CHAPTER 1

CHAPTER 1: Introduction
ROSENBAUER Group is a huge company around the world . They work on manufacture of all type of fire fighting system and disaster protection . develops and produces vehicles, fire extinguishing systems,
equipment and telematics solutions for professional, industrial, plant and volunteer fire services, and systems for preventive firefighting. All of the main sets of standards are covered by products manufactured in Europe, the US and Asia. The Group has an active service and sales network in over 100 countries.
The listed family company is in its sixth generation and has served fire departments for more than 150 years. A strong customer focus, innovative strength and reliability are Rosenbauer’s key assets.
1.1 ROSENBAUER History :

Figure 2
Rosenbauer’s corporate history has been closely linked with that of the fire services for the past 150 years. The company has been active for the fire services since 1866, initially as a trading enterprise and from 1906, as an equipment manufacturer. The first fire trucks were built in the 1920s, which also saw the beginning of exports to China. As a result of its constant inventiveness, Rosenbauer has had a major influence on the fire services in Austria, Germany and the rest of the world and has established a reputation as the branch’s innovation and technology leader.
In the wake of the stock exchange float of 1994 and the systematic policy of internationalization pursued subsequently , the company has developed from an export-oriented , specialist business into a worldwide group and a leading supplier of equipment to fire services around the globe .

ROSENBAUER products and their uses :
There are many product’s use for different function but the main uses is to put out the fire around all the world , save life and protect property.
1.2 Saudi Arabia Rosenbauer
ROSENBAUER in Saudi Arabia :Rosenbauer in Saudi Arabia from 2013 until know. There are five main department in Saudi Arabia the first department is HR department , then Service department, sales department and , finally production department
HR department in Riyadh it is responsible for human resource management, financial management , personnel affairs and, all employee issue.
Service department it’s have many work shop .They have work shop in Jeddah, Riyadh, Dammam and, Abha .Also there are 6 mobile workshop vans to serve all costumer of the kingdom of Saudi Arabia . The department responsible to providing after seals services , do periodic maintenance for the all product and vehicle .
Sales department this department responsible for contact with a new costumer and show to him all new fire fighter systems and vehicle .
The most important department is the production department because it is responsible for manufacture the fire fighter systems and vehicle in high quality standard . In Saudi Arabia there are two faculty or factory here the first factory is in Jeddah on the industrial city (Modon ) and it is responsible for manufacture the tanks (polyethylene tanks) then they send the tank to the second factory in king Abdullah economic city (KAEC) on the industrial valley To complete the process of the product . I had my training for 14 weeks in this department especially on KAEC factory I spend most of my training in manufacture fire fighter vehicles and truck . in this report I will write first about KAEC factory and the product of this factory then about the technology , knowledge and special Techniques of Rosenbauer company. I will share the experience of 14 weeks with you .

Figure 2

Chapter 2: Safety
In production department there are general rules must be observed perfectly and followed strictly :
1 – All trolleys and pallets must be stored in designated area next to the storage .
2 – driveway must be clear and unobstructed at all times.
3 – vehicle equipment and accessory must be kept in the trolley (not on the floor ).
4 – trolleys must be placed only in designed location by the side (and / or ) (front , rear ).
5 – empty trolley must be returned to it is designated area , to be free for use by storage technician.
6 – excess consumable Items must be returned to it is ARCOMA boxes .
7 – ARCOMA boxes are exclusively for storage parts use only.
8 – Technician can use only grey boxes for tools handling (not ARCOMA boxes)
9 – Fabrication, welding, grinding, and cutting jobs with disc must be done in the finishing area ( until further notice )
10 – Working table must be remain in the designed location and they are not allowed to be transferred to another area
11 – Consumable parts and accessories must be monitored and information shall be addressed to storage technician for ordering purposes
12 – Using of mobile phone in the production area is strictly not allowed, except for emergence or authorized cases .
13 – Strictly NO SMOKING in side the production area or any part of facility buildings.
14 – Everyone must be in the production area at all time, staying in the locker room for a long time is not allowed.
15 – All personal belongings must be kept in your designated lockers.
16 – Cleaning of working area must be observed before the end of working hours.
17 – All tools that have been in used during the day must be returned to it is designated tool carts or location.
18 – All technician must accomplish TASK CARD daily with complete details and must be submitted to the direct supervisor (until further notice )
19 – Leaving the working area with out permission from the direct supervisor before the end of the shift is not allowed.
20 –To take items from storage without booking and with out a logistic worker is strictly prohibited .
21 – All worker in production area should wear safety shoes . Also wear goggles when use cutting machines .
Warning notices
The safety information warns the user of risk and informs them how these risks can be avoided. Safety information stands at the beginning of a chapter before handling instructions from which a dangerous situation can occur. Safety instructions that must be followed without fail are highlighted as follows:
DANGER! This symbol warns of an extremely dangerous situation, in which non- observation of the danger warning will lead to death or serious irreversible injury.
WARNING! This symbol warns of a dangerous situation, in which non-observation of the danger warning can lead to death or serious irreversible injury.
CAUTION! This symbol warns of a dangerous situation, in which non-observation of the danger warning can lead to slight reversible injury.
NOTICE This symbol warns of situations, in which non-observation of the warning can lead to material damage.
Danger from electricity.
Impending fire risk.
Risk from oxidising materials.

Risk of harmful or irritating materials.

Impending risk of explosion.
Impending acid burn risk.

Chapter 3:
3.1 Engineering Fundamentals that I had applied in the work in the company:
I had applied many engineering fundamentals like drilling hole , tapping , cutting , assembly superstructure , mounted superstructure , pneumatic system , engineering drafting , wielding , gluing metals and , a lot of automotive industry fundamentals like applied sika glue .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The production department focus on production vehicle so most of the fundamentals is about automotive industry. I learned a lot about manufacturing of automotive , the most important thing is reduce vibration transfer throw the parts because most of automotive products is transport vehicles and it is drive on the road so that produce high vibration . when high vibration transfer throw the parts a lot of problem will happen, many of these problem is to dangerous so to reduce vibration throw parts there are many ways , The most ways is : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- use suspension system or shock absorbers . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Picture for suspension system
2 – applied sika glue between all connected parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Picture of sika glue
Pumps and tanks is the most two thing on the fire fighting systems because the pumps is work to increase pressure and velocity of the maxing between water and foam to make the maxing reach vary long distance as long as possible and tanks is the main source of water and foam to supply the pump in the most cases . On chapter four I will explain the main principle of working with details for each one .

3.2 The system of working :
The production manager is ENG. Mohammed Alnohe . Also he is my training supervisor and he is the main manager for all technicians . I took from him a lot of knowledge in manufacturing of tanks , pumps and , hole fire fighting systems .
On rosenbauer they use special software to assigned the task to the technicians the name of this software is ( the magic ) usually the manager of production Mr , ALNOHIE detect the all daily task every day and upload all the task to the magic software . There are three foreman each one responsible to different projects and each one have his team of technicians . the foreman also assigned the task to technicians then the technicians signed in to the magic by his card to his task and the magic will count the working hour .
On my training I did not use the magic because it is just for the employee but I write all the daily task that I had accomplished and working hours ON THE JOB TRAINING MONTHLY ACCOMPLISMENT .
All the ON THE JOB TRAINING MONTHLY ACCOMPLISMENT papers are attached with this report and it checked already by the production foreman and confirmed by production manager .
About the tasks all the tasks is written on the project plan . the project plan is table to show a lot of information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This all information you can know it by read project plan : . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 1 – work order number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – order code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – project T L – number . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . … . . . . . . 4 – description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – setup time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 – cycle time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 – total time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 – plan start ( actual start ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 – due date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – AGNR number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The KAEC factory has two different production line the first one is the north line the second line is the south line each line have different projects also each line can have more than one project at the same time , all that deboned on the project and the time of delivery of the project . This two line running 10 hours on the day , 6 day on the week because the KAEC factory serve all customer on the MENA area (Middle east and North Africa ) .
On my training I work on many projects on different tasks on both lines and I earned so many skills and , understand the different concept for each one . the most two project was CFR truck ( Combined Fire ; Rescue ) and , SP ( small pumper truck ) . on chapter four I will explain this two projects with details . Also I work with faculty stuff to prepare the projects to deliver .

3.3 some of Saudi Arabia rosenbauer products

Example the project plans

Example for ON THE JOB TRAINING MONTHLY ACCOMPLISMENT

3.4 Rosenbauer ELearning
Also , Rosenbauer’s have ELearning web site for all employees to take a lot type of online courses about fire fighter technology to give them the opportunity to improve them self and you can also use any computer to log in then you can learn a lot about fire fighter . they give me an account in Rosenbauer ELearning so I learn a lot of information and skills and I finish approximately 10 courses in different fire fighter subject Also they give me a certificate for each course .

Example for the certificate

Chapter 4
4.1 pumps and tanks

4.2 CFR projects and SP project

4.3 some important standard and principle of workings

4.4 tools
Rosenbaur provide all tools needed on the projects to improve the product quality because use the correct tools will help you to complete your task on the time and to protract yourself from any injury , also the product life will increase .
Rosenbaur it is company care so much to the quality of their products because this product use to save people life and protect assets so it is very important to use great tools for this job . Always they provide vary expensive and good tools for the tasks to keep the quality on their standards
The benefit of use the correct tools :
1- save time and cost .
2- improve products quality .
3- more safety .
4- increase product life and .

This is the most tools I used on this training :

1- OPEN FLARE NUT SPANNER 2- HEXAGON ALLEN KEY SET
*2
*2.5
*3
*4

1- GRIP WRENCH 4- SCREWDRIVER BIT SOCKET SET

2- ADJUSTIBLE SPANNERs 5- OPEN ENDED SPANNER SET

3- KNIFE 6- SCREWDRIVER BIT SOCKET SET

1-TORX SCREWDRIVER SET 2- PRECISION MECHANICS

*digital caliper No. 711 3- IMPACT DRIVER SET
*thread file

*marker
SOCKET WRENCH SET

1- TOOL MODULE 1/4″ 2- PLIERS SET

3- CHISEL SET

1- KNIPEX PLIERS
2- COMBINATION SPANNER SET 3- SCREWDRIVER SET

1- RING SPANNER SET 2- COMB. RACHET SPANNER

3- VDE SCREWDRIVER SET

1- SOCKET SET 1/4″ 2- ACCESSORIES SOCKET

3- WRENCHES

4- SOCKET SET HEXAGON 1/2″

1- CIRCLIP PLIER 2- SWIVEL HEAD WRENCH SET