2024 Industrial Training 1 Report
Chin Wee Cheng
1002162587
A report submitted to the
Department of Engineering
UCSI University
2nd September 2024 – 31st December 2024
BEM2003 INDUSTRIAL TRAINING 1 REPORT
Carlsberg Brewery Malaysia Berhad
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2024 Industrial Training 1 Report
TITLE PAGE
BEM2003 Industrial Training 1 Report
Course Code: BEM2003
Course Title: Industrial Training 1
Program: Bachelor of Mechanical Engineering with Honours
Semester/Year: 2024-09 Semester
This report is submitted in partial fulfilment of the requirements for the course BEM2003
Industrial Training 1 as part of the Bachelor of Mechanical Engineering program.
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APPROVAL PAGE
This Industrial Training 1 Report is submitted to the Faculty of Engineering, UCSI
University, and has been reviewed and approved by the following supervisor at Carlsberg
Brewery Malaysia Berhad where the training was undertaken.
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DECLARATION
I, Chin Wee Cheng, hereby declare that this Industrial Training 1 Report submitted to the
Faculty of Engineering, UCSI University, is an original record of my work completed at
Carlsberg Brewery Malaysia Berhad as part of the BEM2003 Industrial Training 1 course.
I affirm that all data, figures, and information presented in this report are my own work,
gathered and analyzed during the training period, unless otherwise cited. This report has not
been submitted for any other academic qualification.
I reserve the copyright to all data, figures, and content contained in this report, and unauthorized
use or reproduction without my written permission is prohibited. External sources and
references have been appropriately acknowledged.
______________________________
Chin Wee Cheng
1002162587
19/12/2024
Date: ___________________
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ACKNOWLEDGEMENT
First and foremost, I would like to express my sincere gratitude to the Human Resource team
at Carlsberg Brewery Malaysia Berhad for providing me with the opportunity to complete my
industrial training with such a renowned organization. I am especially thankful to Mr Sures
Supramaniam, Maintenance Manager for the guidance. Along with the entire team, for their
invaluable mentorship. Their patience and willingness to share their knowledge allowed me to
develop essential skills and gain hands-on experience in the engineering field. They welcomed
my questions and curiosities, providing insights into the intricate workings of the brewing
industry and its food packaging processes.
I would also like to extend my heartfelt appreciation to UCSI University, particularly to my
academic coop coordinator, Ms. Fazilah from the Faculty of Engineering and other faculty
members who made this Industrial Training Program possible. This program has been
instrumental in bridging the gap between classroom learning and real-world application, giving
me a practical understanding of the daily responsibilities and challenges faced by a graduate
engineer in a dynamic and fast-paced industry.
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EXECUTIVE SUMMARY
This report provides a comprehensive overview of the cooperative education experience
undertaken at Carlsberg Brewery Malaysia Berhad, located in Shah Alam, during the 2
September 2024 until 31 December 2024. The purpose of the report is to document the tasks
performed, skills acquired, and overall learning outcomes achieved during the co-op placement,
as well as to offer insights and recommendations for future improvements. The primary tasks
involved understanding the packaging basic operation, involved in implementation of CL1
Projects, assisting in reducing breakdown and major operation stops, and beer losses in KP4.
The co-op placement offered a unique opportunity to bridge theoretical knowledge with
practical application, fostering professional growth and a deeper understanding of industry
requirements. Highlights of the experience include machine training which contributed
significantly to personal and professional development. In conclusion, the co-op placement at
Carlsberg Brewery Malaysia Berhad was instrumental in preparing for a successful
engineering career. Recommendations for future students include actively seeking mentorship
opportunities, being proactive in learning, and consistently maintaining a professional attitude
to maximize the benefits of the co-op experience.
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TABLE OF CONTENTS
CONTENTS
TITLE PAGE .............................................................................................................................ii
APPROVAL PAGE .................................................................................................................. iii
DECLARATION....................................................................................................................... iv
ACKNOWLEDGEMENT ......................................................................................................... v
EXECUTIVE SUMMARY....................................................................................................... vi
TABLE OF CONTENTS .........................................................................................................vii
LIST OF FIGURES .................................................................................................................. ix
LIST OF TABLES ..................................................................................................................... x
LIST OF ABBREVIATION ...................................................................................................... xi
CHAPTER 1: INTRODUCTION .............................................................................................. 1
1.0 Introduction ...................................................................................................................... 1
1.1 Objectives ........................................................................................................................ 2
1.2 Scope and Limitations...................................................................................................... 2
1.3 Significance...................................................................................................................... 3
CHAPTER 2: COMPANY PROFILE ....................................................................................... 4
2.0 Company Background ..................................................................................................... 4
2.1 Location of the company ................................................................................................. 4
2.2 Main Products and Services ............................................................................................. 5
2.3.1 Company achievements and improvements.................................................................. 6
2.3.2 Nature of works in the Maintenance Department ......................................................... 7
2.3.3 My Opinion: Enhancing Maintenance Efficiency to Boost Carlsberg's Reputation..... 8
CHAPTER 3: TASK, DUTIES AND RESPONSIBILITIES .................................................... 9
3.0 Tasks Assigned & Completed .......................................................................................... 9
3.1 Identification of Problems.............................................................................................. 12
3.2 Design of Solutions ........................................................................................................ 14
3.3 Safety and Health Awareness ......................................................................................... 16
3.4 Environmental & Sustainability..................................................................................... 22
3.5 Lifelong Learning .......................................................................................................... 23
CHAPTER 4: CONCLUSION AND FUTURE RECOMMENDATION ............................... 25
4.0 Conclusion ..................................................................................................................... 25
4.1 Recommendations .......................................................................................................... 26
References ................................................................................................................................ 27
APPENDIX .............................................................................................................................. 28
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APPENDIX A: OFFER LETTER ............................................................................................ 29
APPENDIX B: SIGNED & STAMPED COOP JOB CONFIRMATION FORM................... 32
APPENDIX C: EMPLOYER TESTIMONIAL ....................................................................... 33
APPENDIX D: STUDENT CO-OP EXPERIENCE SURVEY & FEEDBACK FORM ........ 34
APPENDIX E: PHOTOS WITH LECTURER DURING HIS/HER COOP VISIT AND ANY
PHOTOS RELEVANT TO THE ASSIGNED TASKS ............................................................ 36
APPENDIX F: COOP RELEVANT DOCUMENTS, FIGURES, TABLES ........................... 37
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LIST OF FIGURES
Figure 2.1.1 Map ........................................................................................................................ 4
Figure 2.1.2 Company’s image .................................................................................................. 5
Figure 2.2.3 Carlsberg Products................................................................................................. 5
Figure 2.3.4 Together Towards Zero .......................................................................................... 6
Figure 3.1 Gantt Chart ............................................................................................................... 9
Figure 3.0.1 Kegging Line and Bottling Line Layout ............................................................... 9
Figure 3.0.2 Canning Line Layout ............................................................................................. 9
Figure 3.0.3 Filler Greasing Point............................................................................................ 10
Figure 3.0.4 Maintenance Checklist and Operating Manual Cover Page ................................ 10
Figure 3.0.5 Greasing the Conveyor during service window................................................... 11
Figure 3.0.6 TRANSOMAT Parameter. ................................................................................... 11
Figure 3.1.1 Kegging Line and Bottling Line Layout ............................................................. 12
Figure 3.1.2 Temperature Measurement at Bottle Washer Outfeed ......................................... 12
Figure 3.1.3 “Zero” Value showing at Anton Paar Meter ........................................................ 13
Figure 3.1.4 EBI machine. ....................................................................................................... 13
Figure 3.2.1 Bottle Washer HMI indicates the temperature. ................................................... 14
Figure 3.2.2 OPL of resetting the Anton Paar Meter ............................................................... 14
Figure 3.2.3 EBI HMI showing the type parameters. .............................................................. 15
Figure 3.3.1 Packaging Hall Entry Signboard ......................................................................... 16
Figure 3.3.2/3/4 LOTO paddle lock and LOTO key on machine. ........................................... 17
Figure 3.3.5/6/7/8 Safety signboards on machine. ................................................................... 18
Figure 3.3.9 Handwashing Stations. ........................................................................................ 19
Figure 3.3.10 CL1 Filler running automatic CIP. .................................................................... 19
Figure 3.3.11 Spot Cooling Points in CL1 ............................................................................... 21
Figure 3.4.1 ESG programme Together Towards Zero ............................................................ 22
Figure 3.5.1/2 Heat Tunnel in SP and training. ........................................................................ 23
Figure 3.5.3/4/5 Certificate of Completion for Compliance Learning .................................... 24
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LIST OF TABLES
There is no table in this report.
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LIST OF ABBREVIATION
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CO-OP- Cooperative education
CL5 - Canning Line 5
KP4 - Kegging Plant 4
EBI - Empty Bottle Inspector
HMI - Human Machine Interface
PPE - Personal Protective Equipment
LOTO - Lock Out Tag Out
OPL - One Point Learning
SP
- Shrink Packer
EBI - Empty Bottle Inspector
SKU - Stock Keeping Unit
CDP32 - Carlsberg Danish Pilsner 320 ML
CIP - Cleaning in Place
COP - Cleaning out Place.
ESG - Environmental, Social & Governance
SOP - Standard of Procedure
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CHAPTER 1 : INTRODUCTION
1.0 Introduction
Cooperative education (co-op) is an academic program that links learning in the classroom with
hands-on, real-world job experience. With the co-op, students can apply their theoretical
knowledge practically, get exposure to their interested industry, and acquire critical skills that
improve their employability. Engineering students particularly benefit from co-op programs
because they give them practical experience in handling challenging technological problems
and collaborating in a variety of team settings.
Co-op education has been included into the academic programs of several universities
throughout around the world. Co-op education is included in engineering programs at
Universiti Teknologi Malaysia (UTM) in Malaysia, allows students the opportunity to acquire
skills relevant to the industry before graduation. Additionally, UCSI has a mandatory co-op
education program that requires students to perform industrial training.
However, the Co-op program may be challenging for students to alter with the academic
requirements, and students may find that their study duration need to take longer to graduate
because of the extra time spent on work placements. Additionally, it might be difficult to find
a satisfied co-op placement, which could put additional pressure on students. Other than these
difficulties, co-op education is a useful part of engineering education as, on average, its longterm advantages exceed its disadvantages.
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1.1 Objectives
1. To develop better knowledge and understanding of their chosen future professions.
2. To learn to be a highly motivated and productive employee for the industry.
3. To relate the academic learning within an educational institution with the practical
learning of the workplace.
1.2 Scope and Limitations
Scope
The co-op program was conducted at Carlsberg Brewery Malaysia Berhad, a brewery
company located in Shah Alam, Selangor, Malaysia. During the internship, I was assigned in
the Maintenance Department, where the department primary focus was on ensuring the
smooth operation of machinery and equipment used in the beer production and packaging
processes. The nature of the job involved maintenance engineering, including troubleshooting
mechanical issues, conducting preventive maintenance, assisting in reducing downtime, and
improving equipment efficiency to support the overall production workflow.
Limitations
The scope of my co-op experience was limited to the Maintenance Department at the
Carlsberg facility in Shah Alam. My responsibilities were primarily focused on machinery
maintenance and operational tasks, which limited exposure to other areas such as research and
development, consultation, or process optimization outside the maintenance scope.
Additionally, the co-op was confined to a single department, which restricted my understanding
of other engineering-related operations within the company. Although my work was closely
related to mechanical and maintenance engineering, there were minor limitations in directly
aligning the tasks with more advanced theoretical concepts covered in my academic studies.
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1.3 Significance
My professional and personal growth has improved significantly because of my industrial
training at Carlsberg Brewery Malaysia Berhad. Working as a maintenance internship trainee
I had gain the real-world experience, which enhanced my comprehension of engineering
processes, particularly those related to equipment maintenance and operation. I was able to link
between my practical industry application knowledge and my academic knowledge that I had
learnt from UCSI University through this co-op.
Working with experienced specialists was one of the main advantages of this co-op, as it
enhanced my technical and problem-solving abilities. I learned a lot about preventative
maintenance, machinery troubleshooting, and safety measures including compliance training
and the Lock-Out Tag-Out (LOTO) system. I got lots of personal fulfilment from doing duties
effectively, improving operational effectiveness, and witnessing the real effects of my work.
Even though the program's main objective was professional development, the information and
abilities I gained from this co-op really boosted my self-esteem and preparation for future
career in the engineering sector. Overall, this industrial training has been invaluable in
preparing me for a future career, equipping me with both technical expertise and soft skills that
are essential for success in the workplace.
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CHAPTER 2 : COMPANY PROFILE
2.0 Company Background
Carlsberg Brewery Malaysia Berhad which also can be known as Carlsberg Malaysia Group or
The Group, established in 1969 is a part of the Carlsberg Breweries A/S (The Carlsberg Group).
The Carlsberg Group is one of the world’s leading brewers with its strong market position
across Asia and Europe. Carlsberg is a dynamics brewer with the operations in Malaysia and
Singapore, with a 25% stake in Lion Brewery (Ceylon) PLC in Sri Lanka. There are also the
exports and intercompany sales by Carlsberg to regional markets such as Hong Kong,
Cambodia and Loas. Carlsberg has constantly invested in widening its regional footprint
through strategic collaborations and sustainable practices besides to its main markets. The
Group is listed on the Main Market of Bursa Malaysia and stays a big player in the beer industry
in the region. Carlsberg Malaysia is committed to maintaining high standards of governance,
operational excellence, and innovation, compelling value creation for shareholders and
stakeholders alike. Carlsberg Malaysia aligns itself with the global "Together Towards Zero"
initiative, emphasizing responsible brewing, reduced environmental impact, and positive
societal contributions with a strong focus on sustainability. Through its integrated approach to
market expansion and sustainability, The Group continues to strengthen presence across key
markets while fostering long-term growth and community engagement with the society.
2.1 Location of the company
The company is located at the following address:
55 Persiaran Selangor, Seksyen 15,
40200 Shah Alam,
Selangor Darul Ehsan,
Malaysia.
Figure 2.1.1 Map
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Figure 2.1.2 Company’s image
2.2 Main Products and Services
The main business of Carlsberg Brewery Malaysia Berhad is the production and distribution
of a variety range of alcoholic drinks, including beers. The flagship product is Carlsberg Danish
Pilsner, a popular pilsner-style beer. Additionally, the company also offers Carlsberg Smooth
Draught, a smoother variant of its original beer, along with other premium and international
beer brands, including Kronenbourg 1664 Blanc, Connor’s Stout Porter, and Sapporo.
Beyond beer, Carlsberg Malaysia also markets Somersby cider, a popular non-beer alcoholic
beverage, and holds exclusive distribution rights for certain imported brands. The company
caters to both the domestic market in Malaysia and regional markets such as Singapore, Sri
Lanka, and Hong Kong through exports.
Figure 2.2.3 Carlsberg Products
In addition to its product portfolio, Carlsberg Malaysia offers integrated services such as brand
promotion, marketing campaigns, and community engagement programs. The company also
provides logistical services and partnerships with retailers, ensuring an efficient distribution
network across its key markets.
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2.3.1 Company achievements and improvements
Carlsberg Brewery Malaysia Berhad has achieved significant milestones over the years,
solidifying its position as one of Malaysia's leading brewers The company's notable
achievements include being named the "Best Managed Company" by FinanceAsia and the
"Most Honored Company" by Institutional Investor for its consistent financial performance.
Carlsberg Malaysia has also been listed in the FTSE4Good Bursa Malaysia Index, reflecting
its strong commitment to environmental, social, and governance (ESG) practices.
Through its global "Together Towards Zero" project, which aims for zero carbon emissions,
zero water waste, and responsible drinking, the corporation has continuously enhanced its
environmental efforts. Carlsberg Malaysia has demonstrated its commitment to environmental
stewardship by using energy-efficient brewing procedures, lowering water use, and minimizing
packaging waste.
In terms of innovation, Carlsberg Malaysia has enhanced its product offerings by introducing
smoother and more premium variants of its popular beers, as well as expanding its portfolio to
include non-beer beverages like Somersby cider. Furthermore, the company has strengthened
its market presence by leveraging digital transformation, e-commerce platforms, and strategic
partnerships to improve customer reach and operational efficiency. These improvements reflect
the company's ongoing commitment to excellence, sustainability, and market leadership.
Figure 2.3.4 Together Towards Zero
The lengthy history, robust worldwide support from the Carlsberg Group, and strong dedication
to sustainability are what set Carlsberg Brewery Malaysia Berhad apart. With operations in
Malaysia, Singapore, and Sri Lanka, Carlsberg Malaysia has a wide regional presence in
contrast to many of its rivals. The company stands out for its commitment to corporate social
responsibility through the "Together Towards Zero" campaign and its emphasis on innovation,
which includes the launch of premium brands and smoother beer varieties. It has a competitive
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edge because of its capacity to strike a balance between tradition and cutting-edge methods like
digital transformation and sustainable brewing.
The key to Carlsberg Malaysia’s success lies in its strong brand recognition, continuous
innovation, and commitment to sustainability. The company has cultivated a loyal customer
base through consistent quality, market-leading products, and creative marketing strategies.
Furthermore, its alignment with the global Carlsberg Group allows for access to world-class
resources and expertise, facilitating its growth and market leadership. Carlsberg Malaysia’s
focus on sustainability through initiatives that reduce environmental impact, coupled with
operational efficiency and stakeholder engagement, has also contributed significantly to its
success.
As an intern worked in Carlsberg Brewery Malaysia Berhad maintenance department for 4
months, I had the chance to get the insight into the operations and processes in the packaging
line that able to ensure the seamless production and uphold the company’s product quality
standards. The maintenance department play a crucial role in the brewery daily operations,
ensuring that all the machinery and equipment are operating efficiently and safely. This
department is integral to minimizing production downtime, maintaining product consistency,
and achieving energy efficiency, aligning with the company’s sustainability goals under the
"Together Towards Zero" initiative. The maintenance department also essential to achieving
operational efficiency, product quality, and adherence to environmental standards, directly
contributing to Carlsberg’s commitment to sustainability and market leadership.
2.3.2 Nature of works in the Maintenance Department
1. Preventive Maintenance
Conducting the regular inspection following the maintenance checklist that had been
scheduled to prevent the unexpected breakdowns.
2. Troubleshooting and Repairs
Identifying and resolving the breakdown root cause in the production line the minimize
the delays.
3. Spare Part Management
Assisting in the inventory management to ensure the availability of the critical spare
parts, reducing the risk of machine downtime.
4. Data Recording and Analysis
Monitoring and recording the machine performance and the setpoint for the different
production recipe.
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2.3.3 My Opinion: Enhancing Maintenance Efficiency to Boost Carlsberg's Reputation
The basis of Carlsberg Brewery Malaysia Berhad's operational effectiveness and dedication to
sustainability is the Maintenance Department, where I interned. In order to stay ahead of its
rivals, Carlsberg Malaysia may increase its local and international footprint by embracing
sustainability, utilizing digital technologies, and continuing to innovate. Its position as a world
leader in the brewing sector will be cemented by its strategic focus on growing markets, digital
transformation, and environmentally friendly practices.
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CHAPTER 3 : TASK, DUTIES AND RESPONSIBILITIES
Figure 3.1 Gantt Chart
3.0 Tasks Assigned & Completed
As an intern in the maintenance department, I was assigned with the following job scope:
1. Understand packaging basic operation/function.
Figure 3.0.1 Kegging Line and Bottling Line Layout
Figure 3.0.2 Canning Line Layout
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2. Involved in implementation of CL5 Projects
Machine Greasing Point Labelling
Purpose: To let the maintenance personnel/technician or maintenance engineers refer
while doing the service window. It is also a preventive Maintenance to reduces the
breakdown due to lack of lubrication.
Figure 3.0.3 Filler Greasing Point
Compiling the maintenance agenda from the operation manuals into the checklist
Purpose: Easy to refer and some agenda pages in manuals is jotted down as well as
reduce the breakdown by doing the preventive maintenance.
Figure 3.0.4 Maintenance Checklist and Operating Manual Cover Page
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3. To assist in reducing breakdown and major operation stops
Prepare the OPL for some technical solutions as well as helping in the service window
to ensure all the machine condition is good to start the production.
Figure 3.0.5 Greasing the Conveyor during service window.
4. Beer Losses in KP4
Compiling the TRANSOMAT (Keg Cleaning and Filling Machine in KP4) filling head
parameter in the booklet to ensure the correct filling level to prevent underfill and
overfill therefore the rejection can be reduced.
Figure 3.0.6 TRANSOMAT Parameter.
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3.1 Identification of Problems
Problem 1:
Too many broken bottles after the bottle washer and high rejection at bottle
washer EBI (Empty Bottle Inspector)
Figure 3.1.1 Kegging Line and Bottling Line Layout
Effect:
There will be causing the lower efficiency of production as well as higher cost
on the rejected bottles.
Reason:
Temperature too high while washing causing the bottle to break while
transporting on the conveyor.
Normal Temperature: 36 ℃ (Temperature found is 39 ℃)
Figure 3.1.2 Temperature Measurement at Bottle Washer Outfeed
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Problem 2: The Anton Paar meter having the issue when running the CDP32 with the Alcohol
volume and original extract data.
Figure 3.1.3 “Zero” Value showing at Anton Paar Meter
Reason:
The setting did not load when changing the type in the filler HMI during
changeover from other production type.
Effect:
This will cause lack of quality tracking led to the product quality cannot be
ensure.
After reset by changing the type of the production, the Anton Paar meter has been successfully
reset.
Problem 3: High Rejection at EBI in BL1.
Figure 3.1.4 EBI machine.
Reason:
The parameter is not accurate for running because the changing of the bottle
type in the same SKU causing all bottles rejected after the EBI.
Effect:
The line efficiency has been affected by the issue and there are high machine
downtimes for adjusting the parameters.
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3.2 Design of Solutions
Solution of problem 1: Reduce the fresh water supply temperature in the HMI.
Figure 3.2.1 Bottle Washer HMI indicates the temperature.
Solution of problem 2: Prepare an OPL in how to reset the Anton Paar meter consequently the
maintenance team can solve the issue faster and reduce downtimes.
Figure 3.2.2 OPL of resetting the Anton Paar Meter
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Solution for problem 3: Records on the EBI parameters and make a file to keep the other SKU
for future reference.
Figure 3.2.3 EBI HMI showing the type parameters.
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3.3 Safety and Health Awareness
Safety
Carlsberg Brewery Malaysia Berhad promotes a zero-accidents culture by prioritizing safety
in every aspect. Through rigorous implementation of safety procedures such as LOTO (Lock
Out Tag Out), Personal Protective Equipment (PPE), This culture encourages employees to
identify hazards, report unsafe conditions, and adhere strictly to safety protocols.
Packaging Hall Entry Signboard (Every Entry)
At every entry point of the Packaging Hall in Carlsberg Brewery
Malaysia Berhad, clear and concise signboards are displayed to ensure
the safety of employees and visitors. These signboards follow standard
color-coded safety regulations to communicate hazards, prohibited
actions, and required personal protective equipment.
1. Yellow – Hazard Sign
Purpose:
The yellow hazard sign is used to warn
individuals of potential risks or dangers in the
packaging hall.
Examples:
Slippery Floor, High-Voltage Equipment
Significance: These signs help individuals remain vigilant and
take necessary precautions to avoid accidents and
injuries.
2.
Red – Prohibited Sign
Purpose:
The red prohibited sign specifies actions that are
strictly forbidden in the packaging hall to ensure
safety and compliance with regulations.
Examples:
No Unauthorized Entry, No Smoking or Open
Flames
Significance: Reinforces rules to maintain a safe working
environment and avoid hazards like fires or
contamination.
3.
Red – Blue – PPE Sign
Purpose:
The blue PPE sign mandates the use of specific
personal protective equipment required within
the packaging hall.
Examples:
Wear Safety Shoes, Wear Ear Protection and
Wear Safety Helmets
Significance: Protects employees from potential workplace
Figure 3.3.1
injuries, ensuring adherence to occupational
safety standards.
Packaging Hall Entry
Signboard
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LOTO- Lock Out Tag Out Procedure
A safety standard that ensures that dangerous machines and energy sources are properly shut
off and not unexpectedly started up before the completion of maintenance or servicing work.
Key Objectives of LOTO
1. Prevent Accidental Machine Activation: Ensure equipment remains inoperable until
maintenance or servicing is fully completed.
2. Protect Workers from Hazardous Energy: Safeguard against unexpected releases of
energy such as electrical, mechanical, hydraulic, pneumatic, or thermal energy.
3. Comply with Safety Regulations: Adhere to workplace safety standards and legal
requirements to maintain a safe environment.
Figure 3.3.2/3/4 LOTO paddle lock and LOTO key on machine.
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Safety Signboard on the machine
There are various safety signboards installed on all machinery in the packaging hall of
Carlsberg Brewery Malaysia Berhad. These signboards serve as essential tools to ensure the
safety of employees and visitors by communicating critical information about potential hazards,
prohibited actions, and necessary precautions.
Figure 3.3.5/6/7/8 Safety signboards on machine.
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Food Safety
Strict food safety procedures are used at Carlsberg Brewery Malaysia Berhad to guarantee
the highest standards of cleanliness and product quality. Throughout the production cycle,
workers and procedures must follow procedures that guard against contamination and maintain
safety.
Typhoid Injection
All production workers are required to have a typhoid injection as part of the company's food
safety regulations. By taking this preventative measure, workers and end users are protected
from infectious infections that could jeopardize the safety of the product.
Handwashing Before Entering the Packaging Hall
Employees must fully wash their hands before entering the packaging hall, as hand hygiene is
highly enforced. By reducing the possibility of microbiological contamination, this procedure
keeps the packaging process sanitary and clean. Sanitization stations and handwashing stations
are ideally positioned at the packaging hall's entrance.
Figure 3.3.6 Handwashing Stations.
Machine Cleaning: CIP and COP
The company employs two critical cleaning methods to maintain hygiene in machinery:
1. CIP (Cleaning in Place): Automated cleaning systems are used to clean the internal
surfaces of equipment without disassembly. This method ensures consistent and
thorough sanitation of pipelines and tanks, reducing downtime and maintaining
operational efficiency.
Figure 3.3.7 CL1 Filler running automatic CIP.
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2. COP (Cleaning Out Place): For smaller components, manual cleaning is performed
after disassembly. This process ensures that all parts, especially those not accessible by
CIP, are cleaned to meet strict hygiene standards.
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Health Awareness
Hot environment issue
Production areas can become warm due to continuous machinery operation, which may cause
fatigue and discomfort for employees during long shifts.
Figure 3.3.8 Spot Cooling Points in CL1
Recommendation: Although the hall has spot cooling stations, their efficiency can be
increased by strategically placing them to provide uniform cooling throughout the work area.
Workers should be encouraged to refuel at these cooling stations during brief breaks. Hydration
stations should be easily available to promote staff well-being, and regular maintenance of the
cooling systems is also necessary to guarantee best performance.
Noise Induced Stress
Despite the usage of earplugs, long exposure to operational noise in the production hall can
contribute to stress and reduce focus over time.
Recommendation: Optimize noise reduction strategies by conducting regular machinery
maintenance to reduce noise levels. Introduce quiet zones for breaks, allowing employees to
recover from noise exposure. Providing education on proper earplug use can also enhance their
effectiveness in minimizing noise-related stress.
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3.4 Environmental & Sustainability
Figure 3.4.1 ESG programme Together Towards Zero
Energy-efficient brewing process
The company has implemented the energy-saving initiatives, including the implementing the
advanced brewing technology that reduce the energy consumption and emissions. For example,
the CL1 that just started the production in September in the brewery can reduce the water usage
and energy usage for 47% and 42% while the production capacity increases 33%. These
initiatives are match with Carlsberg’s global "Together Towards Zero" strategy, which aims for
zero carbon footprint at its breweries by 2030.
Water Management and waste reduction
Carlsberg Malaysia emphasizes minimizing water usage through innovative recycling
processes and efficient water management systems. Wastewater is treated before in the
company own treatment plant to ensure compliance with environmental standards, promoting
zero water waste goals.
Green Product Development
Carlsberg Malaysia has also focused on producing eco-friendly products by introducing
biodegradable packaging materials and optimizing the use of sustainable resources. For
example, the use of lightweight and recyclable bottles and cans can minimize the
environmental footprint while maintaining product quality and safety during the production as
well as end users. This also align with the zero-packaging waste in the “Together Towards
Zero” strategy.
Technical and Societal Considerations
Carlsberg Malaysia integrates modern technologies to achieve operational efficiency without
compromising environmental integrity. The company also supports local communities by
promoting zero irresponsible drinking and fostering societal awareness on environmental
preservation, reflecting its commitment to cultural and societal sustainability.
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3.5 Lifelong Learning
During my internship at Carlsberg Brewery Malaysia Berhad, I had the opportunity to
engage in various training sessions and activities that significantly enhanced my technical
knowledge, skills, and professional development.
Machine Training for CL1 Line
I took part in the machine training that aimed to teach about how to operate, maintain, and
troubleshoot production line equipment. I was able to become acquainted with sophisticated
industrial machinery such as fillers, seamers, pasteurizers, inspectors, conveyors, and
packing machines during these training sessions. I had learnt the knowledge and skills that
required to make sure the machine performance and minimize downtime by understanding the
fundamentals, essential parts in the machine, and standard operating procedures (SOPs). These
practical trainings helped me become more familiar at finding issues for the machine and
carrying out preventative maintenance in addition to increasing my technical skills.
Figure 3.5.1 Heat Tunnel in SP and training.
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Compliance Learning
I finished compliance learning courses during my internship at Carlsberg Brewery Malaysia
Berhad to improve my comprehension of moral business conduct and legal requirements.These
included the E-learning & Quiz on SECTION 17A of MACCA 2009, focusing on anticorruption measures; the Anti-Bribery & Anti-Corruption (ABC) Declaration, which
reinforced the company’s zero-tolerance policy toward corruption; and the Gift,
Entertainment & Donations (GED) Manual, which provided guidelines for ethical
interactions and claims as well as the Competition Law. These trainings emphasized integrity,
accountability, and transparency, aligning me with the company’s commitment to fostering a
compliant and responsible work culture.
Figure 3.5.3/4/5 Certificate of Completion for Compliance Learning
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CHAPTER 4 : CONCLUSION AND FUTURE RECOMMENDATION
4.0 Conclusion
My professional and personal development has been greatly influenced by my internship at
Carlsberg Brewery Malaysia Berhad. I was able to link between theory learnt and practice as a
member of the maintenance department. I was able to acquire critical technical and soft skills
through the jobs I performed during these 4 months industrial training, such as troubleshooting
and preventive maintenance. By working with my colleagues on technical issues during my
industrial training period like bottle breakages after the washer and high rejection rates at EBI,
I had enhanced my analytical and problem-solving abilities and gained experience in solving
engineering problems.
Additionally, this industrial training placement had shown how safety and sustainability are
important to industrial operations. The importance of coordinating operational goals with more
general environmental and safety objectives was brought Carlsberg's "Together Towards Zero"
effort and strict safety regulations, such as LOTO and PPE compliance. My understanding of
the part engineers plays a significant role as well in creating safe and sustainable industrial
settings has grown as a result of these learning.
Through cooperative efforts with colleagues, I have personally improved my sense of
flexibility, teamwork, and communication. I shall use the overall viewpoint that these
experiences have given me in my future undertakings. To sum it up, the internship was a
thorough educational experience that equipped me to make a significant contribution to the
engineering community.
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4.1 Recommendations
1. Enhance Digital Integration in Maintenance Processes
Implement a Computerized Maintenance Management System (CMMS) to streamline
scheduling, documentation, and data tracking. This shift from manual processes will improve
efficiency, accuracy, and accessibility.
2. Optimize Machine Parameter Adjustments
Develop standard operating procedures (SOPs) and maintain a well-documented database for
machine parameters to ensure smoother SKU changes. This approach reduces manual errors
and minimizes downtime while maintaining consistent product quality.
3. Improve Workplace Comfort
Enhance the effectiveness of cooling systems by optimizing their placement for uniform
temperature coverage. Invest in noise-dampening solutions to mitigate the impact of prolonged
exposure to operational noise, thereby improving employee comfort and productivity.
4. Encourage Collaborative Problem-Solving
Organize workshops and brainstorming sessions to address recurring operational issues such
as bottle breakages and high EBI rejection rates. Encouraging team involvement fosters
innovation and ownership among employees.
5. Expand Training Programs
Enrich training modules to include advanced troubleshooting, digital tools, and sustainability
practices. Providing employees with updated knowledge and skills will better prepare them
for future challenges and enhance overall operational efficiency.
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REFERENCES
What
is co-op. (2024, November 26). https://drexel.edu/scdc/co-op/what-is-coop/#:~:text=Co%2Dop%2C%20short%20for%20cooperative,on%20experience%20pr
ior%20to%20graduation.
WHO WE ARE » Carlsberg Malaysia « Carlsberg Malaysia. (n.d.). Carlsberg Malaysia.
https://carlsbergmalaysia.com.my/who-we-are/carlsberg-malaysia/
SUSTAINABILITY » Our sustainability « Carlsberg Malaysia. (n.d.). Carlsberg Malaysia.
https://carlsbergmalaysia.com.my/sustainability/our-sustainability/
SUSTAINABILITY » social » ZERO accidents culture « Carlsberg Malaysia. (n.d.). Carlsberg
Malaysia. https://www.carlsbergmalaysia.com.my/sustainability/social/zeroaccidents-culture/
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APPENDIX
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APPENDIX A: OFFER LETTER
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APPENDIX B: SIGNED & STAMPED COOP JOB CONFIRMATION FORM
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APPENDIX C: EMPLOYER TESTIMONIAL
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APPENDIX D: STUDENT CO-OP EXPERIENCE SURVEY & FEEDBACK FORM
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APPENDIX E: PHOTOS WITH LECTURER DURING HIS/HER COOP VISIT AND
ANY PHOTOS RELEVANT TO THE ASSIGNED TASKS
Figure 1 Site Visit Presentation with lecturer
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APPENDIX F: COOP RELEVANT DOCUMENTS, FIGURES, TABLES
Figure 2 Can falls at conveyors
Figure 3 Bottle Washer
Figure 4 Filler Special Tools
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Figure 5 Filling Valve
Figure 6 Conveyor Motor
Figure 7 Palletiser Gripper
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