Practical Training Report at National Cable and Wire Manufacturing Company (CABLECO)

Submitted to the Mechatronics Engineering Department The Hashemite University In partial fulfillment Of the requirements for the degree of Bachelor in Mechatronics Engineering

By Ismail Yousef Jalboush 832841 Semester Year 2011-2012

EXECUTIVE SUMMARY

Through my training schedule on CABLECO company I've to visit all the departments and practice some of their jobs, in first day I was taken to a tour to company machines and departments and have learned some of safety procedures and dangerous situation and places, first I trained on Quality control department for one week where I look at their work and tried the testing machines which some used for raw materials and some for in process testing and I understood the testing procedure through various manufacturing processes, then I moved to maintenance department and work with them for four weeks where I learned the types of maintenance, and went to field with maintenance technician to perform the preventive maintenance daily and worked with technician when a break down occurs, in spite of that the mechanical and electrical maintenance sections are grouped together I've scheduled myself to work two weeks with electrical technicians and two weeks with mechanical technicians, finally I moved to work in production department for three weeks where I learned how production order is made and how production program is made depending on production order and how production engineers are responsible of observing the production procedure and solve problems occurs like machine break down and tell maintenance engineers about it and to deal with the operators mistakes in production and I have a look at all production machines such as rod break down, stranding , insulation and coiling & rewinding machines also I have learned many things about cables types and its applications.

TABLE OF CONTENTS
EXECUTIVE SUMMARY .............................................................................................................. i TABLE OF CONTENTS................................................................................................................. ii LIST OF FIGURES ........................................................................................................................ iii Chapter 1 Introduction ..................................................................................................................... 1 1.1 General nature of the training ............................................................................................... 1 1.2 Training schedule.................................................................................................................. 1 1.3 Background information ....................................................................................................... 1 1.3.1 Company profile : ......................................................................................................... 1 1.4 A brief outline of the report .................................................................................................. 2 Chapter 2 Company Profile ............................................................................................................. 3 2.1 Production Department ......................................................................................................... 3 2.1.1 Drawing Section ........................................................................................................... 4 2.1.2 Stranding Section.......................................................................................................... 5 2.1.3 Insulation Section ......................................................................................................... 9 2.1.4 Coiling and rewinding section: ................................................................................... 10 2.2 Quality Control Department ............................................................................................... 11 2.3 Maintenance Department .................................................................................................... 18 2.3.1 Types of Maintenance: ............................................................................................... 18 2.3.2 Main maintenance department: .................................................................................. 18 Chapter 3 Technical Discussion..................................................................................................... 20 3.1 Problems Encountered and Solutions ................................................................................. 20 3.1.1 Q.C Problems: ............................................................................................................ 20 3.1.2 Electrical Maintenance problems: .............................................................................. 20 3.1.3 Mechanical Maintenance problems: ........................................................................... 24 3.1.4 New installations: ....................................................................................................... 25 3.2 Other Information ............................................................................................................... 26 Chapter 4 Conclusions ................................................................................................................... 29 4.1 Benefits of Training ............................................................................................................ 29 REFERENCES .............................................................................................................................. 30

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LIST OF FIGURES
FIGURE1.1:CABLECOLOGO ................................................................................................................................. . 1 FIGURE2.1:CABLEPRODUCTIONSTAGES................................................................................................................ 3 FIGURE2.2:RODBREAKDOWNMACHINE.............................................................................................................. 4 FIGURE2.3:DOUBLETWISTSRANDINGMACHINE..................................................................................................... 6 FIGURE2.4:BOWSTRANDINGMACHINE................................................................................................................. 7 FIGURE2.5:CAGESTRANDINGMACHINEPARTS....................................................................................................... 8 FIGURE2.6:ARMORINGMACHINE......................................................................................................................... 9 FIGURE2.7:INSULATIONMACHINE...................................................................................................................... 0 1 FIGURE2.8:MICROMETER.................................................................................................................................. 1 1 FIGURE2.9:BENDINGTESTINSTRUMENT.............................................................................................................. 1 1 FIGURE2.10:TORSIONTESTINSTRUMENT............................................................................................................. 2 1 FIGURE2.11:TENSILETESTINSTRUMENTFORMETALS............................................................................................ 2 1 FIGURE2.12:OVENANDWATERPATH,FIGURE2.13:DIGITALTHERMOCOUPLE.............................................. 3 1 FIGURE2.14:TENSILETESTINSTRUMENTFORINSULATIONMATERIALS....................................................................... 3 1 FIGURE2.15:NANOOHMMETER ......................................................................................................................... 5 . 1 FIGURE2.16:MICROSCOPE................................................................................................................................ 5 1 FIGURE2.17:HIGHPOTTESTCONTROLUNIT........................................................................................................ 6 1 FIGURE2.18:INSULATIONRESISTANCEMEASURINGINSTRUMENT.............................................................................. 6 1 FIGURE2.19:INSULATIONRESISTANCETESTPROCEDURE ......................................................................................... 7 . 1 FIGURE2.20:DIAMETERTESTER.......................................................................................................................... 9 1 FIGURE2.21:SPARKTESTERCHAINS,FIGURE2.22:SPARKTESTER................................................... 9 1 FIGURE3.1:EMERSONOPTIONALMODULES,FIGURE3.2:EMERSONUNIDRIVESP........................................ 1 2 FIGURE3.3:SEIMENSMICROMASTER4VARIABLESPEEDDRIVE................................................................................ 1 2 FIGURE3.4:TROUBLESHOOTINGWITHSDPFORMICROMASTER4............................................................................. 2 2 FIGURE3.5:MICROMASTER4FROMINSIDE........................................................................................................... 2 2 FIGURE3.6:EXTRODUREHEADFIGURE3.7:THERMOCOUPLESENSOR................................................... 3 2 FIGURE3.8:ADAMTHERMOCOUPLEINPUTMODULE4018..................................................................................... 3 2 FIGURE3.9:SEIMENSU315FIELDPOWERSUPPLY............................................................................................... 4 2 FIGURE3.10:THREEPHASECIRCUITBREAKER........................................................................................................ 5 2

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Chapter 1 Introduction
1.1 General nature of the training
During my training, I worked in the three major departments in the factory, which are Q.C department, Production department and maintenance department. In Q.C department, I worked on testing instruments and check the product in every production stage. In maintenance department, I worked with technicians in the preventive maintenance and work with them to solve the problems when a break down occurs either it is mechanical or electrical problem. In the production department, I worked with operators on production machines to know how it work, also I worked with production engineers through the observation of production stages.

1.2 Training schedule 1.3 Background information

1.3.1 Company profile :
The National Cable and Wire

Manufacturing company (CABLECO) is a shareholding company was established in 1983 in Jordan, for production of electrical wires (Armoured & not armoured).the factory is

located at Zarqa city, and equipped with series of production lines designed to produce wires and cables of copper and aluminum conductors insulated/sheathed by (ordinary PVC or special kind of PVC) or (XLPE) or (P.E) or (Synthesis
Figure 1.1 : Cableco Logo

Rubber EPR) or (XLLSHF,LSHF Halogen Free) according to international, British,

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German standards (IEC, BS, VDE) to comply with Jordanian and International markets. The factory is also equipped with series of (Testing and Measuring) equipments calibrated according international standard/Traceability to monitor and control the quality of company production, starting from raw material, going through various production/manufacturing stages and up to delivery stages/finished products. The objective of the company is to produce high quality cables to satisfy the customer requirements therefore, it has achieved registration to ISO 9002/1994 in year 1996 and ISO 9001/2000 in year 2003. Figure 1.1 shows the company logo.

1.4 A brief outline of the report

In this report, I have illustrated some of the issues I've faced and worked in, also I explained the main departments and some of its jobs and tools. In chapter 2, first I explained the production department which considered the factory itself and I explained some of the machines used on factory and what are the things the production engineers are responsible of, then I illustrated the jobs of Q.C department and some of the instruments used on this department, finally I explained some of the information about maintenances department and its jobs. In chapter 3 I've explained with a bit of details about some of the problems encountered during my training and how we solved them with technical point of view. Finally, in chapter 4 I illustrated some of the benefits of my training.

Chapter 2 Company Profile

This chapter talks about the company departments and sections with a little detail about each department and its jobs.

2.1 Production Department

This department is the most important part in the factory and without it there is no factory so we can call it the factory itself, this department is responsible of taking customer request , making the production program for making the specific request and the observation of production procedure and solve production problems. The cable production which is the main product on this company can be summarized as in figure 2.1.

Figure 2.1 : Cable Production Stages

2.1.1 Drawing Section

Drawing: it is a manufacturing process of reducing the diameter of rod by pulling it through dies and that results in an elongation of the rod. The raw materials of rod are copper (8 mm in dia) and AL (9.5 mm in dia). There is three types of drawing machines depending on the diameter of output wire that is Rod break down, intermediate drawing and fine drawing. General Parts of Drawing Machines: 1- Pay off : input part where rod enter machine and there is rollers to make it enter straightly. 2-Drawing room : it is the place where the drawing process occurs where there is a series of dies and there is a capstans that is used to hold the wire and make the tension required for drawing, and it is used because when we decrease diameter length increases so it used to take the increasing on length, also there is lubricant oil and water to cool the dies and capstans 3-Annealer: since when rod is drawn it becomes harder so we used DC current to make it as soft it was before drawing, and we used water steam to prevent oxidization of wire when it is in annealer room, note that there is no annealer on aluminum break down because it doesnt become hard when it is drawn. 4-Dryer: used to dry wire after annealing. 5- Dancer: it is used to provide a balance between the speed of Pay off and Take Up. 6-Traverse : it is used to distribute the wire on take up spool. 7- Take Up Figure 2.2 shows general parts of rod break down machine.

Figure 2.2 : Rod Break Down Machine

2.1.2 Stranding Section

There are four operations in this section : 1. Stranding :it is twist operation about central wire 2. Bunching :it is twist operation for thin wire 3. Laying up : it is an operation for twisting of insulated wire 4. Twisting : it is a stranding about central wire for insulated wires 5. Assembly: it is a twisting without a geometrical ordering 6. Steel wire Armouring (SWA),Aluminum Wire Armouring (AWA),Steel Tape Armouring (STA) : it is an operation of armouring an insulated conductors. Due to this variety of operations there is four types of machines on this section: 1. Double Twist machines: those machines make a twist operation two times to provide the specific strand. All the machines make stranding, bunching, assembling operations but for small sizes. General parts of DT'S Machines are: Pay off , Dancer : to make balance between take up and pay off, Eyelets : to provide a place where we can put input wires in specific order, die : to make the strand and make it coherent, cradle : a place where we put the drum, bow : an ellipse shaped piece where we enter wires and it rotates to make the second twist, capstan, variable speed gear box : it control the length of the strand, traverse , take up. Figure 2.3 shows on of DT machines.

Figure 2.3 : Double Twist Sranding Machine

2. Bow Stranding machines : This machine perform stranding operation where it consists of several bows in series and the last bow contain the central wire. This machines used for larger diameter conductor than DT machines. Stranding operation occur on pay off on bow machine. General parts of bow stranding machines: Pay off, bows: several bows to make stranding operation, cradles, eyelets, die, rollers : to make shaped conductor, capstans, gears, traverse, take up. Figure 2.4 Shows one of Bow stranding machines

Figure 2.4 : Bow Stranding Machine

3. Cage Stranding machines : This machine makes stranding operation for large diameter conductor. It consists of many cages and every cage has many payoff's and all the cages spin to make the strand. General parts of cage stranding machines: Cages , die, capstans, gearbox, traverse, take up. Figure 2.5 shows one of cage machines parts.

Figure 2.5 : Cage Stranding Machine Parts

4. Armoring Machines: This machine is used to make a stranded amouring about cables from steel or aluminum to provide a protection for it. Due to the cable diameter is very large all the take ,cater pillar , pay off is spinning to make stranding operation. General parts of armouring machines: Pay off, armouring eyelet , armoring die, steel tape machine : it is used to make a steel tape layer above armouring so that the sheathing layer will not stick with cable, cater pillar : it is used to make a tension to pull cable to the take up, traverse , take up. Figure 2.6 shows general parts of armouring machines

Figure 2.6 : Armoring Machine

2.1.3 Insulation Section

The machines in this section is used make a cover to the conductor or cables (Armoured or not Armoured) through various types of insulation which is Insulation, beading , sheathing. General parts of insulation machines: Pay-off, Dancer, extruder (which includes hopper (insulation materials tank), heaters to melt insulation material and screw to move insulation material to the head) +extruder head, die and tip (wire guide), printing rolls, diameter tester: to test the diameter of insulated wire, cooling paths, dryer, spark tester: to test the insulation of the wire, counter, dancer, traverse, take up. Figure 2.7 shows one of the insulation machine used.

Figure 2.7 : Insulation Machine

2.1.4 Coiling and rewinding section:

The machines on this section are used to pack ready coils in small packages for sale.

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2.2 Quality Control Department

Quality control department is a very important part for every company, it is responsible of testing the products in every stages to provide the costumer with a well controlled product as he requests it. Another important thing that this company main manufactured material is copper and it is not a cheap one so we concern not increase the amount of copper more than necessary it is even controlled up to 0.01 mm. There is three types of testing depending on manufacturing stage as follow: Raw Materials Testing: Tests for metallic material (AL ,COPPER,STEEL) Diameter: we used micrometer to check it, figure 2.8 shows micrometer used.

Figure 2.8 : Micrometer

Bending Test: it is used to count how much bends material can sustain before fracture.

Figure 2.9 shows instrument used.

Figure 2.9 : Bending Test Instrument

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Torsion Test: it is used to how many torsions material can sustain before fracture.

Figure 2.10 shows instrument used.

Figure 2.10 : Torsion Test Instrument

Tensile Test: it is used to know how much material can elongate before fracture.

Figure 2.11 shows instrument used.

Figure 2.11 : Tensile Test Instrument for Metals

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Aging Test: in this tests the material is put in special ovens and hot water path for several days and see how much it sustain before defected. Figure 2.12 shows ovens used and figure 2.13 shows the digital thermocouple used to sense the temperature of water on water path.

Figure 2.12 : Oven and Water Path

Figure 2.13 : Digital Thermocouple

Tests for raw insulation materials (PVC, XLPE, PE, EPR (ethyl propel rubber), Low Smoke Zero Halogen): Tensile Test : it is used to test a specimen called dum-bell from made from some material and shows how much it can elongate before fracture, figure 2.14 shows instrument used.

Figure 2.14 : Tensile Test Instrument for Insulation Materials

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In process testing : Wire drawing Wire drawing (O.H) tests: 1. resistance 2. breaking load 3. diameter_ovality 4. surface 5. wire material 6. other properties Wire drawing (annealed) tests: 1.resistance 2.diameter 3.elongation 4.wire material 5.other properties Stranding conductor Conductor stranding (O.H) tests: 1.resistance_no of wires 2.breaking load of each wire 3.diameter of each wire_ovality 4.diameter of conductor 5.lay length and stranding direction 6.conductor material Conductor stranding (annealed) tests: 1.resistance_No of wire*diameter 2.diameter of conductor 3.elongation of each wire 14

4.lay length and stranding direction 5.conductor material Laying up of cores 1.Non compressed core 2.diameter of each core 3.color sequence, cores No and dummy 4.conductor resistance 5.conductor material 6.lay length an direction 7.insulation material. cure Insulation & sheathing 1.avarege (insulation, sheathing) thickness 2.minimum(insulation,sheathing) thickness 3.over all diameter_ovality 4.conductor resistance 5.conductor material 6.adhesion 7.insulation,sheathing material,curing 8.printing 9.appearence 10.other properties

Resistance Test: this test is a very important one , and it tests the resistance of the conductor because this is what costumer strictly request , because resistance is what determine how much conductor can sustain current.

Figure 2.15 shows the Nano-Ohmmeter used to test resistance.

Figure 2.15 : NanoOhmmeter

Diameter: we used a special microscope to test diameter for very thin wires beside to micrometer. Figure 2.16 shows microscope used,

Figure 2.16 : Microscope

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Finished Products Tests : High Voltage or High Pot Test: in this test the finished product is applied to a high voltage and high current to test its insulation and sustainability. Figure 2.17 shows control unit used in this test.

Figure 2.17 : High Pot Test Control Unit

Insulation Resistance test: we used a special instrument to tests the insulation resistance for finished products.

Figure 2.18 shows the instrument used.

Figure 2.18 :Insulation Resistance Measuring Instrument

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Figure 2.19 shows the procedure of insulation resistance test.

Figure 2.19 : Insulation Resistance Test procedure

Notes : We concern about resistance because it effects current. We concern about insulation resistance because it effects voltage (if insulation can handle voltage and no drop occurs). High voltage test to find small defects. Insulation resistance test to find large defects.

Another mission for Q.C dept is to test in process tools such as SPARK TESTER, COUNTER, DIAMETER TEST, and if there is any wrong with it they request electrical maintenance engineers to fix and calibrate it.

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2.3 Maintenance Department

Maintenance department is a very important part on every factory because it is responsible to deal with all problems to keep production continuous because stopping the production means losses for company and so this department considered a continuous working one.

2.3.1 Types of Maintenance:

Preventive maintenance : it occurs every two months where we check the machine by its external or outside parts, such as checking motors brushes (DC motors) electrical connections for boards and hovering it from dust and this is electrical technicians mission and checking pulleys, pumps, pistons, and make some oiling and this is mechanical technicians mission. Emergency maintenance: when a problem occurs on a machine maintenance engineers and technician try to fix the problem as fast as possible and when they finished the problem and solution is written and save in specific files to keep record for future. Installation maintenance: when there is a new machine or line is required to be

installed it is the maintenance engineers and technician responsibilities to provide the machine with what necessary to make it work from configuration to electrical and mechanical connections and services. Service maintenance : it almost occurs every morning where mechanical and electrical technicians check factory services such as lights, emergency buzzers, water and air supplies , heaters and main water pumps

2.3.2 Main maintenance department:

It consists of electrical and mechanical maintenance sections consolidated to work together. A special job for electrical maintenance engineers is to calibrate in process checking instruments such as diameter checking instruments (see figure 2.20), counters (using specific laser tool) and spark tester (see figure2.21 & 2.22).

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Figure 2.20 : Diameter Tester

Figure 2.21: Spark Tester chains

Figure 2.22 : Spark Tester

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Chapter 3 Technical Discussion

3.1 Problems Encountered and Solutions
This section describes the problems encountered during training and how we solved them.

3.1.1 Q.C Problems:

An operator came with a wire specimen a after drawing operation to check its diameter and found it is not correct, so we went with the operator to the machine and calibrate the tension on machine to give the specific diameter and problem solved.

3.1.2 Electrical Maintenance problems:

1-Traverse motor not work on packing machine (DOMEKS 1) A-First we check the power supply connections on motor if it is well connected (not loose), and we found no problem. b-we check the drive unit pins/connections if it is well connected and found no problem. c-we check safety, sensors, control signal if it is applied to drive or not and we found no problem, then we check the reference voltage on drive if it is well calibrated or not (usually 0 V) and found no problem. d-we check drive parameters if it has good value or not and there was no problem on it. E-we check the drive modules if it work well and found that the encoder module is not work (we found that by replacing each module by another similar one)and we replace this module problem solved. See figures 3.1 & 3.2 below that illustrates the drive that was the problem on it (Emerson ac drive)

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Figure 3.1 : Emerson Optional Modules

Figure 3.2 : Emerson Unidrive SP

2-Emergency light was on at rewinding machine (RL6) The emergency light was on because one of four emergency circuits that are series has a problem on it, those circuits are pay off ready, take up ready, caterpillar ready, traverse ready. We solved this problem by checking every circuit, following it element by element on drawing and we found that one of the contactor on payoff unit was defected so we replaced it an problem solved 3-Traverse motor not working on rewinding machine (RL6) A-First we check the power supply and found no problem and none of the fuse is shorted. B-we then check control circuit and AC Drive unit (Seimens MicroMaster 4, see figure 3.3 ), and found that there is a problem on it because nothing is displayed on screen module (it is off),we start checking the inverter itself and its connection and we found nothing with connections, so we check the Status Display Panel on inverter to found what is problem and referring trouble shooting with SDP and on inverter manual (see figure 3.4 ) we found that the problem is on inverter itself, so we disconnected it from panel and opened it and found that two of three phase wires was cut as in figure 3.5 so we reconnected then return inverter to panel and connect it to motor and power and problem solved. 21
Figure 3.3: Seimens MicroMaster 4 Variable Speed Drive

Figure 3.4 : Troubleshooting with SDP for Micromaster 4

Figure 3.5 : Micromaster 4 From inside

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4-Tempreture reading on insulation machine (Pan 90) was not stable The temperature reading for extruder head (see figure 3.6 ) that is displayed on HMI was not stable ,so first we check the thermocouple sensor (K type) (see figure 3.7 ) that is connected to ADAM Thermocouple Input Module 4018 (see figure 3.8 ) and found that it's wires was defected so we replace the thermocouple and problem was solved. Thermocouple sensor

Figure 3.6 : Extrodure Head

Figure 3.7 : Thermocouple sensor

Figure 3.8 :ADAM Thermocouple Input Module 4018

5-Annealer motor on the Multi-wire drawing machine (MMH101) was not working. A-First we check Operator Panel and found errors F04 & F07. B-We check ladder Manuel that came with the machine and found that F04 means: Not Ready For Operation and found that F07 means : Field Monitoring error on 12G2

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C-we follow the field circuit of the motor on control panel (using drawing) and found that the unit that control the field on motor (SEIMENS U315, see figure 3.9 ) was defected, so we replaced it and problem solved.

Figure 3.9 : SEIMENS U315 Field Power Supply

6-Take up DC motors on Insulation machine (TR100) was not working. A-First we check main power supply (because the problem was on all take up) and we found no problem. B-Then we check control circuits from drawing by following each line and checking components one by one like enable ready, relays, contactors, timers, etc. c- We found a problem that one of ready enables relays was not activated and that means the enable signal on DC DRIVE (SEIMENS SIMOREG 6RA70) is not enabled. d-we check control signal line on drive (24 V DC) from main PLC and we found that the cable is loose so we fasten it and problem solved.

3.1.3 Mechanical Maintenance problems:

1- A noise on the capstans on insulation machine (TR100). A-First we check the belts on the capstans and found that one of it was cut so we replaced it with a new one. B-we checked the motor pulley and found that the screw is loose and fastened it. 24

C-we then checked motor internal bearing and found that it was defected so we replaced it and problem was solved.

3.1.4 New installations:

1-Installation of a new steel braiding machine: First we moved the unit to the place where it will be configured, then put it's part which are payoff, braiding unit ,take up on specific places where we separate them by a distance illustrated on manual and considering safe and comfortable for operator to work and lifting vehicle to move freely, then connecting them together as described on manual and that was mechanical technicians and engineers , after that it was electrical technicians and engineers to connect the power cables to the unit as described on manual and check all the necessary electrical connections , we used a three phase circuit breaker to connect the three main units on same power supply as described on figure 3.10 .

Figure 3.10 : Three Phase Circuit Breaker

Finally the machine needed some services to work such as air lines (for pneumatic cylinders) and that is the mechanical technicians responsibility to provide the machine with that. Now the machine is ready to operate (note that the internal electrical and mechanical connections and the driver and controller programming was ready from the manufacturing company). 25

3.2 Other Information

During my training, I have learned many different things, in this section I will illustrate some of them.

Checking testing tools to make sure of its calibration:

There is many tools and measuring instruments that is used to check instruments that is able to be calibrated continuously. Every instrument has a specific range of readings or a scaled measurement, and theoretically we could divide this range to many values: microvalue, minimum value, average value and maximum value. When we want to check instruments to make sure of its calibration we do the following procedure: 1. First we check that if the instrument can measure its micro value. 2. We make sure if the instrument can measure the minimum value as the accuracy limits that is determined by using the small measurement tool. 3. We make sure if the instrument can measure the average value as the accuracy limits that is determined by using the medium measurement tool. 4. We make sure if the instrument can measure the maximum value as the accuracy limits that is determined by using the large measurement tool. We calculate accuracy as follow:

Accuracy

instrument _ reading measurmenttool _ reading 100% measurmenttool _ reading

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 Standards electrical power cables colors :

If it is three phase wires it is symbols RST where R: red or brown, S: black and T: blue. If it is four wires then red, yellow, blue is the three phase wires and black is neutral. If it is two wires red and black then rd is phase , blk is netural. If it is two wires blue and brown then brn is phase , blu is neutral.

Checking electronics card when it is defected :

A- First we check the card by looking, searching for any defects because some parts can be noticed easily when it is defected such as : Capacitor: it becomes larger and thicker than usual when it is defected. Resistor : becomes burned ( has brown or black color) ,note that defected resistor is not common on electronic cards. Diode : it's pins black and it have bad smell.

B- Second we start checking using testing tools as DMM. First we check relays because it is easiest to discover defects, we check it by applying a control signal on its coil pin and checking if its contactors change position or not. Then we check IC ships (apply signal on input and check output, or apply open and short circuit test on a specific pins), note that most defects happens on those ships. Apply continuity, short , open circuit by following each signal line on card drawing and checking current, voltage levels if it is as desired or not.

To check bearing (rotary or linear) if it is defected and must be replaced, we rotate or move it and if there is a noise on it that means it is defected.
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 To check if the rotating body if it is balanced or not, we can check that by looking or by using a specific instrument on turning machine.

Finding gears ratio practically:

To find that we mark first gear step gear and final gear step then rotates first gear until the final gear rotates full rotation (if the gear box decrease speed), while counting the rotations number of the first gear then dividing each counting number by each other, note that if the gearbox increase speed we rotates final gear until it gives full rotation of first gear, and note when increasing speed torque decreases and vise versa.

Finding minimum number of heaters needed:

Some machines need heaters to convert water to steam as annealers on drawing machines, to find how much heaters does the machine needs to operate well, we check the machine o find how much steam it needs or we can get that from manufacturer then from specific equations that relates the consumed power and the output steam we could know how much heaters we need (not that every heaters comes with an information of how much power it consumed).

International standards used in Q.C department :

DIN : Deutsches Institut fr Normung eV (German Institute for Standardization). ASTM: American Society for Testing and Materials. BS: British Standards. IEC: International Electrotechnical Commission. VDE: Society of German Electrical Engineers.

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Chapter 4 Conclusions
In this chapter, I have talked about the benefits of my training and how it was valuable.

4.1 Benefits of Training

During my training I have learned so many new things that we didn't learn on university, and how to apply some of the principles we have learned in studying on real life, also I have learned how to think of a solutions about the problem I have faced and I got some experience about how to deal with workers and operators and how to communicate with them to do the specific jobs in a way that they could understand. Another benefit is that I got knowledge about industry and how to market products through brochures and exhibitions.

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REFERENCES
[1] Eng.Nabeel Al-Betawi "Head of Production Department" [2] Eng.Majed Mahmoud "Head of Maintenance Department" [3] Eng.Hamza Ali " Head of Q.C Department" [4] Web sites:

a) http://www.cableco.com.jo/ b) http://www.pan-pioneer.biz/ c) http://nirmalaenggworks.com/index.html d) http://www.sketvmb.de/eng/sket-company-image/

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