lukman alhakim_technical portfolio

PORTFOLIO

TECHNICAL

MEng, Mechanical

Engineering (Hons)

Lukman Alhakim Ab Wahid

Lukman Alhakim

Technical Portfolio � (M) 013-477 9922 � [email protected]

Page 1 of 35

Table of Contents

Project Engineering ................................................................................................................ 2 - 12

1. Automatic Lashing Platform (ALP) .................................................................................... 3 - 9

2. Mitsubishi Heavy Industry (MHI) – Stacking Guide .............................................................. 10

3. Evaluation & Qualification of a New Hydraulic Vendor .................................................... 11 - 12

Mechanical Test ................................................................................................................... 13 - 31

1. Evaluation of New Flipper Design for Rotterdam World Gateway Spreader ............................. 15

2. Corrosion Evaluation for Rotterdam World Gateway

(RWG) Spreader – Post Commissioning................................................................................. 16

3. Evaluation of Photovoltaic Sensors Under Harsh Environmental

Conditions – ALP Component Testing ............................................................................. 17 - 18

4. Design & Fabrication of RWG Mechanical Test Jig

& Conceptual Verification of Spreader Unit ........................................................................... 19

5. Corrosion Evaluation of Metric Precision Steel Pipes

for Vendor Comparative Assessment ................................................................................20- 21

6. Evaluation of Anti-Rust Compound for Product

Comparative Assessment – Dinitrol & Techtyl ....................................................................... 22

7. Evaluation of Oil Level & Temperature Indicator for Vendor

Comparative Assessment – IFM & Hemomatik ...................................................................... 23

8. Evaluation of Oil Heater for Vendor Comparative Assessment EVT & AVAK ........................ 24

9. Evaluation of Hydraulic Hoses & Clamps for Suitable Pairing Selection .................................. 25

10. Performance Evaluation of Non-Metallic Dampers – A Comparative Assessment ..................... 26

11. Evaluation of Sheave Wheels for Vendor Comparative Assessment ......................................... 27

12. Provision of Functional Test for Guide Block & Twistlock Arm

for Vendor Comparative Assessment ..................................................................................... 28

13. Provision of Functional Test for Hydraulic Leakage Verification on Hose Assemblies .............. 29

14. Provision of Functional Test for Hydraulic Leakage Verification

on RWG Valves & Manifold Blocks ...................................................................................... 30

15. Recommendations ................................................................................................................ 31

Marine Spreader Design ...................................................................................................... 32 – 35

1. Project Description ............................................................................................................... 33

2. Project List – Local & International ....................................................................................... 34

3. Recommendations ................................................................................................................ 35

Lukman Alhakim


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Project Engineering

Apr 2013 – Mar 2015

“Bridges the boundaries between engineering and

project management”

Lukman Alhakim


Page 3 of 35

1. Automatic Lashing Platform (ALP) Apr 2013 - Mar 2015 (24 months)

Project Description:

ALP (red machine on the ground) is the solution for automated handling of twistlocks1 within

shipping terminals. Located under gantry cranes, this device is aimed to increases operational

efficiency by reducing the load/unload cycle time. It also promotes safer operation by eliminating

human labour.

It is self-sufficient via means of converting & storing potential energy from the weight of containers

into pressurised hydraulic & pneumatic power. Stored within linear actuators & accumulators the

energy will then be gradually released to serve its fundamental & auxiliary functions.

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 13849-1,

EN 13681, EN 1005, EN 547-2, EN 547-3, , ISO 17165-2, 2006/42/EC,

1997/23/EC, ASME B16.5 & ASME B31.3 & NACE

Project Planning, Sheet Metal, Welding, Hydraulic System, Hydraulic

Fluid Power, Ergonomics, Process Piping, European Directives (CE),

Corrosion Study, AutoCAD 2D2, Autodesk Inventor 3D

3, Jig Design,

Testing, Technical Report, & Vendor Management

Challenges Language barrier & work-flow culture

Lesson Learnt Fluidity of information between testing & design team will propel

progress & boost productivity

1 A twistlock and corner casting together form a standardised rotating connector for securing shipping containers. 2 Generally utilized for hydraulic schematic & P&ID designs. 3 Structural design & finite element analysis (FEA) of the overall machine as well as its critical sub-components (i.e. load bearing sections, pick – points segments). In addition the dynamic characteristic of non-metallic components such as rubber

dampers and hydraulic fluid actuators were being simulated via internal solver within Autodesk Inventor software.

Lukman Alhakim


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Scope of work:

1. Design

� Basic Engineering Design (BED)

Site Survey& Prototype Documentation

o Design data acquisition – The 1st generation prototype unit created in Böel, Germany

were being scrutinised for details of piping routes, component allocation &

fundamental system understanding4.

o Subsequent visits were utilized for design verification & endorsement of previous

engineering solutions as well as creating new design entry of past impromptu fixes.

o Each documentation period were segregated into three (3) different phases;

• Initial – Documentation of present technology on the existing prototype unit.

• Intermediate – Reflection of previous way forward; discussion on technical

solution costing & alternative way forward.

• Final – Product development planning for future deliveries; mechanical/

hydraulic design & testing. Components localization for procurement

leverage.

Fundamental Pipe Modelling

4 Only apply to the first site visit where product owner described in detail regarding ALP’s fundamental working principal in

detail in the scope of mechanical, hydraulics, electrical & control system.

1 2

Figure 1: 1 - Fundamental pipe routing, 2 – A pipe sub-drawing with dimensions

Lukman Alhakim


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Fundamental Pipe Modelling (continued)

o Drafting of 3D pipe routing as outline for detail design stage. Sections of interest

were trolley, bottom frame & upper frame.

o Preliminary optimization in the scope of component reduction as well as introduction

of continuous pipe design which promotes higher flow efficiency.

o Improvements updates on hydraulic P&ID that covers the energy, lifting, trolley &

manipulator system; in-sync with product development planning.

Conceptual Design Proposal

o Feasibility studies and engineering concepts were put into action to address on-going

issues & future optimization in the scope of:

• Safety

Focusing on design of safety signs depicting potential hazardous

complication as well as implementation of physical counter measures e.g.

anti-slip floorings.

• Ergonomics

Design modification that advocate ergonomic considerations as stipulated in

ISO 13861, EN 614-1 & 2 as well as CEN guide 414. Personnel access

into/out from machine, lighting intensity & duration of working in abnormal

posture were some of the design examples with ergonomics due diligence.

• Certification

As European terminals will be amongst the potential clients to market this

machine, compliance to the European Directive is paramount. Fundamental

requirements as per stipulated in 97/23/EC & 2006/42/EC were implemented

especially in the scope of machinery process, safety & pressure equipment.

Figure 2 - Conceptual sketches drawn during site survey activities

Lukman Alhakim


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• Cost Reduction

Selection & approval of engineering components with due diligence. This is

achieved via practicing accurate material & steel profile selection; avoiding

over specifications. Working hand in hand with procurement in outsourcing

components with premium price tag & long lead time.

• Function Optimization

Improvements were segregated into multiple-phases; the initial stage tackles

fundamental issues via brainstorming conceptual ideas across multi-

disciplinary division. Locus of development is the energy system where

boosting the hydraulic efficiency is paramount in achieving a self-sufficient

setup.

� Detail Engineering (DE)

Engineering Drawings

Provision of preparing detail engineering drawings5 for in-house fabrication process &

production reference during assembly stage. The following are the type of drawings

produced for this project:

o Component drawings o Hydraulic Schematics

o General Assembly (GA) o Hydraulic P&ID

o Bill of Materials (BOM) o Pipe Assemblies

5 Compliance to EN 15056, ISO 2553, ISO 13920, ISO 2768, & ISO 1302.

1

2

3

4

Figure 3: 1& 2 - Pipe assemblies modelling, 3 - Hydraulic P&ID, 4 – A sample of pipe drawing

Lukman Alhakim


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Operation Manual

ALP operation manual was compiled in a continuous and chronological manner from

detail design until testing phase. In the scope of mechanical & piping, information related

to hydraulic functionality, detail description of sub-system and components were

allocated into respective chapters. Supplementary visual aids were provided in the form

of commercialized perspective drawings.

2. Trainer

Conducted an introductory Product Data Management (PDM)6 training to the ALP technical

team in Böel, Germany on October 2013. Supplemental coaching was also provided on the

Autodesk Inventor 3D - the project primary designing tool.

6 Autodesk Vault 2013 was the PDM system at that time.

Figure 4 - Visual aids for manual compilation; samples depicting various greasing points

Lukman Alhakim


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3. Testing

� In-house testing

Test & conceptual verification of new engineering designs was awarded to local

engineering team in Malaysia. Provision of test procedures, methodology and resource

management were brought up during technical meetings for multi-disciplinary discussion

prior to commencement of any test activities.

Scope of work includes:

o Project Planning – Time scheduling & resource management (human & capital)

o BED – Basic fixture design that able to deliver comparative results from actual

operating conditions. Working closely with sourcing, vendors & fabricators to

achieve fixture design that are reliable, cost efficient and specifications

compliance

o Execution – Initial setup, performing test and data acquisition

o Documentation – Technical report compilation leading to relevant

recommendation on the tested system/components

2

1

Figure 5: 1 - Sensor evaluation setup, 2 - Assessment on manipulator lifting cylinder

Lukman Alhakim


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� Field Test

Engaged in multiple field-test activities in Southampton & Hamburg shipping terminals.

Primary task involves hydraulic data acquisition, fault findings & documentation. These

discoveries will then be analysed and added into the project development punch-list.

Achievements:

✔ Laid groundwork on the 3D piping layout for ALP production unit

✔ Achieved 15% (RM 195,000+) cost7 reduction from continuous collaborative effort

with sourcing team in the field of:

� Localization of hydraulic pipes & auxiliary connectors

� Breaking down costly packages into individual components

� Component harmonisation - Control valves & retaining clamps

✔ Post PDM training session, respective trainees (engineers) were able to independently

monitor design updates remotely; boosting team productivity

Recommendations:

7 In reference to direct cost derived from mechanical components i.e. pipes, hydraulic hoses, actuators and auxiliary valves.

Lukman Alhakim


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2. Provision of Detail Engineering of Hydraulic Schematics Feb – Mar 2014 (1 month)

for Mitsubishi Heavy Industries (MHI) – Stacking Guide


Spearheaded hydraulic design integration between client’s function requirements and the standard

yard spreader; enabling value adding features of side stacking & supplementary pump-failure

prevention. A time critical collaborative project with immense business potential for repeat orders.

Engineering Std.

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302

Hydraulic System, AutoCAD 2D, Autodesk Inventor 3D

Challenges Client’s reference drawings released in stages

Lesson Learnt Communication ought to be made to end-user directly

without an intermediate entity (commercial personnel)

Scope of work:

1. BED & DE

� Integration proposal according to production’s common components8

� Conceptual and cross reference study based on client’s hydraulic P&ID

� Detail design which consist of general assembly (GA), hydraulic P&ID & preparation of

bill of material (BOM)

2. Procurement

� Outsourcing & localization of special valves for cost reduction purposes

Achievements:

The project was successfully offered to client two (2) weeks prior to due date with an additional 13%

cost savings via cost reduction activities.

8 Consist of hydraulic control valves, connecting lines & instrumentation components.

Lukman Alhakim


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3. Evaluation & Qualification of a New Hydraulic Vendor (6 months)


Due to the new management policy9 the existing vendor for hydraulic services were advised to end

their term-contract. The scope of evaluation for the new replacement shall cover the following

province:

1. Internal processes & system evaluation

2. Product features & product process assessment

Engineering

Standard

Skill Segment

DIN 3015, ISO 17165-1, ISO 6606, ISO 14993

& ISO 10289

Vendor Qualification, Hydraulic Fluid Power,

NDT & Technical Report

Challenges A dynamic & thorough assessment program

9 A stringent approach was taken in dealing with underperforming vendors.

Figure 6 - Supplier's warehouse & test facilities

Lukman Alhakim


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Scope of work:

1. Site Visit

� Reviewing internal document control & process flow

� To verify vendor’s facility is within satisfactory operational conditions

� Assessment on measurement techniques, calibration programmes & testing schemes

� Reviewing safety aspects of the facility & their provision for personnel protective

equipment (PPE)

2. Testing

� Evaluation of component10

covering the following scope:

o Labelling – ISO 17165-1

o Material specification – DIN 3015

o Performance – ISO 6606, ISO 14993 & ISO 10289

o Dimensions – Physical dimension vs. technical drawings

3. Documentation

� Site visit evaluation report – An independent review

� Technical report to include rejection/approval of individual component tested

Outcome:

Approval of the new supplier with due diligence. On-going monitoring & evaluation especially in the

realm of dimensional control (DIN 3015 clamps) as well as hoses labelling (ISO 17165‐1)

10 Consisting of hydraulic hose assemblies, DIN 3015 rated clamps & auxiliary supplied loose connectors.

Lukman Alhakim


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Mechanical Testing

Jan 2012 – Aug 2013

“Determination of mechanical properties and

behaviour of materials, structures and machines”

Lukman Alhakim


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Figure 7 – Test Flow Chart

Project Segregation:

Projects were segregated by their requestor/owners as shown in diagram below:

Figure 8 – Chart Depicting Test Ownership

Achievements:

✔ Entirely responsible for revising 2D jigs design into 3D CAD models

✔ A department backbone - Lead to achieve 1/3 of its KPI for 2HFY 2012

✔ Introduced & standardized technical report template for Test Department

✔ PDM database administrator for Test Centre department - Mechanical jigs

✔ Rectified 520 errors in PDM system - Saved RM10k in IT consultancy fees

✔ Centralization of in house power-pack11

units – BED for budgetary approval

✔ Spearheaded design & material selection for Rotterdam World Gateway jig

11 Hydraulic pump sets that can cater up to 250 bar of hydraulic fluid pressure.

Test Owners

Sourcing, R&D, QA &

Engineering

Department

Feasibility Stdy.

Budgetary,

Man power,

& Schedule

Testing

Planning,

BED, FEED,

Jig Fabrication

& Execution

Deliverables

Tech. Report with

Unprejudiced

Recommendation

Revise or 3rd party

Owners/

Requestor

R&D

(Sweden &

Germany)

Customer

Engineering

Sourcing

Department

Quality

Assurance

Lukman Alhakim


Page 15 of 35

1. Evaluation of New Flipper Design for Rotterdam World

Gateway Spreader (3 months)


Mechanical flipper is an essential part of a crane spreader. It provides guidance to align the spreader’s

twistlocks onto container’s corner castings during pickup sequence. For this particular project, a

hybrid design was developed; normal practice of vertical open/close motion was replaced with a

horizontal swing motion. Parameters related to the design efficiency were tested before commencing

to mass production phase.

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005, EN 547-2,

EN 547-3, ISO 4406, ISO 17165-2

Project Planning, Hydraulic System, Jig Design, Testing & Technical Report

Challenges Noble jig design & resource limitations

Scope of work:

1. BED

� Conceptual study & planning of Mechanical Test to allow the following parameters to be

evaluated:

o Locking motion fluidity – To achieve a seamless angular opening & closing by

understanding the relation between location of linear actuator with respect to the

flipper and its structural frame

o Hydraulic hose sizing – To control the of opening & closing swing speed within

the working time-frame. Introduction of reducing connectors to promote hose

size standardization; a procurement leverage activities

o Impact assessment – Noise & vibration data analysis due metal to metal contact

during operation

2. Procurement Support

� Working closely with vendors and sourcing team to achieve a test setup that is technically

verified, reliable & cost effective

3. Testing & Documentation

� Initial fixture setup & component assembly

� Data acquisition with the aid of noise & vibration logger

� Technical report to include approval/rejection of the new design

Outcome:

1. Introduction of reducing connectors for precise motion & speed control

2. Proposal to fine tuning the software algorithm to control the motion sequence - reducing

impact sound emission

Lukman Alhakim


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2. Corrosion Evaluation for Rotterdam World Gateway Spreader

- Post Commissioning (4 months)


A Quality Service Report (QSR) related to corrosion of a spreader occurring in Port of Rotterdam,

Netherland was issued by the in-charged service engineer. This has raised concerned from top

management since it was taken placed in one of the busiest terminal in Europe; global reputation was

as stake. Considering past spreaders were in good working condition with acceptable corrosion

allowance, this project investigated the root cause of this anomaly.

Areas which were severely affected by corrosion:

1. Retainer plate for load bearing shaft

2. Hydraulic linear actuator – piston unit

3. Exposed components prone to regular use – e.g. ladder steps & walkways

Engineering Std.

Skill Segment

ISO 9227, ISO 14993, ISO 2081, ISO 10289 & NACE

Project Planning, Corrosion Study, Testing & Technical Report

Challenges Reference were limited to photos taken by service personnel

Scope of work:

1. BED

� Conceptual study, planning & execution of Environmental Test to allow the following

parameters to be evaluated:

o Corrosion resistance – Evaluation of respective components under in-house salt

spray test in accordance with ISO 14993

o Mounting orientation & location – Comparative evaluation on corrosion rate

o External factors – Environmental acidity & abrasive wind borne particles


� Physical & visual inspection of coating performance as per dictated in ISO 10289

� Technical report to recommend mitigation counter measures to curb rust propagation

Outcome:

1. Introduction of anti-rust coating on unpainted steel structure & hydraulic connectors

2. Other components with low dimensional tolerance to be coated with hot dipped galvanization

3. Based on the spreader’s service condition12

a higher electroplated coating thickness were

suggested - from 12 to 25 micron

12 Corresponding to outdoor service class in severe corrosive conditions e.g. marine or industrial (ISO 2081).

Lukman Alhakim


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3. Evaluation of Photovoltaic Sensors Under Harsh Environmental

Conditions – ALP Component Testing (3 months)


One of the fundamental functions of the ALP machine is its ability to detect the presence/absence of

twistlock via special tool13

. A photovoltaic sensor is cardinal to accomplish this function. However

due to the exposed nature of a marine working condition14

, common issues such as intermittent loss of

sensor signal will need to be addressed for continuity of machinery operation.

The aim is to verify the presence of any of the following failure modes:

1. Signal loss – Under pre-defined conditions with variation in temperature, illumination state &

reflector surface conditions

2. Alignment w.r.t reflector - Due to sensor’s finite field of sensing

Engineering Std.

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768 & ISO 1302

Sheet Metal, Testing, AutoCAD 2D, Autodesk Inventor 3D &

Technical Report

Challenges Simulation of harsh marine conditions within in-house test facility

13 A patented tool that serve the function of locking/unlocking of twistlock to & from container’s corner casting. It is

operated by means of rotary hydraulic actuators. 14 Typical weathering conditions such as heavy rainfall, snowing & ice flakes. Other external contributing factors for

instance accumulation of dirt & oil from prolonged operation period.

1 2

3 4

Figure 9 : 1&2 - Test fixture to evaluate environmental conditions, 3 - Fixture for alignment assessment,

4 - The actual sensor used on the prototype unit

Lukman Alhakim


Page 18 of 35

Scope of work:

1. BED

� Conceptual study, planning & execution of Mechanical Test to allow the following


o Different weathering elements

o Distance limitation w.r.t its reflector (twistlock)

o Fitness-for-purpose evaluation on the weather enclosure design

o Sensor orientation & angular tilt of the sensor w.r.t its reflector (twistlock)

� Working closely with German counterparts to achieve a test setup that is capable of

reproducing the actual operating conditions

2. Testing

� Initial fixture setup & component assembly

� Scheduled planning for test technician to run & exquisite relevant test data

3. Documentation

� Technical report to include approval/rejection of the tested sensor & its enclosure

Outcome:

1. Recommendation on sensor’s optimum operating range & angular tilt

2. Verification of the present weather protection enclosure – A cost effective solution with ease

of visual monitoring, maintenance access & impervious to majority of the tested elements

Lukman Alhakim


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4. Design & Fabrication of RWG Mechanical Test Jig & Conceptual

Verification of Spreader Unit (4 months)


A new and anticipated spreader line equipped with angular tilting features were to be tested within

Malaysia production facility. This project focuses on:

1. The design of its testing fixture

2. Conceptual verification test of the new angular tilting features

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, EN 1005,

EN 547-2, EN 547-3, ISO 4406, ISO 17165-2

Project planning, Sheet Metal, Welding, Hydraulic Fluid Power,

FEA, Autodesk Inventor 3D & Technical Report Writing

Challenges Cost & time constraint & achieving precision a large steel structure

Scope of work:

1. BED & DE

� Project planning from basic engineering phase to delivery into production facility

� Raw materials & fabrication costing, resource allocation, logistics & assembly procedures

� Conceptual design of the test fixture in reference to test parameters & structural limitation

� Detail design which consist of general assembly (GA) & components drawings,

preparation of bill of material (BOM) for fabricators

2. Procurement & Vendor Management

� Localization of raw materials for cost reduction process – Refraining from profiled steel

� Proactively working with external fabricators to ensure design tolerance were achieved

3. Testing

� Planning & execution of Mechanical & Hydraulic Tests on the spreader unit

� Collaboration with QC Department for initial fixture setup, assembly & commissioning

� Data acquisition with Hydac HMG 3010 data logger – pressure, temperature & flow rate

4. Documentation

� Compilation of technical manual, standard operating procedures & maintenance15

scheme

� Technical report to include approval/rejection of individual features

Achievements:

✔ Received recognition from local QC & R&D Sweden post-test fixture commissioning due to its

low setup cost and on-time project delivery

15 Focusing on areas prone to abrasion where greasing procedures & intervals were proposed.

Lukman Alhakim


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5. Corrosion Evaluation of Metric Precision Steel Pipes

for Vendor Comparative Assessment (3 months)


Several hydraulic piping within a prototype machine has been discovered to portray internal

rusting characteristic. Further root‐cause study has exposed an oversight by the supplier

whereby these inner piping were unprotected via oil‐flushing before shipment. Exposure to

high salinity and humid conditions during sea‐freight has degraded their inner surfaces where

passivation protection was not applied.

The sole aim for this test is to get a progressive overview of pipe samples from two (2)

different vendors & their response to salty16

environment.

Engineering Std.

Skill Segment



Challenges Reproducing marine environment within an in-house test facility

Scope of work:

1. BED

� Conceptual study, planning & execution of Environmental Test to allow the following


o Corrosion resistance – In-house salt spray test in accordance with ISO 14993

o Mounting orientation & location – Comparative evaluation on corrosion rate

16 The salt solution used is with 50g/l ±5g/l composition as stipulated in ISO14993 (solution preparation ONLY).

1

2

4

3

Figure 10: 1 - Dimensional verification, 2&3 - Comparison on corrosion outlook between two

suppliers, 4 - Salt spray test setup

Lukman Alhakim


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� Initial sample tagging & test fixture erection

� Physical & visual inspection of coating performance as per dictated in ISO 10289

� Supplementary assessment – Visual aesthetics, deburring quality & dimensional

verification

3. Documentation

� Technical report to recommend mitigation counter measures to curb future rust initiation

Outcome:

1. Comparative assessment had provided firm evidence in which a complete coating (inner &

outer) prevail with lower oxidation characteristics (rust distribution & class rating).

2. To avoid reoccurring predicament only a complete coating should be used on piping of

hydraulic distribution lines.

Lukman Alhakim


Page 22 of 35

6. Evaluation of Anti-Rust Compound for Product Comparative

Assessment – Dinitrol & Techtyl (3 months)

_


Anti‐rust compound is being widely used in Bromma’s production facility to curb rust initiation on

unpainted steel surfaces and hydraulic connectors. A cost driven project to outsource & substitute the

current compound with an alternative option.

Engineering Std.

Skill Segment



Challenges A dynamic & thorough assessment program

Scope of work:


� Planning & execution of:

o Visual & Physical Inspection – Compound clarity, opaqueness & tackiness

upon physical touch.

o Compound Removability – Supplementary test to measure removability of each

compound when subjected to common industrial solvent.

o In-House Salt Spray - To accelerate the rusting process salt mist17

were sprayed

on a twice/day basis.

� Collaboration with SIRIM for 240 hours of accelerated salt spray exposure

� Technical report - Rejection/approval of the new anti-rust compound tested

Outcome:

Both in-house & external assessment converged towards an outcome; Dinitrol outperforms its

counterpart when it comes to protecting components against further rust propagation.

17 The salt solution used is with 50g/l ±5g/l composition which adhered to ISO 14993 (solution preparation ONLY).

1 2

3

Figure 11: 1 - Test samples after tagging, 2 - Compound residual post application, 3 - End result for

after salt spray test

Lukman Alhakim


Page 23 of 35

7. Evaluation of Oil Level & Temperature Indicator for Vendor

Comparative Assessment – IFM & Hemomatik (2 months)

_


LT8022 is an electronic level and temperature sensor from IFM supplier. In this test its performance

characteristics were tested against the pre-existing Hemomatik brand. Temperature range, liquid level

reading and drop test were performed in-house. Supplementary vibration & shock response

certification was delegated to SIRIM.

Engineering Std.

Skill Segment

EN 60068-2-27-Ea & EN 600068-2-6-Fc

Autodesk Inventor 3D & Technical Report

Challenges Overall comparative assessment

Scope of work:



o Simulation Test – Subjection to 3D simulation & physical predictive

experimentation to understand constraint, fitting tolerance & micro-interference

with other components

o Functional Test – Comparison on reading precision & accuracy

o Drop Test - To match realistic spreader operating condition during container

loading/unloading

� Collaboration with SIRIM for the following verification:

o Sinusoidal Vibration - EN 600068-2-6-Fc

o Shock Response - EN 60068-2-27-Ea

� Technical report to include approval/rejection of tested components

Outcome:

Rejection of the new product as it fell short in majority of the critical merits.

1

1

Figure 12: 1 - 3D simulation showing micro-interference, 2 - Performance evaluation post external

SIRIM test

Lukman Alhakim


Page 24 of 35

8. Evaluation of Oil Heater for Vendor Comparative

Assessment - EVT & AVAK (1 month)

_


In brief an immersion heater is used as a direct contact heating method within oil reservoir. AVAK-

11357 is an immersion heater from AVAK whereby its performance characteristics was tested against

pre-existing EVT brand.

Skill Segment Autodesk Inventor 3D, NDT & Technical Report

Challenges Overall comparative assessment

Scope of work:

1. Testing


o Simulation Test – Subjection to 3D simulation & physical predictive

experimentation to understand constraint, fitting tolerance & micro-interference

with other components

2. Documentation

� Technical report - Approval/rejection of the new component

Outcome:

Rejection of the new heater due dimensional non-compliance with spreader’s reservoir design.

1

3

2

4

Figure 13: 1&2 - 3D simulation depicting possible interference, 3 - One to one visual comparisons,

4 - Dimensional checking process

Lukman Alhakim


Page 25 of 35

9. Evaluation of Hydraulic Hoses & Clamps for Suitable

Pairing Selection (2 months)

_


In general a clamp kit is used to ensure a tight hold on the hydraulic hose as well as providing

mechanical mating between hose and the spreader's body. It is also used to absorb shock and vibration

caused by fluid surges within pipes, tubes and hoses in both mobile and stationary applications.

Engineering Std.

Skill Segment

DIN 3015

Dimensional Measurement & Technical Report

Challenges Resource planning for testing on spreader

Scope of work:

1. Testing


o Physical Fitting & Mounting – To observe mating characteristics of each clamp

against their respective hoses on the spreader

o Functional Test – Mating characteristics when hoses were pressurized under

operating pressure

2. Documentation

� Technical report - Approval/rejection of each hose-clamp combinations

Outcome:

Recommendation to revise of a number of hose-clamp pairs due to unsatisfactory clamping attribute.

1

2

3

Figure 14: 1 – The elementary constituents of a DIN 3015 clamp, 2 - Range of clamps to be tested, 3 – Fitting test onto a production spreader

Lukman Alhakim


Page 26 of 35

10. Performance Evaluation of Non-Metallic Dampers

- A Comparative Assessment (18 months)


Bromma’s Spreaders are equipped with landing buffer located between the main frame and

the telescopic beam unit (TBU). It served as shock absorbers to dampen excessive collision

during operation.

Internal guideline dictates for any landing buffer test, the passing upper limit shall be 75,000

cyclic loads under 12T pressure. The sample shall NOT have any resin detachment nor do

any major disfigurements that will affect its dampening function.

Skill Segment Project Planning, Fatigue Testing & Technical Report

Challenges Prolonged test duration, continuous assessment, fixture

prone to fatigue failure

Scope of work:

1. Testing

� Conceptual study, planning & execution of Fatigue Test

� The scope of evaluation shall cover the following province:

o Fatigue life evaluation under continuous cyclic loading

o Static & dynamic understanding of the material under lubricated conditions

� Physical & visual inspection of rubber & resin performance

2. Documentation

� Technical report - Approval/rejection of each batch samples

Outcome:

All samples were showing a wide performance variation but share similar resin detachment modes.

Only natural rubber buffer samples exceeded the required approval threshold of 75,000 cycles.

1

2

3

Figure 15: 1 – A buffer sample with applied grease, 2 - Hydraulic press fixture, 3 – A failure mode showing resin detachment

Lukman Alhakim


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11. Evaluation of Sheave Wheels for Vendor

Comparative Assessment (1 month)


In essence a sheave wheel works in the same principle as a mechanical pulley. In spreader

operation it is utilized to regulate wire ropes that hold a spreader to its respective crane. For

this test, four sheave wheel units from a new supplier will be evaluated against the pre-

existing brand; an indirect process for procurement leverage.

Engineering Std.

Skill Segment

ISO 5817 & ISO 6520-1

CMM, Welding Defects, Fatigue Test & Technical Report

Challenges Non Destructive Test (NDT) limited to visual assessment

Scope of work:



o Functional test – Collaboration with SIRIM to utilize their equipped facility

o Dimensional Verification – Via a coordinate measurement machine

o Visual comparison – Detection of welding imperfection (ISO 6520-1)

� Technical report - Approval/rejection of the tested components

Outcome:

Rejection of new samples due to unsatisfactory dimensional tolerance & fabrication deformities.

1

2

3

Figure 16: 1 - Relative location of sheave wheel w.r.t spreader & crane,

2 – A draft sketch depicting fatigue test concept, 3 – Test samples

Lukman Alhakim


Page 28 of 35

12. Provision of Functional Test for Guide Block & Twistlock Arm

for Vendor Comparative Assessment (1/2 months)


A request for a functional test on a number of guide blocks & twistlock arms was issued by IQC

department. The goals of this test are:

1. Detection of visible defects characterize by the typical deformities18

2. Verifying welding joins are absence from defects that could shorten life cycles

3. Retrieving relevant dimensions from samples via coordinate measurement machine (CMM) &

cross‐checking with respective component drawings

Engineering Std.

Skill Segment

ISO 5817 & ISO 6520-1

CMM, Welding Defects, Fatigue Test & Technical Report

Challenges Non Destructive Test (NDT) limited to visual assessment

Scope of work:

1. Testing


o Functional Test – in house test fitness for purpose

o Field Test – On selected samples under actual operating conditions

o Dimensional verification – With the aid of a coordinate measurement machine

� Visual comparison & detection of welding imperfection according to ISO 6520-1

2. Documentation

� Technical report - Approval/rejection of the tested components

Outcome:

Rejection of new samples due to unsatisfactory welding characteristics; imperfection in:

1. Incorrect weld toe – Imperfection ISO 6520-1 (505)

2. Excessive asymmetry – Imperfection ISO 6520-1 (512)

3. Insufficient throat thickness - Imperfection ISO 6520-1 (5213)

18 Corresponding to scratches, dings and unusual marks on the metal surface.

Lukman Alhakim


Page 29 of 35

13. Provision of Functional Test for Hydraulic Leakage

Verification on Hose Assemblies- (1/2 months)


A request for a functional test on hydraulic hoses foreseen to be faulty was issued by IQC department.

Test aims are as follows:

1. Detection of visible defects on hoses characterize by the typical deformities such as stretched

marks, abrasion on rubber & dings inside metal connectors

2. Verifying hoses are in usable state via pressurizing to their allowable rated pressure

Engineering Std.

Skill Segment

ISO 6606, ISO 13184 (Pressure Decay Technique -

EN 1779) & ISO 17165-2 (Appendix A.1)

Hydraulic Fluid Power & Technical Report Writing

Challenges Resource limitation19

Scope of work:

1. Testing

� Resource coordination & initial assembly setup

� Planning & execution of Pressure Decay Test – According to EN 1779

2. Documentation

� Technical report - Approval/rejection of the tested samples

Outcome:

Approval of samples for production use due to satisfactory pressure retention.

19 At the time of this test, all usable hydraulic pump sets were occupied with dedicated test. An alternative way forward was

to scavenge & repair a faulty pump from an obsolete spreader unit.

Lukman Alhakim


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14. Provision of Functional Test for Hydraulic Leakage Verification

on RWG Valves & Manifold Blocks (1/2 months)


A request for a functional test on valves & manifold blocks foreseen to be faulty was issued by IQC

department. The aim of this test is to verify the components are in usable state via pressurizing to their

allowable rated pressure.

Engineering Std.

Skill Segment

ISO 13184 (Pressure Decay Technique - EN 1779)

Hydraulic Fluid Power & Technical Report

Challenges Root cause analysis & failure mode detection

Scope of work:

1. Testing

� Resource coordination & initial assembly setup

� Planning & execution of Pressure Decay Test – According to EN 1779

2. Documentation

� Technical report - Approval/rejection of tested samples

Outcome:

Approval of samples for production use due to satisfactory pressure retention.

Lukman Alhakim


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Recommendations:

Lukman Alhakim


Page 32 of 35

Marine Spreader Design

Aug 2010 – July 2012

“Devising mechanical machinery designs,

for shipping terminal needs”

Lukman Alhakim


Page 33 of 35


A spreader (red machine in above picture) is a device used for lifting containers and unitized cargo. It

is commonly used for containers that have a locking mechanism at each corner castings. It can be

used on a container crane, a straddle carrier and within shipping terminals.

Engineering

Standard

Skill Segment

EN 15056, ISO 2553, ISO 13920, ISO 2768, ISO 1302, DIN 3015, ISO

17165-2, ISO 4406

Sheet Metal Design, Welding, Hydraulic Fluid Power, Project

Management, AutoCAD 2D, Autodesk Inventor 3D

Challenges Multiple project coordination, last minute technical amendments by clients

Scope of work:

1. BED & DE

� Conceptual and cross reference study based on client’s hydraulic P&ID, headblock20

dimensions, critical component request & painting specifications

� Detail design which leading to preparation of

o General assembly (GA) drawings – Specifying painting requirements, safety

decals & critical parameter notations to aid quality control checking

o Hydraulic schematics – Depicting location of pump, flow dividers, control valves

and other auxiliary components which are fundamental to a spreader operation

o Bill of material (BOM) – For procurement & planning during initial stage of

design. A production check-list during assembly of the spreader unit

2. Procurement Support

� Providing technical steer to sourcing in terms of special components with long lead time

– mechanical & hydraulic items

3. Documentation

� Operational manuals co-ordination between technical writer and sales-force

20 A load bearing mechanical device that act as an intermediate in pairing both quay crane & spreader

Lukman Alhakim


Page 34 of 35

Project List:

1. Local - Malaysia

� ZPMC - Westport, Malaysia – Twin ship to shore

2. International

� Barbados Port Inc. : Single ship to shore spreader

� APM Terminal, Mexico : Twin electric-yard spreader

� DP World - Caucedo, Spain : Single ship to shore spreader

� Suez Canal Container Terminal, Egypt : Twin yard spreader

� ZPMC - Lazaro Cardenas, Mexico : Twin electric-yard spreader

� PSA - Sical Terminal, India - In charge of designing hydraulic system

� ZPMC - WWI, India : Twin electric-yard spreader with new hoisting section

� Terminal de Contentores de Leixoes , Portugal: Twin ship to shore spreader

� Konecranes - Nutep, Russia : Single yard spreader with cold climate structure

� ZPMC - Nansha II, China : Twin ship to shore spreader with new hoisting section

� ZPMC - TESCA, Columbia : Twin electric-yard spreader with new hoisting section

� Gazal Logistics - Umm Qasr, Iraq : Single yard spreader with new hoisting section

� Port of New Orleans, USA : Twin ship to shore spreader with new hoisting section design

� Kocks Krane GmbH - ITC Terminal, Vietnam : Single yard spreader with impact

protection

� Libherr - Petrolesport, Russia : Single ship to shore spreader with ergonomic ladder

design

� SANNY Group Co. - TCDD Izmir Turkey Twin electric-yard spreader with new hoisting

section

� Mitsui - Exolgan, Argentina : Twin electric-yard spreader with ergonomic access holes &

handrail

� Konecranes - Port of Klaipeda, Lithuania : Twin electric-yard spreader with cold climate

structure

Achievements:

✔ Laid groundwork of the 1st hydraulic-headblock order - hydraulic schematics

✔ Design-revamped an existing sensor technology into 2nd generation spreaders

Lukman Alhakim


Page 35 of 35

Recommendations:

lukman alhakim_technical portfolio

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