Institute of Engineering Technology, Katunayaka, Sri Lanka

National Diploma in Engineering Sciences
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Industrial Training Report
On
BASIC INDUSTRIAL TRAINING
At
A I HIGH TECH (PVT) LTD
For the Period of
08/03/2018 to 31/05/2018
DANKOTUWA PORCELAIN PLC
For the Period of
04/06/2018 to 30/11/2018
L.P.G. ENGINEERING SERVICE (PVT) LTD
For the Period of
04/12/2018 to 28/02/2019
By
K.B.S.M.Fernando
(MG/15/10262)
Submitted to
Department of Mechanical Engineering
Industrial Training Division
Institute of Engineering Technology
Katunayake
For
The partial fulfillment of the requirements of National Diploma in Engineering Sciences

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Acknowledgement
I am very much appreciated in obtaining A I Hightech (Pvt) Ltd , Dankotuwa Porcelain PLC and L.P.G
Engineering Services (Pvt) Ltd, as my General Industrial Training that expanded for a period of 12
months.
It’s due to the enormous support of various personalities from different backgrounds that I succeeded
in achieving expected objectives.
At first I extend my gratitude to Mr. Mohan Pathirana Director of A.I.Hightech (Pvt) Ltd
,Mr.W.A.Somasiri Peiris the Senior Manager Of Engineering and Maintenance Department of
Dankotuwa Porcelain PLC and Mr.S.Uduwaka Factory Manager of L.P.G Engineering Services (Pvt)
Ltd for its, because of their organization facilitated industrial trainees in this way.
Especially I’m grateful to Head of Department –Mechanical (Industrial Training) Mr.L.H.Wasantha
Kumara and Mr.Hirantha Fernando for his dedication & determination in finding us the training
establishments & evaluating, guiding us throughout the particular period.
And also my gratitude goes to;
Mr. R.R.Subasinghe - Forman, Maintenance department of Dankotuwa Porcelain PLC
MS. Nilusha Dulanjali - H.R.Assistance of Dankotuwa Porcelain PLC
Mr. R.A.D.S Priyamal - Workshop Engineer of L.P.G Engineering Services (Pvt) Ltd

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Preface
This training report is based on general industrial training period of National Diploma in Engineering
Sciences which I currently following at Institute of Engineering Technology at Katunayake.
It is a great pleasure to have my general training at A I High Tech (Pvt) Ltd, Dankotuwa Porcelain
PLC and L.P.G.Engineering Services (Pvt) Ltd. I got a golden opportunity to improve my practical
skills in mechanical as well as electrical field. And also I got a great chance to have knowledge about
management part.
In This training period of 12 months, I got knowledge about Industrial Hydraulic systems and servicing
during 3 months in A I High Tech (Pvt) Ltd including outdoor servicing. As a matter of fact,
Dankotuwa Porcelain 6-month training experience was really helped me to have a sound knowledge
of everything not only engineering but also social management including Mechanical engineering and
maintenance and, it guides me to put a foundation to my future career. My last 3 months, I spend at
L.P.G. Engineering Services (Pvt) Ltd by learning about fabrication, outdoor servicing and other
Documentation.
It is pleasure to say that I was able to work with different kinds of employees, from top management
to labor. They also satisfied that helping us to improve our knowledge in every possible time during
their working hours.
This training report contains all my experience I had at my training as an industrial trainee. I have
included all those things which I learnt while I attend myself on projects, breakdowns and preventives.
I have presented this report best of my knowledge and fullest effort.

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Table of Contents
Acknowledgement ................................................................................................................................1
Preface...................................................................................................................................................3
Table of Contents .................................................................................................................................4
List of Figures.......................................................................................................................................5
A I High Tech (Pvt) Ltd.......................................................................................................................7
Declaration........................................................................................................................................... 8
Introduction......................................................................................................................................... 9
Training Experience............................................................................................................................. 10
Discussion .......................................................................................................................................... 13
Dankotuwa Porcelain PLC................................................................................................................15
Declaration......................................................................................................................................... 16
Introduction....................................................................................................................................... 17
Training experiences........................................................................................................................... 20
Projects.............................................................................................................................................. 28
Discussion .......................................................................................................................................... 33
L.P.G.Engineering Service (Pvt) Ltd. ..............................................................................................34
Declaration......................................................................................................................................... 35
Introduction....................................................................................................................................... 36
Training Experience............................................................................................................................. 37
Discussion .......................................................................................................................................... 40
Conclusion ..........................................................................................................................................41
Annexes...............................................................................................................................................42

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List of Figures
A I High Tech (Pvt) Ltd
Figure 1- Press brake machine.............................................................................................................10
Figure 2-Manual hydraulic pump ........................................................................................................11
Figure 3-Manual hydraulic pump drawing ..........................................................................................11
Figure 4- Large Hydraulic Cylinder Barrel..........................................................................................12
Figure 5-Radial piston pump ...............................................................................................................14
Figure 6-Gear motor.............................................................................................................................14
Dankotuwa Porcelain PLC
Figure 7- Installing the dryer room wall ..............................................................................................20
Figure 8- Burner unit............................................................................................................................20
Figure 9- Sponging Conveyor extending process................................................................................21
Figure 10- Running smoothly with correct alignment.........................................................................22
Figure 11- Running conveyor with misalignment ...............................................................................22
Figure 12- Designing and making new bush .......................................................................................22
Figure 13- Broken old bush .................................................................................................................22
Figure 14- Checking burner ................................................................................................................23
Figure 15- Installing gas line ...............................................................................................................23
Figure 16- Decoration kiln...................................................................................................................23
Figure 17- New fabricated roller..........................................................................................................24
Figure 18- R.H.Kiln (white ware) Transferring Rollers ......................................................................24
Figure 19- NBC kiln door opening side...............................................................................................24
Figure 20-Machined Door Hinge Parts................................................................................................24
Figure 21- Damaged OMAL VIP Valve..............................................................................................25
Figure 22- Replaced water valve .........................................................................................................25
Figure 23- After mounting new cylinder by making new mounting bracket ......................................26
Figure 24- Damage pneumatic Cylinder & New Cylinder ..................................................................26
Figure 25-Making production..............................................................................................................27
Figure 26- Fixing automatic Scraping tool ..........................................................................................27
Figure 27- After installing Production Line.........................................................................................28
Figure 28- Electrical parts of Water spray unit....................................................................................28
Figure 29- Roller skid drawing............................................................................................................29
Figure 30- Fabricated roller Skids .......................................................................................................29
Figure 31- Unloading from law bed truck ...........................................................................................30
Figure 32- Kiln Placing on law bed truck ............................................................................................30
Figure 33- kiln placing on roller skids.................................................................................................30

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Figure 34- Structure of the kiln............................................................................................................30
Figure 35- Inserting cars and fixing damaged heat Resistant wall ......................................................31
Figure 36- Installing duct line..............................................................................................................31
Figure 37- Joining two parts ................................................................................................................31
Figure 38- Shift kiln in to new area .....................................................................................................31
Figure 39- Checking Samples..............................................................................................................31
Figure 40- Checking burners................................................................................................................31
Figure 41- Testing vacuum gun...........................................................................................................32
Figure 42- Conventional sucker and newly designed vacuum gun .....................................................32
L.P.G.Engineering Service (Pvt) Ltd
Figure 43- Biscuit Crusher Assembly SW drawing.............................................................................37
Figure 44- Solid Works Model ............................................................................................................38
Figure 45- Given sample design ..........................................................................................................38
Figure 46-3D model in solid works .....................................................................................................39

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A I High Tech (Pvt) Ltd.
Duration: From 08/03/2018 to 31/05/2018

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Declaration
Here by I declare that this report contains only materials that are based on the knowledge and skill I
gain as an apprentice during my General Industrial Training at A I Hightech (Pvt) Ltd. There is no any
copy writing except references.
………………………………….
K.B.S.M.Fernando
(MG/15/10262)
Certified by
…………………………………..
(Signature and official stamp of the supervisor)

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Introduction
AI High Tech (Pvt) Ltd Is The Consultants, Designers For Hydraulic Systems. Specialist In
Assembling Industrial Hydraulic Power Packs.
The Customers Have Been Provided Following Services Such As
 Repairing Hydraulic Pumps, Valves, Motors, Cylinders Etc.
And Stock In:
 Hydraulic Valves. Pumps, Valves, Solenoids, Cylinders, Suction & Return Filters, Oil Coolers,
Pressure Gauges, Shaft Couplings, Proportional

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Training Experience
Job: Press brake machine bed Adjustment.
Purpose: Align the plate guiding bed
Machine, Equipment and Tools Used:
 Wrenches
 Pliers
 Screws
 Electrical Connections
Material and Any Consumable Used:
 Grease
 Mild steel Welding Rod
Procedure:
 Bed alignment was checked horizontally and vertically.
 Two guiding buses were lubricated and bed was run checked alignment.
 Transferring screw was lubricated, run and checked alignment.
 Motor gear wheels were lubricated and checked.
My involvement:
 Helped to technician
 Motor gear wheels noise reduction was done.
Job: Repairing 2 Ton Manual Hydraulic Hand Pump
Purpose: Identified the schematic diagram of the pump and identify the faults.
Figure 1- Press brake machine

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 8 Allen key
 Phillips screw
 Hydraulic Oil (HD68)
 Carbon Steel balls
Procedure:
 Pressure Relief valve was checked.
 Law pressure & High pressure adjustment were checked. (ball valve sheet)
 Disassemble all the parts of pump and checked.
 Drawing was sketched.
 Reassemble
My involvement:
 All the procedure was done.
Figure 3-Manual hydraulic pump drawing Figure 2-Manual hydraulic pump

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Job: Apply pressure to the cylinder bottom
Purpose: Add tension to the barrel threads before welding
 2 Ton Manual hydraulic pump
 Dial indicators
 Welding plant
 Lathe machine
 Hydraulic Oil (HD68)
 Welding Rods
Procedure:
 Top and bottom barrel faces were machined in lathe
 Inside of the barrel was polished by polishing machine.
 Cylinder was Assembled
My involvement:
 Pressure was applied to the barrel faces.
 Dial indicator readings were observed.
Figure 4- Large Hydraulic Cylinder Barrel

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Discussion
This was a great place to get lot of ideas about what is Hydraulic, uses of Hydraulic, Hydraulic
components, Hydraulic circuits, Hydraulic Power Packs, repairing Hydraulic systems, maintaining
Hydraulic systems, how check Hydraulic components, safety precautions about Hydraulic systems
and basic knowledge of all things about mechanical.
Hydraulic Components:
The all types of Hydraulic components met in this workshop. Then learnt purposes, functions,
how use of these components.
 Hydraulic Pumps
 Vane Pump
 Piston Pump
 Gear pump
 Hydraulic Motors
 Vane Motor
 Gear Motor
 Hydraulic Valves
 Pressure Relief valve
 Solenoid relief valve
 Directional control valve
 Flow control valve
 Check valves
 Solenoid valve
 Sequence valve
 Lever valves
 Pre-fill valves
 Cartridge valves
 Hydraulic Jacks
 Hydraulic hand pumps
 Hydraulic oil – coolers
 Pressure switches

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During this training period I met a special hydraulic system which used for mini hydro
power. The hydraulic power pack used vane pump, solenoid valves (directional control valves),
pressure relief valve, accumulator. The function of this pack was, the open and close the sluice of
the dam, when drop the electricity the system use the accumulator. The accumulator uses the
nitrogen gas for operate it and their pressure 45bar. Accumulator acts as an energy source. It can
use approximately 7 times for open and close the sluice.
During my training period I could study about the radial piston pump. There were seven
pistons in the pump. The intake ports were located on the end side of the cylinder. This pump is like
a submersible pump. The pump is sink in the reservoir tank. The main issues of this pump was
damages of the pistons and cylinders and the main bearing problems with the time and the size of the
pump(diameter). There is special profile for actuate the pistons via the motor.
Special characteristics of this type of pumps.
 High efficiency
 High reliability
 Low noise
 There is no any axial load applied to the drive shaft.
 High pressure
Figure 5-Radial piston pump
The gear motor for traveling the excavator,
This place was a small workshop, but its jobs are not small. Outdoor services was great experience in
my life. The director Mr. Mohan is a great person. He always guided us to changing the way look at
something.
Figure 6-Gear motor

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Dankotuwa Porcelain PLC
Duration: From 04/06/2018 to 30/11/2018

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Declaration
gain as an apprentice during my General Industrial Training at Dankotuwa Porcelain (Pvt) Ltd. There
is no any copy writing except references.
………………………………….
K.B.S.M.Fernando
(MG/15/10262)
Certified by
…………………………………..

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Introduction
History
Dankotuwa porcelain public quoted company with limited liability under the provisions of Companies
Act No. 17 of 1982 (Registered as a Private Limited company in Sri Lanka on 6th January 1984 and
converted to a Public Company by a special resolution on 8th July 1994) and re registered under the
new Company Act No. 07 of 2007 as Dankotuwa Porcelain PLC (PQ- 79).
About
Dankotuwa Porcelain PLC is a leading manufacturer of Porcelain Tableware Located in Sri Lanka.
Which is a listed company in the Colombo Stock Exchange and the major shareholder is Lanka Century
Investments PLC (LCI)
Have Learned the Art of manufacturing porcelain by combining the oriental Japanese skills with
western technology from Germany.
The High Quality and the Elegance of its products is attributed to ability to combine Human dexterity
with modern porcelain technology. With an eye for detail, and technical and human capabilities to
adapt to the changing tastes of industry and client, continue to serve up the kind of product that has
made Dankotuwa Porcelain synonymous with quality and elegance.
Quality
Proofing quality is the decade long acceptance, have got from our reputed list of customers such as
Macy’s Department Stores, British Home Stores, John Lewis, Jashanmal, El Corte Ingles, Berghoff,
Galeria Kaufhof and many others scattered throughout USA, Asia and Europe.
Being the first tableware manufacturer in Sri Lanka to obtain ISO 9001/2008 certification, it has been
much focused on maintaining consistent quality. These quality values are integrated into our
employees and through them into the systems and motivated staff to continually deliver the best of
them.
Production Capacity
With a white ware production capacity of 700,000 pieces per month and other decorative product
capacity more than 975,000 firings per month, Dankotuwa Porcelain has recognized the necessity of
increasing production capacity and innovativeness in competing globally, while constantly upgrading
its machinery and plant.
Materials
Sri Lanka is blessed with an abundance of raw materials that are necessary for the manufacture of
porcelain. At Dankotuwa these raw materials are combined with imported materials from countries
such as New Zealand, India, Germany and China, to produce that unique brand of quality porcelain
for which Dankotuwa is famed. The challenge is the production of flawless porcelain and the pursuit
of this smoothness, richness and elegance of product dominates the manufacturing process.

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Technology
Dankotuwa’s focus on infrastructure development and IT together with its investment in foreign
technology, and state-of-the-art machinery have been to key to its rapidly increasing productivity and
success. Machinery is sourced from world renowned companies such as Sama, Eisenmann,
Reidhammer, Kajiseki and Sakurai. Have also invested in IT based graphic design software and enter
an era of IT designed tableware. No expense is spared. looking at further IT investment, in order to
provide better quality and customer service
Human Dexterity
The pride of organization is the unmatched skill of Dankotuwa’s 1100 strong workforce, which over
the years has been honed to perfection. Dankotuwa’s working environment and remuneration are
above par in the industry and this together with our worker circles and management style ensures the
smooth and efficient flow of work which is very production-oriented.
Guarantee above average working standards for its employees and signatories to very strict agreements
with our international customers. Have also being audited regularly to ensure our competence with
these agreements. Have agreed to not to use child labor, not to force employees to work excessive
working hours etc.
Through the use of Kaizen, Total Productive Maintenance, Total Quality Management and the 5S
practice we develop human resources for better performance: encouraging and motivating our
employees at all times, providing them with opportunities for career and self-development.
The company’s culture gives employees an opportunity to contribute, grow and advance based on
merit and talent. Encourage employees to further their knowledge by providing them assistance for
professional courses and postgraduate studies.
Design
Our exquisite designs, vibrant colors and peerless quality, continue to enrapture buyers the world over.
Characterized by individual artistry, innovative shapes and superior glazes, Dankotuwa Porcelain aims
to stay ahead of the competition, most often producing state-of-the-art designs and shapes, to
complement individual lifestyles. We also hire experienced designers from UK, Germany and Italy to
design new shapes and motifs. With the new graphic design software able to develop a new decoration
in less than 48hours.
The elegance, sophistication and superiority of Dankotuwa Porcelain, especially the gold and platinum
range and the highly improved imprinting of decals, have earned us the tag of the best in Asia.
We have introduced several new shapes during the last 03 years designed by world famous designers
such as Mr. Jonathan Smith, Mrs. Pamela Greaves, Professor Karnagel and Mr. Robin Levien. As a
result of this Dankotuwa has gained a name been as a trend setter in the Global Tableware industry.

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Export Markets
As a truly global company, Dankotuwa Porcelain is driven in all aspects of design, production and
management to turn out the kind of product that is sought after as the perfect accompaniment to
gourmet cuisine the world over. Superior high class tableware that has captivated customers the world
over.
Reaches
The demand for the ‘Dankotuwa’ spans across over 25 countries, and five continents with our buyers
from Belgium, Czech Republic, Colombia, Dubai, Germany, Greece, India, Ice Land, Italy, Japan,
Kuwait, Norway, Pakistan, Poland, Russia, Spain, Switzerland, U.S.A, U.K, Qatar, Maidives and
Ukraine, etc.
Clients
As a reputed manufacturer and supplier of ‘Upstairs’ or ‘Up-market’ tableware to some of the bigger
departmental stores in the US and Europe including Macy’s, since 1991, white-ware for Lifestyle
Stores in the US, dinnerware for La Printemps in France and in the UK, is seen at British Home Stores
and in John Lewis from year 2010. The feather in the cap of DPL however was the commissioning of
the manufacture of souvenirs for Walt Disney Productions centenary celebrations in March 2001. And
then no one cannot forget the night Dankotuwa came out on top at the Oscar’s banquet in 1996 and
El-Corte ingles in Spain.
It has been its ability to keep abreast of international industry trends (noting that in many markets,
tableware design is driven by fashion) through the dexterity of workers and the flexibility of our
processes and technology that let us adjust product lines to suit the emerging trends of the industry and
the discerning tastes of our customers.
The fusion of elegance, imagination and unorthodoxy in design have given us the edge to constantly
breakthrough into the highly competitive porcelain market and helped us establish ourselves as
manufacturers of truly world-class tableware
Nastassja:24K Gold design Bridal: A realplatinum design

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Training experiences
Job: Installing new preheater
Purpose: Increase temperature of the mold dryer room
 Angle grinder
 Welding plant
 Spark ignition plugs
 Solenoid gas valve
 Thermal couple
 Blower fan
 3mm mild steel plate
 Sager Bricks
 MS Welding rods (SWG 10)
 4 ½ cutting and grinding disks
Procedure:
 2’x1’x3mm, 4 plate and 1’x1’x1mm, 1 plate were cut by angle grinder.
 12.7cm circle was cut out from the center of 1’x1’x1mm front plate and Ø10mm 6 holes were drilled
to mount the burner.
 All plates are welded by arc welding.
 Inside of the burner housing was bestrewed from sager bricks.
 Burner unit was fixed to the housing.
 Complete burner was installed in the drying room
 Power connections are supplied by the electrical department.
My involvement:
 Burner housing drawing was sketched in solid works.
 Engaged with burner housing machining.
 Engaged with testing.
Figure 8- Burner unit Figure 7- Installing the dryer room wall

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Job: Extending sponging conveyor
Purpose: wipe the excess sprayed glaze in the bottom side of the plates
 Angle grinder
 Welding plant
 Hammers
 Screw drives
 Hand drill
 Sponging belt
 Arc Welding rods
 Anticorrosive paint
Procedure:
 Existing conveyor was cut in mid plane
 C channel was butt by welding according to the required length
 Insert new sponging belt and assembling parts
 Holes were drilled to add new rollers
My involvement:
 Suitable c channel was found
 Ideas were given to technicians
Figure 9- Sponging Conveyor extending process

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Job: Designed shaft bush
Purpose: Automatic flat ware manufacturing machine has two PVC synthetic conveyor belt for exit the
rejected items. These two conveyors are run with 3 phase two separate motors aligned with two rollers. In the
previous installment the rollers were directly coupled to the rotor shaft. When the shaft or key get damage or
misalignment the whole rotor shaft should be removed and repaired. It is difficult to disassembled and repair
with such a coupling. Therefore, a suitable coupling shaft with one end solid shaft and other end hollow shaft
was designed to avoid above difficulties.
 Lathe
 Bench drill
 6mm tap set
 30mm MS shaft
 6M Allen bolts
Procedure:
 The part was machined in lathe machine
 One end was coupled to the motor and other end was couple to the roller.
My involvement:
 Measurements was taken
Job: Installing burner to R.H. KILN (Decoration)
Purpose: increase the temperature of the kiln
Figure 12- Broken old bush Figure 11- Running
conveyor with
misalignment
Figure 10- Designing
and making new bush
Figure 13- Running
smoothly with
correct alignment

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 ½ G.I pipe
 Electric gas burner
 Electrical spark ignition unit
Procedure:
 Existing burner was removed.
 New burner was mount to the existing chamber.
 New gas line and electrical connection were installed.
My involvement:
 Supported to installed burner.
 Temperature increasement was observed.
Job: Fabrication of R.H. Kiln transfer rollers.
Purpose: replacing the existing transfer rollers’ bearings and sprockets
 Lathe
 Bench Drill
 4mm Allen key
 Ø30 mm Aluminum bar
 Ø20 mm S/S shaft
 Grubs screw
 50mm x 50mm L-Iron
 Chain sprockets (B type)
Procedure:
 Dimensions were taken from the existing roller.
 S/S shaft and aluminum bushes were machined.
 Aluminum bushes were drilled and tapped.
 Aluminum buses were inserted to S/S shaft and fixed with grab screws.
 Chain sprocket and Kiln bed mounting two L-iron were fixed.
Figure 15- Decoration kiln Figure 14- Installing gas line Figure 16- Checking burner

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My involvement:
 Dimensions were taken.
 Helped to technician.
 Aluminum bushes were Drilled and tapped.
Job: Making NBC kiln door hinge parts
Purpose: Change the door opening side to get extra space
 Lathe machine
 Angle grinder
 Ø65mm MS shaft
 275mm x 150mm x40mm MS plates
 150mm x 60mm MS plate
 150mm x 150mm x 2750mm,5mm G.I box bar
Procedure:
 All parts are machined according to the drawing which were sent by KTS Company.
Figure 18- R.H.Kiln (white
ware) Transferring Rollers
Figure 17- New fabricated roller
Figure 20- NBC kiln door opening side Figure 19-Machined Door Hinge Parts

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My involvement:
 Door hinge and material details were measured and taken.
 Machining difficulties and other matters were discussed with lathe man and engineering consult.
 Engaged with part machining in lathe machine
Job: Replacing the valve of pressure casting machine
Purpose: use alternative valve instead of existing valve
 Spanner
 Wrenches
 ¾ pneumatically operated water valve
 8mm Pneumatic horse and connectors,5mm G.I box bar
Procedure:
 Fault was identified by checking the valves at the pressure casting machine.
 The identified valve was checked whether could be repaired or available in the store.
 In case of out of stores, alternative valve was found.
Necessary adjustments were done to mount and fix that valve
Figure 21- Damaged OMAL VIP Valve
Figure 22- Replaced water valve

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My involvement:
 Fault identification was done
 Suitable alternative valve was selected from the store.
 Necessary adjustment was done to mount alternative water valve to the machine.
Process with new valve was checked.
Job: Making SAMA PCM Cylinder Mounting Brackets
Purpose: Replace new pneumatic cylinder to the machine.
 lathe machine
 bench drill
 welding plant
 MS welding rods
 Ø 65mm MS shaft
 6mm Allen bolts
 35mm x 35mm x 3mm L-iron
Procedure:
 Fault was identified.
 Remove the exiting pneumatic cylinder.
 Suitable cylinder was found on stores.
 Suitable mount for the new cylinder was machined according to the previous mounting.
 New cylinder was installed to the machine.
My involvement:
 Fault identification was done.
 New mount was designed.
 Front mounting bracket was made.
Figure 24- Damage pneumatic
Cylinder & New Cylinder Figure 23- After mounting new cylinder
by making new mounting bracket

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 Helped to fix new cylinder to the machine
Job: service jiggering machine
Purpose: To replace spare parts and service the machine.
 Wrenches and conventional workshop tools
 Bearing inserting tools
 Angle grinder
 Bench drill
 Bearings
 V belt
 Inserting rings
 Chain sprockets
 Chain
Procedure:
 Machine were un mounted from the production area and brought into the workshop.
 All the parts (could be dismantle) were dismantle.
 Serviced and replaced the bearings and other worn parts.
 New function (automatic scraping tool) was added.
 Machine was reinstalled at same area.
My involvement:
 Helped to service the machine.
 Bearing and other worn-out list was taken.
 Automatic scraping blade was designed.
Figure 26- Fixing automatic Scraping tool Figure 25-Making production

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M G / 1 5 / 1 0 2 6 2 P a g e 28 | 43
Projects
Projects: Installing water spray unit to cup unloading section.
Purpose: reduce the labor cost
 Photoelectric proximity sensors.
 2bar 2way spring return Solenoid valve.
 Atomizing water spray nozzle
 220A/C baker, timer, relay, and step down Transformer.
 Capacitors
 8mm pneumatic horses and connectors
 Pneumatic regulators
 Green ware cup items
 8mm SS rod
 3mm flat iron
 30mm MS rod
 8mm Bolt
Work carried under the project:
 The electrically controlled unit with all Components were fixed by the electrical Department.
 All the components of the system were fixed by the mechanical department
My Involvement:
 Helped to assemble the water spray unit and other mechanical parts in cup unloading conveyor No 1.
 All the components of water spray were fixed on cup unloading conveyor No.2.
 New process was checked.
Figure 27- Electrical parts of Water spray unit Figure 28- After installing Production Line

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 29 | 43
Projects: : Designing roller skids
Purpose: Move kiln
 Angle grinder
 Lathe machine
 Hammer
 Bearing fitting tools
 Welding plant
 150x65mm C channel
 Ø 25mm MS shaft
 1’’ hollow shaft
 6205 ZZ Barings.
 2” G.I. pipe
 MS Welding rods (SWG 10)
 Suitable materials can be found in work shop (C Chanel, used Bearing, G.I. Pipes and other shafts)
 The parts were machined, fixed and welded
My Involvement:
 Roller skid were designed.
 Materials, sizes and bearings were selected.
 Engaged with the machining process.
Figure 29- Roller skid drawing
Figure 30- Fabricated roller Skids

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 30 | 43
Projects: NBC kiln Replacement
Purpose: Install The Kiln In New Area.
 Conventional tool set
 Hydraulic car jack
 Folk lift
 Boom truck
 Law bed truck
 Scaffoldings
 Ivory items
 Gas
 Welding rods
 Remove electrical supply and gas line connection. This kiln is fastened by nut and bolt as two main
parts. Hinge scaffolding avoid damaging the structure of kiln.
 Pull and push the kiln with supporting roller skids
 Lift the kiln by boom truck and place on low bed truck
 Shift the kiln to new area
 Installing on new floor & Joining two parts
 Installing Duct lines
 Inserting cars and fixing damaged heat Resistant wall
 Checking burners
 Checking sample items
Figure 34- Structure of
the kiln
Figure 33- kiln placing
on roller skids.
Figure 32- Kiln Placing
on law bed truck
Figure 31- Unloading
from law bed truck

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 31 | 43
My Involvement:
 Two KTS (Italian) Engineers were coordinated with Porcelain Technicians
 Machines, tools and any other required equipment were coordinated with technicians.
Projects: Designing automatic sucker for cup unloading
Purpose: Reduce the labor cost
 1/2 vacuum valve
 Compressed air gun
 8mm pneumatic horse and connectors
 Pneumatic regulator
 Porcelain Green ware cups
 Suitable sucker systems for the porcelain items were studied.
Figure 36- Shift kiln in
to new area
Figure 37- Joining two
parts
Figure 35- Installing
duct line
Figure 38- Inserting cars
and fixing damaged heat
Resistant wall
Figure 40- Checking burners Figure 39- Checking Samples

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 32 | 43
My Involvement:
 Pneumatic sucker systems were studied and designed.
 Sucker gun was fixed at the cup unloading section for the testing.
Figure 42- Conventional sucker and newly
designed vacuum gun
Figure 41- Testing vacuum gun

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 33 | 43
Discussion
I could study lots of conventional mechanics in porcelain manufacturing machines which had been
installed at 80’s and 90’ decade. Other than engineering field, waste water and drinking water treatment
plants maintenance, Gas plant maintenance, fire hydrants, compressor room maintenance, porcelain
production process including laboratory testing, kiln operations (maintenance, oxidation and reduction
cycles) were studied.
There were so many fields to learn, lack of knowledgeable persons those subjects, technology and
machines are going to uneconomical state. There are so many wastages in all the departments,
authorities are always trying to find the solutions for the large matters. As an example, with outing
responsible person for the compressor room maintenance, BOGE genuine screw compressors running
in poor maintaining conditions. It’s a plain fact that finding solutions for grass root level mistakes
conduce to solve many areas as we don’t think. The safety policy of the company was very poor at that
moment.
Considering interpersonal relationships in the people most people are selfish, they are try to felt their
belt by downtroddening people. Not all people, most people are very good, but others tarnish the good
image of the company. The most effective thought working in the people mind is working only for
given salary. Every time This thought cross the development of the company.
As a matter of fact, during my training period I console with top management level people to labor. I
worked with them very friendly and completed all the tasks that given me without distinguishing
difficulties and hardships which found.
Especially interpersonal relationship was a strong pathway for my life.

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 34 | 43
L.P.G.Engineering Service (Pvt) Ltd.
Duration: From 04/12/2018 to 28/02/2019

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 35 | 43
Declaration
gain as an apprentice during my General Industrial Training at L.P.G Engineering Services (Pvt) Ltd.
There is no any copy writing except references.
………………………………….
K.B.S.M.Fernando
(MG/15/10262)
Certified by
……………………....................

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 36 | 43
Introduction
LPG Engineering was established in 14 Feb 1946; and has now grown to become one of Sri Lanka's
largest heavy fabrication, multi-disciplined engineering and trading group of companies. Having a
work force of over 200 dynamic individuals we offer complete industrial engineering services &
solutions. The company is privately owned and we are proud of our background which grew steadily
in a dispute free atmosphere.
Located in the heart of Kaduwela, its large, modern highly facilitated office is situated on three hectares
of land. The weather-proof workshop covers over 10, 000 square meters and it is fully furbished and
serviced to accommodate all engineering equipment.
well-equipped precision machining facility provides highly skilled machining capabilities and includes
some of the most up-to-date equipment and processes available. This facility has developed machining
techniques to provide unique services to specific industries.
Industry Sector Experience
 Pulp and Paper
 Chemical
 Transport
 Mining and Mineral
 Energy Food & Beverage
 Defense
 Hydro Power
 Textile

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 37 | 43
Training Experience
Job: Designing a biscuit crusher.
Purpose: chocolate biscuits crush to the small pieces.
 Solid Works 2016
Procedure:
 Ideas and requirement details were taken
 Simple design was sketch
 Material cost was calculated
 Quotation and drawing were sent to the customer
My involvement:
 Assemble drawing was model in solid works 2016 according to the given details of the sketch drawn
by the engineer.
Figure 43- Biscuit Crusher AssemblySW drawing

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 38 | 43
Job: Modeling Rubber mold
Purpose: Making MS rubber mold
Procedure:
 Sketch the given picture
 Dimensions was taken from the given sample design
 Draw the model in solid works
My involvement:
 Complete model was done.
Job: Modeling SS handling lock
Purpose: To get the drawing of the part
 Sample part
Figure 45- Given sample design Figure 44- Solid Works
Model

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 39 | 43
Procedure:
 Dimensions was taken from the given sample part
 Draw the model in solid works
 Drawing was sent to customer.
My involvement:
 Complete model was done.
Figure 46-3D model in solid works

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 40 | 43
Discussion
I had an opportunity to work here as an engineer with responsible person and could get the sound
knowledge of fabrication of sheet metal works and material handling.
The other areas regarding engineering field such as rubber beading manufacturing, hydraulic horse
clamping and repairing, excavators and other heavy machinery items fabricating and repairing and
automobile servicing.
The hardest task, which I found in my training period was fabricating Rubber Toy mold in CNC
machine. Because this was the first time, that 3D milling Job did here. CNC machine of Mold section
is
not a new one. Therefore, 3D milling operation large programs were unable to run smoothly. Machine
ran with striking. However, the mold was machined without any issue by the effort of Mr.Shanaka and
CNC operator.
During my training period, I had opportunities to go outside companies like Fonterra, CBL, and
Elephant house soft drinks…etc, to visit the job and collecting documentary details. On the other hand,
the safety policy of the Fonterra Company is at no 01. Without following safety policy of the company,
any one can’t enter the premises. In case of safety precautions, L.P.G Engineering service (pvt) LTD
Company also has to make safety policy and safety equipment.

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 41 | 43
Conclusion
This 12 month GIT training were given me a great privilege to improve the ability and knowledge to
corporate with all the levels of people at the industry together to achieve the objectives. Though the
theoretical knowledge is important it alone is not going to make one a successful engineer. Practical
knowledge is also very important. Besides practical and theoretical knowledge, cultivation of qualities
of Kind hearted person as well as to be performing teamwork and to be able to get well with others is
also equally important.
According to my experience gained in the training period I can guarantee that these three places have
a good ability and intension to provide a useful industrial training in mechanical field of study. In fact,
Dankotuwa porcelain training was a best training experience in my life. Another important skill that
engineers should have is communication skill. To meet the objectives of the project effective
communication is very essential. I could enhance my communication skills during the training period
and that will help me in the future.
Training under experienced professionally qualified engineers, I got an opportunity to experience the
ways of quick response taken for the matters arisen. And we could get ideas from them at any time
when we were in difficult situations.
Finally, I realized that there are no limitations to the learning process of engineers as it is a fast
expanding field. In fact, better the knowledge experience we possess the greater the possibility of
selecting the optimum selection from among many options available. I would like to say that training
has a vital role to play in upgrading the quality engineers to in meeting potential

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 42 | 43
Annexes
NBC kilndoorassemblydrawing

GIT
M G / 1 5 / 1 0 2 6 2 P a g e 43 | 43
NBC KilnDoorParts Drawing

Institute of Engineering Technology, Katunayaka, Sri Lanka

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