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ACKNOWLEDGEMENT
In the Name of Allah, the Most Beneficent, the Most Merciful. All praised to the Prophet
Muhammad SAW. Firstly, thankful to Allah SWT for gave me this great chance to go
through industrial training in Jabatan Kerja Raya (JKR) and finish it successfully.
First and foremost, I would like to thank my industrial supervisor, Abd Malek Bin Abd
Ghapar for guidance, information and knowledge during completing my training in JKR.
Besides from that, I also want to thank all the head units, Mr Zainuddin (heavy machinery),
Mr Fadhli (light vehicle), Mr Anuar (VTL) during my training in heavy machinery, vehicle
and VTL for their guidance, knowledge and support. Apart from that, I also want to convey
gratitude to all the staffs and technicians here for their kindness in helping me while
completing my industrial training.
In addition, it is important to have teamwork during my training and here I really want to
thank my colleagues for their kindness, exchange ideas and knowledge during my training
even though we came from different universities. Then, I want to convey my appreciation to
my Universiti Malaysia Pahang lecturers and supervisor, Mr Rosdi bin Daud for his
willingness to come to JKR Kelantan.
Last but not least, I want to thank my family for their love, motivation and support during my
industrial training in JKR. Thanks for all the ideas, opinion, knowledge and suggestion that
have given to me in order for me to complete this report.
ABSTRACT
This report is set out to give the reader full information about my industrial training in
Jabatan Kerja Raya (JKR) Mechanical Branched in Kelantan. Industrial training is one of the
compulsory curriculums in Universiti Malaysia Pahang which students need to complete
whether in consultant, factory and company. This course is sets up for student in order to give
them experience and gain knowledge in working environment before going through the real
working life. My industrial training is at Jabatan Kerja Raya or known as JKR Mechanical
branched which provide maintenance and construction to the public sectors in Malaysia.
In Jabatan Kerja Raya, I have been send to Mechanical branched which located in Panji, Kota
Bharu, Kelantan. At this branched, I have been assigned to workshop, building maintenance
and project. In workshop, there are three units which are heavy machinery, vehicle and
Vehicle Testing Line (VTL). During my placement, I have learned a lot new knowledge
about vehicle maintenance and safety. These knowledge are useful for me in future and gives
me a lot of advantageous to prepare myself for my future career.
Last but not least, in this report included the introduction, brief background about this
company, task and mini project I have been assigned, recommendations and conclusion in
details during my industrial training in JKR.
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TABLE OF CONTENTS
Page
ACKNOWLEDGEMENTS
ABSTRACT
ii
TABLE OF CONTENTS
iii
LIST OF FIGURES
CHAPTER 1
COMPANY PROFILE
1.1
Company Background
1.2
Companys Objective
1.2.1 Vision
1.2.2 Mission
Logo
1.3.1 Description
1.3.2 Colour
Organization Chart
1.3
1.4
1.5
CHAPTER 2
2.1
COMPANY ACTIVITIES
Introduction
10
10
11
11
11
iii
CHAPTER 3
STUDENT ACTIVITIES
3.1
Engine overhauled
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3.2
18
19
20
20
3.3
22
3.4
Project/ Tasks
29
29
31
32
40
3.5
CHAPTER 4
CONCLUSION
4.1
Conclusion
47
4.2
Recommendations
48
49
REFERENCES
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LIST OF FIGURES
Figure No.
Title
Page
1.1
JKRs Logo
1.2
Organizational Chart
1.3
Mechanical Branch
1.4
Project Unit
2.1
2.2
Workshop Department
2.3
Heavy Vehicle
2.4
Vertical Engine
13
2.5
Horizontal Engine
13
2.6
13
2.7
V 8 Engine
14
2.8
Rotary Engine
14
3.1
Light Vehicle
16
3.2
Piston
17
3.3
Assembling
18
3.4
19
3.5
Planetary gear
20
3.6
Excavator
21
3.7
Bulldozer
22
3.8
Test lane
23
3.9
Vehicle Entry
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3.10
24
3.11
Database
25
3.12
25
3.13
Smoke Testing
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3.14
26
3.15
27
3.16
Undercarriage Test
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3.17
Test Report
28
3.18
Drainage Before
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3.19
Insert Grill
30
3.20
Insert Sand
30
3.21
Insert Mat
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3.22
Workshop Layout
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3.23
Full View
33
3.24
Front View
34
3.25
Side View
34
3.26
35
3.27
35
3.28
Back View
36
3.29
36
3.30
37
3.31
Side View
37
3.32
Top View
38
3.33
Side View
39
vi
3.34
Zoomed View
39
3.35
Side View
40
3.36
Gear
41
3.37
Workshop Layout
42
3.38
45
vii
CHAPTER 1
INTRODUCTION OF INDUSTRIAL TRAINING
Jabatan Kerja Raya or Public Works Department as it known has been formed since 100
years ago by Major J.F.A McNair as its first head organization. JKR is the federal
government department in Malaysia under Ministry of Works Malaysia (MOW) which is
responsible for construction and maintenance of public infrastructure in Malaysia. Meanwhile
in Sabah and Sarawak another entity of Public Works Department exists under respective
state governments jurisdiction.
As public government department, JKR has touched many aspects of the nation's life by
providing necessary infrastructure, such as roads and water supply systems. With this, JKR
has been divided into a few branched which experts in their own field such as mechanical,
building, road, slope, electrical, military and water works. The mains infrastructure of public
government which maintained by JKR are federal road, state road, public hospitals, public
school and public government buildings. For this training, I have been assigned to
Mechanical branched in Panji, Kota Bharu, Kelantan. In Mechanical branched, works are
focused on machinery maintenance and mechanical construction for the department.
1.2 COMPANYS OBJECTIVE
1. Complete the mechanical systems design work that meet the standards, quality, time
and cost as prescribed.
2. Deliver mechanical system / projects that meet quality, time and cost as prescribed.
3. Perform maintenance of mechanical systems, vehicles, plant construction and quarry
plant belonging to the government that meet quality, time and cost as prescribed.
1
Helping our customers realize the policy / objectives and deliver services through
cooperation as a strategic partner.
Providing asset management services and the effective and innovative projects.
1.3 LOGO
1.3.1 Description:
1. Generally, the exhibited logo as it mirrors the diversity of fields of work entrusted to
the Jabatan Kerja Raya (JKR).
2. Starting from the base, black colored curved lines symbolizes clean water supply and
reflects that JKR is a dynamic organization.
3. The arch-shaped lines in concentrated black color denotes to construction related
work and maintenance of bridges and as well as a representative of the JKR
organizations assigned as one of the leading the country in implementing engineering
work.
4. Straight black lines, on the line shaped arch symbolize the participation to implement
the road network nationwide.
5. Fourteen lines on a straight line signify a pledge to executing building operations
comprising 14 states and federal territories in Malaysia.
1.3.2 Colour
1. Yellow symbolizes maturity brands of JKR as one of the oldest organizations
established and replicates the image growing in achieving its objectives.
2. Black symbolizes strength / unity quality of branch - the branch in JKR organization
entrusted to implementing development projects.
3. Grey symbolizes existence values - values of human capital in provide services.
Project
Building maintenance
Quarry
Each of the department play an important role in maintaining goverment machinery and
infrastructure.
1.4.2.1 Project Department
Workshop department is divided into three units which are Light Vehicle, Heavy
Machinery/Vehicle and Vehicle Test Line (VTL). Function of Light Vehicle and Heavy
Machinery units are kind of similar. It needs to maintain and repair the government light and
heavy vehicle. In Light Vehicle unit, it provides transportation for staff to go to construction
site while Heavy Machinery unit provides vehicle for construction like backhoe, bulldozer
and etc.
UNIT
HEAVY MACHINERY
- Observation
- Practical
- Operating equipment/
software
- Mini project
VEHICLE
- Observation
- Practical
- Operating equipment/
software
- Mini project
VTL
- Observation
- Data collecting/
analysing
- Writing report
MAINTENANCE
- Site visit
- Observation
- Data collecting/
analysing
PROJECT
- Site visit
- Data collecting/
analysing
- Observation
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CHAPTER 2
COMPANY ACTIVITIES
2.1 INTRODUCTION
In this chapter, I will explain in details about this company activities. As I have explained
above that, this company has five department which is Project, Building Maintenance,
Workshop, Quarry and Administration and Financial. However, for 10 weeks of internship, I
only have been to Workshop, Project and Building Maintenance departments.
2.1.1 Workshop Department
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Workshop department is divided into three units which is Light Vehicle, Heavy
Machinery/Vehicle and Vehicle Testing Line.
machinery, I have watched demonstration on Final Drive. Besides, for Vehicle Test Line
(VTL), I have watched inspection of vehicle. Every government vehicle need to be test to
ensure its safety. It need to go through four stages.
Stage 1: Vehicle Entry, Above Carriage Inspection
Stage 2: Diesel Smoke Test, Emission Test, Sound Level Test And Headlight Beam Test.
Stage 3: Sideslip Test, Roller Brake Test, Suspension Test, Speedometer Test.
Stage 4: Under Carriage Inspection And End Of Lane Test.
2.1.2 Project Department
Carry out work in compliance with the government policies which is will be
introduced from time to time.
Planning, prepare project draft and estimated cost of mechanical system tools for
government building and infrastructure that will build.
Design and prepare drawing with technical specification to call the deal for federation
and state project .
Plan maintenance programme and cost estimated for mechanical system tools in
government building and infrastructure which needed to be maintain
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12
CHAPTER 3
STUDENT ACTIVITIES
Vertical
Horizontal
Horizontal opposed
V 8
Rotary.
13
Mechanical system
1. Engine block
8. Main bearing
2. Crankshaft
3. Piston
4. Cylinder head
11. Tappet
5. Valve
12. Crankcase
6. Piston ring
7. Rocker arm
15
ii.
Fuel system
Function: To distribute fuel into combustion chamber with specific amount at a certain
time.
Component:
iii.
1. Injection pump
7. Throttle body
2. Injector (nozzle)
8. Carburettor
9. Contact point
10. Distributor
5. Fuel tank
Lubrication system
Function:
1. To avoid engine components from wear
2. Gives lubrication to components during using the engine
3. To control engine temperature
Component:
1. Oil sump (crankcase)
4. Oil filter
2. Oil pump
5. Air cleaner
3. Oil gelory
iv.
Cooling system
There are two system in cooling system which are water cooling system and air cooling
system.
Function: to control engines temperature during using the engine, thus to prevent engine
from over heating.
Component:
1. Radiator
2. Water pump
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3. Radiator cap
6. Belting
4. Rubber hose
7. Reserve tank
5. Fan
v.
Electrical system
Function: to distribute electrical current to each section with specific amount .
Component:
1. Battery
5. Ignition switch
2. Starter motor
6. Fuse box
3. Alternator
4. Relay
After knowing all the components in the engine, we will proceed to engine overhaul. An
engine overhaul is a comprehensive engine tune-up that involves removing and
disassembling a vehicle's engine, testing all the components, cleaning and replacing parts as
needed and then reassembling the engine. This is done to improve vehicle performance and
prolong the life of the engine.
Why engine need to be overhaul? The factors of engine need to be overhaul are noise in
engine, component in engine break and engine under power.
17 Vehicle
Figure 3.1 Light
Step 2: Engine
1. Clean outer parts of the engine.
2. Throw away the engine oil from the drain plug.
3. Open cylinder head. Start from side part.
4. Open the crankcase and bolt connecting rod.
5. Remove piston by using wooden hammer.
6. Open bolt main cup to remove the crankshaft.
7. Remove camshaft, push rod and tapped.
8. Open bolt fly wheel and remove it housing.
9. Then, open the bolt rocker arm and remove its valve.
10. Remove main bearing in engine block and main cap
11. After that, open C clip/eyer clip of guindy pin in piston to remove connecting rod
from piston.
12. Remove cylinder head gasket on surface of engine block and clean it.
13. Take out all other remain components and clean them.
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20
21
Material handling
Forestry work
Forestry mulching
Demolition
General grading/landscaping
River dredging
Drilling shafts for footings and rock blasting, by use of an auger or hydraulic drill
attachment
Snow removal with snow plow and snow blower attachments avator
Bulldozer
23
24
Before start the operation, make sure that there is no vehicle and any sensor is switch on on
the test lane. There are four stages of inspection
Stage 1
o Vehicle entry
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Stage 2
o Diesel smoke test
The test is during engine in neutral / free gear. Diesel smoke tester machine is
used to test the pollution emitted by vehicle. If the results are above 50%, the
vehicle will be sued to environmental department and need to change its
component.
26
Stage 3
o Side slip test
27
Sideslip test is carried out to inspect the alignment of the car. It will be done for
front and back wheel.
o Roller brake test
Stage 4
o Undercarriage test
29
The test report will be out at the end of tests to show the results of the test. The
test failed if the results are below the assigned efficiency. For the vehicle that
didnt pass the test, it needs to be send for services.
3.4 PROJECTS/ TASKS
3.4.1
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 didnt 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.
Installation steps:
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3.4.2
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.
32
Stor
o Install used battery and oil.
Toilet (Tandas)
o For worker uses
33
3.4.3
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.
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35
36
37
38
Workshop building
39
Workshop Building
Workers controller
40
41
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 equipments 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
42
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.
3th July 5th July 2016
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.
43
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.
17th July 2016 21th July 2016
5
During this week, I have been assigned to Vehicle Test Line
(VTL) unit.
24th July 2016 28th July 2016
storage, easy to keep the oil drum and to ensure the safety of the
workers.
Only Nissan Nevara passed all test during the inspection while
other vehicle had failed.
The vehicle failed the test if it didnt pass the range or limit that
had been assigned.
As for the Nissan Urvan, it didnt pass the test because the result
of front brake is less than 50%.
While for Toyota Hilux, it didnt pass the test because the result of
rear brake is less than 50%
Vehicle that didnt pass the test will be send to the service center
for services
45
46
10
project.
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.
For tool dispenser, it acts like washing machine but for tools. It is
easy for technician to use tools.
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CHAPTER 4
4.1 CONCLUSION
In conclusion, after undergo three months of Industrial Training, all the objectives of the
program are full-filled. I have learned lot of new things and have acquired sufficient exposure
in new area such as instrumentation, Mechanical and others. I also have a chance to relate all
the theories learned at university with real working life.
Basically the program was successfully completed whereby all the objectives highlighted by
Industrial Training Committee were achieved. I had the opportunity to integrate theory with
practice while completing the assignment and projects given by my supervisor. The
integration of the theoretical knowledge and the industry has enhanced better understanding
on the subjects that I have learned in the university, thus smoothen the learning process.
Moreover, the program was not only beneficial for me in term of technical or academic base
but I could also develop various skills. From this program, I had developed skills in work
ethics, communication and management skills. Since there are different levels of personnel, I
had experience in adapting to this kind of environment.
Jabatan Kerja Raya is an ideal place for Industrial Training Programme as the experience and
knowledge gained is the most valuable lesson which cannot be received in class. The
combination of technical and non-technical skills has provided an opportunity for the student
to prepare in working life culture.
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4.2 RECOMMENDATION
During industrial training, I had been given ample opportunity to learn and experience
working in corporate organization, I feel that there are rooms for further improvement so that
I can meet the requirements of their practical placements particularly in fulfilling the
objectives of the placement; as such I would like to make some recommendations for both
JABATAN KERJA RAYA (JKR) and UMP.
In order for the next candidates to gain better knowledge and experience of working
environment from the Industrial Internship Program, I would like to suggest some
recommendations to be reviewed by industry unit of University Malaysia Pahang.
The time given for me to do industrial training is very short which only ten weeks. I would
like to suggest for the Mechanical Faculty or UMP to extend two more weeks. This is
because most of company only want to take students with 3 months industrial training. With
this, it would be lack of opportunities for us to be chosen. Besides that, from my experience, I
couldnt been assigned to other department as I have only short amount of time.
Other than that, the briefing for Industrial Training should be given one semester before the
search is on. The appropriate verification letter should be given to student before their
semester break so they could search and apply for internship during their holiday. The list of
company previous student had done their internship should also be publish to make the job of
applying internship easier. Almost all University students in Malaysia is applying to do
internship in the same period of time UMP student, so the faster they apply the better chances
they get the placement.
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REFERENCES
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