Week 9

This week, i was busy with the packing of the Protos 90er, which was ready for shipping. The machine was separated back into four parts, VE,SE,MAX and the filter packer HCF. Me and Mr Jega did the dismantelling which took two days. By then the other Protos 80c which i help assembled the MAX was ready to be joint. There are four Protos 80c being rebuilt in the workshop for now, this out of the 12 Protos 80c with was sent by Gudang Garam.

Week 8

For the whole week,i was helping out Mr. Jega with the Protos 90er. The cigarette production slowly incresed up 9000 but it was not still up the maximum capacity of the Protos 90er. There was a series of open seal on the cigarette rods whenever the production went up to 10000 cigaretes per minute. Mr Jega inspected the cigarette rod which was made at the SE station,he thought maybe something is wrong with the glue setings. Even tho after he had adjusted it,the problem still arised. It went on for a few days,until he decided to change the size of glue nozzle to a bigger one. So that it would shoot more glue,which will seal the cigarrete rods firmer. At last this solved the problem,but there was many other minor problems such as the tipping paper(filter paper) not wraped properly and many other problems, but Mr. Jega managed to solve all of it. At the end of that week, the customers(buyers,dhaka tobacco from Bangladash) came to have a look on the machine they were buying, they were quite satisfied.That week i had also learnt how to measure the finished cigarrete`s weight and diameter using the Quality Testing Machine(QTM)

Week 7

Hey people,i`m back dis week,feeling much better and have 3 more blower fan units to be done. But this time, i finished each unit in a day, it took almost three days and i really enjoyed it! Now i was confident with my hands on skills, which was not taught to me in uniten. Then i join my senior Mr. Jega aka Black Jack to help him out with a test run of a Protos 90ER. It was for the Dhaka tobacco company in Bangladesh. I was helping him out to feed tobacco for the machine and to clear the cigarettes trays. But i learned how the process of making the final cigarette product by watching the machine work. Watching all the drum rotating simultaneously was thrilling. I just could not believe this technology was created by the Germans 30 years ago. It was just amazing While i was excited , Mr Jega was having a tough time trouble shooting because the machine was suppose to run 10000 ciggarettes per minute but hardly reached 8000. So he was adjusting the settings again and again until he was sure what was the problem. After he settled one problem, another new one poop up. It was an endless story.

Week 6

This week i was not feeling well, had to take medical leave for 2days. It was due the nerve pains i suffered on my left finger,went to the panel clinic near my company. The doctor said i had severe shoulder ache which infected my nerves till the end of my left finger.The cause may be due to my recent heavy work load. Although, i didn't recover fully even after 2days of rest,i went back to work,i didn't want to let this bring me down. I assembled a Rolling block unit, it is responsible to help the rolling drum wrap the cigarette. After that,came the biggest module i had ever assembled, it was the blower fan, quite a big and heavy unit. Had tough time figuring out which part to start. Plus i used a crane to carry the motor. moving the crane was not easy. I was cracking my head on how get the v belts in to the pulley. But then again i manage to do it found my own way. Firstly i had to the base and the plated on ithe base, then came the moter top of it,then the blower,then filling the motor keys,finally pullry and belt. Actually i learned many things in the process. but took 2 days to finish the first unit. By then it was friday.

Week 5

Okay,things are picking up this week. I assembled quite a number of units this week. Started out with the rolling drum for the control flange. The rolling drum functions to completely roll the filter and cigarette with the tipping paper. The next day, fixed tipping guide. this unit has very sharp edges,so i had to be careful. but still i ended up having a tear on my hands,it was a small one. The tipping guide makes sure the tipping paper does not fall or drop from the cigarette while it is being transferred to the rolling drum, where it is wrapped completely with the cigarette and filter. End of that week,i assembled the swash plate drum which is responsible for joining a double length filter in between two piece of tobacco rods.Tipping paper with glue is also applied to double length filter at the same unit.I was having hard time carrying the drum, because its very heavy,but i manage to transfer it. I couldn't finish up all the 4 units because one of the drums had many missing parts. So had to leave it for later.

Week 4

Well,its been 3 weeks since i came to Hauni Malaysia,but i was still doubtful on how the Protos worked. But then again this week proved to be one of the most important week,because during this week i had learnt how the cigarette was made from scrap and also the function of VE,SE,MAX which makes the Protos and the HCF which is responsible for packing the completed cigarette rods. I also learnt how to handle cir clips which comes in 2 types,inner clip and outer clip.besides that, now i know how read the alignment of sealing ring from a drawing. there's a lot of minor details in a drawing. By the way did i mention to you that we opened and dismantled the frame because the customer wanted to add in a new sensor.(this sensor is optional,depends on the spec ordered by customer). Then i fixed back all the parts i had dismantled including the control flange,final cut knifes motor with belt and pulley. To my suprise, i only took 1 day to fix back every thing which i had fixed in a week and half. That means im progressing! hurray! :)

Week 3

This week was a very tough one.On the first day of the week ,i met my senior Mr Jega aka jack. He just arrived from Bangladesh after going there to solve a few technical problems with our customer Dhaka tobacco. He pushed me with my work,he said moving to slow and i needed to be fast. Read drawing faster and start assembly as soon as i got the parts. The problem was , as time went the units became more larger and complicated but i realized there is proper to way to fix the parts,this is a skill will i needed to develop in my self. The first day i fixed the guard or the housing for cutter knifes. Its was not easy to fix the guard unit on the Max body because i had to make sure that it could be pulled off easily from the body for the cleaning of the knifes. So it shouldn't`t be fixed too tight or too loose. Had to make sure the setting was correct.The next day,i was working on fixing the feed rollers, this is used to pull the tipping,so there will be a tension of the paper to push it to the cutting unit. By the way the feed roller is called a "MV" because it is non-fomat unit so is be pre-assembled in another section. That section is called the MV. The next day, i fixed the tipping patch extraction on the body,which is attached together with the guard. This unit is responsible for sucking all the unwanted dust and rejected tipping paper into a rubbish bin. Later that week, i assembled the motor ,v-belt and pulleys for the final cut knife unit. This motor runs the knife that cuts the double cigaratte filter rod by half.

Week 2

This week i was still in the assembly line with "max"... That week,i had fixed a tipping patch extraction,which was quite easy because the drawing was a exploded view mode. By now, i was quite good in handling the tools,.so I did not have much trouble in fixing the device. With a tipping paper extractor,the machine`s reliability and the cigarette quality increased. The tipping patch extraction is showed on the right. There were 4 units, each 1 unit of tipping paper extraction is for 1 unit of Max. There 4 units of Max which belong to 4 units of Protos 8oeER being rebuilt here.The machines were bounght bt Gudang Garam 20 yrs back. Nw they have sent it here to be rebuilt or overhauled. Coming back to my assembly,I had manage to assemble all the 4 units in three days. while i was doing this, i had learnt how to find for missing parts from the store and also how to locate the parts at the store by myself.

Week 1

On the first day work,i met my host supervisor, Mr Endri Omar,the technical production manager of Hauni Malaysia. He was very warm and friendly,so that was a good sign for me on my first day. He intoduced me to the entire team in hauni,the engineers and the skillful technicians. After that i was sent to the assembly side in the workshop. I was suppose to help out the technicians to assemble "the Max", a part of the Protos 80,which was sent by Gudang Garam to be rebuilt. This Protos 80 can produce 8000 cigarette per minute. Before i carry with the assembly,there was 1 important skill that i needed to learn,which is how to interpret the Hauni catalogue drawing. So i was helped by Abang Aziz and Abang Belli. they are the ones in charge of the assembly of Max. One my first task i fixed the blower pipes on the frame of Max. I learnt about "locktite", a gel like material that is used during tying srew in order to avoided leakage. then i fixed the supports and that was about it.

On the second day,i was given a assembly drawing of a module,where by i have to read it and use it as guide. All the parts were given in packets, Abang Aziz helped to collect all the parts. so then i started to assemble. Initially i was quite blur,didn`t know where to start. But then after a while, i got the flow, that day i assembled a drum and a control flange.

On the third day, i was finish the assembly of the control flange, then i learnt how to read the label on the packet of the parts. You see, each part is packed either straight from "Universelle" (the main spare parts supplier for hauni ) which is in Germany or from the store house. This packets have a label and this label has alot of infomation such as what is German standard for the part,the size,the material is made of,and its name. But its written either in German or English.Then Ang Belli tought me how to access the list of parts from the company system. Later i carried on with the assembly at the workshop throught the week. Oh boy,its was very tiring working in the workshop. I was not used to such heavy hands on work. Actually i learnt alot things about tools and how to hanndle them during that week. Did you that theres actually a proper way on how you should hold an allenkey? how to hold a mallot? so,there i was learning bout the mechanical hands on skills that was not tought to me in school.

hauni malaysia...

hi,first of all,let me tell you about the background of the company i`m doin my training:

Hauni Malaysia is a german based tobacco machinery company. Hauni Malaysia was founded in 2001 to offer partial and general overhaul services for cigarette and filter machinery supplied by Hauni to companies in the Asian region.

The company offers customers based in Asia the usual comprehensive 'made by Hauni' service in addition to maintenance, repairs and partial overhauls at its facility as well as on site at the customer's factory.

By the way,Hauni is the global market and technology leader in the field of engineering for the international tobacco industry. With innovative technologies and solutions for tobacco processing, filter and cigarette production, they are the best in the world. The company was found by the Körber Group, a leading international technology conglomerate. Sales in the year 2009 totaled €800 million with a workforce of approx. 3,750 employees.

The product portfolio encompasses machinery and plants for all process stages – from tobacco processing to the production of filters, cigarettes and special products through to final quality measurements. besides that,they also offer customers tailored services for the entire lifecycle of the machines as well as technical consultancy services.

Hauni Malaysia is located at Lot 16, Jalan Api-Api 26/1 ,Kawasan Perindustrian Hicom ,Section 26,40400 Shah Alam ,Selangor Darul Ehsan.