INDUSTRIAL TRAINING REPORT

FLYFIREFLY SDN BHD

MUHAMMAD AL AFIQ BIN SARUAN

53211217018

REPORT SUBMITTED IN PARTIAL FULFILMENT FOR THE

BACHELOR OF AIRCRAFT ENGINEERING TECHNOLOGY
(HONS) IN MECHANICAL

UNIVERSITY KUALA LUMPUR

MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

JULY 2019
STUDENT PARTICULAR

i
UNIVERSITY SUPERVISOR DETAILS

ii
COMPANY DETAILS

iii
 DECLARATION PAGE

I declare that this report is my original work and all content directly from the
duration of my On-Job-Training daily work and experience.

Date: 28/12/2019 Signature: …………………………....

Full Name: Muhammad Al Afiq Bin

Saruan

ID No. : 53211217018

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This reported was read and verified by:

………………………………………………. DATE:

(IFFRYAL HASHREEQ ABDULLAH HALIM)

COMPANY SUPERVISOR

……………………………………………….. DATE:

(AMIR HAKIMIN BIN HASHIM)

UNIVERSITY SUPERVISOR

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 ACKNOWLEDGEMENT

Firstly, I want to dedicate my thankful to Allah S.W.t for the strength and his blessing
by giving precious health throughout this on job training program. I sincerely express
my profound appreciation to the FlyFirefly Sdn. Bhd. for the opportunity to carry out
on job training at the company. I am grateful for having a chance to meet so many
wonderful people and professionals who led me through this on job training period.

I express my deepest thanks to my supervisor, Mr. Iffryal Hasyreeq (Technical

Services Engineer) for all his advices and guidance throughout this internship program.
His supervision and cooperation allow me to gain more knowledge during the on job
training period. In addition, special thanks to Mrs. Asyikin (Head of CAMO), Mr.
Amir Farid (Senior Tech. Service Engineer), Mr. Zaidi (Senior Tech. Service
Engineer), Mr. Syabil (Reliability Engineer), Mr. Farhan and Mr. Hanafiah (Technical
Services Engineer) for their advice and guidance which were extremely valuable for
my study both theoretically and practically.

Besides that, I would like to express my humbly thanks to my supervisor Mr.

Amir Hakimin Bin Hashim, during my intra at UniKL MIAT, under the supervision
of INTRA period. Thank you so much for helping me completing my INTRA progress
from the beginning until the end.

Finally I would like to dedicate my appreciation to my family for their support

and I would like to thanks for those who has directly or indirectly involved with me
during internship in FireFly, may Allah bless all of you.

Thank you.

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 ABSTRACT

I undergo my industrial training in FlyFireFly Sdn. Bhd., for approximately 6 months

which I started from 31st July 2019 until 27th December 2019.

Firefly has a separate management apart from its parent company, Malaysia
Airlines. Firefly focuses on serving Malaysia as well as Indonesia, Singapore and
Thailand. Idris Jala, Malaysia Airlines' managing director, speaking at a business
briefing and launch of the new airline's logo on 16 March 2007, said Firefly would
work with MAS in breaking new ground and realising a core network over the next
five years. The core network would include markets such as North America, South
America and South Africa. By end of 2018, Firefly will move its Singapore operations
from Changi International Airport to Seletar Airport as Changi Airport Group wishes
to focus more on their jet operations.

I was attached in the Technical Services department which I am responsible

for supporting the engineers in managing publication, technical log analysis, engine
condition monitoring and airworthiness directives (AD) issuance monitoring. During
my internship, I have been exposed to the culture of work that is very unfamiliar in the
first stage, but with the support and knowledge from the Technical Services Engineer,
I manage to handle a lot of thing. During my internship in Firefly, I have seen much
different between management and maintenance. However both field share a lot of
common things because they support each other for an airlines to continue their
operation.

In conclusion, it is a pleasure and great opportunity to develop and enhance my

soft skills, and prepare myself to pursuing the aviation/aerospace career in the future.

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 TABLE OF CONTENTS

STUDENT PARTICULAR ...............................................................................................................i

UNIVERSITY SUPERVISOR DETAILS ............................................................................................ii
COMPANY DETAILS .................................................................................................................. iii
DECLARATION PAGE ................................................................................................................ iv
ACKNOWLEDGEMENT .............................................................................................................. vi
ABSTRACT................................................................................................................................ vii
TABLE OF CONTENTS ............................................................................................................. viii
LIST OF FIGURE.......................................................................................................................... x
CHAPTER 1: INTRODUCTION .................................................................................................... 1
1.1 OBJECTIVE ................................................................................................................ 1
1.2 LOCATION ................................................................................................................ 1
1.3 POSITION ................................................................................................................. 2
1.4 REPORT .................................................................................................................... 2
1.5 MAJOR TASK ............................................................................................................ 2
CHAPTER 2: INTRODUCTION .................................................................................................... 3
2.1 COMPANY PROFILE ................................................................................................. 3
2.2 VISION ...................................................................................................................... 4
2.3 MISSION ................................................................................................................... 4
2.4 MANAGEMENT AND OPERATION ........................................................................... 4
2.5 DESTINATIONS ......................................................................................................... 5
2.6 FLEET ........................................................................................................................ 6
2.7 COMPANY CEO ........................................................................................................ 7
CHAPTER 3: SCOPE OF TRAINING ............................................................................................ 8
3.1 SCOPE OF INDUSTRIAL TRAINING ........................................................................... 8
3.2 TECHNICAL SERVICE DEPARTMENT ........................................................................ 9
3.2.1 TECHNICAL SERVICE (PROPULSION) ............................................................... 9
3.2.2 TECHNICAL SERVICE (RELIABILITY) ................................................................ 12
3.2.3 TECHNICAL PUBLICATION.............................................................................. 14
3.2.4 CONTINUOUS AIRWORTHINESS ................................................................... 17

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ix
 LIST OF FIGURE

Figure 1: Technical Service Office ............................................................................................ 1

Figure 2: Firefly ATR72 aircraft ................................................................................................ 7
Figure 3 Firefly CEO Philip See ................................................................................................. 7
Figure 4: ECTM data ................................................................................................................. 9
Figure 5: WebECTM ............................................................................................................... 10
Figure 6: Engine inspection report (EIR) ................................................................................ 10
Figure 7: Engine inspection report (EIR) ................................................................................ 11
Figure 8: Engine SB................................................................................................................. 11
Figure 9: Technical Log MR1 .................................................................................................. 12
Figure 10: Technical Log MR1 ................................................................................................ 12
Figure 11: Technical log MR2 ................................................................................................. 13
Figure 12: Oil consumption list .............................................................................................. 13
Figure 13: ATR Maintenance Manual .................................................................................... 14
Figure 14: Technical Service Instruction (TSI) ........................................................................ 15
Figure 15: Aircraft Inspection Report (AIR) ............................................................................ 16
Figure 16: Mod list ................................................................................................................. 16
Figure 17: Aircraft Maintenance Program (AMP) .................................................................. 17

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 CHAPTER 1: INTRODUCTION

The industrial training exposes the students to professional skills and experiences in
industrial engineering practices. In preparing the students for the real working
environment as engineers, industrial training helps to produce engineering graduates
with technical and soft skills competency. Industrial training is one of the requirements
for all UniKL MIAT students in order to complete the degree programs. The main
objective of the INTRA is to give students vast exposure to real industrial environment.

1.1 OBJECTIVE

The objectives of the internship are:

1. To expose and understand the real working environment.
2. To gain more experience about the related field study.
3. To apply general knowledge and skills from the study that have been done
before.

1.2 LOCATION

The Industrial training location has successfully done at FlyFirefly Sdn. Bhd. It is
located at a strategic area at Hangar 01 Mas Complex B, Sultan Salahuddin Abdul
Aziz Shah Airport, 47200, Selangor Darul Ehsan, Malaysia. While, the headquarters
of the company is in Citta Mall, Petaling Jaya, it claims to be the first community
airline in Malaysia.

Figure 1: Technical Service Office

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1.3 POSITION

I have attached to the Technical Services Department during the industrial training
program. As a trainee, I need to be responsible and follow the instruction from my
supervisor and any other staff. Commonly, the responsibility that be given by the
technical service engineer related to the technical services task.

1.4 REPORT

Students undergoing their industrial training at an Airline company are required to

record and submit their logbook whereby students that are working in other company
are required to record their activities and submit their report. The report will be present
to my current supervisor, Mr. Iffryal Hashreeq Abdullah Halim and my university
supervisor at the end of industrial training.

1.5 MAJOR TASK

i. Managing maintenance report (MIREP) and pilot report (PIREP) from

technical log MR1 and MR2.
ii. Given the responsibility of managing Firefly's publication on a monthly basis.
iii. Defect study from maintenance report and pilot report.
iv. Compiling and entering data into WebECTM for engine condition monitoring.
v. Collect and analysed oil consumption data of engine.
vi. Aircraft Maintenance Program (AMP) customization by referring Maintenance
Planning Document (MPD).
vii. Monitoring issuance of Airworthiness Directives (AD) from authority.

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 CHAPTER 2: INTRODUCTION

FlyFirefly Sdn Bhd, operating a full-service point-to-point carrier and a full subsidiary
of Malaysia Airlines. Its head office is located in Petaling Jaya, Selangor. It is claim
to be the first community airline in Malaysia. Firefly operates from two hubs - Sultan
Abdul Aziz Shah Airport, Subang, Selangor and Penang International Airport. The
airline's first flight was on 3 April 2007, from Penang to Kota Bharu.

2.1 COMPANY PROFILE

The name of Firefly coming from various language (in Mandarin fei ying; in Bahasa Malaysia
Kunang-Kunang) was chosen to depict the airline’s characteristics, which are agility,
brilliance, charm, and fun. Being unique and evocative, Firefly is easily recognise and has the
potential to grow and command a brand premium in the communities it serves.

Agile

Translated as an act that is well-coordinated, quick, active and lively, this is precisely the key
characteristics we want to adopt. We aim for speed and ease of movement in managing our
business as well as providing our services to ensure the well-being of our passengers.

Brilliant

Firefly is positioned as a brilliant light that captures the imagination. We engage that brilliance
and imagination in our continuous effort in planning, leading, organising and operating our
business to create the best community airline the world can offer.

Charm

Service is about charm and that’s what we strive to provide; to offer you a charming flying
experience that you won’t forget and will keep you coming back for more!

Fun

As a young, growing organisation, we make it a point to align our goals with the right attitude
that can be spelt in three letters: f.u.n. We adopt an upbeat working environment to produce
fresh ideas with substance. A happy worker is a productive worker, and that is reflected in our
service to our passengers.

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2.2 VISION

To be a trusted brand known for offering safe, reliable, accessible premium travel
experiences that resonate with passengers.

2.3 MISSION

To strengthen our footprint by offering exceptional services and sustaining our

profitability above industry average. While we continue to dominate our routes, we
also take pride in aligning our business model and work culture to our social
conscience.

2.4 MANAGEMENT AND OPERATION

Firefly has a separate management apart from its parent company, Malaysia Airlines.
Firefly focuses on serving Malaysia as well as Indonesia, Singapore and Thailand.

Dato' Sri Idris Jala, Malaysia Airlines' managing director, speaking at a

business briefing and launch of the new airline's logo on 16 March 2007, said Firefly
would work with MAS in breaking new ground and realising a core network over the
next five years. The core network would include markets such as North America,
South America and South Africa.

By end of 2018, Firefly, the sole turboprop operator in Changi Airport will
move to Seletar Airport as Changi Airport wants to focus more on their jet operations.

4
2.5 DESTINATIONS

Firefly flies from two hubs, Penang and Subang in Kuala Lumpur. The domestic flights
from Penang are Langkawi, Kota Bharu, Subang, and international flights are Banda
Aceh and Phuket in Thailand. The flights out of Subang are Penang, Langkawi, Alor
Setar, Johor Bahru, Kuala Terengganu and Kota Bharu and Singapore.

1. MALAYSIA
 Subang - Sultan Abdul Aziz Shah Airport (Hub)
 Penang - Penang International Airport (Hub)
 Johor Bahru - Senai International Airport (Secondary Hub)
 Kota Bharu - Sultan Ismail Petra Airport (Secondary Hub)
 Alor Setar - Sultan Abdul Halim Airport
 Ipoh - Sultan Azlan Shah Airport
 Kuala Terengganu - Sultan Mahmud Airport
 Kuantan - Sultan Haji Ahmad Shah Airport
 Langkawi - Langkawi International Airport

2. INDONESIA
 Banda Aceh - Sultan Iskandar Muda International Airport

3. SINGAPORE
 Singapore - Singapore Changi Airport

4. THAILAND
 Phuket - Phuket International Airport

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2.6 FLEET

As of 26 March 2018, the Firefly fleet consists of the following aircraft

AIRCRAFT In Service Orders Passengers Notes

ATR72-500 12 - 72

Firefly started operations with two 50-seater Fokker 50 aircraft. It also took delivery
of a third leased Fokker 50 aircraft to expand its services.

On 26 June 2007, Malaysia Airlines signed an agreement for the acquisition of

ten ATR 72-500 aircraft with options for ten more (which was exercised), to replace
the Fokker 50s. The aircraft started to arrive from 11 August 2008, with five delivered
in 2008, five in 2009, four in 2010 and the rest in 2011. All Fokker F50s retired by the
end of 2008

On 25 August 2010, Firefly announced that it would take up four ATR 72s in
the option clause of the purchase agreement. On 8 November 2010, Firefly announced
an order for 30 Boeing 737-800 aircraft from year-end to 2015 as part of its expansion
into east Malaysia initially, and into regional markets in the future. Firefly's first
Boeing 737-800 arrived in December 2010 and began its operations on 15 January
2011.

On 16 August 2011, Firefly announced that it would only operate the ATR
aircraft from Subang and Penang, and cease its Boeing 737-800 and Boeing 737-400
flights. Jet operations were discontinued in accordance with a restructuring-of-services
agreement made between Malaysia Airlines (Firefly's parent company) and AirAsia.
On 16 September 2011, Firefly ceased the Johor Bahru - Kuching route. Other Boeing
737 services, including Kuala Lumpur - Kuching, Kuala Lumpur - Kota Kinabalu and
Kuala Lumpur - Jakarta, were transferred to Malaysia Airlines in October 2011.

On 18 December 2012, MASwings' parent company, Malaysia Airlines,

ordered 36 ATR 72-600s for its subsidiaries. Twenty of the ordered aircraft will be
delivered to Firefly while the remaining sixteen will enter service with MASwings.

6
 Figure 2: Firefly ATR72 aircraft

2.7 COMPANY CEO

Figure 3 Firefly CEO Philip See

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 CHAPTER 3: SCOPE OF TRAINING

3.1 SCOPE OF INDUSTRIAL TRAINING

The industrial training exposes the students to professional skills and experiences in
industrial engineering practices. In preparing the students for the real working
environment as engineers, industrial training helps to produce engineering graduates
with technical and soft skills competency.

In addition, students also had to do research on what is learned during the training
progress. It is to ensure the student enable to gain the knowledge and experience
throughout their 6 months training. Efforts were very needed by a student so that
students can achieve the objectives of industrial training.

After the completion of the industrial training, undergraduates are expected to:

i. Practice actual engineering knowledge and skills at the industry.

ii. Practice and implement soft skills in actual engineering working environment
such as project management skill, planning skill, presentation skill and writing
skill.
iii. Have interpersonal skills and professional ethics.
iv. Have insights into the future professional life of engineers.
v. The internship has to be completed in an industrial enterprise.
vi. The students work in current projects of the company in the development,
production or distribution process.

Sometimes, the task given being carried out alone and supervised by skilled workers
in any circumstances. Surveillance is necessary to ensure that task assigned will be
prepared properly and correctly according to the engineering profession's ethics.

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3.2 TECHNICAL SERVICE DEPARTMENT

This chapter will discuss about the technical service department in Firefly. Each of the
technical service engineer have their own allocate task and responsibility such as propulsion,
avionics, structure and etc. in order to ensure the aircraft, engines, components and associated
equipment are able to perform their specific function as required by the company and Aviation
Authorities. Technical Services Engineer also have to ensure the availability of technical
specialists to support maintenance and liaise with OEMs and other operationally relevant
external entities.

3.2.1 TECHNICAL SERVICE (PROPULSION)

For the propulsion monitoring site, each engine ECTM data were download and
collected from each aircraft. These data were compiled and entered into WebECTM
for engine condition monitoring. This task is important in order to monitor engine
health performance. ECTM is one of the tools to prevent from any unscheduled engine
removal. So, technical service for propulsion need to monitor the data and hours of the
engine to maintain and prevent the engine unscheduled removal.

Figure 4: ECTM data

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 Figure 5: WebECTM

Besides, each aircraft engine have its own engine inspection report (EIR). From
this report, some important data can be consume in order to ensure the airworthiness
of the engine. From EIR, the related Service Bulletin (SB) were collected and managed
for easier monitoring. The issuance of SB were monitored for each engine in order to
ensure the SB issued and airworthy.

Figure 6: Engine inspection report (EIR)

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Figure 7: Engine inspection report (EIR)

Figure 8: Engine SB

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 3.2.2 TECHNICAL SERVICE (RELIABILITY)

The task of the technical service reliability is to do analysis about the trend of the
defect. The aircraft and its system were being monitored in order to maintain the
reliability of the aircraft. The maintenance report (MIREP) and pilot report (PIREP)
from technical log MR1 (Figure 9) and MR2 (Figure 11) for the use of reliability
analysis. The report were collected to ensure no irregular trend of defect on aircraft. In
addition, it is for further analysis such as root cause analysis.

Figure 9: Technical Log MR1

Figure 10: Technical Log MR1

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 Figure 11: Technical log MR2

Figure 12 shows that the data of the oil consumption/uplift for all
ATR72-500 engine. The task is carried out to monitored and ensure there is no
irregular trend of the oil consumption. The data were collected each day from the
technical log MR1 and MR2.

Figure 12: Oil consumption list

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 3.2.3 TECHNICAL PUBLICATION

Figure 13 shows the manual that have been provided by the ATR for aircraft ATR72-
500. If there are any updates, the manual need to be uploaded into the server. This task
has been given in order to ensure that the Firefly’s publication manual is always up to
date when there is new approve manuals issued.

Figure 13: ATR Maintenance Manual

The next task that has been given is to monitor issuance of airworthiness directives
(AD) from authority such as EASA or FAA. If there is AD issued by the authority that effect
ATR72-500, the ETSI (Figure 14) should be raised as instruction to the maintenance personnel
to complete the AD that have been issued. The ETSI is issue by Technical Service department.

14
Figure 14: Technical Service Instruction (TSI)

15
Figure 15 shows the aircraft inspection report (AIR). Aircraft inspection report is used to
refer the mod of each aircraft. The mod list (Figure 16) for each aircraft is being produced
with referring the AIR.

Figure 15: Aircraft Inspection Report (AIR)

Figure 16: Mod list

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 3.2.4 CONTINUOUS AIRWORTHINESS

Figure 17 shows the aircraft maintenance program (AMP) which has been customized
by referring Maintenance Planning Document (MPD). The AMP is being constructed
for easier reference. The responsibility has been given to check with the MPD in
ensuring which aircraft were affected with the task.

Figure 17: Aircraft Maintenance Program (AMP)

17