PTP Tech-TC TGB Towards Kariangau DRAFT=v20140114

8/13/2019 PTP Tech-TC TGB Towards Kariangau DRAFT=v20140114

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Future Technical Training Centre

at TGBtoward Construction at Kariangau

Proposal for Establishment of Training Facility


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BACKGROUND


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Why TGB (Tanjung Batu)?

Anticipation of existing-inevitable constraints.

o Implementation of non-existing on-the-job training (e.g. precision

work, repair to cylinder heads & rebuild of major components).

o Delivery of training in line with PTP development/improvement plan

prioritized for Asset maintenance crews (e.g. service crew,

mechanics, auto-electricians & welders).

Alternative use of the existing facility for technical training purposes.

o Optimizing PTP rebuild shop at TGB for practical training facility prior

to construction of the new facility.

o Provision of On-the-Job training for related tasks above.

o Provision of maintenance/storage for precision tools, measuring

device & special hand/power tools.


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Why TGB (Tanjung Batu)?

Anticipation of existing-inevitable constraints.

o Implementation of non-existing on-the-job training (e.g. precision

work, repair to cylinder heads & rebuild of major components).

o Delivery of training in line with PTP development/improvement plan

prioritized for Asset maintenance crews (e.g. service crew,

mechanics, auto-electricians & welders).

Alternative use of the existing facility for technical training purposes.

o Optimizing PTP rebuild shop at TGB for practical training facility prior

to construction of the new facility,

o Provision of On-the-Job training for related tasks above.

o Provision of maintenance/storage for precision tools, measuring

device & special hand/power tools.


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Objectives of Proposal

Identification of immediate actions for full delivery of overall technicaltraining programmed for Asset Mgmt.

Provision of main workshop drawings with as-build dimensions at TGB.

Draft of possible-generated expenses for provision of facilitybased onpricing from the big picture only.

Draft of building models for review from Management prior to

preparation of detail technical drawing for construction.


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Objectives of Proposal

Identification of immediate actions for full delivery of overall technicaltraining programmed for Asset Mgmt.

Provision of main workshop drawings with as-build dimensions at TGB,

Draft of building models for review from Management prior topreparation of detail technical drawing for construction,

Draft of possible-generated expenses for provision of facilitybased on

the big picture pricing only.


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EXISTING FACILITY


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Technical TrainingTemporary Facility


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Main Workshopwith Training Ground

Training temporary

facility


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Main Workshopwith Training Ground

1200 x 1000cm

ground area


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Main Workshop as-build Layout

Training ground;

1200 x 1000cm


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Technical TrainingTemporary Facility

1200 x 1000cm

ground area

Rebuild Shop


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IMPLEMENTATION


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Project MilestoneRefurbishment

PIC

2013 2014

Attendee week51 week52 week 1 week 2 week 3 week 4

1 Brainstorming --quick study on feasibility of

training/rebuild centre establishment at TGB.

Asri, Greg, Salim,

Donny, Fahry

y y

2 Provision of draft of drawing, project plan/proposal &

technical training curricullum

Heru/Syamsul,

Fahry

o

3 Review/revision & approval processes of project plans. Adrian, Bobby &

E&C

p p

4 Construction of training centre & refurbishment of TGBrebuild shop

Asset Mgmt. &HCOD

p p

5 Purchase of training supporting equipment^ Asset Trg. &

Procure.

6 Finishing of comp't rebuild shop refurbishment &

commissioning of training facility.

E&C, Asset Trg.

7 One-day visit & official opening of Technical training facility

at TGB.

Asset Mgmt. &

HCOD

8 Start of use^^ for 2014 --e.g. recommencing 100 hours of

cluster/RPL type of refresher program.

Asset Trg.

Note:

^ Wish-list for purchase is only to suit training program 2014

^^ Program calendar 2014 --to be customized, is provided separately to take place at TGB.

PeriodTasks


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Project MilestoneRefurbishment (contd)

week 5 week 6 week 7 week 8 week 9 week 10 week 11 week 12 week 13 week 14 week 15 week 16 week 17

1

2

3

4 p p p p p p p p p

5 p p p p p p p p p

6 p p

7 p

8 p p p

UPDATE: 24-DEC-2013Legend:

y yes --done

o ongoing now

f project forecasted

p expected programs


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Project MilestoneCurriculum H#1 2014

Legend:

y yes --done

o ongoing now

f project forecasted

p expected programs

2014

week 17 week 18 week 19 week 20 week 21 week 22 week 23 week 24

7 (Cont'd)

8 Start of use^^ for 2014 --e.g. recommencing 100 hours of

cluster/RPL type of refresher program.

p

9 Precision & Rebuild Work -- Cluster Training

5-week Batch #1

f f f f f

10 Precision & Rebuild Work -- Cluster Training5-week Batch #2

f f

Note:

^ Wish-list for purchase is only to suit training program 2014

^^ Program calendar 2014 --to be customized, is provided separately to take place at TGB.

PeriodTasks


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Wish ListTraining Aid

Click to view Total unbudgeted costs

# Description Qty. USD x100

1 Lathe Machines; good condition 2ndhand 1 ea. 176.50

2 Bench Drill, electric; good condition 2ndhand 1 ea. 11.87

3 Line-boring Set; including equipment for MIG weld 1 ea. 294.15

4 Measuring Tools (e.g. Electronic monitoring/testing measuring device,

Inside/outside/depth micrometers, Vernier calipers, Dial gauge set, etc.)

1 lot 58.83

5 Precision Toolsfor reconditioning Cylinder heads & Valves mechanism 1 lot 235.30

6 Special/common hand tools & standard fasteners (e.g. Multi-torque,

dial/manual torque wrench, heavy-duty sockets, soft-hammer, etc.)

1 lot 94.12

7 Used machines, powertrain & major components; ex-rebuild 1 lot 188.25

8 Engine/transmission, Final drive & Steering brakes Stands; fabricated 1 lot 20.00

9 Electrical .Air-con& Hydraulic/pneumatic Simulators; new or fabricated 1 lot 105.90

10 Mounting/dismantling device (e.g. bench vice, puller, hydraulic ramps, etc.) 1 lot 94.12

11 Steel cabinets & Work benches; new or fabricated 1 lot 20.64

12 Emergency (OHSE) device, Document cameras & electric whiteboard;

new & ex-TGB

1 lot 35.30

Items need in place before end of H#1 2014


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CURRICULUM


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Program Outline5 weeks Cluster Training

# Unit of Competency

Main Point of

Performance Criteria

Critical Aspects

in Assessment/Training

1 Mounting/dismantling,

inspection & repair; (1 of 2)*

MEM18003C Use tools for

precision work

MEM18006C Repair and fit

engineering components.

Required Reference/Evidence;

Engineering references --

specifications, plans,

drawings

Codes and Standards

Standard Operating

Procedures

Workplace documentation

Work safety practices

Waste minimisation

Effective communication

Manufacturers instructions

for materials and equipment.

1.1 Maintenance and

precision fitting you

have carried out.

Use of tools for repair; e.g.

a) reaming,

b) broaching,

c) scrapping,

d) re-threading, or

e) any other form of precision

fitting tasks.

1.2 Component-based

repairs have you

performed & how to

complete the task

Demonstration of MEM18055B

with advancement;

a) stripping and assessing of

damage,

b) repairs, re/manufacturing ofparts, material selection,

c) calculations performed and

tools used, safety aspects.


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Program Outline5 weeks Cluster (contd)

# Unit of Competency Main Point of


Critical Aspects


2 Contd (2 of 2)

MEM18033B Perform engine

bottom-end overhaul,

MEM18034B Perform top-

end engine overhaul*

* Note: units clustered to coverprecision work/repair in

the engine top-end

overhaul.

Required Reference/Evidence;

Specifications/job instructions

Manufacturers manuals/

data/catalogues

Standard operating

procedures

OH&S procedures

Calculations and numerical

operations

2.1 Dismantling stage of

performing a

bottom-end

overhaul and how

you have cleaned

and assessed parts.

Draining oil from engine

Removing cowling and

disconnects hoses, pipes, etc.

Removing engine from plant

Removes top-end

components*

Dismantling block/headassembly

Assessment of parts for

abnormal wear and defects

Assessment of parts for reuse

or replacement

Selection and use of cleaning

solution

Setting out or racking parts

per original location in the

engine.


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Critical Aspects


2.2 Measurements as

part of an engine

top & bottom-end

overhaul and what

were the

measurements used

for.

Ovality of pistons and

journals

Straightness of block and

crankshaft

Flatness of block

Taper of bores and journals

Squareness of block Alignment of crankshaft and

crankshaft bores

Use of measurement to

determine appropriate

under/ oversize of parts and

bearing clearance in

reconditioning

Identification of ridges, gaps,

tapers, ovality and

protrusions.


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Critical Aspects


(contd).

*)Assessment of abnormality

on cylinder head

components; e.g.

a) Major parts for abnormal

wear and defects; e.g.

b) Cylinder head for cracks &warpage.

c) Valve guides, springs &

seats for excessive wear &

fatigue.

d) Injectors --if non-electrical

controlled-- for improper

function.

Major parts repair, reuse or

replacementin accordance

with critical aspects of

MEM18006B;


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Critical Aspects


(contd) in accordance with

MEM18006B;

a) Valve springs, seats &

inserts/ guides

testing/measurement.

b) Refacing valve seats; e.g.

with cutters & reamers.

2.3 How to recondition

components

Disassembling engine

Cleaning components

thoroughly

Checks for wear

Replacement of worn

components

Appropriate corrective action.


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Critical Aspects


Use of tools & equipment

correctly --tension wrench,

dial gauge & feeler gauge

Reconditioning components

to factory specifications

Determination of bearing

clearance Re-assembling components to

factory specification.


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FUTURE TRAINING FACILITY


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Training CentreNew Facility outside TGB

10000 x 12000cm

--Main Shop & TC


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GENERATED COSTS


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Unbudgeted CostsTemporary Facility Only

Facility Refurbishment

USD 5,930.00

Items from Wish-list

USD 133,500.00

Total unbudgetedUSD 139,430.00

Simply click the box above to go to Training Ground Model

Click the above to view Wish List


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Prepared by

Technical Training Asset Mgmt.

End of Presentation

Date post:	04-Jun-2018
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PTP Tech-TC TGB Towards Kariangau DRAFT=v20140114

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