Laporan Teknikal Latihan Industri

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

FACULTY OF MECHANICAL ENGINEERING

INDUSTRIAL TRAINING TECHNICAL REPORT

NAME : NUR FARAH HANI BINTI NOR ALZAHARI

COURSE : DIPLOMA IN MECHANICAL ENGINEERING

YEAR : 2015

TRAINING DURATION : 10 WEEKS

NAME OF INDUSTRY : AIROD SDN. BHD.

INDUSTRIAL TRAINING TECHNICAL REPORT

AT

AIROD SDN. BHD.

Training Duration:

29 June 2015 – 4 September 2015

Submitted By:

Nur Farah Hani Binti Nor Alzahari

This Technical Report for Industrial Training is submitted to:

Faculty of Mechanical Engineering,

Universiti Teknikal Malaysia Melaka

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

(September/2015)

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Table of Contents

Contents Pages

ABSTRACT 5

ACKNOWLEDGEMENT 6

LIST OF FIGURES 7 – 9

NOMENCLATURE 10

1) INTRODUCTION

1.1 Objective 11

1.2 Scope 12

2) INDUSTRIAL BACKGROUND

2.1 Introduction 13

2.2 Facilities 14 - 15

2.3 Human Power 16

2.4 Quality Assurance 16 - 18

2.5 Partnership 18 - 19

2.6 Achievements 19

3) TRAINING ACTIVITIES

3.1 Early Briefing on Department Division 20

3.2 Early Revision of The Principles of Flights 21

3.3 Maintenance, Repair and Overhaul of Aircraft and

Components Workshop’s Tours 21 - 22

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3.4 Introduction to Types of Aircraft 23 - 26

3.5 Entering Data for Component per Unit Aircraft 26 - 27

3.6 Learning Procedures to Assemble the Propeller to Engine 28 - 29

3.7 Dissembled Parts Of Aircraft C-130 29 - 32

3.8 Corrosion Removal Process 32 - 33

3.9 Packing Parts In A Container 33 - 38

3.10 Making Kit For Components of Aircrafts 38 - 40

3.11 Updating Quantity Of Chemicals Left In Safe Storage Area 40 - 42

3.12 Theory Of Flight 42 - 44

3.13 Assembling The Blade Spacing System On Main Rotor

Head For Alouette 44 - 45

3.14 Make Marking On Locking Components And Put

On New Stickers 45 - 47

3.15 Dissembling Wheel Of Aircraft (Global Express) 47 - 48

3.16 Assembling Retracting Cylinder For Landing

Gear Of Nuri Aircraft 48 - 53

3.17 Test Cell Unit Activities 53 - 55

4) CONCLUSION 56

APPENDIX: 57 -

59

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ABSTRACT

Industrial training is held to introduce and train the students to learn deeper and be

familiar to industrial works and elaborate what have been studied in the classroom. It is

compulsory for every student to do their industrial training before entering the last semester.

For student who is in Diploma courses, 10 weeks are given for them to complete their training

in any industry wherever they choose to join. Each of the student has to write a daily report in

a logbook provided by the faculty and complete one technical report that is in a formal form.

Students need to hand in their reports and log books by the due date that the faculty has

decided. Due to that, students need to gain experiences from the training that they will attend

to write completely, what have been done in 2 months and a half. During industrial training,

students can collect ideas and knowledge on how to do their final year project by observing

and working technically in real industries.

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ACKNOWLEDGEMENT

“In the name of Allah, The Most Beneficent and The Most Merciful”

Praise to Allah SWT for His bestowing, I have got many experiences and has

successfully completed the industrial training in Airod Sdn. Bhd for 10 weeks from 29th of

June 2015 to 4th of September 2015.

I want to give a million of appreciation and the highest thank to all the staffs and

workers in Airod Sdn. Bhd. especially Sir Ismail Bin Mokti, the Head of Department of

Aircraft MRO (Maintenance, Repair and Overhaul) and Sir Adeeb Bin Mohammed Ali the

Head of Department of Engine MRO for giving me the chance to join groups of workers that

have over 25 years of experiences and many skills that I can learn from every sub department

that they leads on.

I express my deepest thanks to Mr. Haidhir, Mr. Fahrul, Mr. Asri, managers and staffs

in Aircraft MRO’s Department, Mr. Azizan, Mr. Azli, Mr. Azizul , supervisor and staffs in

Engine and Component MRO and all the staffs who guided me to learn something new to

gain more knowledge and experiences so that. A lot of appreciation I want to give for letting

me took part in useful decision and giving necessary advices and guidance and for arranging

all facilities for me to learn easier in Airod Sdn. Bhd.

I perceive as this opportunity as a big milestone in my career development. I will

strive to use gained skills and knowledge in the best possible way. I will continue to work on

their improvement, and will continue working with their best working discipline in order to

attain desired career objectives. I hope to continue to cooperate with all the employee in Airod

Sdn. Bhd. in the future.

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LIST OF FIGURES

FIGURE PAGE

Figure 1: Operating area of Airod Sdn. Bhd. from helicopter’s view. 14

Figure 2: Layout of Airod Sdn. Bhd. Main Depot in Subang. 15

Figure 3: Among the enforcement certificates received by Airod Sdn. Bhd. 17

Figure 4: Enforcement certificates for Agusta aircraft’s servicing

centre owned by Airod. 18

Figure 5: The awards received by Airod Sdn. Bhd. 19

Figure 6: Schedule division of training during the industrial training

for 10 weeks. 20

Figure 7: C-130 type of aircraft, better known by the name of Charlie. 23

Figure 8: BAE Hawk 208 type of aircraft. 23

Figure 9: Beechcraft King Air B200T type of aircraft. 24

Figure 10: Aermacchi type of aircraft. 24

Figure 11: Nuri Royal Malaysian Air Force type of aircraft. 24

Figure 12: Agusta A109 aircraft types. 25

Figure 13: Agusta 816-N type of aircraft. 25

Figure 14: Aloutte type of aircraft. 26

Figure 15: Documenting the number of components per

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unit plane for a thorough examination of the plane C130H. 27

Figure 16: Learning to assemble the propeller to the engine of C-130. 29

Figure 17: Speedy is being used to take out the screw from floorboard. 31

Figure 18: Team of workers for mandatory removal of Safair’s C-130. 31

Figure 19: A worker uses a scrabber to remove dusts from the head of

screws. 32

Figure 20: Rivet joint where deep corrosion takes place. 33

Figure 21: Sealant that has been pressed along the joining section of the

upper and the bottom parts of the container. 34

Figure 22: The upper part of the container being held. 35

Figure 23: The lower part of the container where the main gearbox is filled. 36

Figure 24: Tools and materials being used in the process. 36

Figure 25: Humidity indicator that still in a good condition. 37

Figure 26: LPS 3, the corrosion preventive materials used to prevent

corrosion on parts. 37

Figure 27: Impact gun is being used to tighten bolts and nuts to close the

container. 38

Figure 28: Flow of parts and components in Airod Sdn. Bhd. 39

Figure 29: Racks that are provided in RPC and Kitting Area. 40

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Figure 30: Safe storage area that stores chemicals in RPC & Kitting Area. 42

Figure 31: Figure shows the direction for each force of flight. 43

Figure 32: Figure shows the parts where the blade spacing systems are

assembled. 45

Figure 33: Parts of components that have been marked with paint as they

are required. 46

Figure 34: Figure shows the stickers with adhesive solvent soothed onto them. 47

Figure 35: Components involve in aircrafts wheel. 47

Figure 36: Dissembling the weight balance by using impact tools. 48

Figure 37: Exploded view of components in retracting cylinder. 49

Figure 38: Installation of piston locks. 51

Figure 39: Tools and components need to be assemble for retracting cylinder. 53

Figure 40: Test Cell where engines are tested for their performances. 54

Figure 41: Exploded view of a Nuri’s aircraft engine. 55

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NOMENCLATURE

MRO = Maintenance, Repair & Overhaul

NADI = National Aerospace & Defence Industries

RMAF = Royal Malaysian Air Force

LASI = Lockheed Aircraft Systems International

DCA = Department of Civil Aviation

FAA = Federal Aviation Administration

DGAC = Directorate General of Civil Aviation (France)

CAA = Civil Aviation Authority

USAF = United State Air Force

BVQI = Bureau Veritas Quality International

RPC = Remote Procedure Calls

FOD = Foreign Object Damage

LPS = Lipopolysaccharides (LPS)

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1. INTRODUCTION

Industrial sector is one of the developing economy in Malaysia. As what we can

observe, many countries in Malaysia that have large industrial region, develop faster

than other countries that focus on other sectors. For example, Johor and Selangor that

have many industries that produce various products, both growth faster compared to

other countries in Malaysia. Industrial training is a great initiative for students to

watch and learn how to practice what have been studied in the lecture in industries

they have chosen. These days, to create a fresh graduate with qualities is important to

be conducted for every students before they continue their career further after

graduate. By industrial training, students will know more on what to focus and what is

needed to work in real industry connected to courses they have joined.

1.1 Objectives

In the implementation of the training industry, there are several objectives:

To train the students to collect information based on experience during

training conducted to prepare comprehensive and organized report.

Identify closer on industry background preferred.

Make the training industry research undertaken to facilitate the preparation

for the final year project.

Demonstrate in detail, the work and activities undertaken during the

industrial training.

Meeting the demands for the successful industrial training mandatory for

all students.

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1.2 Scope of Training

The scope or the limit of the training should be made as reference to ensure the

implementation of the industrial training will not deviate from the objectives to be

achieved. Scope is determined by the implementation of training objectives and

training goals.

Among them are:

To learn how tasks are performed by every worker in the industry.

To carry out the tasks that have been assigned referred to the instructions

given.

Gather information based on experience gained through training in the

industry.

Prepare daily reports and full technical report as required by the faculty

2. INDUSTRIAL BACKGROUND

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2.1 Introduction

AIROD stands for “Aircraft Inspection, Repair & Overhaul Depot”, the depot of

inspection, overhaul and maintenance of airplanes. Airod Sdn Bhd is a subsidiary of

NADI (National Aerospace & Defence Industries) where Airod Sdn Bhd is assigned to

the maintenance and repair of aircraft and aircraft components, in particular belonging

to the armies of both local and foreign. Airod was established in 1976 and is the first

and only company in the country to help maintain, inspect and repair aircraft of the

Royal Malaysian Air Force (RMAF).

In 1985, Airod Sdn. Bhd. was privatized as a joint venture company between

NADI and US Company Lockheed Aircraft Systems International (LASI). On this

day, Airod has become a company owned by local workers alone under NADI group

of companies and leading facilities Maintenance, Repair & Overhaul (MRO) in

providing quality service in the region and abroad.

2.2 Facilities

Airod Sdn. Bhd. still operating in strategic areas in the complex Sultan Abdul

Aziz Shah Airport in the northwest of the capital, Kuala Lumpur. Airod Sdn. Bhd. has

a total land area of 77.4 acres operates in the north-eastern part of the track. Facilities

owned by Airod Sdn Bhd, which is worth millions of dollars have already gained

international recognition as a centre of repairing and modification of aerospace.

Facilities owned by the Airod Sdn Bhd including hangars for the two types of

airplanes body, type of small aircraft and aircraft width, hangar for painting and

removing paint on the body of the plane, workshops, support shop and area for testing

engine.

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Figure 1: Operating area of Airod Sdn. Bhd. from helicopter’s view.

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Figure 2: Layout of Airod Sdn. Bhd. Main Depot in Subang.

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2.3 Human Power

Workers in Airod Sdn. Bhd. is totaling up to 1,086 skilled workers who have

technical experience an average of 15 years working in Airod Sdn. Bhd. Airod Sdn.

Bhd. is difficult to recruit new workers because they are concerned about the quality

of the skills of maintaining, repairing and checking aircraft.

2.4 Quality Assurance

Facilities at Airod Sdn. Bhd. have been audited and approved by many Civil

Aviation Authorities from various countries around the world and the approving body.

Here is the list of approvals granted approval for Airod to operate:

Malaysian DCA, AO/0021/81

FAA, Air Agency Certificate 33AY686Y

Indonesian DGAC, 145/13200/07

Papua New Guinea CAA, MOC 145/029

Nepal CAA, APP/011/052

South Africa DCA, 1034

Uganda CAA, CMO no.122

PMEL ISO/IEC 17025

BVQI, ISO 9001:2000

USAF DCMC

Airod Sdn. Bhd. is the premier centre for the maintenance and modification of aircraft

C-130 / L-100 Hercules Lockheed Martin. Airod Sdn. Bhd has been given the

responsibility from Lockheed Martin's to operate in:

C-130 / L-100 Service Centre

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C-130 Tanker Conversion Centre

C-130 Landing Gear MRO Centre

C-130 Fuselage Stretch Mod Centre

Airod hold certificates enforcement servicing centre C-130 aircraft from 1986 until

today has managed to maintain more than 220 C-130 Hercules aircraft.

Figure 3: Among the enforcement certificates received by Airod Sdn. Bhd.

Airod Sdn. Bhd. also holds enforcement certificates of servicing centre for Agusta

A109 series aircraft and A119 helicopter.

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Figure 4: Enforcement certificates for Agusta aircraft’s servicing centre owned by

Airod.

2.5 Partnership

Airod Sdn. Bhd is in collaboration with the following companies:

Lockheed Martin

Northrop Grumman

Ulan Ude Aviation Plant

Fokker Aircraft

Pilatus Aircraft

Aermachhi

Agusta

Westland Helicopters

BAe Defense

General Electric

Pratt & Whitney

Motor Sich

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Solar Turbines

AAR Corporation

2.6 Achievements

Airod Sdn. Bhd. has received many awards for excellence in service and

quality of management. In 2008, Airod Sdn. Bhd. is awarded Frost and Sullivan's Asia

Pacific for Customised MRO Centre of the Year. In 2005, Airod Sdn. Bhd. has won

Export Excellence Award in Services in 2004. Airod Sdn. Bhd. Also listed in the Top

5 Finalists for National HR Excellence Award in 2004.

Figure 5: The awards received by Airod Sdn. Bhd.

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3. ACTIVITIES DURING THE TRAINING

3.1 Early Briefing on Department Division

The Human Resources of Airod Sdn. Bhd. has drawn up a work schedule for

my 10-week industrial training in Airod Sdn. Bhd. My duty schedule is as follows:

Figure 6: Schedule division of training during the industrial training for 10 weeks.

I was placed for 5 weeks at the aircraft MRO hangar 70 where military

aircrafts from inside and outside the country are restored, maintained and inspected. I

was placed under the patronage of Mr. Ismail Bin Mokti where he was the Head of the

Department of Aircraft MRO in Airod Sdn. Bhd. Mr. Ismail Bin Mokti put me under

the care of Mr. Haidhir. Mr. Haidhir is the head of planning or 'planner' where he

designed the work to be done before any aircraft came in, during the flight in, and how

the plane was about to be delivered from Airod.

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3.2 Early Revision of The Principles of Flights

According to Mr. Haidhir, aircrafts is something that is complex to

understand and learn. As the aircraft is the air transport from a small size that can fit a

person, up to an enormous size that can accommodate hundreds of people, the safety

aspect must be taken into account when maintaining and repairing airplanes. I am just

demanding in general mechanical course that are not geared to the aerospace

engineering field, because of that I need to understand in advance the types of aircraft,

the names of the components and aircraft parts and functions of the parts and know

how it needs to be maintained and completely refurbished. Among the sources for

acquiring knowledge of the aircraft are:

Technical Library of Airod Sdn. Bhd.

Explanation from experienced workers in Airod Sdn. Bhd.

Manuals of the aircraft acquired from Airod Sdn. Bhd.

Direct observation of working environment in Airod Sdn. Bhd.

Airod Sdn. Bhd. provides reference materials for employees to review and

finalize their work by following the procedures by the types of aircraft that are

maintained. Thus, the materials to be referenced can easily be found here.

3.3 Maintenance, Repair and Overhaul of Aircraft and Components Workshop’s

Tours

On the third day I was in Airod Sdn. Bhd., Mr. Haidhir put me under the

guide of Mr. Fahrul to take me to get trained under him for about 2 weeks until the

festive holidays ended. Mr. Fahrul is the manager at the RPC & Kitting Area for

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aircraft MRO department. RPC & Kitting Area is an area for storing components and

parts received from the shipping division in Airod Sdn. Bhd. to meet the demands of

the workers on the production line if any parts or components are required during

maintenance and repair of aircraft are operated. Mr. Fahrul is an employee who has

more than 25 years’ experience working with Airod Sdn Bhd. and he started from the

ground up again at that time. He went through a variety of jobs in Airod Sdn. Bhd

from a variety of departments. Mr. Fahrul welcomed me with open arms and promised

to give me as much as what he can to pour a bit of knowledge that I need in the

aerospace field. Mr. Fahrul took me to visit areas of maintenance and overhaul of

aircraft around Airod Sdn. Bhd. There are many workshops for repairing aircraft

components and parts here. Among them are:

Component Workshop

Avionics

Support Workshop

Engine Workshop

Under the workshops there are more fragments of workshops for example,

the workshop component, there is a hydraulic workshop. I was shown by workers in

Airod Sdn. Bhd on how to perform procedures in each section. Most workers in Airod

Sdn. Bhd. use their experience to complete their tasks while using the reference

provided for a particular task. The machines are used for maintaining and repairing

aircraft components and parts in Airod Sdn. Bhd. has been used since the 1980s. It is

not difficult for experienced workers in Airod Sdn. Bhd. to perform the tasks they

need to do.

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3.4 Introduction to Types of Aircraft

Not all types of aircraft are maintained under Airod Sdn. Bhd. They provide

service, maintenance and repair of aircraft based on a certificate that allows them to

maintain a certain type of aircraft. Mr. Fahrul have explained to me about the types of

aircraft that are serviced here. Among them are:

Figure 7: C-130 type of aircraft, better known by the name of Charlie.

Figure 8: BAE Hawk 208 type of aircraft.

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Figure 9: Beechcraft King Air B200T type of aircraft.

Figure 10: Aermacchi type of aircraft.

Figure 11: Nuri Royal Malaysian Air Force type of aircraft.

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Figure 12: Agusta A109 aircraft types.

Figure 13: Agusta 816-N type of aircraft.

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Figure 14: Aloutte type of aircraft.

Airod has three sites of operation for maintenance and repairs of the airplane,

namely in Subang, Labuan and Kuantan. In Labuan, Airod Sdn. Bhd. depot operates

as maintaining and repairing 'Fighter' aircraft.

3.5 Entering Data For Component Per Unit Aircraft

Through Mr. Fahrul, I was taught how to enter data via a search on the IPC or

IPB which stands for Illustrated Parts Breakdown for a thorough inspection or

maintenance purposes comprehensive one unit C130H aircraft. As what I have

learned, each aircraft will be maintained every three years in a row. For each

maintenance, it will be named ST. For example, ST3 for the maintenance of aircraft in

operation for three years, while ST6 for aircraft maintenance operations that reach six

years. For each complete year of such ST6, ST12, ST18, the planes would be serviced

and checked thoroughly. As for ST3, ST9, ST15, the planes would be serviced and

checked for future minor operations. For data collection the number of components

per unit airplane, Microsoft Excel is used. According to the head of the planning or

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'planner', Mr Haidhir, one must be proficient using Microsoft Excel and Microsoft

Project to complete work like him. Brief survey of the number of components per unit

plane is as shown below:

Figure 15: Documenting the number of components per unit plane for a thorough

examination of the plane C130H.

I've been doing the data collection that has been presented to representatives

of AFRO which is the representatives from the Royal Malaysian Air Force. Based on

the codes registered for each type of component, we will know the number of

components required for each system in the aircraft. There are eight overall system

require research to find the total number of components per unit of aircraft type

C130H. Among the existing system is a system of hydraulic, pneumatic, electrical,

electronic and other systems that exist in a plane.

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3.6 Learning Procedures To Assemble The Propeller To Engine

On 10th of July 2015, I joined a team of worker that has been ordered to

assemble the propeller to the engine for the 3rd engine of an aircraft C-130. A propeller

that has been serviced and maintained in the workshop has to be checked first by the

specialists on this part in hangar before being assembled to the engine. Specialist will

checked whether the part has been properly assemble with all the locking wires and

the position of every big or small component has been set up in a correct procedure.

I met Mr. Hamid who has been working in Airod for about 25-30 years who is

the specialist of the propeller and engine part. He guided me through the process to set

up the propeller to the engine. A crane is needed in this process to lift up and place the

propeller right to its place before we assemble it by locking it to the engine. Special

tool was placed onto the middle area of the propeller to lift it up. By controlling the

crane, when the propeller was in a correct place to be pushed into the area where it

will be locked, the team started to push the propeller together until it gone through a

little inch. After it completely gone into the area where it cannot be moved, then only

the team start using the tools to lock it up. Mr. Hamid and his team taught me that

everything will be easier to work out when we keep the teamwork in the first place.

The duration for assembling a propeller to engine is about 1-2 hours and we managed

to get the job done in 45-50 minutes.

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Figure 16: Learning to assemble the propeller to the engine of C-130.

3.7 Dissembled Parts Of Aircraft C-130

When aircrafts arrived in Airod Sdn. Bhd., after the induction process has

been held, mandatory removal has to be done. I have joined many job involving the

process on two aircrafts. The first aircraft I have joined in this process is C-130 of

RMAF and the second aircraft is Safair, a C-130 cargo plane, property of South Africa

and United Nation. In aircraft C-130 of RMAF, I removed the bottom part of the rear

door of the plane. The common tools to be used in this process of removing parts of an

aircraft is speedy, spanner, wrench, extension, socket, screwdriver and torchlight. A

speedy with an extension will make the removing job easier due to the small force

needed to remove the locking components to the parts. Gloves are needed while doing

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the job because the hydraulic fluid that has dried are everywhere spreading on the

locking components.

For the parts that are locked by nuts and bolts that are in the narrow area to

use the tools and to put on forces, torchlight and some skills are needed to unlock

them. I have been given the correct guide to use tools and skills to unlock components

by skilled workers there. When all the locking parts have been removed, we pull out

the parts by using chisel and hammer with a strong forces from total power of 5 person

from our working team to pull the part fully.

In Safair’s aircraft, I was working with another team that was ordered to

remove the floorboard of the aircraft. The tools used were same as on RMAF’s aircraft

but were added with automatic tools that used compressed air to enhance our work. To

remove floorboard, we must remove the screw first. The condition of the aircraft was

quite poor due to the place where it has been used to operate as a cargo plane. The

space on the head of the screws were totally have been filled up with dust. Scrabber

need to be used to remove the dust before speedy took the part to remove the screws

completely from the floorboard. When using the speedy, if a screw are hard to be spin

out, speedy must be stopped from being used or else, the screw will be rounded or

damaged. Screws that cannot be moved by speedy will be taken out by using the

impact gun that use the compressed air as its source of power.

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Figure 17: Speedy is being used to take out the screw from floorboard.

Figure 18: Team of workers for mandatory removal of Safair’s C-130.

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Figure 19: A worker uses a scrabber to remove dusts from the head of screws.

3.8 Corrosion Removal Process

After removing parts from the body of an aircraft, before repairing or servicing

the part, the corrosion from the parts must be removed. Technical workers that have

been ordered to perform the job must know the procedure to remove the corrosion and

to prevent them from occurring back after been removed.

Screws are commonly corrode and usually the part where they will put more

focus on the joining of the parts that used screws. I helped the team of workers to first,

grind the part with an impact grinder, then put primer on it. For any surface that

corrodes, we must put Aledine onto the surface. Along the process of repairing and

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servicing, parts must always being brushed with this corrosion preventive so they

won’t get corrode easily before the process completed and will be repainted.

Figure 20: Rivet joint where deep corrosion takes place.

3.9 Packing Parts In A Container

It is not as simple as packing things into a bag or packing vegetables into a

polystyrene container. A part of an aircraft has to be packed in a correct and detail

procedure that need to be followed to make sure the quality of the part is still in 100

percent in the best condition. On 12th of August 2015, I have helped a worker to pack a

main gearbox for Nuri, a property of RMAF. A large container with a special

modification have been made up to keep the inner part of the container from humid

air.

To prevent the main gearbox from corrosion, LPS 3 has been sprayed onto the

part. LPS 3 acts as the preventive for the part itself to withstand corrosion. For the

container to be durable from humid air to come into it, packs of anti-humidity have

been put into the container. After the main gearbox has been put into the container,

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seal was pressed along the joining section for the upper and the bottom part of the

container to be joined together. The seal will close all the spaces along the joint so the

air cannot enter the container after being closed. All the nuts and bolts will finally

completed the procedure of the packing after being assembled. Not forgetting the

humidity indicator. It also has to be changed because it is the most important part of

the container. The function of the humidity indicator is to indicate whether humid air

present in the container. The true colour of the indicator is blue and when humid air

present in the container, it will change to pink colour.

The final procedure to be taken is to write the part number and the serial

number of the main gearbox on the outer part of the container so, when the next hands

that took over the job to service the main gearbox, they will know what type of the

part is in the container and the detail that can be found just by looking at the number

written there.

Figure 21: Sealant that has been pressed along the joining section of the upper and the

bottom parts of the container.

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Figure 22: The upper part of the container being held.

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Figure 23: The lower part of the container where the main gearbox is filled.

Figure 24: Tools and materials being used in the process.

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Figure 25: Humidity indicator that still in a good condition.

Figure 26: LPS 3, the corrosion preventive materials used to prevent corrosion on

parts.

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Figure 27: Impact gun is being used to tighten bolts and nuts to close the container.

3.10 Making Kit For Components of Aircrafts

Every components and parts of aircrafts that have been received from vendors

or customers at the shipping area will be sent to RPC & Kitting Area for kitting and

finally will be sent to the production to assemble or use the parts and the components

they have demanded. The diagram below shows the flow of the parts and components

that have been received by Airod Sdn. Bhd.

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Figure 28: Flow of parts and components in Airod Sdn. Bhd.

In RPC & Kitting Area of Aircraft MRO, we will segregate the parts and

components by the types of aircrafts that will need to use them. It can be done by

checking the serial number or the task card that are included with the components.

There are six racks provided to store the components received and one bounded store

that stores parts that need consistent cool temperature and have higher prices per part.

Bounded store is located at the inner side of hangar and always being maintained its

temperature. All the components that being stored in the kitting area are tagged in

yellow tag that mean they are serviceable.

The parts and components will be given to the production workers that

demanded to complete their works on aircrafts or in the workshops. Before taking the

parts and components, they need to sign some documents for the proof that they have

took the parts and components so if anything happen, we can refer back the documents

that they have signed before.

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Shipping Area

RPC & Kitting Area

Production

Figure 29: Racks that are provided in RPC and Kitting Area.

3.11 Updating Quantity Of Chemicals Left In Safe Storage Area

In RPC & Kitting Area, I have learned how to store chemicals that are

hazardous, flammable, explosive and corrosive in the right ways according to the

requirements acquired. I have been ordered to update the quantity of chemicals that

being stored in the storage area by checking each type of chemicals that are being used

in Airod Sdn. Bhd.

Airod practice to maintain the safety requirements made by the government to

control in and out of the chemicals being stored in the company. All the chemicals

received after the demand will be provided with manuals on how to use them in a right

and safe way, also on how to keep them in a correct way when in use or not in use.

Manufacturers also provide the chemicals with labels and the date of expire for each

type of chemicals they sold.

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We just need to maintain the safety ways to prevent any hazard to occur. In the

safe storage area, they are good ventilation system to prevent any gas leaking that is

dangerous for our breathing or can turn very bad when it will mix up with the source

of fire that can burn the whole area or explode in a short time. Also, they are labels

that shows the type of chemicals being store in each container. Human error is the

biggest cause of every bad situation that occurs every day.

Due to that, we must always think before we act and as a human, we cannot

just use the experiences we have to get our job done. We need to keep referring to the

manuals and if we do not know how to perform a job, ask the professionals instead of

doing the job using our own instinct. When I use any chemical to perform a job, I read

the label first and ask for advice from experienced workers there. Because sometimes,

chemicals can be more dangerous than what you can read on their labels.

The followings are some of the chemicals’ type used in Airod Sdn. Bhd.:

Toluene

Thinner

CN13

WD-40

Aeroshell Fluid 41

I calculated one by one the chemicals by their types and recorded them to be

sent to the auditors of Airod Sdn. Bhd. They wanted to know how many chemical

received and how many have been consumed. I managed to segregate them in the

racks according to their various type.

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Figure 30: Safe storage area that stores chemicals in RPC & Kitting Area.

3.12 Theory Of Flight

Theory of Flight that I have learned form a worker that has 30 years

experiences in Aeronautical Engineering and still working on the technical parts on

aircraft states that the Theory of Flight is, ‘to make aircrafts fly and land safely’ which

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everyone who want to involve in aeronautical works has to know. There are 4 forces

of flight, which are drag, thrust, weight and lift.

Figure 31: Figure shows the direction for each force of flight.

Bernoulli’s Theorem states that when a gas or fluid is flowing through a

restricted area, as it flows a venture, its speed will increase and its temperature and

pressure will decrease. If the area is increased then the reverse is true. That happens in

the diffuser. In the engines of an aircraft, they use the same principle, The Venturi

Principle made by Bernoulli. A diffuser does not change the total energy level but its

only change the form of one energy to another. For divergent duct, it will increase the

pressure same as temperature while the velocity is being decreased. For convergent

duct, it will decrease the pressure as well the temperature when the velocity is

increased.

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A rocket does not using the same principle to fly, they use the momentum

principle to launch. Although a rocket engine is a jet, it has one major difference in

that it does not use atmospheric air as the propulsive fluid stream. Instead, it produces

its own propelling fluid by the combustion of liquid or chemically decomposed fuel

with oxygen, which it carries, thus enabling it to operate outside the earth’s

atmosphere. It is therefore, only suitable for operation over short periods.

3.13 Assembling The Blade Spacing System On Main Rotor Head For Alouette

I was given a job to assemble the blade spacing system on the main rotor

head of an Alouette aircraft. The blade spacing system are assembled to make the

blades go up and down uniformly when the aircraft is functioning. The cables used in

this system must fit the requirements for their uniform length. If they are shorter than

the requirement, they must go through the process to make them longer in their length.

If they are longer than the requirement, they cannot be used and must be thrown away.

The step to assemble the blade spacing system are as follows:

1. Put the cables between the spacing systems.

2. Lock them with bolts and nuts. (Self-locking nuts and bolts come with holes

for wire locking)

3. Tighten the nuts and bolts with spanner and wrench.

4. Use the pin lock through the nuts and bolts for more safety locking.

5. Sooth the parts with the anti-corrosive materials.

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Figure 32: Figure shows the parts where the blade spacing systems are assembled.

3.14 Make Marking On Locking Components And Put On New Stickers

Every components and parts that have been assembled needs to be marked

with a short line of paint to make it easier for the future check to be done. It is also to

remark where the perfect turn of the parts to be assembled. If the future check that will

be taken found out that the straight line for two components is not in a straight form, it

means that the locking of the two components have moved during the flight. During

the flight, vibration occurs everywhere. They will exist even a little vibration. Nothing

in an aircraft that does not vibrate during it is in use. The components need to be

cleaned first using the CN13 Cleaning Solvent before they were marked with the red

paint on a single straight line form.

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Figure 33: Parts of components that have been marked with paint as they are required.

For placing new stickers on the main rotor head, first, we need to clean the

surface with CN13. Next, we stick the stickers to the surface where we have to put

them. Then, we must sooth the stickers and the parts where there were put on with

adhesive solvent. This to ensure that the stickers won’t be able to be taken off when

the aircraft is functioning. Moreover it will help the stickers to withstand any weather.

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Figure 34: Figure shows the stickers with adhesive solvent soothed onto them.

3.15 Dissembling Wheel Of Aircraft (Global Express)

Figure 35: Components involve in aircrafts wheel.

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Dissembling a wheel of an aircraft is not the same as dissembling an

automobile’s wheel. The correct procedures must be carried out as follows:

1. Remove nuts, washers, balance weight and bolts.

2. Referred to the Technical Manual, before removing the balance weights,

impression stamp the wheel half to show the location and weight of the

balance weights. This permits the wheel half to be assembled again with no

need to adjust the balance.

Figure 36: Dissembling the weight balance by using impact tools.

3.16 Assembling Retracting Cylinder For Landing Gear Of Nuri Aircraft

Retracting cylinder is the main part of hydraulic system used in landing gear. It

moves the landing gear to make it up or down during landing and take off for an

aircraft. The components in the retracting cylinder are as follows:

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Figure 37: Exploded view of components in retracting cylinder.

1. Pin, washer, cotter pin

2. Lock washer

3. Nut

4. Rod end

5. Plate

6. Gasket

7. Bolt, washer, nut

8. Ball

9. Switch housing

10. Plug

11. Gasket

12. Cartridge valve

13. Nut

14. Rear cap

15. Packing

16. Retainer

17. Lockring

18. Retaining ring

19. Scraper

20. Felt strip

21. Packing

22. Retainer

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23. Piston stop

24. Nut

25. Bearing

26. Forward cap

27. Locknut

28. Packing

29. Retainer

30. Packing

31. Retainer

32. Nameplate

33. Barrel

34. Piston lock

35. Locking race

36. Nut

37. Washer

38. Packing

39. Retainer

40. Packing

41. Retainer

42. Locking cam

43. Spring

44. Nut

45. Washer

46. Switch cam

47. Actuating rod

48. Packing

49. Retainer

50. Retainer

51. Piston

The procedures that I have taken to assemble the components to complete the

full part of the retracting cylinder are as follows:

1. The parts were cleaned and removed from any corrosion preventive materials.

2. All packings, retainers and felt strip were soaked in hydraulic fluid before

assembly.

3. Lock wire was installed.

4. Piston that does not come in contact with hydraulic fluid was coated with

corrosion preventive compound.

5. Locking cam was attached to actuating rod with washer and nut.

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6. Spring was slided onto actuating rod and actuating rod was inserted into the

piston. Spring was then been compressed and switch cam, washer, and nut

were installed on actuating rod.

7. Retainers and packings were installed on piston.

8. Locknut, retainer and packing were installed next on barrel.

9. Piston was inserted into barrel and thread switch housing, two to three turns,

onto piston. Locking race chamfer was installed outboard on piston. Locking

cam was placed up, in bed of an arbor pressed.

10. With using a suitable cylinder, locking cam was pressed down until piston

locks can be inserted into piston as shown below:

Figure 38: Installation of piston locks.

11. With piston locks in place, locking race was slided up onto piston locks and

pressure that was applied to locking cam was released.

12. Cap was slided forward over locking race and thread onto barrel until

bottomed. Locknut was tightened up against forward cap and locking wire was

used to enhance its safety.

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13. Switch housing was removed from piston.

14. Felt strip, packing and retainer were installed in piston stop. Scraper and

retaining ring were inserted in the end of piston stop and secured with lock

ring.

15. Piston stop was inserted and attached in rear cap with nut.

16. Cartridge valve, gasket and plug were installed in rear cap. Nut, retainer and

packings were installed on barrel.

17. Nut and lock washer were installed on rod end and rod end was threaded into

switch housing.

18. Sealant was applied to last two engagement threads of piston and switch

housing was threaded onto piston. Switch housing was torqued to 140-160 inch

pounds. Pin holes in switch housing and piston was lined up, pin, washer and

cotter were installed.

19. All threads and entrants of retracting cylinder were sealed with sealing

compound.

20. Bearings were lubricated with grease.

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Figure 39: Tools and components need to be assemble for retracting cylinder.

3.17 Test Cell Unit Activities

Test cell is a department that is used for testing engine performance whether

they fit the requirements or not. It is a part of Engine Maintenance, Repair and

Overhaul Department.

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Figure 40: Test Cell where engines are tested for their performances.

First, I was introduced to engine parts, the inner and the outer parts of an

engine. Engine is a machine that has combustion that will produce heat energy and

will be converted into mechanical energy. A basic aircraft’s engine is divided into 5

parts, which are, air intake, compressor, heat combustion chamber, turbine and

exhaust in a correct flow.

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Figure 41: Exploded view of a Nuri’s aircraft engine.

I was given a task to remove a Nuri’s engine (GE T-58) from the test cell

platform. Before removing the engine, preservation steps need to be done especially at

the internal of the engine. Preservation are done by applying WD-40 from the air

intake, while running the engine on idle speed. It is a compulsory to preserve the

engine in order to extent the lifespan of the component and to prevent corrosion. Then,

the engine are dismount from the rig engine and tagged by ‘Serviceable Tag’.

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4. CONCLUSION

10 weeks of industrial training in Airod Sdn Bhd, there are so many knowledge

and experience I have gained that can never be found in classroom. I was not only

given the chance to learn by observing and reading technical manuals, I was given the

chance to experience by myself the work that need to be done as a technician, as an

engineer and as a manager in the company. Industrial training has exposed me to the

real life job where I managed to build up my confidence, self-discipline and strengthen

my communication skills while working with other experienced workers in Airod Sdn

Bhd.

On the first day I joined internship program in Airod Sdn Bhd, I was zero in the

world of aircraft whether the types of aircraft, parts, components and the way they are

functioning. But at the end of the day of the training, I know a lot of knowledge in the

aircraft industries. The environment working in Airod Sdn Bhd was so friendly and

everyone enjoy doing their job in a team that cooperate as one big family. Every

problem that occurred in the company, we solved in the most perfect way that we can

think of. The average of experience of a worker in Airod Sdn Bhd is about 20 to 25

years experiences. They have gone to technical learning program overseas, provided

by the company to familiarize them with the way to maintain, repair and overhaul

aircrafts well. I did not have a problem to ask for more information from them because

they love to share the knowledge to people who ask for it.

From this industrial training, I was given the ideas on how to make my final

year project to work. I learned by observing the system on aircrafts’ components and

parts that use many mechanical principles that I have studied some in lectures. Lastly,

by industrial training, we can understand the theory better when doing hands-on than

just learning the basic and not putting ourselves in the real situation.

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APPENDIX

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Laporan Teknikal Latihan Industri

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