DIPLOMA KOMPENTENSI KIMPALAN

(MMW30353)WELDING METERIAL AND CONSUMABLE PROCUREMENT

ARRANGEMENT

SEMESTER 3 / JAN – JUN 2024

STUDENT NAME MUHAMMAD DANISH ISKANDAR BIN KHAIRUL ASRI

NAME OF SYED LUQMAN BIN SYED MUHAMMAD ARIF

LECTURER

IDENTITY CARD 041016-10-0171

NUMBER

MATRIX NUMBER 240995

ASSIGMENT TITLE "WELDING METARIAL AND CONSUMABLE REQUIREMENT

ACCORDING TO SPECIFICATION / PROCUREMENT
ARRANGEMENT ACTIVITIES AND PROCEDURE”
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NO TITLE PAGES

1 PENGAKUAN PELAJAR 3

2 OBJECTIVE 6

3 INTRODUCTION 7

4 PROJET PLAN ( HEAVY STEEL PRISON DOOR) 8

5 CONSUMABLE, HAND TOO, MACHINERY AND SAFETY 9-17

6 EQUIPMENT AND SPECIFICATION 18-25

7 MATERIAL USED IN THE PROJECT 26

8 CONSUMABLE 27-29

9 VENDOR THAT SUPPLIES MATERIAL 30

10 PURCHASE PROSEDURE 31-32

11 CONCLUSION 33

12 REFERENCE 34

CONTENT

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PENGAKUAN PELAJAR

I hereby acknowledge that this assignment is the result of my own coffin and is made
in accordance with the laws enshrined under the rules of the Institute of Skills.MARA
Beseri, Perlis. It's the original of me. This report has not been produced by any party
or institute for any diploma or any qualification.

With this that this report is the result of my work and the point of sweat say itself and
I believe that all my work that I have produced is not the same as any other student
and my sema hail search is based on reliable sources.

Student Name: MUHAMMAD DANISH ISKANDAR BIN KHAIRUL ASRI

Identity card number: 041016-10-0171

Couse: WELDING COMPETENCE DIPLOMA

Institute: INSTITUTE KEMAHIRAN MARA BESERI, PERLIS

Project title: "WELDING METARIAL AND CONSUMABLE REQUIREMENT

ACCORDING TO SPECIFICATION / PROCUREMENT ARRANGEMENT
ACTIVITIES AND PROCEDURE”

Date:

………………………………….

(TANDATANGAN PELAJAR)

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OBJECTIVE

In general, this study aims to learn and understand the form of documents and the
manufacture of heavy steel prison door. In particular, the purpose of this study is:

 Explain the list of consumables, hand equipment, machinery and welding

safety equipment
 Describes the requirement of the used of the equipment used in the project,
as well as its specification
 Clarify the list of metarials used in the project as well as its specification
 Identify suppliers for the purpose of supplying project materials
 Review the list of purchase procedure

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INTRODUCTION

Heavy steel prison doors are a critical component of security infrastructure within
correctional facilities, designed to provide robust containment and prevent
unauthorized access. These doors are specifically engineered with durability,
strength, and security in mind, aiming to withstand various challenges unique to
prison environments.

Heavy steel prison doors are constructed using high-quality, thick-gauge steel to
ensure maximum strength and resistance to forced entry. The materials used are
carefully selected to withstand wear and tear over time. The door frames are
reinforced to enhance overall structural integrity. This includes reinforced hinges and
mounting points, making it difficult for inmates to compromise the door's stability
through tampering or physical force. Advanced and highly secure locking
mechanisms are a hallmark of heavy steel prison doors. These may include heavy-
duty deadbolts, multiple-point locking systems, or electronic access control systems.
The goal is to provide a high level of control over access and egress. Given the
potential for violent incidents in prison settings, these doors are designed to resist
impact and physical attacks. The heavy steel construction helps prevent attempts at
forced entry using tools, blunt force, or other means. Some heavy steel prison doors
are equipped with fire-resistant features to comply with safety regulations. This is
essential for containing fire within specific areas of the facility and ensuring the
safety of inmates and staff. Many heavy steel prison doors include features for
communication between inmates and staff, such as small windows or intercom
systems. These elements allow for visual checks and communication without
compromising the door's security.

In conclusion, heavy steel prison doors are a crucial component in maintaining

security and control within correctional facilities. Their heavy-duty construction,
reinforced framework, advanced locking systems, and resistance to impact and fire
make them essential for the overall safety and security of both inmates and staff.

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1)PROJECT PLAN (HEAVY STEEL DOOR)

Length:70.7 inch

Width :28.3 inch

Weight : 1480 lb

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2)CONSUMABLES, HAND TOOL, MACHINERY AND SAFETY EQUIPMENT

2.1CONSUMABLE
No. Name Picture
1 ELECTRODE

2 WELDING WIRE

3 WELDING GAS

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No. Name Picture

8 GRINDER DISC

9 CUTTING DISC

8 PRIMER PAINT

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2.2) HAND EQUIPMENT

No. Name Picture
1 WRENCHES

2 PLIERS

3 SCREWDRIVERS

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No. Name Picture

4 CHIPPING
HAMMER

5 WATER LEVEL

6 CUP BRUSH

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No. Name Picture

7 MEASURING
TAPE RULES

8 TRY SQUARE

9 WIRE BRUSH

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2.3)MACHINE
No Name Picture
1 GRINDER

2 CNC PLASMA
CUTTER

3 AUTOMATIC
GAS CUTTING

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No Name Picture
4 AIR COMPRESSOR
MACHINE

5 METAL CUT-OFF
MACHINE

6 AIRLESS PAINT
SPRAYER

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No Name Picture

7 DRILL PRESS MACHINE

8 SHEARING MACHINE

9 SMAW MACHINE
WELDING

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2.4)SAFETY EQUIPMENT
No Name Picture
1 HEAD SHIELD

2 WELDING GLOVE

3 SAFETY JACKET

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No Name Picture
4 SAFETY BOOTS

5 SAFETY GLASSES

6 EAR PROTECTION

No. Name Description / Specification Picture

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1 GRINDER Bosch Angle Grinder GWS 060

Rated power input: 670 W
No-load speed: 12,000 rpm
Grinding spindle thread: M10
Disc diameter: 100 mm
Length: 263 mm
Width: 77 mm
Height: 95 mm
Weight: 1.5 kg (without cables and
accessories)

2 CNC Jasic Pro Cut 1000 CNC Plasma

PLASMA Cutting Table - 1.25M X 1.25M
CUTTER Table input voltage - 230V AC 50/60
Hz
Plasma cutter power source input
voltage - 230V AC (CUT 45), 400V AC
(CUT 61) or 400V AC (CUT 81)
Cutting area - 1.25M x 1.25M
Cutting speed - Up to 6000MM per
minte
Max weight on table bed - 160KG
Plasma torch - 6M TM125 with
positioning rack
Dimensions of table - 1.7M x 1.7M x
1.2M
3 AUTOMATI Model CG-30
C GAS Cutting Capacity 5 to 60 mm
CUTTING Bevels: 0o to 45o
Straight Cuts: 1.8 m and multiples
Circle Cutting (Diameter): 30 to 2400
mm
Cutting Speed: 180 to 800 mm/min
(50HZ)100 to1000 mm/min (60HZ)
Torch: Injector Type to suit Acetylene /
LPG
Gas Connection (Fuel LH & Oxygen
RH): 1/4" G,91/6o
Gross Weight: 10 kgs w/1 torch.
14.5kgs w/2 torches
Dimensions W/O rail (m):
350x140x175 w/1 torch 14.5kgs w/2
torches
Dimensions W/O rail (m): 350x140x175

3)EQUIPMENT AND SPECIFICATION

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3)EQUIPMENT AND SPECIFICATION

No. Name Description / Specification Picture

4 AIR Hp:10
COMPRESSO Kw:7.5
R MACHINE Displacement
(l/min/cfm):1538/54.3
R.p.m: 816
No. Of cyl: 3
Max pressure (kg/cm2/psi):10/142
Working pressure
(kg/cm2/psi):8/115
Tank capacity: 300/79
N.w:362 kg 796 lbs
Dimension (cm):191x76x121
5 METAL CUT- Rated input power:2,200 W
OFF MACHINE Cutting disc diameter:355 mm
Cutting disc bore:25.4 mm
No-load speed:3,800 rpm
Cutting capacity at rectangle 0º
:100 x 196 mm
Cutting capacity at square 0º
:119 x 119 mm
Cutting capacity at L-profile 0º
:130 x 130 mm
Weight:15 kg
Cutting capacity at
rectangle :45º mitre 107 x 115
mm
Cutting capacity at square 45º
mitre:110 x 110 mm
Cutting capacity at L-profile 45º
mitre:115 x 115 mm
Tool dimensions (width x length
x height):256 x 520 x 400 mm
6 AIRLESS Brand: aeropro
PAINT Model:470
SPRAYER Voltage/ frequency:220v / 50hz
Motor size:1.0 hp (840 w)
Flow rate:2.1 l/min
Standard nozzle size:517
Max nozzle size :621
(0.021”)
Max pressure:3300 psi (22.7
mpa)
Length of high pressure hose
:15 m
Spraying width:250 – 310 mm
Net weight:20 kg (44 lbs)

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No Name Description / Specification Picture

7 DRILL PRESS Voltage:230v - 50hz

MACHINE Power:350w
No load speed:580 - 2.650
rpm / min
Choke:13mm
Spindle speed settings:5
Spindle traval:50mm
Column diameter:46mm
Base size:291 x 183mm
Table size:160 x 160mm
Total height:59cm
Weight:19 kg
Warranty 1 year

8 SHEARING Cutting Capacity ( in MS )

MACHINE Length x Thickness:1250 x 2
Crank Shaft Dia:65
Fly Wheel Dia:550
Gear Dia:500
Depth of Throat:25
Height of Table:750
Power Required:2 H.P.

9 SMAW Input Voltage (V):Three phase

MACHINE 415V + 15%
WELDING Frequency (HZ): 50/60
Rated input capacity
(KVA):6.5
Rated input current(A):38.5
Output current(A):40-450
No-load Voltage (V) :72
Rated output voltage(V):35.6
Rated Duty Cycle (%):60
Power factor:0.93
Efficiency(%):≥85
Insulation grade: F
Housing protection
grade :IP21S
Electrode Size (mm):2.6/ 3.2/
4.0/ 5.0

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No Name Description / Specification Picture

10 HEAD MATERIAL: Thermoplastic

SHIELD DIMENSION (W x H): 11" x 12"
LENS DIMENSION (W X H):4" x
2"

11 WELDING Item type: Work Gloves

GLOVE Applicable: Work repair, Driving,
Welding, Oil & Gas Size: Free
Size, 10.5 inch length
Weight: 165g
Colour: Yellow and
Silver
Material: Leather and cotton

12 SAFETY Model Number: Work

JACKET wear
Usage: Utility & Safety
Material: Cotton
Item Type: Tops
Color: Orange
Size: S,M,L and XL

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No Name Description / Specification Picture

13 SAFETY Features: Insulated, puncture-
BOOTS proof, smash-proof, tear-
resistant, durable
Standard:CE
Fabric:EVA
Color:Black. Customizable
Size:Customizable
Reflective:Tape Customizable if
you need
Company Certificate ISO
9001 : 2015 / ISO 14001 : 2015
/ ISO 45001 : 2018/ CE
14 SAFETY Features
GLASSES ●It is a wide view sealed
specification easy to see left
and right.
●Optimum for liquid droplets,
dust, dioxin, asbestos.
Specification
●Lens Color:Clear
●SPQ(piece):10
●ANSI Standard
Product（Z87.1）
●Air-Tight Type
●Lens Thickness: 2.2mm
Materials
●Lens: Polycarbonate
●Frame: Soft Polyvinyl
Chloride（Soft PVC）
●Band:Cloth/Rubber Blend
15 EAR Ringing Telephone - 80dB
PROTECTION Loud Radio - 80dB
Busy Traffic - 80dB
Band Saws - 85dB
Power Lawn Mower - 90dB
Belt Sander - 93dB
Tractor - 96db
Electric Drill - 98dB
Bulldozer - 105dBBlasting -
110dB
Nail Gun - 110dB
Chainsaw - 120dB
Propeller Aircraft - 120db
Gun Shot - 130dB
Rivetting Hammers - 130dB let
Engine Aircraft - 140dB

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No. Name Description / Specification Picture

16 WRENCHES Size : 5/8, 19/32, 9/16, 1/2,
7/16, 3/8, 11/32, 5/16, 9/32,
1/4, 7/32, 3/16, 5/32, and 1/8

17 PLIERS Function as CUTTING,

CRIMPING AND STRIPPING

18 SCREWDRIVERS a hand tool for turning a

screw, consisting of a handle
attached to a long, narrow
shank, usually of metal,
which tapers and flattens out
to a tip that fits into the
slotted head of a screw.
Material stainless steel and
plastic

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No. Name Description / Specification Picture

19 MEASURING TAPE  different length
RULES alternatives for the
yellow steel strip
 rubber-like housing in
red and black
 automatic tape
rewind with stop
buffer
 detachable belt clip
30-50 mm printable area for
your advertising

20 TRY SQUARE This Kreator try square is

300 mm in length and made
of hardened steel. It can be
used for both 90° and 45°
angles.

21 WIRE BRUSH Trim length refers to the

length of the bristles or
filament extending from the
base.
Shapes/type : Acid Brush,
Belt Brush, Block / Pad, Cup
Brush, and etc.

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No. Name Description / Specification Picture

22 CHIPPING The chipping hammer head
HAMMER shall be clearly forged and
shall be well shaped.
The handles shall be welded
or forged.
The working edges of
hammer shall be hardened
and tempered.
The hardness of the working
edge shall be within the
range of 45.9
HRC to 55 HRC.

23 WATER LEVEL Brand: XD Collection

Material: Aluminium
Second material: Acrylonitril
Butadieen Styrene (ABS)
Net item weight (gr): 150
Gross weight item (gr):
168.2
P M S main colour: 430

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4.METERIAL USED IN THE PROJECT

No Name Description / Picture
Specification
1 HOLLOW Material: carbon steel
STEEL Size :1219.2mm x
152.4 mm x 6 mm

2 MILD STEEL Material : Carbon Steel

PLATE Size: 1830 X 6300mm
X 9mm

No. Name Description / Picture

Specification
1 ELECTRODE AWS E6013 Welding
Electrode
Product information: The

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normal sizes: 2.0*300mm,

2.5*300mm, 2.5*350mm,
3.2*350mm, 3.2*400mm,
4.0*400mm, 4.0*450mm,
5.0*400mm, 5.0*450mm.
Welding Electrode AWS
E6013 is a low carton steel
electrode with high
titanium-potassium type
coating, and suitable for
both AC and DC.

2 WELDING WIRE made of metal, typically

steel or aluminum, or they
can have a copper coating
and are spooled on a drum
or coil

3 WELDING GAS Weight: 60kg

Volume: 8400 liters
High Fund: 143cm
Weight: 20kg
Volume: 5000 liters
High Fund: 99cm

5.CONSUMABLES

No. Name Description / Picture

Specification

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4 GRINDER DISC Type: SA 60 TBF

Diameter: 7”
Bore Diameter: 22.23mm
Thickness: 6.0mm
Material to be cut: Metaal,
Stainless Steel
Max. Circumferential
speed:
80m/s

5 CUTTING DISC Material: Composite

corundum abrasive
Outer Diameter: 75mm
Bore diameter: 10mm
Thickness: 1.2mm
Color: Black

6 PRIMER PAINT Type: Primer

Color: Yellow

No Name Description / Picture

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Specification
7 CUP BRUSH Product TypeCup Type
Brush
Outer Diameter 75
Wire diameter 0.27
Mounting part Screw
Thread Diameter
M10(P1.5)

6. VENDOR THAT SUPPLIES MATERIALS

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NO NAME ADDRESS NO. TEL AREAS OF

EXPERTISE
1
Malaysia Steel Petaling Jaya, 29c, Jalan 03- 7781 1611 - MILD STEEL
Works Tandang 204a, Seksyen 51, PLATE
46050 Petaling Jaya,
(KL) Bhd -HOLLOW
Selangor, Malaysia
STEEL

2
CT HARDWARE NO.1, Jalan SS2/3, 47300 03- 7873 0000 - WELDING
SDN. BHD Petaling Jaya, Selangor, ACCESSORIES
Malaysia

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7. PURCHASE PROCEDURE

1)Sales Department Request

The first flow in the purchase process starts from the sales department or the
production department that submits a request for goods. Where this request can be
determined in 3 ways, namely:

• Intuitive; This method is carried out by predicting what items the client needs.

• Market Research; Conducted by researching the most consumer demand or by

constantly plunging into the general public.

• calculation of the stock of goods; The sales department will submit a request for
goods to the warehouse.

2) Create a purchase order for the supplier

A purchase order is also a contract that forms an agreement between the buyer and
the seller regarding the goods that the buyer wants to buy. Once the purchase order
has been placed and sent to the seller, the seller then decides whether to accept the
contract or not. If the purchase order is received, the seller has agreed to sell the
product and the quantity listed at the price set by the buyer.

3) Notification of Acceptance of Goods

A letter of acceptance of goods is a letter made by the buyer on the basis of a

reference to the purchase order or a letter of delivery received by the warehouse.
The letter of notification of goods is considered valid after the warehouse inspects
the goods and is compared with.

4) Purchase invoice

A purchase invoice is an invoice or invoice that a user or buyer receives from a

seller.

A purchase invoice is a term for a sales invoice for which the purchased goods or
services have been received. So, in other words, a purchase invoice is actually the
same as a sales invoice but just a different point of view. The specifics of the

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function of purchase invoices in accounting is to recognize debts from buyers to

suppliers.

5) Supplier Payment Letter

The supplier's payment letter is a letter used by the purchasing department to make
a special receipt signed by the supplier that the payment has been made by the
buyer.

6) Attach consent to each document

In addition to the purchase letter that has been discussed above, it is also very
important to make a letter of approval for each of the above purchase letters. The
importance of the approval letter is as a control tool of the company to avoid
unwanted possibilities.

Therefore, the correct purchasing process that the company usually performs in
each purchase of goods to the supplier. Simplifying purchases is very important to
make it easier for each part to control each other, therefore in companies that use
accounting software to record purchasing activities. One is to use the right line where
there are already provisioning, sales and purchase features integrated with each
other.

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CONCLUSION
This assignment can increase knowledge and experience about the heavy steel
prison door manufacturing process. In the manufacturing process. In the process of
making this project, the workers involved are exposed to be creative, innovative and
independent to produce better quality products and bring progress to the country.
employees involved can also improve their knowledge and skill level based on work
procedures.

In addition, the workers involved can also learn about safety clothing and safety
equipment (PPE). Safety should be emphasized in order to avoid accidents and
avoid losses. This can also educate employees to be more disciplined and more
careful when doing work.

Next, this task can also open the mind of an individual in the process of purchasing
goods according to the type of goods needed in the project. In addition, money
management and purchase budgets can be managed efficiently and systematically.
This task also allows us to get to know and find out what suppliers of materials and
equipment.

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REFERENCE
 https://millerweldseurope.com/products/dynasty-210/
 https://www.cruxweld.com/blog/types-of-welding-processes/
 https://www.linkedin.com/uas/login?session_redirect=https%3A%2F
%2Fwww.linkedin.com%2Fpulse%2Fnavigating-welding-documentation-wps-
pqr-wpq-chidanand-harale#:~:text=WPS%2C%20PQR%2C%20and%20WPQ
%20are,and%20integrity%20of%20welded%20joints.
 https://tackly.com/product/aeropro-airless-paint-sprayer-470/
 https://www.boschhardware.com/bosch-power-tools/bosch-angle-grinders/
500w-1500w/angle-grinder-gws-060
 https://yeswelder.com/blogs/yeswelder/mig-welding-wire-types#:~:text=These
%20wires%20are%20made%20of,two%20pieces%20of%20metal
%20together.
 https://www.dictionary.com/browse/screwdriver
 https://bilba.com.au/products/automatic-single-straight-line-gas-cutting-
machine
 https://www.safetyjogger.com/document/PRODUCT_SHEET/TURBO/en/
TURBO_en.pdf
 https://my.misumi-ec.com/vona2/detail/223000778672/
 https://www.vkf-renzel.com/steel-tape-measure-black-red-3-5-or-8-meters-
length-14597.html
 https://www.varo.com/p/krt704030/try-square-300mm
 https://bhel.com/sites/default/files/tech-spec-i-1528946488.pdf
 https://www.globalspec.com/specsearch/searchform/
manufacturing_process_equipment/abrasives_grinding_finishing/
surface_finishing_products_equipment/wire_brushes

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 https://lyrecomerch.com/product/magnetic-level-ruler-medium-p22160

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