CONTENTS

CONTENTS PAGE
Title i
Students confirmation ii
Acknowledgement iii
Contents iv
CHAPTER 1 INTRODUCTION OF ON JOB
TRAINING
1.1 Introduction 1
1.2 Objective of on job training 2
1.3 Objective of training report 2
1.4 The importance of on job training 3
CHAPTER 2 ORGANIZATIONAL
BACKGROUND
2.1 Introduction of the organisation 4
2.2 Organisation background 4
2.3 Organisation activity 5
2.4 Direction of the organization 6
2.5 Organizational Chart 7
CHAPTER 3 SUMMARY OF ON JOB TRAINING
ACTIVITIES
3.1 Introduction 8
3.2 Summary of On Job Training 9
Activities
CHAPTER 4 TOOLS AND APPARATUS
4.1 Introduction
4.2 List of tools and apparatus
CONCLUSION
CHAPTER 5
CHAPTER 6 SUGGESTION
BIBLIOGRAPHY/REFERENCE
APPENDIX

BY

AHMAD FIKRI BIN HANG JEBAT

(24DAM15F1005)
 11 SKUADRON
PU GONG KEDAK
22000 JERTEH
TERENGGANU
MALAYSIA

This On Job Training Report is Reported to Assessment Lecturer at Aircraft

Maintenance Department To Meet Part of On Job Training Evaluation and
Aircraft Maintenance Diploma Award

POLITEKNIK BANTING

DIS 2017

STUDENTS CONFIRMATION

“I admit that this on job training report is my own work except the summaries
that I have made each of them in the references.”

Signature : .............................................................................

Name : ..............................................................................

Matric No. : ..............................................................................

Date : ..............................................................................

ACKNOWLEDGEMENT

During my practical at No 11 Squadron at Gong Kedak, Terengganu, the

staff and also the officer help me to understand the meaning of working ethics
and also exposed us to the working environment during tweenty weeks of my
stay. In performing my practical task, I had to take the help and guideline of
some respected person who deserve my greatest gratitude. The completion of
my tweenty weeks give me so much pleasure and greatest honor to work in
working environment that I feel that very interesting. I would like to show my
gratitude to PW U I Encik Mohd Zaidi bin Mohd Shafei for showing me a good
guideline for my practical throughout numerous consultations. Other than that, I
also want to give my biggest gratitude to PW U II Encik Mat Robi bin Ali, our
TCI() for manage the time table for working time at the squadron. Also, I also
want to give my gratitude to PW U I Encik Rizal bin Hamid, our RNP (Rancang
dan Piawai) for guiding us when I working with one of the most latest and
greatest fighter in TUDM that are Sukhoi 30-MKM Flanker. Many people,
especially to the staff and team member in squadron have made valuable
comment suggestion on my practical which give me inspiration to improve my
skills. I want to thank all the people for helping me directly and indirectly to
complete my practical at No 11 Squadron at Gong Kedak Terengganu. May God
repay the kindness for those that helping me during my practical to the most
awesome working place that ive ever been during my service for TUDM.

CHAPTER 1
INTRODUCTION OF ON JOB TRAINING

1.1 Introduction

On-the-job training (sometimes abbreviated OTJ or OJT, and sometimes

called direct instruction) is one of the earliest forms of training observational
learning is probably the earliest. It is one-on-one training located at the job
site, where someone who knows how to do a task shows another how to
perform it.

In antiquity, the work performed by most people did not rely on abstract
thinking or academic education. Parents or community members, who knew
the skills necessary for survival, passed their knowledge on to the children
through direct instruction. This method is still widely used today. It is a
frequently used because it requires only a person who knows how to do the
task and the tools the person uses to do the task. It may not be the most
effective or the most efficient method at times, but it is normally the easiest
to arrange and manage. Because the training takes place on the job, it can
be highly realistic and no transfer of learning is required. It is often
inexpensive because no special equipment is needed other than what is
normally used on the job. One drawback is that OJT takes the trainer and
materials out of production for the duration of the training time. In addition,
due to safety or other production factors, it is prohibitive in some
environment. Even many researchers show the importance of the On the
 Job Training. For instance, in a research conducted by Arun Paul confirms
the significance of providing social skills training to professional social
workers.

A large majority of employee learning is accomplished through on-the-job

training. Well designed OJT training programs are well planned and
resourced, staff managers with competent coaching ability, and define the
criterion for performance standards.

1.2 Objective of on job training

The objective of On-Job-training (OJT) is directly related to the teaching

learning experiences and should help the student to:

i. Enhance their knowledge and skills acquired in the class in order to

become more responsive to the demands of Engineering Aircraft
Profession.
ii. Develop the value of professionalism, love of work and
commitment to people they serve.
iii. Apply the relevant theories of Engineering Aircraft and Code of
Ethics into practice.
iv. Feel and experience the actual world of work in practical.

1.3 Objective of training report

On Job Training Report is an important document to each of the

students. It is a document with the activities that have been learned
throughout the industrial training. One excellent work would mean
nothing if it can’t be reported in a statement that it is excellent. Therefore,
writing reports requires special attention of every student to be able to
follow every instruction set and can meet the needs of an institution.
Each student will be grateful to be able to prepare this report in a timely
manner and can generate a report that includes all the parts that have
been learned during the training industry in their own company.
Among the advantages and benefits to be obtained for this report are:

i. With the existence of this report then it could be used as evidence

to the Polytechnic that students have to undergo on job training at
the industrial training place.
 ii. In addition, the objective of this report is to document all activities
that have been carried out during the period of industrial training for
five months
iii. If this report is made, it can train students to follow the directions
set by the Polytechnic.
iv. The report also presents a challenge for students to attend an
interview which will be conducted by the Polytechnic by leveraging
existing experience.
v. Can be used as a reference by prospective employers during a
later interview.
vi. Provide guidance or as reference materials to students after
completing their studies.
vii. Students can train themselves to do some paperwork, this is
because of the style of writing and the report is more or less the
same for the completion of paperwork.
viii. Enable students to think and remember what you have learned and
have practiced during training industry.

1.4 The importance of on job training

i. It is an avenue for applying, enriching and enhancing the acquired

knowledge in the school in their particular field of endeavor.
ii. It is a way of changing the student’s outlook in life through
exposure in the performance of actual work relevant to IT that may
serve as a stepping-stone for future career.
iii. It develops interpersonal relationship with other employees within
the cooperating agency.

CHAPTER 2
ORGANIZATIONAL BACKGROUND

2.1 Introduction of the organization

RMAF Gong Kedak is an airforce base operated by the Royal Malaysian

Air Force. It is located 3.7 nautical miles (6.9 km; 4.3 m) from Jerteh in
 Gong Kedak, a town in between the state of Kelantan and Terengganu in
Malaysia. It is known as “The Home of the Flankers”, as the Sukhoi Su-
30MKM (Flanker-G) of 11 Squadron is based there.

Generally, the base is located about 10 km to Jerteh and 12 km to Besut.

It is connected to Pasir Puteh through the base back way about 16 km.
The base area is divided into two regions, namely Gong Kedak Complex
(technical area) and Bukit Puteri Complex (domestic area). The
distributions of these areas are separated by Jerteh – Kuala Besut road.

Gong Kedak is a small village in Pasir Puteh District

in Kelantan state, Malaysia with covered by rainforest. Bukit Puteri hill
suit the Gong Kedak as most strategic place for air force military base.
The new Royal Malaysian Air Force Base, RMAF Gong Kedak is located
here in Pasir Puteh territory Kelantan state.

2.2 Organisation background

History of the Royal Malaysian Air Force (RMAF) began when the Air
Force Ordinance was passed by Parliament on Monday, June 2, 1958
and when it was established it was known as the "Royal Air Force of the
Federation".

Air Commodore A.V.R. Johnstone, a British Royal Air Force officer (RAF)
was loaned to advise the Federal Government of Malaya and was later
appointed First Air Force Chief.
He is responsible for drafting the Federal Royal Air Force for a new
independent nation in terms of organization, human resources, assets
and terms of service. As the youngest force in the Armed Forces, his
long-time member was comprised of officers and members lent from the
Royal Air Force.

A group of officers and members pioneering the Royal Air Force was
converted from the Royal Air Force in November 1958. Those who
became the driving force of the RMAF organization were Flying Officer Li
Heng Lip, Sergeant Subramaniam, Corporal Razi Osman, Corporal
Othman Mohd Ismail, Corporal Wan Said, Corporal JD Pasley, Corporal
Mahevan, Senior Aircraftsman (SAC) Surindran, SAC Md Noor, SAC
 Zainal Abidin, SAC Mohd Hussain and Junior Technician (JT) Ismail
Arifin.

As a young force of early duty entrusted to the Royal Air Force at that
time was to provide air services and to assist the security forces in
combating communist operations that threaten the country. With the
formation of Malaysia on 16 September 1963, the name of the Air Force
was changed to "Royal Malaysian Air Force" or better known as RMAF.

2.3 Organisation activity

The RMAF goal is to provide, operate and mobilize an air force that is
always ready and able to emphasize the power of air power in order to
preserve and safeguard the interests of the nation. As one of the
elements of defense within the Malaysian Armed Forces, the RMAF has
a role to play in the following tasks:

Space Control to be used for peaceful purposes besides preventing its

use by the enemy. It involves "offensive airstrike", "defensive counter-air"
and "defensive suppressive" operations.

Application of Force to deal with threats on the surface whether on earth

or in the air. It involves strategic attacks, operations and maritime
attacks.
Increased Power to increase air and ground capabilities involving air-oil
refills, surveillance and surveys, transport missions, "electronic counter
measures" and air combat rescue operations.

Power strength to carry out the operation successfully. It involves base

defense, logistical support and base support to provide essential services
to organizations and members.

2.4 Direction of the organisation

Vision Of 11 Squadron
To get generate and sustain our image and reputation that is second to
none by providing quality engineering service.

Mission
To apply correct skills, attitude and knowledge of engineering and
technician in maintaining the SU-30MKM fleet.
 2.5 Organizational chart
KETUA BAHAGIAN KEJURUTERAAN

LT KOL. NOR MIZAN BIN MD NOOR TUDM

(372890)
KETUA SEK SIS/QA

PWBK LT LIM CHIN HAN TUDM (374861)

720271 PW U I MOHD ZAIDI BIN MOHD SHAFEI

PW R&P
PENYELIA SEK SIS
720784 PW U I MOHD RIZAL BIN HAMID
719034 PW U I ABD RAHMAN BIN
SEL TCI
RAHMAT

-720299 PW U II MAT ROBI BIN ALI

PW QA
-724432 SJN U MUHAMAD MAHAFIZ BIN
MAHMOOD 720016 PW U II MOHAMAD ZAKARIYA BIN
MUSA

SEL PUBLIKASI
SEL KAWALAN KEJ
724342 SJN U MOHD IMRAN SHAHRANI BIN
MAT SALLEH -721359 PW UII SYED MOHD NAZRI BIN
SYED NOOH
724532 SJN U WAN ZULHAFIZI BIN WAN
YUSUF -723033 F/SJN ZULFAZLI BIN SHAFEI
(TPME/TOOL STORE)

KETUA FLAIT HANGAR KETUA FLAIT PENGENDALIAN

MEJ MOHD RIZAL BIN ABD MALEK TUDM MEJ MOHD KHAIRIL ASHRAF BIN MATON
(374084) TUDM (374236)

SHIFT A SHIFT B

TIM HANGAR AGSE/V LT MOHAMAD ASYRAF BIN MOHAMAD LT MUHAMMAD FAIZ BIN DZAFARULLAH
ARIFIN TUDM (374989) TUDM (375125)
720658 PW U II SAIDIN 725636 SJN U SYAZWAN BIN
DERAWI BIN KASSIM NASHRUDDIN
 I/C SHIFT I/C SHIFT

721864 F/SJN MAZLAN BIN MALIN 721054 F/SJN MOHD KHAIRUL

OSMAN RIZAL BIN AB AZIZ

CHAPTER 3
SUMMARY OF ON JOB TRAINING ACTIVITIES

3.1 Introduction

This chapter is a summary of the activities done during training in 11

Squadron at Gong Kedak TUDM base at Terengganu. Activities done will be
written down in reflection journal book. In undergoing industrial training,
students are disclosed with a whole lot of new things. Apart from practicing
theory learnt in polytechnic, students also get the chance to experience working
by doing assignments given to them according to respective courses.

This will increase student’s confidence level and skills may be developed
during this training. On the other hand, students have to obey rules and
regulations from premises which they trained with. This can be helpful for
students by disciplining them and make them familiar with working hours and
their future nature of work. This is especially for students that have no idea
about things they need to face in the future.

During the training, our supervisor, PW Mohd Zaidi organized my stay in

Gong Kedak TUDM base. Firstly, he asks for my detail to make K-pass for me.
This is to ease our movement in and out from the base. If anyone did not have
this pass, they will have to stop at the Provost (Air Force Security) to change
our ID card with the pass. The application for the K-pass is made in the first
week of my stay here.

He also made a timetable (Appendix C) for us as we moved around the

squadron and flait from time to time. So, this makes my working hours a bit
different. While staying in 11 Squadron, the working hours is the same as
government office hour, but for squadron, we need to be there for 24 hours,
which is from 12 noon to the 12 noon for the next day. We works in Shift that
were Shift A and Shift B. Here is how my 20 weeks in Gong Kedak TUDM base
goes.

First week (November 27- November 31, 2017)

1. Reporting in to 11 Squadron.
2. Tour around the 11 Squadron Hangar, Squadron Headquarter and
School System.
3. Meeting with 11 Squadron (Ketua Bahagian Kejuruteraan), Lt Kol
Normizan bin Md Noor Tudm.
4. K-pass application.
5. Temporary Arrival for Gong Kedak Tudm Base.
6. Friday, Maulidur Rasul.

Second week (December 4- December 8, 2017)

1. Tour to the Technical Library in the 11 Squadron that store “Publikasi

Udara” (PU) for information about the aircraft.
2. Learn about the Engine Control from PU books. (76 Engine Controls).
3. Acknowledge about the service life of the Sukhoi 30-MKM aircraft.
4. Acknowledge about the main features of the aircraft, mostly of the
fuselage.
5. Acknowledge about the Flight Control System of the Sukhoi 30-MKM
aircraft.

Third week (December 11- December 15, 2017)

1. Learn about the fuel system of the aircraft.

2. Learn about the tank capacity of the Sukhoi 30-MKM and the location of
the tank at the aircraft that classify in section.
3. Learn about the geometrical data of the Sukhoi 30-MKM that are length,
height and wing span.
4. Acknowledge about the electrical system of the Sukhoi -30MKM such as
special features and the main function.
5. Learning the feature of the battery of the Sukhoi 30-MKM aircraft and the
construction of the battery shell.
Fourth Week (December 18- December 22, 2017)

1. Acknowledge about the FDR (Flight Data Recorder) and the function and
its system serviceability of the Sukhoi 30-MKM.
2. Learning the process of jacking of the aircraft (aircraft on jack) and ASE
(Air Support Equipment) that are Hydraulic Test Rig).
3. Learning the procedure of Daily servicing Routine for GPU (Ground
Power Unit) that supply power for Engine Startup of the aircraft.
4. Acknowledge about the Progressive Maintenance that are (P8) that
stands for aircraft number 08.
5. Acknowledge about the fuel filter and the process of cleaning the fuel
filter and installation of the fuel filter.

Fifth Week (December 26- December 29, 2017)

1. Because of the Christmas holiday, we got off day from 23 December until
25 December. We start working on Tuesday 26 December 2017.
2. Acknowledge about the component for starter of the engine and the
colour of the pipeline.
3. Learning the general of the aircraft Sukhoi 30-MKM (General information
and specification of the aircraft).
4. Done jacking procedure of the aircraft that need to be jack for servicing.
5. Un-jacking the aircraft by following the procedure from the PU.

Sixth Week (January 2- January 5, 2018)

1. Due to the New Year Celebration, our Squadron give off day from 30
December 2017 until 1 January 2018 (Monday) and we start working on
Tuesday.
2. Acknowledge about the principle of operation of drain valve for draining
fuel of the tank if overpressure.
3. Learning about the Nato Symbol at the Sukhoi 30-MKM.
4. Installing the drain valve.
5. Learning the procedure of adjusting the sensor because of Main Landing
Gear late command.
Seventh Week (January 8- January 12, 2018)

1. Unscheduled Maintenance because of the rough landing of the aircraft.

(examination to the landing gear).
2. Acknowledge about the Engine Control System Drive Pulley for removal
and installation.
3. Acknowledge about the front cockpit panel removal.
4. Acknowledge about the launcher of the aircraft and role equipment for
the launcher.
5. Learning about the Sukhoi 30-MKM ejection seat.

Eight Week (January 15- January 19, 2018)

1. Introduction of the Russian alphabets.

2. Acknowledge about the ASE (Air Support Equipment).
3. Learning about the aircraft cockpit arrangement.
4. Learning about the front cockpit arrangement of the aircraft.
5. Acknowledge about the SSEW (Safety Surface Equipment Workers).

Ninth Week (January 22- January 26, 2018)

1. Acknowledge about the armament general system and specification.

2. Acknowledge about the engine of the Sukhoi 30-MKM that are AL31 FP
Saturn Turbo Jet Engine.
3. Acknowledge about the avionic system of the aircraft.
4. Learning the general system of the airframe of the aircraft.
5. Learning the flight control system of the aircraft.

Tenth Week (January 29- February 2, 2018)

1. Doing visual inspection procedure after the crew report about the aircraft
damage by lightning discharge.
2. Learning the process of the KM-36M oxygen mask cleaning.
3. Doing visual inspection on pipes and flexible hoses without using
instrument.
4. Checking the engine oil system of the aircraft.
5. Doing oil draining from the aircraft.

Eleventh Week (February 5- February 9, 2018)

1. Acknowledge about the grounding of the aircraft and connection of

ground equipment.
2. Removal and installation of horizontal stabilizer pivot on aircraft.
 3. Doing manual test for engine indicating devices.
4. Doing visual inspection of rear fuselage without using instrument.
5. Checking the oil volume of the pneumatic hydraulic canopy actuating
cylinder on the aircraft.

Twelve Week (February 12- February 16, 2018)

1. Checking serviceability for canopy icing protection of the aircraft.

2. Doing “Check A” procedure for prior flight inspection.
3. Acknowledge about the procedure of “Check B” for post flight preparation
for airframe trade.
4. Doing pre-flight preparation for fueling and filling in “Check A”.
5. In Friday, our officer give off day for us because of Chinese New Year
Holiday.

Thirteenth Week (February 19- February 23, 2018)

1. Acknowledge about the assesment of electrical wires and connectors.

2. Doing visual inspection for airbrake located behind the canopy.

3. Acknowledge about the visual inspection of nose landing gear.

4. Checking pressure of the wheels of nose landing gear and main landing
gear for the aircraft.

5. Assesment of the radome by installation of radome fairing.

Fourtheen Week (February 26- March 2, 2018)

1. Acknowledge about the removal and installation of drag chute container

lock.

2. Doing removal and installation of landing gear door.

3. Assesment of the nose landing gear to remove the alcohol tank.

4. Learning the anti icing system function of the aircraft of Sukhoi 30-MKM.
 5. Installation of the alcohol tank at the bay of nose landing gear.

Fifteen Week (March 5- March 9, 2018)

1. Doing the removal of the aircraft from jack.

2. Doing the procedure of lifting and lowering of the landing gear with
hydraulic jack.

3. Doing visual inspection without instrument for pipes and manifolds.

4. Opening the radome (front parts of the aircraft) from aircraft.

5. Base activity (sports).

Sixteen Week (March 12- March 16, 2018)

1. Closing of the radome of the aircraft.

2. Doing visual inspection for rear fuselage of the aircraft.

3. Doing serviceability check for canopy icing protection.

4. Acknowledge about the visual inspection of the nose landing gear (NLG).

5. Base activity (sports).

Seventeen Week (March 19- March 25, 2018)

1. Doing prior flight inspection for aircraft M52-12.

2. From Tuesday (20 March 2018) until Wednesday (21 March 2018), we
do the canard removal for the aircraft M52-12 due to detection of crack at
both right and left canard from prior flight inspection yesterday. Due to
detection of the crack, our officer command us to change both of the
canard immediately. The operation is hard due to lack of experience of
removing the canard. It takes us 2 full day for removing both of the
canard.

3. On Thursday (22 March 2018) until Sunday (25 March 2018), we do the
canard installation for the aircraft M52-12.

Eighteen Week (March 26- March 30, 2018)

1. Doing the removal of cassete at video recorder located at cockpit.

2. Doing installation of cassete at video recorder.

3. Introduction of pitot static system at the aircraft of Sukhoi 30-MKM.

4. Introduction of engine compressor for engine Saturn AL31 FP turbojet

engine.

5. Squadron activity (Sports).

Nineteen Week (April 2- April 6, 2018)

1. Acknowledge about the nitrogen generator from ASE (Air Support

Equipment) and its general specification.

2. Doing engine oil drain for engine oil system from aircraft M52-16 Sukhoi
30-MKM.

3. Acknowledge about the function of engine oil system and how does filling
the oil on engine system.

4. Acknowledge about how to check engine oil system on aircraft.

5. Base activity (Sports and domestic cleaning of surounding).

Tweenty Week (April 9 – April 13, 2018)

1. Acknowledge about the ration, water supply system and water waste
supply system.

2. Acknowledge about the flight ration for crew during flight and how to
determine the expired shell life, swallon package and unsealled package.

3. Acknowledge of how inspection was being done from ground to aircraft.

4. Doing check B to engine during post flight of the aircraft.

5. Doing repeated check C of the aircraft.

6. During this weeks, we also do the base clearance because of we done

for our practical in our Squadron.
 CHAPTER 4

Job Training Activities