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MY EMPLOYERS AND CLIENTELLES
A THOUGHT
It’s wonderful to revisit the past, though not every memory is nostalgic some can drain your spirit to live. I find the present while learning valuable lessons from the past (so they’re not repeated), and focus on the future gives me a sense of closure, ownership, even drives me to move forward, and feels truly empowering.
Perhaps it's time to recite this daily mantra - that "enough is enough" - "no more being a victim, I'm retaking control of myself and my life"
Kelantanese, Alumni of Sultan Ismail College Kelantan (SICA), Business Management/Administration, IT Competency Cert, Certified Written English Professional US. Has participated in many seminars/conferences (local/ international) in the capacity of trainer/lecturer and participant.
Affiliations :- Council/Network Member of Gerson Lehrman Group, Institute of Quality Malaysia, Auditor ISO 9000 IRCAUK, Auditor OHSMS (SIRIM and STS) /EMS ISO 14000 and Construction Quality Assessment System CONQUAS, CIDB (Now BCA) Singapore),
* Possesses almost 30 years of experience/hands-on in the multi-modern management & technical disciplines (systems & methodologies) such as Knowledge Management (Hi-Impact Management/ICT Solutions), Quality (TQM/ISO), Safety Health Environment, Civil & Building (Construction), Manufacturing, Motivation & Team Building, HR, Marketing/Branding, Business Process Reengineering, Economy/Stock Market, Contracts/Project Management, Finance & Banking, etc. He was employed to international bluechips involving in national/international megaprojects such as Balfour Beatty Construction/Knight Piesold & Partners UK, MMI Insurance Group Australia, Hazama Corporation (Hazamagumi) Japan (with Mitsubishi Corporation, JA Jones US, MMCE and Ho-Hup) and Sunway Construction Berhad (The Sunway Group of Companies). Among major projects undertaken : Pergau Hydro Electric Project, KLCC Petronas Twin Towers, LRT Tunnelling, KLIA, Petronas Refineries Melaka, Putrajaya Government Complex, Sistem Lingkaran Lebuhraya Kajang (SILK), Mex Highway, KLIA1, KLIA2 etc. Once serviced SMPD Management Consultants as Associate Consultant cum Lecturer for Diploma in Management, Institute of Supervisory Management UK/SMPD JV. Currently – Associate/Visiting Consultants/Facilitators, Advisors/Technical Experts for leading consulting firms (local and international), certification bodies including project management. To name a few – Noma SWO Consult, Amiosh Resources, Timur West Consultant Sdn. Bhd., TIJ Consultants Group (Malaysia and Singapore), QHSEL Consultancy Sdn. Bhd.
He is also currently holding the Position of Principal Consultant/Executive Director (Special Projects) - Systems and Methods, ESG, QHSE at QHSEL Consultancy Sdn. Bhd.* Ex-Resident Weekly Columnist of Utusan Malaysia (1995-1998) and have produced more than 100 articles related to ISO-9000– Management System and Documentation Models, TQM Strategic Management, Occupational Safety and Health (now OHSAS 18000) and Environmental Management Systems ISO 14000. His write-ups/experience has assisted many students/researchers alike in module developments based on competency or academics and completion of many theses. Once commended by the then Chief Secretary to the Government of Malaysia for his diligence in promoting and training the civil services (government sector) based on “Total Quality Management and Quality Management System ISO-9000 in Malaysian Civil Service – Paradigm Shift Scalar for Assessment System”
Among Nik Zafri’s clients : Adabi Consumer Industries Sdn. Bhd, (MRP II, Accounts/Credit Control) The HQ of Royal Customs and Excise Malaysia (ISO 9000), Veterinary Services Dept. Negeri Sembilan (ISO 9000), The Institution of Engineers Malaysia (Aspects of Project Management – KLCC construction), Corporate HQ of RHB (Peter Drucker's MBO/KRA), NEC Semiconductor - Klang Selangor (Productivity Management), Prime Minister’s Department Malaysia (ISO 9000), State Secretarial Office Negeri Sembilan (ISO 9000), Hidrological Department KL (ISO 9000), Asahi Kluang Johor(System Audit, Management/Supervisory Development), Tunku Mahmood (2) Primary School Kluang Johor (ISO 9000), Consortium PANZANA (HSSE 3rd Party Audit), Lecturer for Information Technology Training Centre (ITTC) – Authorised Training Center (ATC) – University of Technology Malaysia (UTM) Kluang Branch Johor, Kluang General Hospital Johor (Management/Supervision Development, Office Technology/Administration, ISO 9000 & Construction Management), Kahang Timur Secondary School Johor (ISO 9000), Sultan Abdul Jalil Secondary School Kluang Johor (Islamic Motivation and Team Building), Guocera Tiles Industries Kluang Johor (EMS ISO 14000), MNE Construction (M) Sdn. Bhd. Kota Tinggi Johor (ISO 9000 – Construction), UITM Shah Alam Selangor (Knowledge Management/Knowledge Based Economy /TQM), Telesystem Electronics/Digico Cable(ODM/OEM for Astro – ISO 9000), Sungai Long Industries Sdn. Bhd. (Bina Puri Group) - ISO 9000 Construction), Secura Security Printing Sdn. Bhd,(ISO 9000 – Security Printing) ROTOL AMS Bumi Sdn. Bhd & ROTOL Architectural Services Sdn. Bhd. (ROTOL Group) – ISO 9000 –Architecture, Bond M & E (KL) Sdn. Bhd. (ISO 9000 – Construction/M & E), Skyline Telco (M) Sdn. Bhd. (Knowledge Management),Technochase Sdn. Bhd JB (ISO 9000 – Construction), Institut Kefahaman Islam Malaysia (IKIM – ISO 9000 & Internal Audit Refresher), Shinryo/Steamline Consortium (Petronas/OGP Power Co-Generation Plant Melaka – Construction Management and Safety, Health, Environment), Hospital Universiti Kebangsaan Malaysia (Negotiation Skills), Association for Retired Intelligence Operatives of Malaysia (Cyber Security – Arpa/NSFUsenet, Cobit, Till, ISO/IEC ISMS 27000 for Law/Enforcement/Military), T.Yamaichi Corp. (M) Sdn. Bhd. (EMS ISO 14000) LSB Manufacturing Solutions Sdn. Bhd., (Lean Scoreboard (including a full development of System-Software-Application - MSC Malaysia & Six Sigma) PJZ Marine Services Sdn. Bhd., (Safety Management Systems and Internal Audit based on International Marine Organization Standards) UNITAR/UNTEC (Degree in Accountacy – Career Path/Roadmap) Cobrain Holdings Sdn. Bhd.(Managing Construction Safety & Health), Speaker for International Finance & Management Strategy (Closed Conference), Pembinaan Jaya Zira Sdn. Bhd. (ISO 9001:2008-Internal Audit for Construction Industry & Overview of version 2015), Straits Consulting Engineers Sdn. Bhd. (Full Integrated Management System – ISO 9000, OHSAS 18000 (ISO 45000) and EMS ISO 14000 for Civil/Structural/Geotechnical Consulting), Malaysia Management & Science University (MSU – (Managing Business in an Organization), Innoseven Sdn. Bhd. (KVMRT Line 1 MSPR8 – Awareness and Internal Audit (Construction), ISO 9001:2008 and 2015 overview for the Construction Industry), Kemakmuran Sdn. Bhd. (KVMRT Line 1 - Signages/Wayfinding - Project Quality Plan and Construction Method Statement ), Lembaga Tabung Haji - Flood ERP, WNA Consultants - DID/JPS -Flood Risk Assessment and Management Plan - Prelim, Conceptual Design, Interim and Final Report etc., Tunnel Fire Safety - Fire Risk Assessment Report - Design Fire Scenario), Safety, Health and Environmental Management Plans leading construction/property companies/corporations in Malaysia, Timur West Consultant : Business Methodology and System, Information Security Management Systems (ISMS) ISO/IEC 27001:2013 for Majlis Bandaraya Petaling Jaya ISMS/Audit/Risk/ITP Technical Team, MPDT Capital Berhad - ISO 9001: 2015 - Consultancy, Construction, Project Rehabilitation, Desalination (first one in Malaysia to receive certification on trades such as Reverse Osmosis Seawater Desalination and Project Recovery/Rehabilitation), ABAC Centre of Excellence UK (ABMS ISO 37001) Joint Assessment (Technical Expert)
He is also rediscovering long time passions in Artificial Intelligence, ICT and National Security, Urban Intelligence/Smart Cities, Environmental Social and Governance, Solar Energy, Data Centers - BESS, Tiers etc. and how these are being applied.
* Has appeared for 10 consecutive series in “Good Morning Malaysia RTM TV1’ Corporate Talk Segment discussing on ISO 9000/14000 in various industries. For ICT, his inputs garnered from his expertise have successfully led to development of work-process e-enabling systems in the environments of intranet, portal and interactive web design especially for the construction and manufacturing. Some of the end products have won various competitions of innovativeness, quality, continual-improvements and construction industry award at national level. He has also in advisory capacity – involved in development and moderation of websites, portals and e-profiles for mainly corporate and private sectors, public figures etc. He is also one of the recipients for MOSTE Innovation for RFID use in Electronic Toll Collection in Malaysia.
Note :
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ON THE"LABEL" SECTION BELOW (RIGHT SIDE COLUMN), YOU CAN CLICK ON ANY TAG - TO READ ALL ARTICLES ACCORDING TO ITS CATEGORY (E.G. LABEL : CONSTRUCTION)OR GO TO THE VERY END OF THIS BLOG AND CLICK "Older Posts"
Sunday, November 30, 2025
CASE STUDY AT A FOOD PROCESSING FACTORY
A friend once asked me to join him in a routine assessment at a food-processing factory, something that I have passion in but I was there only to check on the documentation as my friend was the technical expert.
Findings
The boiler’s feedwater tank was found to have excessive sediment buildup, causing slight fluctuation in boiler pressure and reduced heating efficiency.
The sediment layer indicated inconsistent water treatment and infrequent blowdown, leading to partial blockage at the feedwater inlet strainer.
Root Cause
The excessive sediment buildup in the boiler feedwater system was primarily caused by inconsistent water treatment and infrequent blowdown, resulting from inadequate operator adherence to the established maintenance schedule.
Contributing factors include insufficient monitoring of feedwater quality, leading to undetected increases in total dissolved solids (TDS) and sludge accumulation, and a clogged feedwater strainer that was not cleaned according to the preventive maintenance plan.
Solution
1) Perform immediate blowdown to remove accumulated sludge.
2) Clean or replace the feedwater strainer.
3) Reinstate proper water treatment dosing and implement a scheduled blowdown routine (daily/weekly depending on load).
4) Include feedwater quality checks in the preventive maintenance checklist.
This is the primary DOSH regulation under the Factories and Machinery Act 1967 that governs steam boilers and unfired pressure vessels requiring regular inspection, maintenance, and safety controls of boilers.
OSHA on Certification and Competency Requirements - requirement for competent persons - both a steam boiler engineer and boiler operator must be designated.
Certificate of Fitness (CF) - Boiler/pressure vessels require a valid DOSH's CF issued after inspection to confirm compliance with the safety regulations.
(This case study was from early 2023 but latest DOSH Regulations (2024–2025 Updates) - New CF Regime - OSH Regulations 2024 (PUA 99/2024) effective 1 June 2024 - (Plant requiring CF) Certain plants, including steam boilers, must obtain a CF before they can operate. Periodic inspections required to maintain validity. CF is not unlimited: the validity is capped (e.g. as per industry commentary, not exceeding 15 months).
If there are repairs that affect the strength of the boiler, DOSH may require another hydrostatic test before recertification.
Owner/Occupier Duties - must operate and maintain the boiler in a safe and proper condition including testing the control and safety devices (e.g., safety valves, pressure gauges) periodically according to manufacturer’s recommendations, keeping logbook and records of operation, inspections, repairs, breakdowns.
During a DOSH inspection, they need to ensure the boiler is ready for inspection per DOSH’s checklist
SSI
Plants approved under SSI, the CF period can be extended much longer depending on type of plant, risk category, integrity history inspection intervals approved by DOSH,
Typical extensions under SSI may allow:
a) Pressure vessels to run on extended intervals b) Inspection schedules aligned with API 510, API 570, API 653 c) Boilers or critical equipment to follow risk-based inspection (RBI) intervals d) Major shutdown cycles (e.g., every 4–6 years) instead of annual shutdowns
It only allows extended intervals for inspection and CF renewal with DOSH approval.
e.g.
A normal air receiver or pressure vessel:
a) CF renewed every 12–15 months
Same vessel under SSI with RBI approval:
- CF may be aligned to a 3–5 year inspection cycle - Internal inspection may coincide with major turnaround - Online NDT and monitoring replace some physical shutdowns
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