worker starts the job.


5. Forming - reinstall vibrator feeder at forming silo
After maintenance, the vibrator feeder must be reinstalled in order for client to run the
production. Task given was to confirm the date with maintenance staff and arrange
workers to do the job.
6. Forming - fabricate 2 units toolbox
Fabricate 2 units of toolbox according to the sample that have been given by client. Task
given was design and measure the toolbox according to the client desire.
7. Forming - fabricate and install handrail for platform at level 1
Fabricate safety handrail for platform at forming level 1. This job takes 2 days to
complete where 1 day to take measurement and fabricate and 1 day to install the
handrail.
8. Forming - improvement flash conveyor and fabricate scrapbox
This tender required Engmeh to modify the flash conveyor according to design given.
The flash conveyor added a scrapbox that can be lift by forklift to empty the scrap inside
it.
9. Forming - install handrail at moving hopper level 5
This tender required Engmech to fabricate safety handrail for moving hopper at forming
level 6. The safety handrail is following the diameter of the moving hopper. Task given
is to get information about the dimension of moving hopper with SGL staff in order to
engineer roll the pipe according to correct diameter.
10. Forming - install new spool piece cover at extrusion oil line mixer level 3
This tender required Engmech to install piping system for automation according to the
circuit given by SGL engineer.
11. Forming - install opening door cover at chain conveyor concrete silo
This project required engmech to make a square hole at the roof of conveyor and
fabricate opening cover for the hole. The purpose of this project is to ease the
maintenance of the conveyor

12. Forming - replace guide flatbar at C29 at forming level 9
This project required Engmech to change the guide flatbar which at the C29 conveyor
because the flatbar is damage. The task given is to discuss with system owner when and
how long to stop the conveyor in order to work on location. The system must be proper
lockout (LOTO) to avoid any incident at the conveyor during the maintenance process.

13. Graphite - machining new graphite head for furnace 8
This tender required Engmech to machining new graphite head which used for for
furnace 8. The graphite head is create e at the Engmech workshop in Puchong.

14. Graphite - maintenance of furnace 4
This project required Engmech to dismantle and maintenance the cooling channel of
furnace no 8 at graphitization shop. The cooling channel either straightens or fabricate
back according to the condition of the cooling channel.

15. Graphite 2 - move blower and lathe machine to graphite 2
This tender required Engmech supply labor and appropriate equipment to remove the
blower and lathe machine from the container and move these components to the
graphitization shop 2. The process of removing the components must finish before 3pm
since the container must be send back to the shipping before 3pm. 45 ton of crane was
being used to lift the component out from the container. SGL carbon supply 8 ton
forklift to move these component to the graphitization shop 2. Task given is to ensure
the tools and equipment used to move the components are complete and discuss with the
SGL engineer about the arrangement of the components.

16. Graphite -repair wind separator at DEMCO crane graphite
The the wind separator at DEMCO crane was crack. Engmech was responsible to
welding the crack in order to repair it. Task given is to get information about the
material of the wind separator in order to choose the suitable welding rod.

17. Graphite -reposition furnace 8
This tender required Engmech to shorten the current length of furnace number 8 in order
to follow the standard design of all the furnaces at the graphitization shop. There are 4
sets metallic bed and tie rod need to be modified. The short circuit side components also
need to be relocated to the new position. This is the largest and longest project at the
SGL Carbon. Task given is to follow up from the beginning until this project is finished.

18. PI - fabricate and install spool piece
This tender required Engmech to supply and install spool piece at pitch impregnation
pipeline system.
19. PI - install valve and fabricated jacketed pipe together with insulation
Install valve at the thermo oil pipeline and insulate for safety purpose. The jacketed pipe
is fabricated to supply to the client for cooling system.
20. PI - welding coil in the pitch tank and do radiographic test (RT) for the joint
This tender required Engmech to repair the leakage at the thermo oil coil inside the pitch
tank. The coil was been repair by using argon welding. The joint need to be tested using
RT in order to ensure zero defects at the joint to avoid another leakage.















4.0 INDUSTRIAL PROJECTS
Reposition furnace number 8
This tender required Engmech to shorten the current length of furnace number 8 in order to
follow the standard design of all the furnaces at the graphitization shop. There are 4 sets metallic
bed and tie rod need to be modified. Furthermore it also required civil work to modify the base
for the new position of the furnace. Cooperation of these 2 course, mechanical and civil, to solve
the problem shows how the real industries work where it is rarely been taught in the class.
4.1 Job Scheduling
Engineer has figure out the required task to complete this project through discussion with the
client. Engmech need to complete the job within 6 weeks with 16 activities during in the week.
In industrial management subject, student have been taught on how to planning the work by
using gant chart. This knowledge has been applied during the internship by doing a schedule to
plan the work for the project. To plan these work, logical thinking need to be applied. For
instance, refractory head is very heavy component, thus its required a crane to lift the block.
The gant chart also helps the engineer when to order the crane and estimate the total cost need to
rent a crane for the applicable activities.

Figure 4: Gant Chart for project reposition furnace 8

4.2 Technical Drawing
Technical drawing is very important in real industry since it is used by engineer to ease the
visualization of all component either it visible or hidden. The engineer gave me the drawing of
furnace 8 to study the components required to be modified and also the actual length need to be
shorten. From the drawing, 4 sets of metallic bed needed to be shorten by 1050mm each. The tie
rod also must be shorten same as the length of metallic bed. The components affected by the
modification are the short circuit, cooling system, column and refractory block. All these
components need to be relocated according to the new position.
Drawing for reposition of furnace 8 can be refer appendix 1 until 3.

4.3 Scope of Jobs
The scope of jobs to has been discussed within the engineers in order to identify the components
and procedure to reposition the furnace 8.
4.3.1 Access platform

Figure 5: Access platform being remove by crane
The first components need to be dismantle is the access platform. the platform was being
removed by using overhead crane. To install it to new location, it must have good inter connect
with platform at furnace 7 and the base must be put cement grouting.
4.3.2 Refractory head

Figure 6: Refractory head being remove by crane

The components to dismantle and reinstall in this activity are 2 sets of upper block, 2set of lower
block, 2 sets of side block, and a center block. The activity required 45 ton of crane to lift the
components. This activity must be done carefully to avoid item fall which might break the
components.

4.3.3 Graphite head and water piping
The components to dismantle and reinstall in this activity is 2 sets of graphite head, 2 sets of
water cooling channel and all the mounting bolt and nut including all bracket. The graphite head
need to dismantle using crane. Water cooling channel can be dismantle by unmounts the bolts
and nuts.





4.3.4 Short circuit flohe set

Figure 7: Flohe set being remove by crane

Short circuit flohe set also being move by a crane to facilitate the removing process of other
component. It is then being relocated to new position according to the new length.
4.3.5 Tie rod

Figure 8: Tie rods being remove and modified
The tie rods are dismantle by using chain block. It is then being cut and modifies to shorten the
length by 1050mm. The joint must be checked with magnetic particle inspection (MPI) spray to
ensure no crack at the welded joint.


4.3.6 Process cooling
The components which involve in process cooling are accumulator, hose, valve and all its fitting.
All this components must be removed and relocated to new position. The 6inch sch 40 pipe for
water supply also must be extended 2.1m from the previous location.
4.3.7 Metallic bed

Figure 9: Metallic bed being remove and modified

The metallic bed has been remove by crane and been modified at green area. To modified the
metallic bed it taking a long duration and use many of grinding and cutting disk as well as
oxygen cylinder and acetylene cylinder for process of cutting and grinding.








4.3.8 Refractory (U shape and Pillar)

Figure 10: refractory block being remove by crane
The refractory which include 2 sets of U shape and 4 pillars is a very heavy component. It has
been remove by 45 ton crane. Before reinstall it to new position, the base must be hack and
install new grouting.

All the work above are the component involve to complete the project reposition furnace 8
following the same design as the other furnace at graphitization shop by shorten it 2.1m.
Basically, trainee monitors the progress of the project and inform project engineer and project
manager. Trainee also responsible to ensure the equipment and tools as well as material well
provided to smooth the progression of the project. However, apart from this project there is also
a maintenance jobs need to be done. Some of the project are urgent and have its deadline usually
due to the shutdown of plant. Therefore it is very important for me to arrange workers and keep
update the jobs to engineer and project manager so that all the projects can be done follow the
time frame. If the project did not follow the time frame, Engmech need to use profit gain from
the tender to pay worker salary. Thus the longer the duration of the project been extend, the
lower the profit gain. This knowledge already learnt from the subject Industrial Management
where profit is equal to total revenue deducts with total expenses. In order to get higher profit,
total expenses must be lower since total revenue are difficult to manipulate. By reduce working
time can minimize total expenses of a company.


5.0 SUMMARY
5.1 Conclusion
In conclusion, the industrial training had given me a lot of new knowledge and experience as a
mechanical student and also as a person. I expect to involve more on engineering calculation
related work or task, however much of my training time were focusing more on operation and
management aspect. However this didnt affect my excitement and focus on the ongoing training
period. On the contrary I am happy to have been able to take this valuables opportunity to
explore and experience new dimension of work in industry which I never experience before.
During my placement I had the practical work experience under project engineer En Zubari
which treated me as his real assistant. I was capable to contribute my ideas and insights in his
works. At the same time, he provided me with productive and stimulating learning environment.
I try to apply what I have learned in the lecture class at UiTM to actual work setting. I also able
to get a better understanding about the production process in a SGL Carbon especially related to
Electrode production. From the task and project given by my supervisor, I able to understand
manufacturing related aspect such as scheduling, manpower planning, and material flow. This
training has exposed me to the invaluable experience that I can't gain from the lecture hall or
classroom. Lastly, the industrial training is not only the knowledge outside the classroom but it
also opens my world view wider.

5.2 Recommendation
I recommend the company to create more structured training program. I understand that the
person responsible to supervise the practical student is already busy with their work burden.
However I believe that they can spend small portion of their time to plan more comprehensive,
structured and organized training for the practical student. The supervisor in charge should list
and arrange the training task which will be performed by the trainee.
A training schedule also should be made in order to optimize the training period. In arranging
and assigning the training task, the supervisor also should try to fill the training period with task
that significant in developing the trainee knowledge, skills and experience for its future career.