INDUSTRIAL TRAINING REPORT (ACSON MALAYSIA SALES & SERVICE SDN.BHD.

STUDENT: TAN CHUN KEAT (KEM090056)

LECTURER: DR ABUL KALAM

MECHANICAL ENGINEERING DEPARTMENT ENGINEERING FACULTY UNIVERSITY MALAYA

Abstract

This report describes the overview of what I did and learned during my industrial training in Acson Malaysia Sales & Service Sdn Bhd. The report is a requirement to fulfill the internship program of Bachelor of Mechanical Engineering. The report primarily focuses on the practical knowledge in air conditioning system, design of duct system, project handled and responsibility, and working environment. During the internship period, I had been assigned into products and projects department. I was assigned with two supervisors, Mr. Chua Yean Shin and Miss See Lee Foon. They had taught me that to apply the engineering knowledge in the work. In addition, I have the opportunity to learn the necessary soft skills in dealing with other peoples. Through this training, I gained valuable working experience which I can apply in the future. This report proves that I had undergone and completed my industrial training in this company. Also, this report serves as a reference to the future employer to evaluate my performance and working experience gained from the industrial training.

Acknowledgement First of all, I would like to express my greatest gratitude to my supervisors, Mr Chua Yean Shin and Miss See Lee Foon who are the engineers of Acson Malaysia Sales & Service Sdn Bhd. Mr Chua serve as the project engineer and Miss See is the product engineer. During these ten weeks of industrial training in this company, they are willing to share their knowledge and experience, with me. Mr Chua shared more on practise and site visit for more exposure on working engineers life to me. Miss See was willing to give me the technically support on my assigned task. Then, I would like to give my appreciation to Mr. Lee Chuan Yee, who is the person-in-charge for internship programme. He had done a good jobs in arranging the task and works for us. In addition, I would like to thank Mr. Lee Nam Chuan, who is the general manager of Acson Malaysia Company for providing chance to me for the internship . Mr. Lee always shares his experience and knowledge in air condition industry. At the same moment, he taught me soft skills which are needed to be equipped with before entering the real working life. Next, I would like to thank Dr Abul Kalam who is my supervisor from UM. He advises us to be nice with the colleagues. Besides, he also play his part as the faculty supervisor in this industrial training program well. Lastly, I would like to address my sincere appreciation for all my colleagues for their teaching, advice and also cooperation with me during my whole internship training. . It was a meaningful environment to have my friendly colleagues during the training.

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Contents
Abstract ........................................................................................................................................... i Acknowledgement ..........................................................................................................................ii List of Figures ................................................................................................................................. iv List of Tables .................................................................................................................................. iv CHAPTER 1: INTRODUCTION .......................................................................................................... 1 1.1 History of OYL and ACSON ................................................................................................... 1 1.2 Company Profile ................................................................................................................... 2 1.3 Principles, Corporate Values and Total Customer Satisfaction ........................................... 4 1.4 Organization Structure ......................................................................................................... 1 1.5 Industrial Training program ................................................................................................. 1 CHAPTER 2: INTERNSHIP PROGAMME........................................................................................... 2 2.1. Main Assignment ................................................................................................................ 2 2.2. Training ............................................................................................................................... 4 2.2.1. Basic Refrigerant Cycle ................................................................................................. 4 2.2.2. Type of Air Conditioning System .................................................................................. 5 2.2.3. ACSON Product Range ................................................................................................. 6 2.2.4. Heat Load Calculation .................................................................................................. 7 2.2.5. Duct System Design...................................................................................................... 9 2.2.6. Other Training ............................................................................................................ 10 2.4. Factory Visit....................................................................................................................... 11 2.5. Site Visit............................................................................................................................. 11 2.6. Soft skill Training ............................................................................................................... 12 CHAPTER 3: INTERNSHIP OUTCOME ............................................................................................ 13 3.1. Beneficial Experiences ...................................................................................................... 13 3.2. Relevance between Work Experience and Studies........................................................... 14 CHAPTER 4: CONCLUSION AND RECOMMENDATION.................................................................. 16 4.1. Conclusion ......................................................................................................................... 16 4.2. Recommendations ............................................................................................................ 16 REFERENCE ................................................................................................................................... 17 iii

List of Figures
Figure 1: Organization Chart .......................................................................................................... 1 Figure 2: The basic refrigeration system with R-22 flowing as shown in direction ....................... 4 Figure 3: General specifications of air conditioning system .......................................................... 5 Figure 4: The cooling loads in a room ............................................................................................ 8 Figure 5: Duct Calculator................................................................................................................ 9

List of Tables
Table 1: Principles, Corporate Values and Total Customer Satisfaction........................................ 4 Table 2: Weekly progress ............................................................................................................... 2

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CHAPTER 1: INTRODUCTION

1.1 History of OYL and ACSON In 4 February 1974, O.Y.L Industries Sdn Bhd was incorporated in Malaysia as a private limited company. O.Y.L. commenced its operations with the assembly of gas cookers and GLEM gas ovens in Shah Alam. The company joint venture with Guthrie Malaysia Holdings Berhad in year 1976 to form O.Y.L. Condair Industries Sdn Bhd. O.Y.L. started manufacturing industrial air conditioners and refrigeration equipment. This company was then known as Mulpha International Trading Corporation Berhad. In year 1982, O.Y.L success to acquire ACMA Electrical Industries Sdn Bhd and became the main distributor of refrigerator and air conditioner in Malaysia. In year 1983, O.Y.L made a long term contracts with Mitsubishi Electric Corporation, Japan. OYL created the ACSON brand in 1984. ACSON later achieved international recognition. Since that, Acson had grown positively from a steady home appliances business, selling high quality and proud Malaysian made products from stand fans to air conditioners. Then it became a public listed company on Kuala Lumpur Stock

Exchange (KLSE). In 1990, Hume Industries had acquired O.Y.L and placed it under the Hong Leong Group, Malaysia. In 1992, this company made an important step toward globalization of its activities. By achieving the growth and expansion of the company, it acquired J&K Hall of UK and US-based Company, AAF and McQuay. In September

2006, the Daikin Industries Ltd had acquired O.Y.L. to strengthen their business operation.

1.2 Company Profile ACSON MALAYSIA SALES & SERVICE SDN BHD is a subsidiary of O.Y.L Industries Bhd (formerly, a public listed company in the KLSE and a member of the renowned Hong Leong Group, Malaysia) which was then acquired by Daikin Industries Ltd, since September 2006. Since its incorporation in 1984, Acson has grown positively from a steady home appliances business, selling high quality & proud Malaysian made products from stand fans to air conditioners. Today, the company has consolidated its business and is now specialized in the air conditioning industry. In testimony to the high standards of product quality, ACSON products have been awarded the CE marking for entry into European Markets. Moreover, ACSON has penetrated and joined the competitive international scene. With that, the proclaimed ACSON brand name is proudly transformed to ACSON INTERNATIONAL, which is a move to reflect worldwide brand recognition. ACSON International is a leading brand of air-conditioner, made-in-Malaysia, exported to more than 50 countries in 5 continents with annual turnover of USD 1.4 billion. ACSON International is set to reach for greater heights. Since its inception in 1984, it has recorded many milestones in its growth and set many exemplary benchmarks of success. All of this is due to the companys commitment to quality,

product development as well as dedication and professionalism of its management and staff. In the new millennium, ACSON Malaysia Sales & Service Sdn Bhd has consolidated and its business strives to become a leading air-conditioners distributor under the ACSON INTERNATIONAL label, renowned for performance and technological innovation. In addition, it is also an industry leading service and support provider. Their mission is to provide excellent value added service and support to customers ACSON product year after year. The strong service teams which made up of over 50 service technicians and engineers and an extensive network of Authorized Service Dealer (ASD), are tactically situated across Malaysia. The headquarter of ACSON Malaysia Sales & Services Sdn Bhd is located at Lot 4, Lorong 19/1A, Seksyen 19, Petaling Jaya, Selangor Darul Ehsan. I had my industrial training for 10 weeks in this company. In headquarter engineering and management departments are placed at the upper floor while the service department is placed on ground floor. The first floor is used as office for the core company of Acson, which is Daikin Industries Ltd. For information, there are seven branches of Acson in Malaysia which locate at Penang, Kuantan, Johor Bahru , Ipoh, Melaka, Kota Bahru and Kota Kinabalu.

1.3 Principles, Corporate Values and Total Customer Satisfaction In order to compete with the global competitors, ACSON Malaysia Sales & Service Sdn Bhd always holding four principles: Acson are always there when you need any service and support, as the tagline We care, we share.

Acson Malaysia always put their valued customers at the first place.

Acson Malaysia is always committed to provide the highest quality of product at all time.

Acson Malaysia insist on using genuine part in all service we provide, whether under or after warranty, to provide the maximum value to our customer.

Table 1: Principles, Corporate Values and Total Customer Satisfaction

In addition, there are corporate values that contribute to the uniqueness of this company a) Absolute Credibility b) Enterprising Management c) Harmonious Personal Relations
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Every morning, there is an assembly which is attended by all the staff of headquarter, including all other branches. During the assembly, every staff is required to speak loudly the three corporate values as listed above. Then, they may sing the song Bersatu Kita Maju. A representative may read the one of the guidelines in Total Customer Satisfaction (created by Acson which has total of 31 set of guidelines). The guidelines are interpreted at the customers point of views on servicing, the desired behavior as a salesperson and also the important of the quality of servicing to a company. Therefore, all these efforts equip them with not only continues improvement in productivity as well as excellent customer service to gain customers confidence in Acsons products and services.

1.4 Organization Structure

Figure 1: Organization Chart

The chart above shows the organization structure in Acson Sales & Services Sdn Bhd. There are seven departments in this company, which are sales, marketing and planning, project and application, service, finance and administrative, product and engineering and part business development. However, the departments I had been placed at are product and projects department..

1.5 Industrial Training program This company has a well-planned schedule for trainee throughout the internship. Each trainee is assigned to two mentors, one from the product engineer and one project engineer. There is a long term project for each trainee with different topic. Besides, there are several technical trainings for trainees to gain extra knowledge regarding the air conditioning system. The trainings include heat load calculation, classification of air conditioner and product range of ACSON Malaysia. Meanwhile, trainee also participated in several exhibition and factory visit.

CHAPTER 2: INTERNSHIP PROGAMME

2.1. Main Assignment During the internship period, each of the trainees is given a project to be followed. My project title is EZ-Series, which is the control system of ACSON products. Based on each topic, I have been assigned to study the product system, and come out with a report according to the outline. Project outline Activity Introduction of the product What is this History of why this kind of product was developed Working principle Market survey Collecting and understanding markets needs and demands Current status of this product in the market Countries where it is popular Application Comparison with similar product system Advantages and disadvantages Comparison with other brands Recommendations Are the products good enough Way to improve Conclusion Report submission and project presentation
Table 2: Weekly progress

Week Week 1-2

Week 3-4

Week 5-6

Week 7-8

Week 9 Week 10

A report and a presentation are done for this assignment. The report is about a product from ACSON, EZ-Series. EZ-Series consist of EZ-LINZ, EZ-SOL, and EZ-LI. In this report, the focus will be on EZ-LINZ, a centralized control system of air conditioners. EZ-LINZ can be categorized in Building Management System. There are 5 chapters in the report. There will be a brief introduction of Building Management System in the Chapter 1. The working principle of the product will also be explained in the Chapter1. Chapter 2 is about the market demand on BMS system. In this section, market survey researches from different survey and research companies are taken as references. In Chapter 3, the features of the product and similar products will be discussed. Chapter 4 is about the recommendation of improvement of this product. Lastly, Chapter 5 is the conclusion. In the last week of the internship period, a presentation has been done to the mentors.

2.2. Training

2.2.1. Basic Refrigerant Cycle During the first week, Mr Yeo Jian Rong, one of the project engineers, has given us training on the basic refrigerant cycle. Basically, the air conditioning system is defined as a system used to simultaneously control its temperature, humidity, cleanness and distribution to meet the requirement of the conditioned space. Air conditioners are built fundamentally on the principal of refrigeration cycle which consist mainly the following component: i. ii. iii. iv. Evaporator Compressor Expansion Device Condenser The diagram below shows how the basic components are connected in an air conditioning system. Condensing Unit (Outdoor Unit) Fan Coil Unit (Indoor Unit)

Figure 2: The basic refrigeration system with R-22 flowing as shown in direction

From this diagram, the first component is the evaporator. The evaporator is used to cool the air in the indoor. A heat transfer occurs between the indoor air and refrigerant passing through copper coil in the evaporator. The heat of indoor air (higher temperature) is transfer to refrigerant (lower temperature) and carried away to compressor. Inside compressor, it pressurizes the vapor refrigerant to obtain high temperature and pressure state. Then the vapor refrigerant is allowed to pass through the condenser where a heat transfer occurs between the refrigerant (higher temperature) and outdoor air (lower temperature). The heat carried by refrigerant is transfer to outdoor air due to temperature difference and become in liquid form. After that, the liquid refrigerant enters the expansion valve and expands to become a low pressure mixture of liquid and vapor refrigerant. The cycle is then repeated again.

2.2.2. Type of Air Conditioning System After the refrigerant cycle briefing, Mr Yeo also brief us about the type of air conditioning system.

Figure 3: General specifications of air conditioning system

The air conditioning has come to a new era. Nowadays, the air conditioning system is divided into two categories according to the medium used in the system. They are Direct Expansion (DX) and Chilled Water (CW) system. The DX system uses refrigerant as a medium for heat transfer process to take place in indoor section while for CW system, water is used as the medium for heat transfer process in indoor section. Besides that, under these two groups, they are categorized into two groups depend on the manner the medium (air or water) being cooled at condenser. They are known as air-cooled or water-cooled DX or CW system. The air cooled DX or CW system uses outdoor air to cool the heated medium which is passing through the condenser. While the water-cooled DX or CW system utilizes the water to cool the heated medium in the condenser. And, the water will carry the heat to cooling tower which are then dissipated to surrounding.

2.2.3. ACSON Product Range There is a briefing on ACSON product by Mr. Lee Chuan Yee. Besides that, I also refer to the catalogues of the products. Acson Products are divided into seven categories which are listed as below:(i) Air Cooled DX System Single Split Units

(ii) Air Cooled DX System Multi Split Units (iii) Air Cooled DX System Packaged Units (iv) Water Cooled Units
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(v) Chilled Water System Units (Air Cooled) (vi) Complimentary products (vii) R410A Products

2.2.4. Heat Load Calculation There is also training on heat load calculation by the technical assistant, Mr. Muhd Nasir bin Mhd Yusuf. The first step is to calculate the heat load of an area which is being airconditioned. Calculating the heat load is important in determining the suitable cooling capacity of air conditioner to meet the requirements of user. Heat load is defined as the amount of heats that required to remove in order to achieve the desired condition. Heat load is classified into two main types which are sensible and latent heat. If a substance is heated and its temperature rises or falls as the heat is added or removed, the increase of heat is called sensible heat. On the other hand, the latent heat is heat which causes a change in state of a substance without change in temperature. In air conditioning system, cooling load is another term which has the same meaning of heat load. In this context, the term of cooling load is used for the following discussion. Basically, cooling load can be classified into three types which are skin load, internal load and other load. The below figure show the three cooling loads in a room.

Figure 4: The cooling loads in a room

As show in the figure, skin loads originate from the heat sources from the outside or external to the conditioned space such as sunlight and transmission gain through glass, walls and roofs, transmission through glass, ceiling, partitions or floors, infiltration and ventilation. The internal loads are produced from the sources inside the conditioned space such as people loads, equipment loads and lighting loads. Other cooling loads occur from heat gains or losses associated with moving cool fluids to and from the conditioned space. For example, heat is generated from supply air side, return air side and outside or ventilation air along the ducting system. The total heat loads in this room is the sum of the three cooling loads. There are two methods which are Rules of Thumbs and DACCS-PC HKGSG software to calculate the total heat load of conditioned space. However, due to time constraint, I am only able to learn the first method. Rules of Thumbs: This method is an approximation of calculation and thus the fastest way to obtain the heat load. The procedures of using this method are:1) Calculate the area which is being conditioned. The unit of area is in feet square
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2) Refer the Design and Cooling Check diagram. Choose the suitable application and Grant Total Value. 3) Multiply the Grant Total Value with the area calculated in step 1 to obtain heat load (Btu/Hr). 4) The suitable model of air conditioner is selected based on the calculated heat load. Usually, the cooling capacity of air conditioner must be higher than the heat load calculated.

2.2.5. Duct System Design Another important aspect in air conditioning system design is the duct system design. For information, the function of air duct is to conduct air from one point to another. This design is introduced to determine the dimension of air duct which is used to connect the indoor unit with outdoor unit. Duct Calculator is used to calculate the size of duct provided the pre-determined air quantity.

Figure 5: Duct Calculator

Below are the major steps in using the duct calculator to determine the size of air duct.

1) Establish the friction rate and air quantity (in CFM unit). Usually, the friction rate is set at 0.1 in wg/100 ft and air quantity is obtained from the result of equipment selection process. 2) Set the air quantity opposite to friction loss. Then, obtain the velocity (in FPM unit) opposite to air quantity. 3) Read the diameter of round duct at opposite of arrow 4) The step 3 is repeated for equivalent rectangular duct

2.2.6. Other Training Besides the training above, there are also other training and briefings. For example, the technical sharing from the service department. In those sharing, some basic knowledge is learnt such as basic wiring, starter connection etc.

2.3. Schedule of Technical Specification The preparation of technical specification of each selected air conditioning units is carried out before tendering a project. This procedure is important before tendering a project because the consultant or contractor will compare the technical specification sheets provided by various air conditioner suppliers such as ACSON, YORK and PANASONIC. For information, there are complete technical manual provided by Acson Company to prepare an accurate technical specification of every air conditioning unit. Generally, the most common specifications are model no, country of manufacturer,
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electrical properties, features of cooling coil, compressor, and motor, temperature of air entering and leaving coil, dimension of indoor and outdoor unit and also operating weight.

2.4. Factory Visit We have a change of visiting the O.Y.L. Manufacturing Factory at Sungai Buloh. On the visit, I am exposed to the manufacturing process line. Next to O.Y.L.M. is the O.Y.L. R&D centre. There are four sectors in O/\.Y.L. R&D: Test Room, Sound Room, Component Testing Lab and CADCAM Lab.

2.5. Site Visit During my internship period, I have change to go outside to the site with my mentor, Mr. Chua. The purpose of going to the site is to have more understanding of the demand o the customers, collect data of the project, giving advises to the consultants and contractor about ACSON products or to propose ACSON products to them. For me, Mr. Chua taking me to the site is also one of the ways to make me having more exposure for more product information on its application. Another task for me in the site is to collect the data and dimension of the compound.

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2.6. Soft skill Training Part of the internship program is to train our soft skill like communication skill and presentation skill. In the program, the trainees have to present any topic in front of all the staff of the company. For me, I group up with another trainee to present a topic on Yellow Pages versus Google in the presentation, we mention about the use of yellow pages and google search and compare them. The presentation end up with the conclusion of downfall of the yellow pages usage due to the internet usage is more popular nowadays.

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CHAPTER 3: INTERNSHIP OUTCOME

3.1. Beneficial Experiences These ten weeks of industrial training at Acson Malaysia Company provide me experiences which have significantly altered my perception of air conditioning industry. The following are some beneficial experiences that I gained from working in this company:-

a) This internship provides me an exposure to air conditioning industry. Through this program, I had learnt how to design a good quality air conditioning system, select suitable air conditioner based on requirement, engineering calculation and so forth. In addition, I have the opportunity to learn the new engineering software such as Duct Seizer Software and DACCS-PC HKGSG Software, which are the platform to design the dimension of air duct and calculate the heat load in a conditioned space respectively. b) Apply the engineering knowledge which I had acquired back at university in air conditioning industry. For instance, I applied the thermodynamic and heat transfer theory in order to understand the principle working of air conditioning system. c) Working on projects assigned allows me to have better understanding on air conditioning industry. The mistakes appear when I carried out the project would serve as the lesson in the future. In addition, this move allows me to listen to ideas

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and opinion of others. Then I would develop new ways to solve the problem faced independently. d) This internship is surrounded by network of people from different parts of world. Therefore, I need to equipped myself with soft skills which I learnt from my supervisor and experienced colleagues in this company. e) Working with colleagues from different positions allows me to have an insight on how to shape my careers towards engineering job in the near future.

3.2. Relevance between Work Experience and Studies Several courses which I have learnt in university come into practical use during the work experience. For example: i. Applied Thermodynamics (KMEM2216) is widely used in this industry. Knowledge on refrigerant cycle is also useful as it is the most basic concept that has to clearly understand by each of the employee to promote the air conditioning system. ii. Heat Transfer (KMEM3119), is also the basic knowledge used in this industry especially when studying about the heat exchanger in the air conditioning. iii. Engineering Drawing and CAD (KMEM1104) is another useful thing that I have learnt in university which applicable here. During designing the air conditioning system used in a building, AutoCAD is used. I have widened my view on how this software is used in a real working industry.
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iv.

Instrumentation and Measurement Technique (KMEM3116) is the subjects where I learned about sensors and calibration. During the intership period, when I went to site visit, my mentor asked me to collect data and performed measurement. This is where the Instrumentation and Measurement Technique that I learnt come into practical use.

v.

There are a few training given by the company are relevant with the subjects I learnt from university. For example, when they taught about wiring for air conditioner, there are a few terms that I learnt from Power Electric and Machine (KMEM3110). The knowledge I learnt from this subject help me understanding the topic easier.

vi.

There is a project given to each of the trainee as the task to be completed to fulfill the requirement of internship. Thinking and communication skill course that I have taken during my university life have enhanced my thinking skill which is useful while doing this project.

vii.

In the main assignment, I was asked to perform benchmarking for the ACSON products with similar competitor products. SWOT analysis was done for the product. This is another practice that I learnt from Product Development and Design (KMEM2218)

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CHAPTER 4: CONCLUSION AND RECOMMENDATION

4.1. Conclusion These ten weeks of internship greatly boost up my engineering knowledge of both theoretically and practically. I have meet with quite a number of professionals whom expertise in air conditioning system and experienced the real working life. Other than that, the projects that have been assigned to me also improve my confidence and soft skill level.

4.2. Recommendations I would like to propose several recommendations to Acson Malaysia as following: i. Trainee should be given more chance to participate in company project so that they know what are the skills required in a real working environment.

ii.

Project given should be relevant to the type company. For example in Acson Malaysia it is a Sales and Service Company, however the project assigned is more research based topic. This company does not have R and D department, which is a barrier to obtain information regarding the project.

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REFERENCE

1. ACCA. 1995. Duct design for residential winter and summer air conditioning and equipment selection. Manual D, 3rd ed. Air-Conditioning Contractors of America, Washington, D.C. 2. Yunus A. Cengel, Heat and Mass Transfer: A Practical Approach, 3rd Edition, McGraw-Hill, Singapore, 2006. 3. OYL Manufacturing Company Sdn Bhd. (2008). Retrieved April 10, 2010, from http://www.oyl.com.my/OYL/profile.html 4. Acson Malaysia Sales & Service Sdn. Bhd. (2009). Retrieved April 10, 2010, from http://www.acson.com.my/index.asp

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