INDUSTRIAL TRAINING REPORT

SOUTHERN CABLE SDN BHD

LOT 42, JALAN MERBAU PULAS,
KAWASAN PERUSAHAAN KUALA KETIL,
9300 KUALA KETIL, KEDAH

MUHAMMAD HARITH HILMI BIN ZEN AZHAR

2019218292

FACULTY OF MECHANICAL ENGINEEEING

UNIVERSITI TEKNOLOGI MARA

OKTOBER 2022

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ABSTRACT

SOUTHERN CABLE SDN. BHD. incorporated in 1993, becomes one of the leading
and dynamic manufacturer for great range of cables and wires products include Low
Voltage Cables, Medium Voltage Cables, Fire Resistant Cables, Telecommunication
System Cables, Instrument & Control Cables and Overhead Transmission Line
Cables. SOUTHERN CABLE SDN. BHD. has single-mindedly pursued a policy of
excellence in every process, innovated in mechanisation, automation and
computerisation. In depth attitudes of providing quality products, on-time delivery,
superb customer service and competitive pricing are the core of their Quality Policy.

This industrial training report will demonstrate student’s learning experiences

throughout the internship duration which is from 8 August to 16 October. The
student will undergo internship at Copper Plant. This 8 weeks to 10 weeks industrial
training programme is compulsory for the completion of MEC 698 Industrial
Training subject and is conducted between semester break of 6th and 7th semester .

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TABLE OF CONTENTS
Catalog
1.0 INTRODUCION .................................................................................................... 4
1.1 Background History .........................................................................................4
1.2 Structural main activity ....................................................................................5
1.3 Objective ..........................................................................................................9
1.4 Job scope ..........................................................................................................9
2.0 INDUSTRIAL ENVIRONMENT ........................................................................10
2.1 Adaption and Adjustment to the industry ......................................................10
2.2 Practice of Occupational Safety, Health, and Environment .......................... 11
3.0 INDUSTRIAL EXPERIENCE .............................................................................12
3.1 Task that you carried out ............................................................................... 12
3.1.1 Checking the orders from clerk or officer ............................................12
3.1.2 Learn about Drawing machine .............................................................13
3.1.3 Learn about stranding machine ............................................................ 15
3.1.4 Learn Conform machine ...................................................................... 17
4.0 INDUSTRIAL PROJECTS ..................................................................................19
4.1 Relation Between the Tasks to the Mechanical Engineering Course ............ 19
4.2 Integrating the theorectical knowledge with practical works ........................ 19
REFERENCES ...........................................................................................................26
APPENDIX ................................................................................................................ 27

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1.0 INTRODUCION

1.1 Background History

As a producer of cables and wires, Southern Cable Sdn. Bhd. has a reputable track
record. Cables and wires for power distribution and transmission, communications,
control, and instrumentation applications are all part of the comprehensive offering.
The cables and wires are utilised in a variety of industries, including oil and gas
processing, petrochemical plants, building and construction, infrastructure,
telecommunications, and electricity distribution and transmission. Southern Cable
was founded in 1993, and since then, it has earned a solid name on its dedication to
quality, technical know-how, and client-centered services.

As one of Southeast Asia's most sought-after suppliers for infrastructure

development, the company's mission is to be the leading business that takes pleasure
in innovation and inspiration through smart cable manufacturing services.

Figure 1: Southern Cable

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The goal of this organisation is to manufacture cables and wires of the highest
quality using recognised processes, such as SIRIM QAS International certification,
while also offering reliable services for our wide range of cables and wires.

Southern Cable Sdn. Bhd. Management uphold far-sighted vision and planning with
emphasis on customer satisfaction. We are committed to ongoing excellence of wire
and cable production, the acquisition of new and sophisticated technologies in order
to add value to our products as to optimise the opportunity in the regional and
international markets.

Figure 2: The Drums

1.2 Structural main activity

Southern Cable is primarily involved in the manufacturing of cables and wires, and
production and trading of other related products and services. These are
complemented by key supporting activities, namely furnace and continuous casting
operations, and the manufacturing of plastic compounds.

Southern Cable Sdn Bhd is principally involved in the business of manufacturing of

cables and wires and related products and services. Southern is operating at Kawasan
Perusahaan Kuala Ketil in Kedah Darul Aman and its production facilities have a
total built-up area of 448,267 sq. ft. to support its cables and wires manufacturing
activities. Southern Cable possesses numerous accreditations and certifications from
various bodies, such as SIRIM, Energy Commission of Malaysia, and Fire and
Rescue Department Malaysia (Bomba). The products have certificate of product

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acceptance from Tenaga Nasional Berhad and comply to either Malaysian Standards,
International Electrotechnical Commission standards or British Standards. These
assure the quality of our cables and wires in accordance with domestic and
international standards. Additionally, we have established a loyal customer base from
various industries, with notable customers including major public utilities and
telecommunication providers such as Tenaga Nasional Berhad and Telekom
Malaysia Berhad.

This company manufacture a wide range of cables and wires to meet various
customer requirements and specifications. The cables and wires that we manufacture
can be broadly categorised as below:

Power cables and wires

Power cables and wires are generally used in electrical systems for the distribution
and transmission of power. Our power cables and wires are used in overhead and
underground power distribution networks, as well as for internal wiring within
buildings. We are capable of manufacturing power cables and wires ranging from
300V up to 132kV, for use in power utility, transportation, renewable energy,
petrochemical plants, and other factories or operations that require direct supply of
electricity for its operations. Furthermore, Southern Cable is a registered supplier of
cables and wires with Tenaga Nasional Berhad, Sabah Electricity Sdn Bhd and
PETRONAS and a certified supplier of low voltage solar photovoltaic (PV) power
cables. We are also registered with the Construction Industry Development Board of
Malaysia (CIDB) since 2016, which allows us to bid for projects of any amount.

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 Figure 3: Products

Communications cables and wires

Our communications cables and wires are primarily used in communications

equipment, network devices and electronic devices to transmit data such as text,
sound and images. Our products, which include telephone cables, coaxial cables, and
alarm cables, are mainly supplied to the telecommunications industry. We are a
registered supplier to Telekom Malaysia Berhad.

Figure 4: products

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Control and instrumentation

Our control and instrumentation cables and wires are mainly used for connecting
machinery, equipment, instruments and process control systems. The primary
functions of these type of cables are to control and automate processes, by obtaining
and transmitting data and communications among various devices. These type of
cables are used in virtually all manufacturing and processing industries that are
automated as well as modern buildings, amenities, and infrastructures. Among others,
they include power generation, oil and gas, petrochemical and chemical plants, as
well as oil and gas platforms and marine vessels.

Figure 5: Example of products

Figure 6: Examples of products

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1.3 Objective

 Learn about the current working culture and industrial practices.

 To improve self-employability and motivate the trainee to exercise proper
working attitude and professionalism.
 Using theoretical understanding learnt in university into industry.
 Give assistance and support to the copper plant’s team with guidance from
supervisor.
 Execute the task given by supervisor with correct implementation and
knowledge.

1.4 Job scope

For this industrial training, I have been placed in copper plant. My Head of
Department is Encik Hasnen Bin Abdul Ghani and my supervisor is Encik Ghazali
Bin Lazim. The engineers in charge for assiting me during the training is Encik
Aiman Safwan Bin Said and Encik Ahmad Shaekir Bin Mohamad Bakhori. The
product must be met the customer’s requirement and specification. For this training,
my job scope or the task given is to handle and understand the copper plant works as
much as possible. Since the plant have a lot of process and the time given for this
practical training is just 9 weeks, I just need to understand to process which is
drawing, stranding and the conform machine.

Figure 7: Copper plant

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2.0 INDUSTRIAL ENVIRONMENT

2.1 Adaption and Adjustment to the industry

Since I was received and accepted in a very positive manner by everyone at the
company, adjusting to the working environment at Southern Cable as an intern has
been effortless. All the workers in the Copper Plant Department were very willing to
share their knowledge and previous work experiences despite my lack of expertise in
the cable industry. It is interesting to talk with them, as they are eager to explain
things to me that I do not understand.

Cable industry is a fast-paced working environment that requires its employees to

alert on latest issues and news around the world. My supervisor always encourages
me to read and stay up to date to the current news locally or around the world.
During my internship, I mainly worked on tasks and projects that required
engagement and communication with superiors and employees from other
departments. In addition, I managed to become used to the company's working hours.
The company working hours is starting from 8.30 am until 5.30pm. When I am
working on the copper plant’s team, I typically begin my day by checking the order
from the clerk. After that, report the order to the engineers and the supervisors.

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2.2 Practice of Occupational Safety, Health, and Environment

Since Southern Cable is committed to ensure safety, I was instructed by the company
to follow the safety rules while working. We are required to wear proper Personal
Protection Equipment (PPE) that is suitable for our working environment. PPE is
equipment that protects the user from health and safety hazards at work. That
equipment includes safety helmets, gloves, and safety footwear. Even though I
mainly intern at the office I also wear PPEs when visiting the other plants.

The company also appoint members for the safety committee that is in charge of the
company's environmental and safety plans, procedures, and emergency action plans.
The company also has rules regarding clothing and personal protective equipment,
particularly in the production and warehouse areas. Personal protective equipment,
such as safety shoes and helmets, must be worn in all designated areas, and all safety
policies must be followed.

Figure 8: Personal Protection Equipment, PPE

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3.0 INDUSTRIAL EXPERIENCE

The student or trainee has gained industrial experiences by running out activities by
participating and contributing to tasks that have been given. These tasks assess the
student’s ability in segregating multiple informations, handling the tools or machines
and applying the knowledge that have been learnt. Basically as I mention before, in
the copper plant there many machines and processes involved. My supervisor only
give me a look and give experience on some machines which are drawing machine,
stranding machine and conform machine.

3.1 Task that you carried out

3.1.1 Checking the orders from clerk or officer

At the first week in my internship, I have been given the task to learn about the
orders given by the officer. For the copper plant, the orders must be deliver to the
operators to run the machine to produce the products. Therefore, before entering the
plant, my job is check the order from the officer and collect the data after the
products produced have done.

Figure 9: Order for drawing

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Figure 10: Order for stranding

3.1.2 Learn about Drawing machine

The engineer which is Encik Aiman give me a look about Drawing process. The
main part of the drawing process is the wire drawing machine. The wire drawing
machine, manufactures wire drawing. Part of the steel wire rod as raw material and
reduces its diameter as much as you want. This processis generally from a rod or bar.
The wire drawing process consists of pointing the rod, threading the pointed end
through a die, and attaching the end to a drawing block. The block, made to revolve
by an electric motor, pulls the lubricated rod through the die, reducing it in diameter
and increasing its length. Fine wire is made by a multiple-block machine, because the
reduction cannot be performed in a single draft.

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 Figure 11: Drawing machine

Figure 12: size and type of die

The product from the drawing process is the bobbin.

Figure 13: Raw copper rod

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 Figure 14: The bobbin

3.1.3 Learn about stranding machine

The engineer which is Encik Aiman give me a look and give a little explaination
about stranding process. The main part of the drawing process is the stranding
machine. There are three type of stranding machines in the plant which are ST-11,
ST-12 and ST-13. So, how the stranding machine works?

Cables for fixed installation in wire channels or long walls or long sealings of rooms
need to be bendable. Cores for moveable electric devices and units need to be
flexible. The required processability is achieved by using stranded conductors inside
the cable which are produced on stranding machines.

Stranding is the process where a particular number of stranding elements are joined
together while winding them round a common axis.

Stranding is a result of rotating and forward movement. The rotation creates winding
of the stranding elements around an axis or a center element. The forward movement
is made using a capstan.

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Figure 15: Stranding machine

The product from the stranding process is the drum.

Figure 16: The drum (Copper cable)

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3.1.4 Learn Conform machine

The conform extrusion machine or also known as conform machine equipment heats
feedstock metals by using friction. When deformation temperature is achieved, the
metal will be able to be created into desired shapes under die and wheel.

In the course of rotary extruding, the extrusion wheel with groove continuously
rotates. By means of the friction between the wheel groove and feedstock, the
feedstock is continuously transported to the extruder, allowing extremely long end
products to be created due to the unceasingly delivery movement. The development
of such a process truly realizes the continuous production, so this technique has been
widely employed. Complete processes of Conform extrusion machine such as:
feedstock the coil, straightening,cutting, cleaning,continuous extrusion, cooling,
length metering, and take-up.

Continuous rotary extrusion line supports copper, aluminum, and their alloys. It is a
great solution to manufacture solid and hollow section products: conductor wires,
trolley wires, busbars, strips, round tubes, multi-port tubes etc. These extruded
products are widely used for transformers, electric motors, switching devices, electric
locomotives, as well as the evaporator and condenser units of refrigerators and air
conditioners.

Figure 17: Stranding machine

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The product from the extrusion process is the Strip.

Figure 18: Aluminium strip

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4.0 INDUSTRIAL PROJECTS

4.1 Relation Between the Tasks to the Mechanical Engineering Course

The tasks that I have completed has relations mainly to subject Industrial
Management to understand the plant location. Subject Occupational Safety and
Health to apply the safety during the industrial training. Manufacturing Processes
subject also help me to better understand what happens during supplier site visit and
accident case visit. Besides, I also apply knowledge about tensile stregth, tensile
loading, mechanics properties of material and etc which I learn from Subject
Material. Next, Subject Electrical Power and Machines also help me to understand
what type of power there are using in industries.

4.2 Integrating the theorectical knowledge with practical works

Theoretical knowledge that I notice integrated during practical works is applying

knowledge about the tensile strength, tensile load and mechanics properties of
copper wire. There is a case in the copper plant whne the copper wire cannot be
running in the drawing machine. So the engineers investigate the case. From the
investigation, finally found out that there are broken or cracks in raw copper rod.

The engineer ask me to bring the sample to the lab at Quality Control Department
(QC) for testing. They take the sample and test the tensile of the raw copper rod
sample. After that, they give me the results of the test and make the data report to
the engineers.

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 Figure 19: Result of the tensile test

In week 4, My Head of Department which is Encik Hasnen give the task to study
about the conform machine. He handed me the file of conform machine to study
about the machine. Besides, He also explain to me about the advantages of the
machine. Below are the advantages of the machine:

1. Shorter Process Flow and Lower Equipment Investment

2. Lower Energy Consumption
3. Low Waste but High Rate Finished Products
4. Low Labor Intensity

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5. Same Product Quality
6. Higher Electric Conductivity
7. continuous extruding machines require smaller installation space and easy
working.

Work flow of the conform machine

Figure 20: The flow of the production

1. The pay off

- The raw material such as copper rod or aluminium rod

Figure 21

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2. Straightener
- Sraightened up the rod before entering the machine.

Figure 22

3. Main machine (extrusion, hydraulic, lubricating)

- Where the extrusion process happen.

Figure 23

4. Cooling tank
- Cooling down the temperature of the material.

Figure 24

5. Counter and Oiling

- Counter function is to know hoe long the product has been produced.
- There are oil at the counter to make sure the strip is not being oxidize.

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Figure 25

6. Arming
- To make sure the strip in a good line (same as straightener)

Figure 26

7. Coiling
- Coiled up the strip

Figure 27

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The product of the this process is the strip.

Figure 28

Figure 29

The working condition of the prodution line

1. Voltage range of electric 342V to 418V.

2. The condition temperature cannot exceed 40 Celcius.
3. The temperature of all equipments and electrical parts after working continously
for 24 hours cannot exceeds permissible value
4. The filter on main motor of extruding machine should be fluent
5. The temperature of cooling water tank should be 20 Celcius to 50 Celcius.
6. The oil temperature of hydraulic system and lubricating system should be within
10 to 40 Celcius, if the temperature is too low, it can be heated by heater of the
system.
7. The pressure of compressed air should not be lower than 0.4 MPa.

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5.0 SUMMARY
During my internship I was able to learn proper ways to communicate with the
employees professionally. Learning communication skills and have an overview
about how the industry works from an established company such as Southern Cable
needs to be professional. This reflects the company’s image as an efficient and
friendly workplace. This opportunity also gives me a chance to expose myself on
other branch of engineering. I have improved my knowledge on procurement related
job scopes and its association to mechanical engineering. Lastly. I have gain precious
work experience that is unbelievably valuable for my future careers.

For recommendations, I belief a longer period of internship such as 6 months will

benefit the students and company more. With extended duration of internship
company can assign a more specific job scope to student for learning experiences.
The company especially supervisor have more time to monitor students’ performance
and evaluate their progress while interning.

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REFERENCES

Automatic wire drawing machine for drawing wire in different calibres. (2018).
JACOM. https://jacomgroup.com/wire-drawing-machine/
conform machine. (2021). Aluminium Extrusion Die Manufacturers in
China,Aluminium Extrusion Press Manufacturer,Aluminium Extrusion Mould
Maker, Aluminum Extrusion Press,Matrices Para Extrusión de Aluminio,Matriz
de Extrusión de Aluminio,Aluminium Extrusion Tooling Manufactuer.
http://www.rextrusion.com/product-detail/conform-machine/
Stranding - Lamifil. (2022, January 25). Lamifil. https://lamifil.be/high-quality-
products/stranding/
Stranding | Machines to make cable and rope | STOLBERGER. (2022).
Stolberger.com. https://www.stolberger.com/en/solutions/stranding/

Howard F. Gospel, Industrial Training and Technological Innovation: A

Comparative and Historical Study, Vol. 4, Taylor & Francis, 2010 (ISBN:
978-0415043403)

Howard K. Morgan, Industrial Training and Testing, BiblioBazaar, 2011

(ISBN:978-1406713954)

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APPENDIX

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