THE FINAL REPORT OF THE INDUSTRIAL TRAINING AT

CSC STEEL SDN.BHD

SHAKTIVELL A/L M. LETCHUMANAN

This Report is Submitted in Partial Fulfilment of Requirements for the

Bachelor of Mechanical Engineering with Honors

FACULTY OF MECHANICAL AND MANUFACTURING ENGINEERING

UNIVERSITI TUN HUSSEIN ONN MALAYSIA

SEPTEMBER 2019
“I declare that I have read this report. In my opinion this report is sufficient in terms of scope
Bachelor of Mechanical Engineering with Honors

Signature :… …………………………
Supervisor’s Name : MR. FOO CHUAN WOO

Date : 06th SEPTEMBER 2019

 “I hereby declare that this report entitled “The Final Report of The Industrial
Training At CSC Steel Sdn.Bhd ” is the result of my experiences and knowledge
except as citied in the references.

Signature : ………………………………….
Name : SHAKTIVELL A/L M. LETCHUMANAN

Date : 06th SEPTEMBER 2019

 ACKNOWLEDGEMENT

“In the name of God, the most gracious, the most compassable”

It has been God’s blessing that the completion of my Industrial Training for the
Degree level at CSC Steel had been achieved and completed after crossing over lots of barriers.
I wish to express my sincere and interest, that this report would not have been the same as
presented here. Firstly, I would like to express my heartfelt gratitude to CSC Steel Sdn. Bhd. for
giving me a chance to complete my internship here. I would also like to thank all the General
Affairs and training section staff that have briefed and trained me from the beginning.
Special gratitude to the P620 Mechanical Maintenance Department for their full
support and guidance during my internship period. My special thanks to the Managing Director
of CSC Steel for permitting me to do my internship here. Special appreciation to my beloved
Supervisor; Mr. Foo Chuan Woo (the P620 Department Manager) and all the Engineers, Team
Leaders, Foreman followed by all the Technicians. Without them, I couldn’t have learned all
the skills and knowledge that I have gained so far. It was definitely having a positive experience
working around them, They also showed me that teamwork and patience are necessary in
completing any task. My sincere thanks to all the staff and operators that had helped me during
my internship period at this company. I would like to thank all the management staff for being
cooperative and very helpful
Last but not least, I also indebted to Universiti Tun Hussein Onn Malaysia (UTHM) for
providing me proper guidelines and advices throughout my internship period. My heartfelt
thanks to Dr.Reazul Haq Bin Abdul Haq for being my faculty supervisor during my internship.
Staff at the Faculty of Mechanical and Manufacturing Engineering followed by the University
and Industry Relations Office also deserves special thanks for their assistance.
 ABSTRACT

The purpose of this Industrial Training is to provide exposure for the students on
practical engineering fields. Through this exposure, myself had better understanding of
engineering practice in general and sense of frequent and possible problems. This training is
part of the learning process. So, the exposure that uplifts my knowledge and experience are
properly documented in the form of a report. Through this report, the experience gain had been
delivered to my peers. A properly prepared report can facilitate the presentation of the practical
experience in an orderly, precise and interesting manner. As a part of the curriculum, and for the
partial fulfilment of the requirements for completion of the Bachelor of Mechanical Engineering
with Honors from UTHM, myself had underwent an industrial training at the CSC Steel
Sdn.Bhd (MBT) for 10 weeks during the Two months and a week’s period from July 2019 till
September 2019. Since the founding of CSC Steel Group in 1991, our world has changed in
many ways. Progressive globalization is causing our world to grow ever closer. Societal
structures have evolved and innovative technologies are enriching our lives in many facets. It’s
a development in which CSC Steels have played a large part over the past 28 years since its
establishment. This plant is located at the state of Melaka; the historical city. Under the guidance
of Mr. Foo Chuan Woo (the P620 Department Manager) I got the opportunity to have exposure
to the works carried out in this department of the industry, and hence learn a good deal from
them. During the period of industrial training, the works primarily assigned were concerned with
Steel Coil manufacturing machine maintenance. A brief discussion on the assignments given
and training undergone during this period follows.
 TABLE OF CONTENT

CHAPTER TITLE PAGE

1 INTRODUCTION

1.1 Industrial Practical Training Introduction 1

1.2 Background of Industrial Training 2
1.3 Objectives 2
1.4 Scope 2
1.5 Overall Daily Routine 4

2 COMPANY BACKGROUND

2.1 CSC Steel Group Introduction 5

2.2 Company Profile 10
2.3 Vision and Operating Policy 12
2.4 Certification 12
2.5 Organizational Chart 15
2.6 CSC Steel Sdn.Bhd Products 17
2.7 Overall Manufacturing Process and Various Line 26

3 INDUSTRIAL TRAINING ACTIVITIES

3.1 The Safety Job Procedure 37

3.2 Designing Layout for Store 39
3.3 Learnt on How to Use the Oxy Cutter 39
3.4 Learnt on How to Examine a Rollers Condition 40
3.5 Learnt on How to Examine Various Type of 42
Machine Oil
3.6 Learnt on How to Read and Record the 44
Vibration Meter
3.7 Learnt on How to Read and Record the Dial 47
Gauge.
3.8 Learnt on How to Identify the Pitch of the Screw 48

4 CONCLUSION 49
 CHAPTER 1

INTRODUCTION

1.1 INDUSTRIAL PRACTICAL TRAINING INTRODUCTION

The main objective of this internship under the name of University Tun
Hussein Onn Malaysia for Bachelor of Mechanical Engineering with Honors of
course is to develop potential and experienced candidates in the mechanical field for
their great development. Since this internship has been scheduled at the final year of
this course, students get to practice all their theoretical knowledge and experiences
that they gained throughout their past semester through this. Engineering field has
been challenging and competitive all this while. Through this internship students get
to experience the working environment and this part of curriculum has not failed to
prepare these students to be expertise in this field.

Experience has been the main requirement for the employers to appoint
freshly graduates. Internship has been a great platform that build up the students’
skills, experience and knowledge for their bright future environment. Even this
internship has given a great opportunity for the students develop their High Order
Thinking Skills (HOTS) that has been a great skill for problem solving. Creative,
Critical and Innovative thinking are tended to be developed through this internship.

1
1.2 BACKGROUND OF INDUSTRIAL TRAINING

Industrial training program is an important component in the diploma and

degree curriculum that has been offered by University Tun Hussein Onn Malaysia.
University Tun Hussein Onn Malaysia initially was known as Kolej Universiti Tun
Hussein Onn Malaysia (KUiTTHO). Industrial Training is compulsory for all the
students to develop knowledge and technical skills besides adapting to working
lifestyle that will endeavor.

1.3 OBJECTIVES
➢ To improve students’ technical skills.
➢ To improve soft skills among the students.
➢ To manure the spirit of working in groups.
➢ To generate the professional ethic value among the students.
➢ To expose the students to the desired field of study
➢ To provide opportunities for the students to communicate and mingle
with professionals.
➢ To develop students’ creative, critical and innovative skills

1.4 SCOPE

The author has been doing various maintenance jobs within ten weeks of
Industrial Training programmed. The author was assigned in the department of
P620 Mechanical Maintenance Section 1. Besides, the author also had been given a
jobs task from the manager of the P620 Mechanical Maintenance department.
Besides, the author also had been given opportunities to doing any maintenance
work as long as there are other workers supervising the author.

2
 Table 1: Scope of training
No Training subjects

1 Understanding maintenance organization chart

2 Understanding maintenance flow chart

3 Introduction to PPL

4 Introduction to 4’ CRM

5 Introduction to ECL

6 Introduction to BAF & Kathabar

7 Introduction to TPM

8 Introduction to Kathabar

9 Introduction to TPM

10 Understanding of RCL/TLL

11 Understanding of mechanical tools

12 Introduction to 5S system

3
1.5 OVERALL DAILY ROUTINE

TIME ACTIVITES

7.57 a.m. ✓ Scan in / check in

8.05 a.m. ✓ Read out Safety Job Procedure for

related line. (3SJP as training)
✓ Get signature from each technician

8.40 a.m till 9.40 a.m. ✓ Check EIP system and update SJP

9.45 a.m till 10.30 a.m. ✓ Get signature for SJP from each
technician
10.40 a.m till 11.45 a.m. ✓ Workshop and line visit

12.00 p.m till 1.00 p.m. ✓ Lunch break

1.05 p.m till 2.40 p.m. ✓ Check EIP system and update SJP or
HIRAARC
2.40 p.m till 3.40 p.m. ✓ Get signature for SJP from each
technician

3.45p.m till 5.00pm ✓ Workshop and line visit

5.30p.m ✓ Scan out

4
 CHAPTER 2

COMPANY BACKGROUND

2.1 CSC STEEL GROUP INTRODUCTION

In December 2000, China Steel

Corporation of Taiwan (CSC) had acquired its
first offshore steel companies, namely CSC Steel
Sdn. Bhd. (CSC Steel) and Group Steel
Corporation (M) Sdn. Bhd. (Group Steel). Since then, both CSC Steel and Group Steel
have been fully operated under the management of CSC. In January 2004, Ornasteel
Holdings Berhad was established and acquired CSC Steel and Group Steel as its
wholly-owned subsidiaries in the same year. Subsequently, Ornasteel Holdings Berhad
was successfully listed on the Main Market of Bursa Malaysia in December 2004 and
renamed CSC Steel Holdings Berhad (CHB) in 2008 (Collectively known as CSC
Malaysia or the Group).

At the helm of its parent company, CSC, the productivity as well as the
competitiveness of CSC Malaysia in both domestic and international markets has been
strengthened with the capital injection in upgrading equipment and expanding
production lines, providing technical support, and enhancing its management
performance. In recent years, the Group has actively broadened its market reach to

5
 countries in Southeast Asia and Oceania. This move would help the CSC Group to
further penetrate into the steel markets in Southeast Asia.

The main products of CSC Steel include pickled and oiled steel coils (PO),
cold rolled steel coils (CR), galvanized steel coils (GI) and pre-painted steel coils
(PPGI). CSCM is actively shaping its brands, namely and ,
to expand its market share in the building material industry. The Group is keen on
developing new coated steel products by cooperating with related chemical suppliers
closely.

In addition, the Group is committed to increasing the values for the

shareholders and the community and reducing the impact to the environment so as to
achieve its sustainable development.

CSC Steel Sdn. Bhd. had about 10 hectares area in Ayer Keroh. There is a building for
administration, 2 building for production, a building for workshop and store, two guard
houses and a large car park. All the products are mainly being export to foreign countries like
Indonesia, Thailand, Philippines, India, China, Taiwan and Europe. On the other hand, there
are also huge demands in domestic market too.

There are over 700 employees in the CSC Steel currently. Among the 700 employees,
about 80% of them are male. For male, most of them work at production department,
maintenance department, electrical department, computer department and other departments.
For female, they work at purchasing department, finance department, personal department,
marketing administration, and other departments.

6
MILESTONES

7
8
9
2.2 COMPANY PROFILE

Registered name : CSC Steel Sdn.Bhd.

Address : 180, Kawasan Industri Ayer Keroh, 75450,

Melaka, Malaysia.

Total Employee Enrolment : 700 employees

Telephone No. : +606 231 0169

Facsimile No. : +606 231 0167 / +606 231 9166

Year of Incorporation : 1991

Floor space area : 10 hectares

Location:

10
CSC STEEL SDN.BHD INDUSTRIAL LAYOUT.

11
2.3 VISION AND OPERATING POLICY

2.3.1 VISION

❑ To be a trustworthy and excellent steel company in Malaysia as well as South

East Asia.

2.3.2 OPERATING POLICY

Operating policy to achieve the Group’s vision:

❑ Refinement by reinforcing sales, production and delivery
❑ Advancement by enhancing product grades and technical sophistication
❑ Prosperity by consolidating customer services and sales network
❑ People-oriented by emphasizing on work safety, environment and learning.

2.4 CERTIFICATION

ISO 9001:2015
At CSC Steel, we believe quality is the responsibilities of all employees. We are
committed to supply competitively priced products that meet our customer's requirements.
We have been ISO registered since 2001. We have met the requirements of ISO 9001:
2015 and is registered within SGS Certificate Scheme.
This dedicated to quality and service will continue to move CSC Steel forward, enhancing
our ability to meet and well into the future. Contact us today to learn how we can help you

12
ISO 14001:2015
In year 2009, CSC Steel had accredited with the Environmental Management System ISO
14001:2004 by SGS and upgraded to ISO14001:2015 in year 2018. The ISO 14001 is a
series of international standards on environmental management to help organizations
minimize how their operations negatively affect the environment (cause adverse changes to
air, water or land) and comply with applicable laws and regulations.

13
ISO 50001:2011
In year 2013, CSC Steel had accredited with the Energy management systems ISO
50001:2011. The ISO 50001:2011 is a standard specifies the requirements for establishing,
implementing, maintaining and improving an energy management system, whose purpose is
to enable an organization to follow a systematic approach in achieving continual improvement
of energy performance.

OHSAS 18001:2007
In 2016, CSC Steel had obtained Occupational Safety and Health Management System
OHSAS 18001 certificate from SGS Malaysia under
accreditation from SM Standard Malaysia.
OHSAS 18001 is the standard against which
organizations are assessed on their Occupational Health
and Safety performance. As with other standards, it is
based around the setting of objectives and targets and
the monitoring of the business occupational health and
safety performance against this standard. The aim of
OHSAS 18001 is to assist organizations establish and
maintain a system of management to improve the health
and safety of employees at the workplaces.

14
2.5 ORGANIZATIONAL CHART
2.5.1 Overall

15
2.5.2 P620 Mechanical Maintenance Department Organizational Chart

In this maintenance department, it consists of manager as a head in this department, then supervisor or foreman to supervise the technicians. The
engineers are assigned to their respective lines whereby it is responsibility to take care their line and responsible for any issue or problem that
occurs in the line. Moreover, the technician groups are led by leader to perform any maintenance work at the production line or in the workshop.

16
2.6 CSC STEEL SDN.BHD PRODUCTS.

The following are the steel products that are produced in CSC Steel plant. We will be
focusing in Hot Rolled & Oiled Steel and Cold Steel only as only these two products
are under the responsibility of P620 Mechanical Maintenance Department.

17
2.6.1 Hot Rolled & Oiled Steel

Hot rolled pickled and oiled steel (PO) is the basic structural material for underbodies,
automotive wheels and inner parts, strapping, tubing, and rack.

Hardware & Accessories

Specifications

Standard and Grade

Thickness Width
Category MS 1705 JIS G3131 JFS A1001 (mm) (mm)

Commercial quality SPHC SPHC JSH270C 1.40~6.00 600~1,350

Drawing quality SPHD SPHD JSH270D

Deep drawing quality SPHE SPHE JSH270E

Application

Car Jack Scalffolding

Steel Mesh for Floor Deck Steel Tube

18
Automotive

Specifications

Standard and Grade

Thickness Width
Category MS 1705 JIS G3131 JFS A1001 (mm) (mm)

Commercial quality SPHC SPHC JSH270C 1.40~6.00 600~1,350

Standard and Grade

Thickness Width
Category JIS G3131 JFS A1001 (mm) (mm)

Automobile structural SAPH310 JSH310W 1.40~6.00 600~1,350

usage quality

SAPH370 JSH370W

SAPH400 JSH400W

SAPH440 JSH440W

Standard and Grade

Thickness Width
Category JIS G3134 JFS A1001 (mm) (mm)

Improved formability SPFH490 JSH490 2.00~3.20 600~1,250

for automobile
structural usage
quality SPFH540 JSH540

SPFH590 JSH590

19
Application

Absorber Tube Mounting Bracket Car Wheel

Car Seat Rail Castor Wheel (SPHC)

Air cleaner bracket

Engine Chassis Arm

20
A Brief Hot Rolled Pickled & Oil Steel Product Flow

21
2.6.2 Cold Rolled Steel

Cold rolled steel (CR) is widely used in various industries such as automotive, home
appliances, drum, pipe, tube, steel furniture, office equipment, etc. It is also used as the base
metal for coated steel products.

Full-Hard Quality

Specification

Standard and Grade

MS JIS SNI 07- JFS Thickness Width

Category 2651 G3141 3567 A2001 (mm) (mm)

Commercial SPCC- SPCC-1B Bj DC – 1K - 0.20 ~ 600~1,250

quality 1B 2.60

Semi Hard Quality

Specification

Standard and Grade

SNI
MS JIS 07- JFS Thickness Width
Category 2651 G3141 3567 A2001 (mm) (mm) Application

Semi- SPCC- SPCC- Bj DC - 0.30~2.00 600~1,250 Electrical/

hard 2D/B 2D/B - Electronic/
quality 2K/R Automotive
Parts
(Special
SPCC- SPCC- Bj DC Hardness
4D/B 4D/B - Requirement)
4K/R

SPCC- SPCC- Bj DC

22
 Standard and Grade

SNI
MS JIS 07- JFS Thickness Width
Category 2651 G3141 3567 A2001 (mm) (mm) Application

8D/B 8D/B -
8K/R

- SPCCT- - - 0.30~2.60
2D/B

SPCCT-
4D/B

SPCCT-
8D/B

Commercial Quality

Standard and Grade

SNI
MS JIS 07- JFS Thickness Width
Category 2651 G3141 3567 A2001 (mm) (mm) Application

Commercial SPCC- SPCC- Bj JSC2 0.30~2.60 600~1,314 Automotive,P

quality SD SD DC - 70C ipe, Drum,
SR Furniture,
Service
Center Slit /
Sheet etc.

23
Drawing Quality

Standard and Grade

SNI
MS JIS 07- JFS Thickness Width
Category 2651 G3141 3567 A2001 (mm) (mm) Application

Drawing SPCD- SPCD- Bj JSC270D 0.30~2.00 600~1,250 Automotive,

Quality SD SD DC - Home
SR Appliance,
Speaker Frame,
Satelite Panel,
SPCE- SPCD- Bj JSC270E Welding
SD SD DD2 Electrode,Wheel
- SR Barrow Tray,
Fire
Extinguisher,
SPCF- SPCD- Bj JSC270F 0.30~1.80
Canister etc.
SD SD DD3
- SR

SPCG- SPCD- - JSC260G 0.30~1.60

SD SD

Automotive

Standard and Grade

JIS Thickness Width

Category G3135 JFS A2001 (mm) (mm) Application

Automotive SPFC340 JSC340W/P 0.30~2.60 600~1,250 Automotive Structural

drawing Parts (Special Tensile
quality Requirement)
SPFC370 JSC370W/P 0.30~2.30

Automotive SPFC390 JSC390W/P 0.30~2.00

forming
quality
SPFC440 JSC440W/P

24
A Brief Hot Rolled Pickled & Oil Steel Product Flow

25
2.7 OVERALL MANUFACTURING PROCESS AND VARIOUS LINE

26
 Figure above shows the main processes that occur in the CSC Steel Sdn. Bhd. Firstly,
Hot Rolled Coil (HRC) will be purchased from other company. Whenever HRC are brought
in generally the coils are rusted. So, the HCR will undergo through several process. The HCR
will undergo through pickling line in order to remove rust from coil. Then the coils go
through the Cold Rolling Mill (4’ CRM) to get desired coil’s thickness. Then coil will be sent
into three various lines which are coil are left cold and ready to be packing and another one
sent to continuous galvanizing line then through the color coating line and then ready to be
packing. This part is where the coil has various colors that being coated at the coil. After coil
undergo cold rolling mill, it will be sent to the electrolytic cleaning line (ECL) to clean the
coil. Then it goes through a heat transfer treatment in batch annealing furnace (BAF) and
Kathabar (Now not use). Then it goes through the temper mill (TPM) to provide a desired
surface of the coil. Then it is sent to the tension leveler line or recoiling coil line to control the
flatness of the coil and anti-rust are applied to the coil. After undergoing the HSR process
through this process, the HRC will become Cold Roll Coil (CRC). Lastly, the HRC will be
packed into two categories one for domestic market another one for the international market.

2.7.1 Push Pickling Line

27
 Squeeze
Rinsing Tanks Taper Shear
rolls x12 sets
Bridle Rolls
Flattener
Side trimmer Rolls

Crop Shear
Chopper
Dryer
Recoiler Unit Uncoiler
Pickling Tanks

Push pickling line is the first process in cold rolling process. PPL is a long line which
consist several parts that perform different functions. The main function is to remove the
metal oxide on the hot rolled coil (HRC) by putting it through Hydrochloric (HCL) acid bath
with concentration of 16%. The strip will go through the four pickling tanks to remove rust
and dirt. Then, continuous with passing four rinsing tanks to remove HCL from the strip. The
medium used is hot water. The function of the side trimmer knife is to trim the edge according
to the specification and this knife must be in good condition in order to avoid any defects
happen such as saw tooth edge or edge crack defects of coils. This PPL machine is
manufactured by Andritz Ruther, Austria 1993 and operated in April 1994. The machine type
is push pickling line and the maximum line speed is 150 mpm.

Procedure:
1) Pickling tanks, to wash the oxide scale.
2) Rinse tank, to wash or clean up the HCL from surface of strip.
3) Trimmer, to trim the strip to the required width.
4) Deburr unit, to smooth the strip edges.
5) After that, the coil will be sent to 4’ CRM or 3’ CRM for further process.

28
2.7.2 4’ Reversing Cold Mill (RCM)

Entry cobble
Hydraulic Roll force
guard
Cylinder Press woods
Vertical rolls

Wiper rolls Entry feed roll Threading

Peeler
ABB table
X-ray gauge Back up knife table Hold
measuring
roll Leveler down roll
roll
Stripper rolls
Left reel

Work
Shear
rolls Deflector
cutter Pay off
Back up X-ray gauge roll
reel
ABB roll Wiper Pinch rolls
measuring rolls
roll Flipper
table
Flipper table Deflector roll
Stripper Pay off
coil car
Right reel
Wedge of pass line coil car
Right reel Right reel
adjustment
coil car

Cool rolling is use to roll down the HCR to the required thickness and obtain a specific
mechanical strength. The minimum thickness can be reduced to 0.2mm.

Procedure:
1) Strip from pay off reel pass through the leveler unit to flatten the strip.
2) Billy roll or stressometer roll are used to inspect the tension on the strip. Control unit
of the system (Automatic Gauge Control System) will use this value to control the

29
 amount of force that transfer from backup roll to the work roll. The strip will pass
through the gap between two work roll and the strip is compressed by the gap to
desired thickness.
3) Coolant will apply through nozzle to the strip for reduce the heat generated and as a
lubricant medium.
4) The strip also will pass the x-ray gauge before enter the mill stand and after exit the
mill stand. This x-ray gauge is used to measure the thickness of the strip.
5) After exit from the mill stand, the strip is recoiled by the right tension reel. The strip
will pass the mill stand from right to left and left to right for a several times until the
desired thickness is achieved.

2.7.3 Electrolytic Cleaning Line (ECL)

Wringer roll
Strip Dryer
(pneumatic)
Direction Unit Edge
Positioning
Control
Brush Hot Rinse (EPC)
Entry
Tank #1 Spray System Exit
Crop Electrolytic
Flushing Crop
Shear Section
Section Shear

Brush
Wheel
Wringer roll Tank #2 Center Snubber
Welder Tension
Flattener (manual) Positioning roll
Pay Off Scrap Car M/C Mandrel
Control
Reel
Rinsing (CPC)
Tank

ECL is use to clean the cool coil surface which contains residual rolling oil, iron powder and
dust by putting the coil through alkaline properties. Besides that, is also function to provide a
layer of silicate to prevent sticking when through annealing process. The alkali that used in
ECL is Na2SiO3, PH is around 13.
The main equipment and it function in ECL as:
1) Flattener unit – To flatness the strip.
2) Flush tank – As a pre-cleaning section. The medium use in the flush tank is D.
I water.

30
 3) No. 1 brush tank – Brush tank contains brush roll that brush away most of the
oil, iron particles and other dirties. The cleaning medium, D.I water is spray on surface
of the strip.
4) Electro bath – To reduce residue oil to the surface of steel trip by using
electrostatic mechanism. The medium use in flush tank is alkaline.
5) No. 2 brush tank and rinse tank – To wash the residue of alkaline.
6) Air dryer unit – To dry the strip.

2.7.4 Batch Annealing Furnace (BAF)

31
 In the cold rolling mill process, strip was compressed to desired thickness. This
process changes molecules structure or crystal of steel strip and cause the steel strips become
harder and difficult for further processes as bending, forging, welding for example. Annealing
process is use to recrystallize the iron molecules of the coil in order to obtain the required
mechanical properties, such as hardness and yield point. Thus, the workability of steel is
improved as desired. There are 17 base of annealing, 10 heating hood and 9 cooling hoods.

Procedure:
1) Stacking the coils on the annealing based. Each coil has to separate with each
convector plate.
2) Cover the coil by using by using inner cover. Inner cover is use to protect the
coils from directly contact with burning fire or the cooling medium, water.
3) Cover the inner cover by heating hood.
4) Nitrogen is purging to remove oxygen before the hydrogen gas is purged in to
avoid explosion.
5) Hydrogen gas is purged in to remove the nitrogen gas. Hydrogen is use for
cleaning purpose before the heating process.
6) The coil will heat around 600 – 700 °C for 7 to 12 hours depending on the
properties of raw materials.
7) After the heating process, change the heating hood to cooling hood.
Atmosphere air will supply to the cooling hood through the blower for
cooling purpose until the temperature reach 300°C. After that, water will be
use for further cooling purpose until the temperature reach 90-100°C.
8) Hydrogen will be discharged by purge in nitrogen and then replaced by
atmosphere air. The cooling process takes time bout 15 to 20 hours.

32
2.7.5 Temper Mill

Hydraulic
Roll force Cylinder

Gamma Top
gauge Shear
Cutter work roll

Backup Anti crimping Roll

Roll
Oiler roll
Pinch roll

Backup
Exit Billy Exit Anti- Roll Entry Billy
Tension Roll Crimping Roll
Reel Roll
Bottom
work roll Pay Off
Exit Coil Reel
Car Wedge of pass line Entry Coil
adjustment Car

The function of TPM is to pull the coil until it reaches its yield strength to eliminate
the yield point of the strip by means of elongation. The tension of the coil is created by both
side tension reels while the yield strength is produced by compression of the backup roll. The

33
strip thickness is normally compressed by 0.1mm of the strip thickness. TPM is also
responsible to create roughness on the strip surface through sand blasted work roll.
The main item and it function as:
1) Strip go through the mill stand; backup roll will transfer force to the work roll.
This work roll will compress the steel strip to produce a desired surface finish and
mechanical properties.
2) Gamma gauge is used to measure the thickness of the strip.
3) Billy roll is used to measure the elongation.

34
2.7.6 Recoiling Line (RCL) or Tension Leveler Line (TLL)

35
 RCL consist of tension leveling which creates elongation to give superimposition of
tensile and bending stress in the strip which results in plastic deformation. RCL provides
uniform oil on the strip surface. There are two types of oil which are DOS and ARO oil. DOS
oil is made of synthetic palm oil and suitable for food application. It can protect the coil for 3
months before it rust. DOS oil is usually used in drum maker. ARO oil can resist rust for half
to one year, which gives an advantage in shipping purpose that consumes time. ARO oil is
applied though electromagnetic spray mechanism on the strip surface. DOS is applied on the
strip surface by mist created by air turbine atomizer. RCL also cut off the coil from massive
weight to few smaller coils according to the customer demand. RCL is a continuous process
which end of the strip must be weld with the beginning of new strip. This process is essential
since the new strip cannot pass though the tension leveler by itself.

36
 CHAPTER 3

INDUSTRIAL TRAINING ACTIVITIES

3.1 THE SAFETY JOB PROCEDURE

The Safety Job Procedure can be considered as the heart of P620 Mechanical
Maintenance Department. Basically, it can be considered as a safety guideline to perform each
task in various line. SJP is used in all lines that are under the P620 department. Even SJP is
applied to each tools and machines that are exist in the workshop and lines. It is necessary to
review the SJP for every 2 years once. It mainly focusses on the Unsafe Condition that may
exist and the possible solution to counter it. After reviewing each SJP it will be submitted to
the manager for verification and will be forwarded to the General Manager for approval
through the EIP system. It mainly Throughout the Internship I had reviewed SJP for general,
Push Pickling Line, Batch Annealing Furnace, Pomini and Tension Leveler Line. After
completing the training I have to make sure all the technicians and operators had sign the
training record . The following is how each SJP number for various line are read.

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The EIP system where all SJP are been uploaded, verified and approved

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3.2 DESIGNING LAYOUT FOR STORE

In this task I have to figure out the layout for the 6 different locations. It is basically
drawing a map from top view based on the location code that are stated/tagged on the
cupboards and rocks. Through this I get to know about various tools that are used for several
machines and applications. I transferred al my sketches into virtual drawings. I assigned
locations for the materials that were in the store. Right after assigning and listing down
appropriate locations I printed and laminated the tagging in the areas

3.3 LEARNT ON HOW TO USE THE OXY CUTTER

The oxy cutter is a very unique metal cutter. It uses the combination of oxygen and
acetylene. It can be use to crave, cut thick metals. It needs to be handled by skillful
professional as it needs a very precise cutting. Only a very minimal shake or vibration is
allowed during the handling of the oxy cutter. The person whom are handling it have to squirt
and need to rest his arm for better handling.

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3.4 LEARNT ON HOW TO EXAMINE A ROLLERS CONDITION

It is very important to always check the condition of rollers so that the thickness of the
steel coil is always maintained based on the requirements and promised specifications. I was
brought to Electrolytic Cleaning Line to examine the defector roller. This defector roller is
used to transfer the uncoiled steel from one process to another at an angle. Basically, this
defector roller is used at places where the coil is transferred from high platform to the lower
one. Previously the defector roller used PU material and was changed to MBR material. PU
material will be harder at early stages and softer at end. Moreover, the operating temperature
of PU is 80℃ which is not compatible with the processing temperature which will be up to
100℃. MBR material will be softer at starting and harder at end and it could sustain the
surrounding temperature since its operating temperature would be from 35℃ 𝑡𝑜 120℃ . There
are 3 types of measurements need to be taken to make sure the defector roll is suitable for the
process. They are:

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Hardness test (one
time reading)
•Type A: Softer one
•Type B: Harder one

Diameter tape test

•Determine average
diameter

Level test
•To make sure the roller
have an uniform surface

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3.5 LEARNT ON HOW TO EXAMINE VARIOUS TYPE OF MACHINE OIL

NO. PROCEDURES ILLUSTRATION

1 The residues in the oil samples need to be filtered
using the Membrane filter paper to justify the
size of the residues. The oil samples will be
absorbed by a membrane filter paper which will
be placed in between the oil filter glass. The
specification of the paper is shown in figure
below.

2 The membrane filter paper is then placed

between the oil filter glass. In some
circumstances a oil vacuum motor may be used
to make sure the oil flow through the filter paper
so that the entire residue content in the oil will be
filtered.

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3 The residue that are been filtered are then placed
on the sample visual plate This sample visual
plate will be placed under the microscope.

4 The size and amount of the residues in the half

section will justified to specifically identify the
oil quality.

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3.6 LEARNT ON HOW TO READ AND RECORD THE VIBRATION METER

Vibration is a very serious condition that needs to be maintained in each operating

machine. Vibration may lead to both long and short term effects. It has been a monthly
routine for the Mechanical Maintenance Department to read and record the vibration from
every machine that exist in each line. The data will be compared and analyzed to make sure
that the existing vibration doesn’t exits its limits. During the internship I get to participate in
read and recording the vibration in the machines that exist in 4’ CRM Mill. The specific
points to take the vibration reading is clearly illustrated in the following figure.

Basically, there are four points that are specified to determine the vibration. By taking
up the reading using the vibration meter we tend to get the operating temperature, the bearing
condition and off course the vibration reading. The following is the procedures on how to
carry out the task.

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Apparatus: FLUKE 805 Vibration Meter

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Procedures
1) Check the sensor tip
2) Check the bearing temperature
3) On, cursor down to select 2nd (Overall Vibration), start and record. Be careful during
measurement because the shaft is rotating.

The challenges that possibly will be placed are the motor, shaft is not rotating beyond 600
RPM whereby it is necessary to obtain the vibration beyond this reading.

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3.7 LEARNT ON HOW TO READ AND RECORD THE DIAL GAUGE.

The Dial Gauge is a gauge that is used to read and check the whether the gear in the
side trimmer is in a uniform rotation. This done because there are few gear mesh are involved
and to maintain the uniform rotation by the trimmer. The reading should not exit 0.05mm
when it is rotated manually.

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3.8 LEARNT ON HOW TO IDENTIFY THE PITCH OF THE SCREW

The pitch of a screw is identified using the Pitch Gauge. The Pitch Gauge has various
sizes of screw measurement and those measurements can be obtained both in inches and
metric units. The following is the Pitch gauge and the way how does the pitch is obtained.

The suitable pitch

measurement for the crew is
identified when all the screw
groove is fully close to the
Pitch gauge teeth where here
should not be any gap.

This the pitch measurement

is wrong where the screw
groove is not close enough
with pitch gauge teeth.

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 CHAPTER 4

CONCLUSION

I participated in 10 weeks of industrial training at CSC steel Sdn. Bhd and I

had gained a lot of valuable experiences, particularly in the profession that I would
be in the future. However, I felt in this limited period I had equipped with lots skills
and knowledges that are considered the basic of Mechanical engineering.

I think this curriculum standard can be considered at its level best where it
provides the theoretical knowledge and simultaneously gave the space to practice
the theory into reality. This curriculum basis had produced lots of skillful
professional graduates. Experience is the main core in engineering. Theoretical
knowledge can only be practiced in a minor way but experience plays the major role
for a better career development. Can be said industrial training had given me the
chance on being in an organization and the real working lifestyle. In addition, it has
given me confidents and the skills during interaction among employees.

I was able to establish good relations with all employees in the whole
company. Even I was able to communicate the higher officials from other departments.
Well this had developed my interaction with professional people. Admitting, there
were lots of developments that I had experienced throughout this internship whether
from hands-on site or even from the soft skill site. I also had the chance to acquired
many new contacts among the workers in the company.

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With my Industrial Supervisor, Mr. Foo Chuan Woo and my Faculty Supervisor Dr. Reazul
Haq Bin Abdul Haq.

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