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
Performance Criteria
Critical Aspects
in Assessment/Training
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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Program Outline5 weeks Cluster (contd)
# Unit of Competency Main Point of
Performance Criteria
Critical Aspects
in Assessment/Training
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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Program Outline5 weeks Cluster (contd)
# Unit of Competency Main Point of
Performance Criteria
Critical Aspects
in Assessment/Training
(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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Program Outline5 weeks Cluster (contd)
# Unit of Competency Main Point of
Performance Criteria
Critical Aspects
in Assessment/Training
(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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Program Outline5 weeks Cluster (contd)
# Unit of Competency Main Point of
Performance Criteria
Critical Aspects
in Assessment/Training
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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Training CentreNew Facility outside TGB
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Training CentreNew Facility outside TGB
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Training CentreNew Facility outside TGB
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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
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