Internship in Nestlé - Wednesday, 30th Nov 2016 (8am - 5pm)

 Wednesday, 30^th Nov 2016 (8am - 5pm)

At 9.15 a.m., we had a routine meeting with operators for any updates of each service section. I informed Tee about the tasks I had done in the past two days and asked him for any tasks for this week.

At 10.00 a.m., I met a chillerman, Shahwal in the WWTP control room. He told me that each operator should understand all utility services such as boiler, chiller, WWTP, etc. although one is assigned to only certain service.

At 1.45 p.m., I walked around the WWTP to gather much information about the overall WWTP. Recently there have been several ongoing constructions for upgrading WWTP. I observed that the new equipment with pipelines, fittings and pumps are stored in either metal containers or plastic covers for installation of the direct portable reuse system (DPRS), a sophisticated system to be introduced and operated in WWTP in the future.

At 4.45 p.m., Tee gave me the latest process flow diagram (PFD) and P&ID drawings of DPRS, generated by the manufacturer, for my own reference. 

One of the control panel (photo taken on the same day)

Internship in Nestlé - 28-29th Nov 2016

Monday, 28^th Nov 2016 (8am - 5pm)

At 9.15 a.m., there was no meeting as my coach, Tee was attending a training course during these two days.

At 10.00 a.m., I explained to Ridzuan my task of redrawing the WWTP process diagram so I wished to study each equipment in detail. Then I followed him to the first equipment in WWTP, a raw pit. He opened the manhole and shared the knowledge relating raw pit, such as the incoming water sources, pipings and fittings.

At 11.15 a.m., he received a call from a boiler chargehand, Satiya, to ask me to come to his office. Mr Satiya asked me to help him type out the SOP for the loading and unloading of diesel and LPG cylinders.

At 2.00 pm, I continued to study the information about raw pit under the guidance of Ridzuan. The raw pit is used to collect all influent sources before pumping to the balance tank. I recorded all the details explained by him in my notebook.

At 4.00 p.m., I went back to the office and sketched the raw pit based on the information obtained. 

Tuesday, 29^th Nov 2016 (8am - 5pm)

At 9.15 a.m., there was no meeting.

At 10.00 a.m., Ridzuan and I went to the existing DAF equipment. He was adding the polymer in the dosing tank while monitoring to ensure sufficient dosing for flocculation to occur in DAF. At the same time, I observed the chemical dosing system of DAF which is under operation. Then for certain doubts, I asked him for further information.

Polyacrylamide, used a flocculant in wastewater treatment

At 11.45 a.m., I was asked by Satiya to assist him in completing the piping and instrumentation diagram (P&ID) of updating the air compressor system in the Beverage Mixed plant using Microsoft Visio. I took this opportunity to study the P&ID drawing prepared in real industry.

At 1.30 p.m., I continued to finish the P&ID before sending it to Satiya for checking. He also explained the information and meaning of symbols used in P&ID.

Internship in Nestlé - 24-25th Nov 2016 (8am - 5pm)

Thursday, 24^th Nov 2016 (8am - 5pm)

At 8 a.m., I met my colleague, Jaclyn Yee in the office. She had been working in this department for four months.

At 9.15am I followed Jaclyn to attend the routine meeting in the boiler control room. In this room, various performance graphs of power consumption are displayed on the wall. The on-duty operators from each section were gathered and reported the feedback to Tee. The meeting lasted 10 minutes.

At 10.00 a.m., I went to the WWTP control room and met the on-duty operator, Mr. Vasu. He shared the process flow chart of existing WWTP and explained each process. Suddenly one alarm was triggered and he pressed a button to switch off the alarm. He told me there was a case when there was a high level in the balance tank due to incoming industrial effluent from the production plant, however, it was considerably accepted.

At 3 p.m., I went to the control room again. This time Mr. Ridzuan was on duty. He had shared his knowledge about the WWTP operation. I took this opportunity to understand the daily tasks carried out by the WWTP operators.

Friday, 25^th Nov 2016 (8am - 5pm)

At 9.15 a.m., I attended the routine meeting in the boiler control room. Before the meeting, there is a tradition of making a swear, ‘Safety begins with me’ by all attendees. As usual, the on-duty operators from each section gave feedback to Tee. The meeting lasted 10 minutes.

At 3 p.m., Ridzuan brought me around WWTP while collecting the samples from the final discharge point, DAF inlet and outlet, etc. Next, he conducted the laboratory test using these samples to check the water characteristics such as pH, colour and chemical oxygen demand (COD), etc.

I was taking this opportunity to observe the procedure of testing samples. He willingly explained the details of these procedures. He explained that these are routine tasks to be carried out by operators and several water parameters must be recorded for further reference.  

Inside the laboratory (photo taken on the same day)

Internship in Nestlé - Wednesday, 23rd Nov 2016 (8am - 5pm)

At 8 a.m., we gathered in the HR meeting room before we were sent to our respective departments and met our training supervisor/coach.

At 9 a.m., we took the anti-typhoid vaccination at the factory clinic for health and hygiene purposes.

At 10 a.m., three of us including me followed Ms Jiwana to the Engineering department. In the office, we had a short meeting with our manager of the Engineering department, Mr Shinya Nakagawa. He welcomed us and gave us some pieces of advice.

I was arranged to have my three-month internship in the General Service section. My supervisor is Tee Chee Sin and he is a General Service Engineer. He is mainly in charge of all utility services of the whole plant. He had assigned and briefly explained the tasks I should complete during my internship period (See Appendix A). He advised me to communicate effectively with operators throughout this period to assist me in completing the tasks successfully.

At 11 a.m., I followed Tee to the utility site. He briefly explained to me the existing utility services in the plant such as steam boilers, chillers and industrial wastewater treatment plant (WWTP) in the plant.

Then he gave me an operation manual of the existing dissolved air flotation (DAF) system and assigned me to understand all the information about the DAF system. He told me that recently there would be new equipment to be installed in WWTP. He assigned me to be involved in this project and to prepare the standard operating procedure (SOP) for the start-up of the new DAF during commissioning.

A safety helmet must be worn since there is ongoing construction in WWTP.

At 2.30 p.m., I followed Tee to visit the coffee ground processing plant. Again he emphasized prioritizing the safety aspect of the site. The process of handling coffee grounds involves equipment such as furnaces, hoppers, etc.

At 3 p.m., we went to the WWTP control room and Tee was doing routine log book checking. At the same time Mr Ridzuan, a WWTP operator shared his experience working in WWTP.

Place where I learnt most during internship period

First day of My Internship Period

Tuesday, 22^nd Nov 2016 (8am - 5pm)

At 7.30 a.m., I arrived at the main gate and registered myself at the security office. In the following working days, we should report ourselves here before entering the plant.

An officer from the Human Resources (HR) department, Ms Jiwana briefly introduced today’s schedule in S.H.E (Safety, Health and Environment) meeting room. Then we collected a pair of safety shoes. Wearing safety shoes is mandatory during the working hours.

At 10 a.m., Mr Izwan bin Zainal, senior S.H.E. officer, gave a detailed presentation about the safety aspect in the Nestlé manufacturing factory. He emphasized that the safety issue is always the first priority for us as the employees when in the factory. He shared his experience with the aid of video, statistics and cases that he dealt with during his career life.

At 11.30 a.m., we attended a course about the master plan of Nestlé in the future. It is totally new for trainees to understand the concepts, however, I took the opportunity to understand the benefits and opportunities given by Nestlé to its employees.

At 2.00 p.m., we attended the training session relating to hygiene issues by Mr Lee Heng Hooi, HR executive. He mentioned that hygiene is an important concern for the food industry and the employees are strictly required to follow the rules and regulations when involved the food processing. Employees are not allowed to bring the uniform back home and the laundry services are provided. Then we had a simple visit of the whole plant led by him.

Before the end of the day, we were required to sit for a short test about safety and hygiene to pass the requirements before working. 

Junior's working uniform