Transcript
International Islamic University
Malaysia
Engineering industrial training
(Eit 4004)
OMNI OIL TECHNOLOGIES (ASIA)
SDN BHD
Name: Mohd Affizul Ariff Bin Salim
Matric No: (0710841)
Discipline: Bachelor of Mechanical Automotive Engineering
Department: Mechanical
Visiting Lecturer: Dr Mirghani
Training Period: 12th April 2010 – 2
nd July 2010
Year: 2010
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
COMPANY VERIFICATION STATEMENT
I hereby declared that, MOHD AFFIZUL ARIFF BIN SALIM (Matric No: 0710841) student of
DEPARTMENT OF MECHANICAL ENGINEERING, International Islamic University Malaysia (IIUM)
has successfully completed his Engineering Industrial Training from 12th April 2010 till 2nd July
2010 at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD under Quality Control Department and
Engineering Department.
This report is prepared by above-mentioned student as a partial fulfillment of this training. All
information given in this report is true and does not contain any confidential information or
classified data that might in a way or another abuse the company’s policies
Approved by,
Mr. Zulkiflee Samsi
Manufacturing Engineer act as Plant Manager
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(i)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
ACKNOWLEDGEMENT
In the name of ALLAH, the Most Gracious and Most Merciful, I thank ALLAH SWT for
bestowing me with health, knowledge, patience and determination to complete the
Engineering Industrial Training at OMNI OIL TECHNOLOGIES (ASIA) SDN BHD.
Therefore, I acknowledge with great gratitude to Engineering Department and Quality
Control department of OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, which supervised by Mr.
Zulkiflee Samsi and Mr. Hanafi Mamat for willingness to train me, giving advices, sharing
experiences, and giving encouragement to me. Biggest appreciation to Quality Control
Inspector, Mr. Md Shah and Mr. Yazid Sabarani for continuously supporting and providing me
with all great lessons and valuable experiences during the time I was in the company.
Acknowledgement also to Mr. Hisham Serry act as Production Engineer for his kindness
and for treating me nicely and equally like other permanent staffs in OMNI OIL TECHNOLOGIES
(ASIA) SDN BHD. Millions appreciation goes to all staffs, engineers, senior technicians and
technicians for sharing their knowledge and for welcoming me to be part of OMNI OIL
TENOLOGIES member.
Also I would like to express my greatest appreciation to my visiting lecturer Dr MIrghani
for his consultation and advice to complete my final presentation and report and also for the
assessment throughout this engineering industrial training. Special thank goes to my
colleagues, Bro Khairul Muhaimin who always helped and support to solve all engineering work
throughout the training process. Finally, my highest appreciation goes to my beloved parents
for the moral support and encouragement to fulfill successfully this engineering industrial
training.
(ii)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
SUMMARY
This Engineering Industrial Training report is prepared for the purpose of fulfilling the
final requirement upon completion of the EIT program which had been underwent during
semester 3, 2009/2010 session. This report contains all the relevant information and
description regarding the training program which has been successfully completed at OMNI OIL
TECHNOLOGIES (ASIA) SDN BHD. It also discusses the activities and contribution towards the
company throughout the training program period.
There were no specific projects assigned to the students, instead the students were
placed to various section within the company such as Quality Control Department section
Assembly Department section and Engineering Department section. Any tasks given are
subjected to the supervision of personnel of each section.
This Engineering Industrial Training is beneficial for the students since it will enhance
their knowledge regarding engineering work throughout the practical training. During the
training, it helps the student to build up their level of confidence as well as how to respect
other peoples such as technician or engineer. It is a platform for the students to be more
adaptable to real working environment and to develop as well as to enhance their interpersonal
skills. More over it can develop the skills, ability, and competency of the students throughout
this industrial training.
(iii)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
BACKGROUND OF OMNI OIL TECHNOLOGIES
Omni Oil Technologies is the first leading edge integrated technology development and
manufacturing center that was set up in the Middle East early 2004 for drilling tools for the Oil
and Gas industry. It is conveniently based in Dubai prominent Free Zone, Jebel Ali, United Arab
Emirates. Omni oil is capable of developing, modifying and producing customized tools to deal
with even the most extreme down holes challenges.
Omni currently operates throughout the Middle East and North Africa in major oilfield
centers such as Saudi Arabia, U.A.E., Oman, Kuwait, Egypt and Sudan. A larger manufacturing
facility for OMNI is currently under construction in Jebel Ali Free Zone in order to face up to the
increased demand for OMNI products. In addition, another manufacturing center is under
establishment in Malaysia to cover the Asia Pacific market needs.
“We are committed to excellence in standards and quality control and providing unmatched
local support,” says Mr. Mohammad Makhlouf, the President/CEO of the company.
All OMNI products adhere to API standards and are assured through a quality
management system in accordance with ISO-9001 2000. All OMNI tools are designed and
analyzed using leading edge technologies in design and stress analysis using Finite Element
Analysis (FEA) computer simulation packages. The manufacturing facility is equipped with
Computer Numerically Controlled (CNC) production lines, delivering precisions manufacturing
to the highest worldwide standards.
(1)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
MISSION AND VISION OF OMNI OIL TECHNOLOGIES
To create a product development and manufacturing organization that serves the oil
and gas industry in the Middle East and grows profitably and independently into the global markets in an environmentally friendly manner while maximizing value to its shareholders and surrounding community and become the preferred organization of choice to its employees and customers
To provide a training and development platform for emerging regional human capital and place the region on the front end of technical innovation and development in the global oil and gas industry
To become the leading global technology development and manufacturing organization in the oil and gas industry originating from the Middle East
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MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
PRODUCT OF OMNI OIL TECHNOLOGIES
OMNI Oil Technologies is an approved supplier of Drilling Enhancement Tools for the major national oil companies through the Middle East. OMNI Drilling Enhancement Tools are deployed in many locations and in a variety of different formation lithologies around the region. Furthermore, these tools have shown outstanding performance in total operating hours. OMNI Oil Technologies Drilling Enhancement Tools are compatible with any BHA configuration thereby improving the overall drilling performance in well bores of all sizes. OMNI's current products are branded as the “Bassal” generation of products after their chief designer, Mr. Adel Bassal.
OMNI products are classified into three groups:
(3)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
OBJECTIVES OF ENGINEERING INDUSTRIAL TRAINING
To provide student with industrial working environment
To provide students with job experience
To assist students to acquire knowledge related to Oil and Gas industry, and company
Administration Systems.
To assist student to gain informal learning process regarding engineering studies
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MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
ROLES DURING ENGINEERING INDUSTRIAL TRAINING
Join Quality Control Department on 12th April 2010
1st week – to be familiar with all measuring tools and equipment in QC department such as Holtest, Digital Calliper, Vernier Calliper, Rotary work plug, Rotary work ring, Block Gauge, Dial Gauge and others.
2nd week – to be able to measure threading for different bodies such as flexi joint 6.5 inches and flexi joint 8.00 inches also for roller reamer 17.5 inches. There different types of threading which are 4 ½ Internal Flush Threading, 6 5/8 Regular Threading, 7 5/8 Regular Threading. The threading measurement done by using thread height gauge, rotary work plug, rotary work ring, bore gauge, outer micrometer, thread profile 4 1/2 IF, 6 5/8 REG, 7 5/8 REG, API Gauge, Lead gauge and others. Also measure the diameter of flexi joint 8.00 inches and 6.75 inches.
3rd week – Do the quality file for flexi Joint 8.00 inches and 6.75 inches. In this quality file, it includes inspection standard, inspection test plan (bubble drawing), Inspection check sheet, Drawing A3 size and also the NCR report. Before the inspection check sheet is done, must refer to the drawing to check the tolerance for each parameter and also check the bubble drawing parameter
4th week - Check the flexi joint again with brother Shah to confirm the length dimension by using the Big Milling Centre 3 (BMC 3) machine. This due to the accuracy of measurement by using the BMC 3 is higher rather than by using measuring tape. The measurement by using BMC 3 machine is up to 3 decimal points rather than using tape measure which is up to only 2 decimal points. With BMC 3 machine also we can check the straightness and roundness of the flexi joint.
5th week – Check the dimension of RR Pin since it cannot be assembles with the RR cutter. Do the measurement for the diameter of the RR Pin and all the dimension are within the tolerance. Then, carry out the straightness check for RR Pin at the Granite table by using the Filler Gauge. Then only we can detect the straightness problem which is around 50 micron.
(5)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
6th week – Do the length measurement for driver sub 10 inches and driver sub tapered 7.5 inches with brother shah. Also check the straightness and roundness of driver sub 10 inches and driver sub tapered 7.5. Also check the surface roughness at the machining site for mandrel upper and mandrel lower. Regarding the measurement of radius which is difficult to be measured, brother shah and me do the testing by using the silicon putty and put the silicon putty at the designated area so that the radius can be measured by using CMM machine.
7th week – Do the inspection check sheet of mandrel upper and mandrel lower, also the inspection standard for mandrel upper and mandrel lower, with the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Do the inspection check sheet of driver sub, also the inspection standard, the inspection test plan (bubble drawing) and the original drawing for mandrel upper and mandrel lower. Revise the flexi joint check sheet, inspection test plan (bubble drawing), inspection standard and the original drawing A3 size. The entire documents are in soft copy form.
8th week – Do the checking and inspection for the quality control’s equipment such as outer micrometer, rotary work plug and rotary work ring. This due to the existence of corrosion at the surface of the equipment and need to be removed from the surface. Also do the checking for all equipment’s serial numbers and do the marking of the serial number at all equipments.
9th week – Do the inspection for upper block and lower block with bro Yazid and identify the incomplete inspection for upper block and lower block. There are 2 batches which consist of 24 pieces. Also do the packing for cutter, upper block, and lower block and pin to be sent for nitriding process.
10th week – Join Assembly Process Department on 8th June 2010. Do the assembly process between tungsten carbide insert and cutter. Do the hardness test for the heat treated jig with Bro Halim. Do the assembly process for cartridge, which consist of upper block, lower block and cutter.
(6)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
11th week – Do assembly process for cutter and pin with piston, spring and oil ring. Then do the assembly for cartridge, which consist of upper block, lower block and cutter. Do inspection for raw material which given from the supplier. Need to confirm the dimension such as diameter and length.
12th week – Visit to Umetoko Company in Kota Kemuning Shah Alam to see the nitriding process. Preparation of final presentation slide and also final report on Engineering Industrial Training
(7)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
MANUFACTURING PROCESS
The word manufacturing is derived from the Latin manu factus, meaning made by hand.
The word manufacture first appeared in 1567 and the word “manufacturing” appeared in 1683.
The word product and production first appeared sometime during the 15th century. The word
“manufacturing” and “production” often are used interchangeably.
For any manufacturing company such as OMNI OIL TECHNOLOGIES (ASIA) SDN BHD,
manufacturing is generally a complex activity involving a wide variety of resources such as:
- Product design
- Machinery and tooling
- Process planning
- Materials
- Purchasing
- Manufacturing
- Production control
- Support services
- Marketing
- Sales
- Shipping
- Customer service
(8)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
MANUFACTURING PROCESS AT OMNI OIL TECHNOLOGIES
(9)
Raw material
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(10)
Tools (Steady rest)
Equipment
(CNC BIG MILLING
CENTER)
Equipment
(CNC BIG TURNING
CENTER)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(11)
Labor / Workforce
Waste (chips)
Finished Product Rejected Product
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
It is essential that manufacturing activities be responsive to several demands and trends:
1. Product must fully meet design requirement, product specification and standard
2. A product must be manufactured by the most economical and environmentally friendly
methods
3. Quality must be build into the product at each stage, from design to assembly rather
than relying on quality testing after the product is manufactured
4. In the highly competitive environment of today, production methods must be
sufficiently flexible to respond changing market demands, types of products, production
rates, production quantities, and provide on time delivery to customer.
5. Continuous developments in materials, production methods, and computer integration
of both technological and managerial activities in a manufacturing organization must be
evaluated constantly with a view to their appropriate, timely, and economical
implementation
6. Manufacturing activities must be reviewed as a large system, all parts of which are
interrelated to varying degrees. Such systems can now be modeled in order to study the
effect of factors such as changes in market demands, product design, materials, and
production methods on product quality and cost.
7. The manufacturer must work with customer for timely feedback for continuous product
improvement.
8. A manufacturing organization constantly must strive for higher levels of productivity,
defined as the optimum use of all its resources such as materials, machines, energy,
capital, labor, and technology; output per employee per hour in phase must be
maximized.
(12)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
SELECTION OF MATERIAL
(13)
Selection of material
Properties of material Cost and availability Appearance, service life and
recycling
The appearance of materials,
after they have been
manufactured into products,
influences their appeal to the
consumer. Color, feel and surface
texture are characteristics that we
all consider when marking a
decision about purchasing a
particular product.
The economic aspects of material
selection are also important as
technological consideration of the
properties and characteristic of
material. If raw materials or
manufactured component are not
available in desired shapes,
dimension, and quantities, hence
additional processing will be
required and this situation will
lead to increase in the production
cost.
The first consideration is the
mechanical properties of the
material such as strength,
toughness, ductility, hardness,
elasticity, fatigue and creep.
The next consideration is the
physical properties of the material
such as density, specific heat,
thermal expansion, thermal
conductivity, melting points, and
electrical and magnetic properties.
A combination of mechanical and
physical properties is the strength
to weight and stiffness to weight
ratios of the material, particularly
important aerospace, automotive
and petroleum industry.
Chemical properties play an
important part such as oxidation,
corrosion, general degradation,
toxicity and flammability.
Manufacturing properties of
material whether it can be cast,
formed, machined, joined, and
heat treated, with relative ease.
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
BEHAVIOUR AND MANUFACTURING
PROPERTIES OF MATERIAL
(14)
-Heat Treatment
-Precipitation Hardening
-Annealing
-Tempering
-Surface Treatment
-Alloying
-Reinforcement
-Composites
-Laminations
-Fillers
-Density
-Melting Point
-Specific Heat
-Thermal Conductivity
-Thermal Expansion
-Electrical Conductivity
-Magnetic Property
-Oxidation
-Corrosion
-Atomic bond:
Metallic, covalent and ionic
-Crystalline
-Amorphous
-Partly Crystalline
-Polymer Chains
-Strength
-Ductility
-Elasticity
-Hardness
-Fatigue
-Creep
-Toughness
-Fracture
Structure of
materials
Mechanical properties Physical and Chemical
properties
Property modification
Behavior and manufacturing
properties of materials
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
HEAT TREATMENT PROCESS
The properties and behavior of metal and alloy during manufacturing and performance
during their service life depend on their composition, structure, processing history and as well
as heat treatment process to which they have been subjected. The important properties such
as strength, hardness, ductility, toughness and resistance to wear are influenced greatly by
alloying elements and heat treatment process. By doing heat treatment processes it can
modifies the microstructures and change the mechanical properties such as formability,
machinability, hardness, toughness and strength.
As for OMNI OIL TECHNOLOGIES (ASIA), the implementation of heat treatment process
is done for the purpose of hardening the jigs which is used for machining process and quality
inspection process.
As shown in the picture, it is during the heating process of the jig. The required
temperature is about 800 °C and the increment of the temperature is measured by using the
temperature sensor.
(15)
JIG
COOLANT
FLAME
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
After about 3 hours heating the jig, thus the temperature reaches 800 °C. So after that we
need to immediately immerse the jig inside the coolant. This is rapid cooling process since we
desired the properties of the jig to be very hard as compared to initial properties of the jig. This
process is known as quenching process.
There are 7 different cooling processes which are:
Quenching
This is the process in which the heated material is being rapidly cooled by using water, oil,
coolant or other cooling liquid as a medium of cooling. By doing quenching process, it has
great rate of cooling and instantaneously the heated material will be in the normal
temperature again. The property of the material differ from the untreated material such as
increase in hardness value, become brittle, increase in strength and toughness value and
not uniform grain structure (Formation of martensite microstructure)
Normalizing
This is the process in which the heated material is cooled down in the open air in the room
temperature. By doing normalizing process, it has better rate of cooling as compared to
annealing process and the will be in the normal temperature again for about 4 to 5 hours.
The property of the material will be different than the untreated material such as slightly
increase in hardness value, increase in ductility, and slightly increase in strength and
toughness value, and also slightly uniform grain structure (Formation of partly martensite
and partly pearlite microstructure). The normalizing process also is done to refine the grain
boundaries.
(16)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Annealing
This is the process in which the heated material is cooled down very slowly inside the
heating furnace. By doing annealing process, it has the lowest cooling rate as compared to
the normalizing process and quenching process. The material will be in the normal
temperature again for about 1 day after the heating process is done. The property of the
material will differ than the untreated material in term of the hardness since annealing
process will have the lowest hardness value than quenching and normalizing process. The
other property which differs is the ductility in which the annealed material will be very
ductile. Furthermore, the annealed material will have less strength and toughness value.
The annealed material also will have very fine and uniform grain structure. (Formation of
pearlite microstructure)
Tampering
In tempering process the material is heated to a specific temperature (depend on the
composition of the material) and it is cooled down under prescribed rate of cooling.
Tempering process is used to reduce brittleness, increase ductility and toughness and
reduce the residual stress.
Austempering
In austempering process, the heated material is quenched rapidly from the austenitizing
temperature to avoid formation of ferrite and pearlite microstructure. It is then held at a
certain temperature until isothermal transformation from austenite to bainite
microstructure is complete. It is then cooled down to room temperature. Austempering
process is used to substitute the conventional quenching and tempering in which to reduce
the tendency toward cracking, and distortion during quenching, to improve ductility and
toughness while maintaining hardness value.
Martempering
In martempering process, the heated material is first quenched from austenitizing
temperature in a hot fluid medium such as hot oil or molten salt. Then it is held at that
temperature until the temperature is uniform throughout the material, and being cooled at
moderate rate such as in air. Martempered material has fewer tendencies to crack, distort,
or develop residual stress during heat treatment process.
(17)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Ausforming
In ausforming process the material is formed into desired shapes within controlled ranges
of temperature and time to avoid formation of nonmartensitic transformation product. The
part is then cooled at various rates to obtain the desired microstructures. Ausformed
material has superior mechanical properties.
To clearly see the different microstructures such as pearlite, bainite, ferrite and
martensite, it can be visualize through microscope and electron microscope.
(18)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
SURFACE TREATMENTS AND COATINGS
After the part is manufactured, some of its surfaces may have to be processed further in
order to ensure certain properties and characteristics. It may be necessary to perform surface
treatments in order to:
Improve resistance to wear, erosion, and indentation
Control friction (sliding surfaces of tools, dies, bearings, and machine ways)
Reduce adhesion (electrical contact)
Improve lubrication
Improve resistance to corrosion and oxidation
Improve fatigue resistance
Rebuild surfaces
Modify surface textures
Impart decorative features
(19)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(1) Mechanical Surface Treatment Shot Peening Process
In shot peening the workpiece surface is impacted repeatedly with a large number of
cast steel, glass, or ceramic shot (small ball), which make overlapping indentation on the
surface. This action causes plastic surface deformation at depths up to 1.25 mm using shot sizes
that ranges from 0.125 to 5 mm in diameter. Because of the plastic deformation is not uniform,
throughout the part’s thickness, shot peening causes compressive residual stresses on the
surface, thus improving the fatigue life of the component by delaying fatigue crack initiation.
Unless the process parameters are controlled properly, the plastic deformation of the surface
can be so severe that it can damage the surface. However it should be noted that (if these parts
are subjected to high temperature) the residual stress will begin to relax (thermal relaxation)
and their beneficial effects will be diminished greatly.
(20)
Shot peening surface
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(2) Case Hardening Nitriding Process
Methods of case hardening are such as carburizing, carbonitriding, cyaniding, nitriding,
flame hardening, and induction hardening. Case hardening as well as some of other surface
treatment processes induces residual stresses on the surface of the material. The formation of
martensite microstructure during case hardening causes compressive residual stresses on
surface. Such stresses are desirable since it will improve the fatigue life of the component by
delaying the initiation of fatigue crack.
As the engineering industrial training (EIT) conducted at OMNI OIL TECHNOOGIES (ASIA)
SDN BHD, the case hardening process also already implemented to improve the fatigue life of
the material such as roller reamer. The case hardening process that being used is nitriding.
Nitriding is a heat treating process that alloys nitrogen into the surface of a metal to
create a case hardened surface. It is predominantly used on steel but also titanium, aluminum
and molybdenum. The processes are named after the medium used to donate nitrogen. The
three main methods used are:
Gas nitriding
Salt bath nitriding
Plasma nitriding
(21)
After nitriding process
(surface are slightly darker)
Before nitriding process
(surface are shining)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Gas Nitriding
In gas nitriding the donor is nitrogen rich gas usually ammonia (NH3), which is why it
is sometimes known as ammonia nitriding. When ammonia comes into contact with the
heated work piece it disassociates into nitrogen and hydrogen. The nitrogen then
diffuses from the surface into the core of the material.
The advantages of gas nitriding are:
All round nitriding effect
Large batch sizes possible
With modern computer control of the atmosphere the nitriding result can be
tightly controlled
Relative cheap equipment cost
The disadvantages of gas nitriding are:
Reaction kinetics heavily influenced by surface condition
Surface activation is sometimes required to successfully treat with a high
chromium content
Ammonia as nitriding medium (toxicity which is harmful when inhaled in large
quantities and when there is presence of oxygen there is risk of explosion)
(22)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Salt Bath Nitriding
In salt bath nitriding the nitrogen donating medium is a nitrogen containing salt such as
cyanide salt. The salt used also donates carbon to the workpiece surface making salt bath a
nitrocarburizing process. The temperature used is typical of all nitrocarburizing processes 550-
590 °C
The advantages of salt bath nitriding are:
Quick processing time
Simple operation
The disadvantages of gas nitriding are:
The salt used are highly toxic
Only one process possible with a particular salt type
Plasma Nitriding
Plasma nitriding also known as ion nitriding, plasma ion nitriding, or glow discharge is an
industrial surface hardening treatment for metallic materials. There is hot plasma, typified by
plasma jets used for metal cutting, welding, cladding or spraying. There is also cold plasma
usually generated inside vacuum chambers at low pressure regimes. Here high temperature
characteristics of the ionized gases are not used, but the electronic properties become useful.
Thus an ionized gas like nitrogen in such a low pressure regime becomes much more reactive.
The advantages of plasma nitriding are:
Close control of the nitride microstructure
Allowing nitriding with or without compound layer formation
Performance of metal parts get enhance
Working lifespan gets boosted
Strain limit and fatigue strength are being treated
(23)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(3) Conversion coatings Phosphate conversion coating
Conversion coating is the process of producing a coating that forms on metal surfaces
as a result of chemical or electrochemical reactions. Various metals can be conversion coated
such as steel, aluminum, and zinc. Oxides that naturally form on their surfaces are a form of
conversion coating.
Usually phosphate coatings are used on steel part for corrosion resistance, lubricity or as
a foundation for subsequent coating or painting.
The application of phosphate coating make use of phosphoric acid and takes advantages
of the low solubility of phosphates in medium or high pH solution. Iron, zinc, or manganese
phosphate salt are dissolved into solution of phosphoric acid. When steel are placed in the
phosphoric acid metal reaction takes place which locally depletes the hydroxonium ions, raising
the pH and causing the dissolved salt to fall out of the solution and be precipitated on the
surface. The acid and metal reaction also creates iron phosphate locally which may also be
deposited. In the case of depositing zinc phosphate or manganese phosphate the additional
iron phosphate is frequently an undesirable addition to the coating.
(24)
Semi finish area at OMNI OIL
TECHNOLOGIES (ASIA) SDN BHD
Phosphate coating at the 12.25
inches Roller Reamer body
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Typical phosphate procedures:
(1) Cleaning the surface
(2) Rinsing
(3) Surface activation
(4) Phosphating
(5) Rinsing
(6) Neutralizing rinse
(7) Drying
(8) Application of supplement coating
(25)
Surface of material after
phospating
Surface of material before
phospating
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(4) Hard Facing
In this process a relatively thick layer, edge, or point of wear resistance hard metal is
deposited on the workpiece surface using the fusion welding techniques. Numerous layers
can be deposited to repair worn part. Hard facing enhances wear resistance of the material,
hence such material are used in the manufacture of tools, dies and various industrial
components. Worn part also can be hard faces for extended use.
(26)
The picture before hard facing
process is done.
This is the surface whereby the hard
facing process is conducted
During hard facing process
The picture after hard facing
process is done.
Stress concentration initiated
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
STRESS CONCENTRATION
The torsion formula (shear stress) τmax = Tc / J, whereby T is torsion, c is the outer radius
and J is the polar moment of inertia. This formula can be applied to regions of a shaft having
circular cross section that is constant or tapers slightly. When sudden changes arise in the cross
section, both the shear stress and shear strain distribution in the shaft become complex and
can be obtained only by using experimental methods or possibly by a mathematical analysis
based on the theory of elasticity.
In order to eliminate the necessity for the engineer to perform a complex stress
analysis, the maximum shear stress can be determined for a specified geometry using a
torsional stress concentration factor, K. As in the case of axially loaded members, K is usually
taken from the value of graph. To use this graph, first we must determine the geometric ratio
D/d to define the appropriate curve and then once the abscissa r/d is calculated, the value of K
is found along the ordinate. The maximum shear stress is then determined from the equation:
It can be noted from the graph that an increase in fillet radius, r causes a decrease in K.
Hence the maximum shear stress can be reduced by increasing the fillet radius. Also if the
diameter of the material is reduced, the ratio D/d will be lower and so the value of K and
therefore τmax will be lower.
Like the case of axially loaded member, torsional stress concentration factors should
always be used when designing part or material that will be subjected to fatigue or cyclic
torsional loadings. These conditions give rise to the formation of cracks at the stress
concentration, and this often lead to sudden failure of the part or material. Thus it is necessary
to strengthen the region which has stress concentration though hardening process such as hard
facing.
(27)
τmax = KTc / J
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
Stress concentration in material occurs at point of sudden cross sectional change, such
as couplings, keyways and at shoulder fillets. The more severe change the larger the stress
concentration. As for the design analysis it is not necessary to know the exact shear stress
distribution on the cross section. Instead it is possible to obtain the maximum shear stress
concentration factor, K which is determined through experiment and is only a function of the
geometry of the material. Normally the stress concentration in a ductile material subjected to a
static torque will not have to be considered in design. However if the material is brittle or
subjected to fatigue loadings, thus stress concentration become important parameter.
(28)
D d
r
Ratio: D/d Ratio: r/d
Stress concentration
section
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
HARDNESS TEST
The hardness test is conducted to test the hardness of the material after the material
undergoes the heat treatment process. As for the heat treatment process, it can alter the
microstructure of the material as well as it can change the properties of the material. Thus
hardness is one of the characteristics or properties that also changed after the heat treatment
process is conducted.
(29)
Portable Brinell hardness
Tester
Specimen
Pressure Lever
Proper way to use the
Portable Brinell hardness
Tester
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(30)
The impact diameter after
hardness test is conducted
The impact diameter at the
surface of the specimen is
observe through the King
Brinell Microscope
King Brinell Microscope
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(31)
Portable Brinell hardness
table
Impact Diameter
Brinell hardness value
Rockwell hardness value
Tensile strength value
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
PROCEDURE FOR USING BRINELL HARDNESS TESTER
After the hardness test is conducted then only we can compare the hardness value of
untreated material with the heat treated material. The result shows that the hardness value
increased as the material undergoes heat treatment process.
(32)
1. Put the specimen at the Brinell hardness tester.
2. Assemble the Pressure Lever at the Portable Brinell hardness Tester.
3. Slowly apply force at the Pressure Lever until the indicator reach the value of 3000 kg.
4. Remove the specimen and observe the impact diameter at the surface of the specimen.
5. Observe the impact diameter through King Brinell Microscope
6. Compare the value of impact diameter with the portable Brinell hardness table.
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
ENGINEERING METROLOGY AND INSTRUMENTATION
Engineering Metrology is defined as the measurement dimensions such as length,
thickness, diameter, taper, angle, flatness, profile, and others. Traditionally, measurement has
been after the part has been produce (known as post-process inspection). The term inspection
means checking the dimension of what has been produced or is being produced and
determining whether it complies with the specified dimensional tolerances and other
specification. However, for current situation, measurement is being made while the part is
being produced on the machine known as in-process or on-line or real-time inspection.
An important aspect of metrology in manufacturing processes is the dimensional
tolerance. Tolerance is the permissible variation in the dimension of a part. Tolerance is
important because of their impact on the proper functioning of a product, part
interchangeability and manufacturing cost. Generally, the smaller the tolerance the higher are
production costs.
Numerous measuring instrument and devices are used in engineering metrology each of
which has its own application, resolution, precision and other features. Two terms that
commonly are used to describe the type and quality of an instrument are:-
Resolution- It is the smallest difference in dimension that the measuring instrument can detect
or distinguish.
Precision- It is the degree to which the instrument gives repeated measurements of the same
standard.
In Engineering Metrology, the word instrument and gage are used interchangeably. The
temperature control is very important, particularly for making measurement with precision
instruments. The standard measuring temperature is 20 °C, and all gages are calibrated at this
temperature. In the interest of accuracy, measurement should be taken in controlled
environments which have the tolerance ±0.3 °C.
(33)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
GEOMETRIC FEATURE OF PART AND PRODUCT
The most common quantities and geometric features that typically are measured in engineering
practice and products made by the manufacturing processes as described:-
Length – including all linear dimension part
Diameter – outside and inside, including part with different outside and inside diameter
(steps)
Roundness – including out-of-roundness, concentricity, and eccentricity
Depth – such as drilled or bored holes and cavities in dies and molds
Straightness – such as shafts, bars and tubing
Flatness – such as machined and ground surfaces
Parallelism – such as two shafts and slide ways in machine
Perpendicularity – such as threaded bar inserted into a flat plate
Angle – including internal and external angles
Profile – such as curvatures in castings, forgings, and car bodies
(34)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
GENERAL CHARACTERISTICS AND SELECTION OF MEASURING
INSTRUMENTS
The characteristics and quality of measuring instruments generally are described by various
specific terms such as:-
Accuracy – The degree of agreement of the measured dimension with true value
Amplification – See magnification
Calibration – Setting of instrument to give reading that are accurate according reference
standard
Drift – See stability
Linearity – The accuracy of reading of instrument over its full working range
Magnification – The ratio of instrument output to the input dimension
Precision – Degree to which instrument gives repeated measurement of same standard
Repeat accuracy – The same as accuracy but repeat many times
Resolution – Smallest dimension that can be read on instrument
Rule of 10 – An instrument or gage should be 10 times more accurate than the
dimensional tolerances of the part being measured
Sensitivity – Smallest difference in dimension that an instrument can distinguish or
detect
Speed of response – How rapidly an instrument indicates the measurement
Stability – An instrument’s capability to maintain its calibration over period of time
(35)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
MEASURING TOOLS AND INSTRUMENTS
(36)
API External Taper Gauge
API Lead Gauge
API Internal Taper Gauge
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(37)
API Thread Height Gauge
Setting
API Thread Profile Gauge
API Thread Height Gauge
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(38)
Rotary Pin Work Plug
API Thread Lead Gauge
Setting
Rotary Ring Work Plug
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(39)
Ring Gauge
Torque Wrench
Portable Brinell Hardness
Tester
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(40)
3 Point Holtest
Outer Micrometer
Steel Ruler
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(41)
Angle Protractor
Feeler Gauge
Bore Gauge
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(42)
Depth Caliper
Vernier Caliper
Digital Caliper
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(43)
Tape Measures
Surface Roughness Tester
Height Gauge
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(44)
Master Gauges
Silicon Putty
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
QUALITY CONTROL, QUALITY ASSURANCE AND INSPECTION
As the product is manufactured, there are 2 characteristic which can observe at the
product or part. The 2 characteristics are external characteristic and internal characteristic.
External characteristic most commonly involve dimensions, size, and surface finish and also
integrity issues such as surface damage from cutting tools or friction during the processing of
the workpiece. Internal characteristics include defects, such as porosity, impurities, inclusion,
phase transformation, embrittlement, cracks, debonding of laminations and residual stress.
Some of these defects may exist in the original stocks, and some are introduced or
induced during machining or other manufacturing process operation. Before the manufactured
products are marketed, the products need to be inspected for several characteristics. This is
very important since to:-
Ensure dimensional accuracy so that the parts properly fits into other components
during assembly process
Identify the products whose failure or malfunction has potentially serious implications,
such as bodily injury or fatality.
The prevention of defects in products and on-line inspection of part are the major goals in
all manufacturing activities. Product quality always has been one of the most important aspects
of manufacturing operation. If the product has poor quality, thus it will result toward:-
Difficulties in assembling process and maintaining component
Result in the need for in-field repair
Have significant build-in-cost of customer dissatisfaction
(45)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
QUALITY CONTROL'S JOB SCOPE
To do inspection process of the manufactured product at Omni Oil Technologies
To prepare the check sheet all manufactured product at Omni Oil Technologies
To prepare inspection standard of all manufactured product at Omni Oil Technologies
To prepare inspection test plan (bubble drawing) of all manufactured product at Omni
Oil Technologies
QUALITY MANAGEMENT SYSTEM (QMS)
Original drawing A-3 size
Inspection test plan
Inspection standard
Inspection check sheet
Out sourcing
Need conformation report (NCR)
(46)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
INSPECTION PROCESS
(47)
Post-process
inspection
The quality control
inspectors do the
post process
inspection for the
manufactured
product
In-process
inspection
The quality control
inspectors need to
inspect the semi
finish manufactured
product at the CNC
milling machine
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(48)
The length inspection by
using height gauge
The total length inspection by
using tape measure
The outer diameter
inspection by using outer
micrometer
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(49)
The angle inspection by using
angle protractor
The inner diameter
inspection by using holtest
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
ASSEMBLY PROCESS
Assembly process is the process whereby the individual parts and components produced
by manufacturing processes are assembled into finished products by various methods. In OMNI
OIL TECHNOLOGIES (ASIA) SDN BHD, the manual assembly process is used to assemble the
manufactured product.
Manual assembly use simple tools and generally is economical for small lot. Because of
dexterity of the human hand and fingers and their capability of feedback through various
senses, worker can manually assemble even complex part without much difficulty. Human hand
is capable of doing this simple operation with relative ease.
(50)
The assembly process between Cutter and
Tungsten Carbide Insert (TCI)
TCI
Cutter
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
(51)
Cutter
Block
Pin
Complete assembled Cartridge
Block, Pin and
Cutter are
assembled
together
After the Cartridge
is completely
assembled, it is
then to be
assembled with
Roller Reamer
body
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(52)
Roller Reamer
Body
The Pocket at
the Roller
Reamer Body
After the
assembly
process between
the Cartridge
and Roller
Reamer Body
The complete
assembled
Roller Reamer
Body
The assembly
process is done
by using Torque
wrench
There are 3
Pockets for each
Roller Reamer
Body
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
DESIGNING PROCESS
Before any product is manufactured, firstly we need to design the product. To design a
product, we can use computer-aided design (CAD) which involves the use of computer to create
design drawings and products models. In OMNI OIL TECHNOLOGIES (ASIA) SDN BHD, the
implementation of SOLID WORKS is very useful to design any product. Once we receive the
drawing from customer, then we need to make it in 3-D representation by using SOLID WORKS.
There is other software such as CATIA (computer aided three dimensional interactive
application). The design can be subjected to engineering analysis and can identify potential
problem such as excessive load, deflection or interference at mating surface during assembly.
Information such as list of material, specification and manufacturing instruction also included in
CAD database. Thus the designer can analyze the manufacturing economics of alternative
designs.
(53)
The design of
the product in
three
dimensional
representations
After the
product is
manufactured
The
product of
Halliburton
Company
(Flexi Joint)
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
DESIGNS OF PRODUCT
(54)
Flexi Joint Design
AGS Mandrel Lower
Design
Driver Sub Design
AGS Mandrel Upper
Design
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
DESIGNS OF JIGS
(55)
Design of the jig to be
used during assembly
process between cutter
and tungsten carbide
insert
Design of the jig for
inner diameter
inspection
Design of the jig for
outer diameter
inspection
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
PROBLEMS AND DIFFICULTIES
ASSEMBLY DIFFICULTIES:-
Before the assembly process is done, the inspection process need to be done first to ensure all
the parameters are within the tolerance
Even if all parameters are within test plan (bubble drawing) tolerance but the part cannot be
assembled properly due to:-
Straightness problem
Roundness problem
(56)
Straightness
Roundness
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
MEASUREMENT DIFFICULTIES:-
1. Difficulties to measure the radius value
Measured by using silicon putty and coordinate measuring machine
(CMM)
2. Difficulties to measure total length of the body
Measured by using big milling centre 3 (BMC-3) rather than using tape
measure since the machine coordinate is more accurate and more
precise
3. Difficulties to measure the inner diameter of the body
Measured by using jig
(57)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
LESSON AND EXPERIENCED LEARNED
Engineering Industrial Training is very essential to all students since it will provide the
student with knowledge and experience regarding engineering discipline. Throughout 12 weeks
Engineering Industrial Training, it help me a lot in term of discipline, time management, the
ethics at work, practicing health and safety procedures, and most importantly how to adapt
with the real working environment as well as how to tackle the problems.
Furthermore, this Engineering Industrial Training enhances my communication skills
effectively since the interaction between different kinds of people in various situations. It
teaches me the proper way to mingle with my supervisor and senior technicians. In fact, all the
staffs at OMNI OIL TECHNOLOGIES are very friendly and they give me a full cooperation in order
to accomplish the job assigned to me.
For me, the main objectives of Engineering Industrial Training which is to expose the
students to the real working environment, to learn how to handle and working with various
engineering equipments, getting familiar with the ethics at work, and how to deal with difficult
situation regarding engineering discipline, has been achieved. The students were given the
opportunity to deals with hands-on-experience and a place to apply related engineering theory
which already learned in university. Lastly, OMNI OIL TECHNOLOGIES is a good place to have
industrial training since it can provide student with related engineering studies as well as it can
build up the engineering attitude for the student benefits.
(58)
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OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
SUGGESTION AND RECOMMENDATION
During Engineering Industrial Training, it is brilliant way for the students to gain
knowledge and industrial experience. The Engineering Industrial Training is essential since it will
enable the students to face challenge in real working environment and yet can provide
exposure to the students.
As for university future implantation of Engineering Industrial Training program, it is
suggested that the duration should be more than 12 weeks. Instead of 3 months or 12 weeks
Engineering Industrial Training, the Kuliyyah of Engineering should conduct the industrial
training to be for about at least for 4 to 6 months. As far as this matter is concern, most of the
companies require the industrial training to be for about 4 to 6 months. This is because during
the Engineering Industrial Training, most of the companies assigned the students with certain
project which need to be complete at the end of the industrial training. Hence, if the student
only have short period of time, the students cannot completely solve the projects within the
time provided.
Furthermore, for the industrial company, it is wise and suggested to have proper plan
for the practical students. This is due to students can learn more on the things that had to be
done during the practical training. It is also recommended for the company to send the
industrial trainee to various departments accordingly in order to familiarize the students with
whole working process.
(59)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
CONCLUSION
As conclusion, Engineering Industrial Training has provided the student with real
exposure of industrial environment. After 12 weeks of industrial training, there are so many
experiences that have been gained such as what is quality control job description, how the
company manages their worker, how to deal with difficult task and how to solve it and many
others.
During Engineering Industrial Training, it can help the student to get clear view about
real life engineering situation whereby all the workers are dedicated to solve any task related to
engineering discipline. Some of the knowledge may not be learned from the books or in lecture
but it can be learned through Engineering Industrial Training. Analytical and critical thinking
skills are very important to make a good decision. Book may tell the facts and the truth but may
not teach the way to solve every problem in real life situation.
Besides the technical skills, trainees will also learn to improve their communication skills
and how to develop good character. This is because to build up a good relationship, one must
have a good attitude and characteristic. An engineer may be the superior of the technician but
if the characteristic and attitude showed by the engineer is bad, the technician or the people
who work with the engineer may not respect the engineer as their superior. So that is why the
proper attitude and characteristics need to be developed.
Lastly, the students is eventually turned to be more mature and independent as they
complete the Engineering Industrial Training since the projects or activities conducted require
the student to be more proactive. As the result, the students will be equipped more in term of
technical part as well as attitude and characteristics part to be future engineer. Insyallah.
(60)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
REFERENCES
Wikipedia – hardening process
Mechanics of Materials (seventh edition) by R. C. Hibbeler
Manufacturing Engineering Technology (fifth edition in SI unit) by Serope Kalpakjian and
Steven Schmid
Umetoko (Malaysia) Sdn Bhd – pamphlet
Omni Oil Technologies (Asia) Sdn Bhd – Omni sealed bearing roller reamer inspection
and maintenance manual
Mr. Zulkiflee Samsi (Manufacturing Engineer act as Plant manager Omni Oil
Technologies) – 06-799 6203
Mr. Hanafi Mamat (Quality Control Supervisor Omni Oil Technologies) – 06-799 6203
(61)
MOHD AFFIZUL ARIFF BIN SALIM 0710841
OMNI OIL TECHNOLOGIES (ASIA) SDN BHD
APPENDIX A
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