Team Journal

World Skills International Comp — Shizuoka, it was to be our final test incorporating a years worth of competition preparation and project design as well as a lifetime worth of skill and knowledge.

The month prior to our flight out was the start of a competition mind set, race face. The blinkers were on and we were focused on the main event. From a short stay in Tasmania, where we caught a few sights and sounds as well as attending an awards/farewell function, to Sydney where we had our final farewell with family, friends and Steven Bradbury attending for an entertaining night. We were raring to go.

Our flight out was the Saturday 11th of November arriving in Japan early Sunday morning. The first journey through Tokyo was simply jaw dropping, it was great to see how other cultures live, work and play. Our time prior to the competition was filled with some great experiences as we visited a primary school, the Australian embassy, some very different natural terrain and attractions, as well as meeting some interesting people along the way. Mount Fuji was a definite highlight, the day we arrived in Japan Mount Fuji became visible with the clouds parting. As rare as it apparently is to see the great mountain, we were lucky enough to get a look just about every day we were there, from wherever we ventured.

The competition was another thing; it was just jaw dropping the first day we walked in, it really is the "Skill Olympics". Everything there was top of the line in every trade, the venue was huge with a constant flow of visitors. To compete in this environment was a once in a lifetime experience, I thought the national competition was elite but this was ten fold what I experienced in Melbourne. Competitors of all categories were extremely skilled and prepared, a talking point was some of the sizes of the toolboxes, some containing a small workshop; every competitor had an excellent support base.

In conclusion, I can't cover everything I have experienced in Japan or this past year, above is just a small glimpse of an event that will be remembered all my life. In short World Skills has allowed me to change for the better in everything, personally I have grown into a different person, which has changed my outlook and way of thinking. On the job I have developed and learnt many new skills and I've expanded my trade knowledge, working under pressure in the competition has given me more confidence in my skills. The amount of positives this year has just been immense. Although all year we were developing a project design, a hell of a lot more happened than just competition preparation. We were turning ourselves into people that can think, plan, work and communicate clearer and better. We are now in the ultimate position to take on our lives and careers, the rest is up to us.

Just a very appreciative thank you to DSF and especially Geoff Ball who basically allowed us to complete this great adventure, not to mention everyone that has helped along the way in all aspects. You are all very valuable and your help has been greatly appreciated.

Joshua Morsillo, 2007 Competitor

October 2007

Pre-Departure Q's and A's

SAMUEL POP

1. How do you feel your preparation has gone?

I feel that the preparation is going really well, with the comp being just around the corner, we are starting to finalise things and put the portfolio together.

2. Are you confident about your performance in the upcoming competition?

I would have to say yes, because work has given me the opportunity to work on the MTC project and have really supported me, and continue to support me. So if all goes well and not so well, the performance will still be there.

3. Name one personal and one technical person that has helped you develop throughout the MTC preparation?

- Ross McLean has provided me with lots of support and advice thought the Project.
- Graeme Carr (Relieved Instructor) Has given me lots of technical advice and has contributed to some of the Prototypes made through the preparation.

JOSHUA MORSILLO

1. How do you feel your preparation has gone?

Our preparation up to this time has been very extensive, we have all have learnt new things we would not usually come across day to day. I feel that we are very prepared for Japan in both our project design and our training in different fields.
 
2. Are you confident about your performance in the upcoming competition?

I am confident in our design and in the team, the design of the project is on the money and our team covers a wide range of skill areas that we will need for the competition, we work well together and I am confident we will do our best.
 
3. Name one personal and one technical attribute that has developed throughout the MTC preparation?

I have picked up a few new skills and honed some old ones in preparation for Japan, welding being one. As well my confidence in the trade and myself have grown immensely over this time. I have learnt so may new things this past year both personally and from my technical training, no matter what I will be definitely walking away from this year a changed tradesman.

September 2007

This was to be our final practical workshop. It was an extremely crucial weekend leading up to the competition, as our toolbox was departing for Japan in 2-3 weeks. It was only 4 weeks prior that we were all together but we had all progressed things in that time. We had jigs, drawings and a few fresh ideas. Throughout the weekend, we commenced the build, encountering some minor difficulties in certain areas. We were able to negotiate these by trying some alternative methods, and continuously discussing ideas or problems between ourselves and with some extremely knowledgeable people who have helped us immensely over our design period.    
  
By Sunday we had our unit up and running. We once again went over it with a fine toothcomb to confirm materials, documentation, fasteners, tooling and build methods. The day was closing fast and we proceeded to pack the toolbox, which was a huge sign at that time that things are close. Later that week I received my team Australia uniform and that definitely confirmed that things are coming down to the hammer now. The weekend was another success, and we are confident moving into competition time. Again there are still things to do, we have to complete some documentation regarding the unit prior to the comp and we are all training and practising heavily. At the time it was 60 days to go, and we are all primarily in focus on Japan, just can't wait to get over there and build something.

Joshua Morsillo, 2007 Competitor

August 2007

August Workshop Agenda:
 
 - Manufacturing process for each part
 - Test new DC motor
 - Draw sketches for each of the components
 
During this workshop we tried to focus on the manufacturing process for each of the component. The manufacturing process consisted of a step-by-step operation to make the particular component. Although we were sidetracked with the generator a little bit, we did manage to improve the manufacturing process for the pump housing. We also looked at the slip ring design and managed to improve that a little as well.
 
Overall, a very good workshop, even though we did not do too much on the manufacturing process for each of the components of the project.
 
Samuel Pop, 2007 Competitor

This weekend was aimed at completing a full build of the unit and to finalise the design. We looked at pretty much all aspects of the project including part design, manufacturing methods, possible faults and searched for any possible improvements to be made. Throughout the weekend we had a few visitors drop in, like the Skills One camera crew who spent the majority of the day with us, interviewing and filming us in our preparation for the comp.

Overall, once again, we had a very good and productive weekend; the design meets the criteria and it is a good practical unit. There are still things to look at but we are confident with the manufacture of it and all of the components. We are working as a team, and continuing to learn more and more along the way. It is now 86 days until Japan, and things are looking good.

Joshua Morsillo, 2007 Competitor

July 2007

The July workshop came around extremely quick, with only a month since our last one. Our design was definitely on track, but there were some crucial and some less particular items that needed to be looked at and adapted to the project and this was the weekend to do it.

Throughout the weekend we manufactured new and modified some of the old components of the wind generator, we were in constant conversation about the design and function of all parts which allowed us to come to a more informed and more practical decision. We came away from the weekend with a design that is starting to be ironed out, as far as simplifying certain items and making sure things will work. Between now and the next training camp we all have things to do as far as practising making and building the project, drawings, project information, and just general preparation for the competition. Things are definitely going that quick now, that was one of the quickest weekends I think we've had.

Joshua Morsillo, 2007 Competitor

June 2007

At the past workshop, we looked and tested a variety of things. We had all worked on different things between workshops; such as a mounting structure along with tail, slip rings, blade design, jigs and circuitry. Over the weekend we achieved progress in our design by agreeing on certain parts of the project. We were able to come away with plans to finalise these parts with the preparation of drawings, manufacturing notes and also material/tooling requirements, as well as plans to practice the ways we make the components. We learn a lot every weekend we meet and test; this helps us in the development of the project and our ability to assess components and understand what is happening. The three of us are also developing our ways of working together and our communication on and off the job. Japan is drawing ever closer and our project is continuing to develop and change. I think we are on track and it definitely is an exciting hands-on learning experience.
 
 Joshua Morsillo, 2007 Competitor

As usual the workshop started with a sharing of ideas and any prototype parts we had been working on.  We also took some time to discuss the requirements of the control circuit to suit our pump, leaving me with some work to do when I go back home.  To keep progressing on the whole wind generator we needed to start putting together whole parts of the unit.   It didn’t take too long to assemble the first test parts and discover some unexpected problems. Although the end result for the weekend wasn’t as good as I’d hoped, we have managed to produce a working part of the wind generator.

Matthew Nunn, 2007 Competitor

April 2007

This workshop gave us the chance to focus on the area of the wind generator that I’m most concerned about.  The goal for the weekend was to develop a working turbine and generator.  After testing for the requirements for the generator we made a few turbines to suit, and began the process of trial and error. A lot of time was spent trying to make a manufacturable turbine that gives us the output we need.  By the end of the weekend, we had achieved what we set out to do and learnt a lot about wind power in the process.

Matthew Nunn, 2007 Competitor

The battle was on and this time it was against the wind generator. I had thought from the tests I did at work that this was not going to work. But achieving what we wanted was what made the second workshop such a success.

Although it was hard at the beginning of the workshop to get the power output that we needed, we managed to tackle that and achieve a solution on the last day of the workshop. It proved a huge success. I couldn’t believe my eyes because I was convinced that it was not possible. It just goes to show how important getting together really is. Overall a very promising workshop, which answered a lot of the questions that were in the air.

Samuel Pop, 2007 Competitor
  
This workshop had been a long time coming. We all spent the 6 weeks in between workshops researching and prototyping wind generators in and around work. We all came prepared with a variety of different generators and turbines; so much that we almost needed a trailer. Friday was spent testing different electrical generators; we set up a test where we could monitor the electrical output and torque required at different speeds. Again, we compared all our results and decided on a couple of generators which worked best and that we could test our turbines on.

Over Saturday we tested some different turbine designs; the day was spent modifying our designs to achieve the greatest efficiency. It was great delving into a subject that I would not usually be involved with. At the end of the day we were almost near our aim of a certain power output, after testing many set-ups and learning a lot.
  
On Sunday, we were nearing our expected requirements with the generator. The morning was spent manufacturing new blades and attachments. The design was confirmed by testing different shape and size blades, proving which were efficient and which were not. By the end of the day we had achieved our requirements in power output, we were constantly learning from modifying blade design and seeing the effects. A great weekend in the end.

   
Joshua Morsillo, 2007 Competitor

March 2007

Our first workshop after the training camp was very successful. We managed to tackle the water pump very well; each of us had bought in a few designs and prototypes and put them to the test. Some worked really well where as others didn’t work out at all. By the last day (Sunday) we managed to finalise our design and select the most efficient one. Overall, a very productive weekend with lots of work done.

Samuel Pop, 2007 Competitor

It had been about 6 weeks since we had all seen each other in Melbourne, and this weekend was aimed at focusing on our pump/filter design. We started the weekend with a brief on the design of the pump, then moved on to testing and comparing some prototypes we manufactured prior to the weekend, as well as some commercial pumps. During this, we recorded the differences between pumps, and then modified them slightly to see if it gave a positive effect. Another aspect we had to decide on was a motor to drive the pump, which would need to be efficient as possible. That afternoon we also met with Tjerk, Kerry and Emily from Dusseldorp Skills Forum to explain the project and show them some work in progress.

Saturday came around and we decided to primarily focus on the best pump and motor from Friday. We spent the day modifying our pump design further and machined up a few new features, again recording the effects. As we went along, we continued to discuss filter design and storage tanks that may suit a particular set-up. By the end of the day we had an assortment of different prototypes and a few that stood out as more efficient set-ups. At night we would have a break from the project. It was great to sit down and have a conversation about anything but a pump.

The last day we finished up by doing a final test to find which pump was the most efficient. We tested different requirements that we wanted to meet, and were more than happy to confirm a final design. Once again, every time we meet up we learn something new about what we're working on or about each other. It was a pretty successful weekend.

Joshua Morsillo, 2007 Competitor

February 2007

The training camp was bloody great. This was the first real opportunity we had to socialise as a team and put aside the task at hand, not only did I learn a lot about the boys and their backgrounds both professionally and personally but my confidence increased in the fact that I think we've got the right team for the job. Prior to the camp, now that I look back I think that I had no real set training plan, I was looking too much at the big picture and not focusing on the smaller more particular details, but during the camp we set out a map of where we want to be at certain dates regarding our design and what skills we will need to hone or pickup along the way. This definitely provided us with some direction and goals for the team. During the camp we also covered information on the competition, rules, marking etc, and shared some ideas on designs for a portable wind generator. Not all the camp was discussion time, we had a few activities to keep us going, kayaking, raft building, some great ones with the use of some blindfolds and also the many walking/biking tracks and the lake.
  
The fact that we are all in different states will always be hard, especially on sharing ideas and working together as a team. We are making the most of the internet for our communication with a regular weekly e-mail keeping the team up to date with everyones progress, and we are planing numerous training camps so we can all come together and work on the project. As part of the lead up I am nearly always thinking about the design in the back of my head, I also have picked up a welding course which I am really enjoying, and not to mention the constant notes, rough drawings and prototype parts or examples littering my workplace and home. Now that we have started to work on the project I am finding myself enjoying the work, thinking differently and trying new things all to achieve the final outcome.

Josh Morsillo, 2007 Competitor

The training camp at Lake Dewar Lodge was the first opportunity the MTC team had to get to know each other a bit better.  The 3 days were broken up with team building activities, training plans and some free time in the evenings to relax. Opportunities for the MTC team to get together will be rare and making the most of the time is important.  We managed to discuss the objectives further, put together training plans for each of us, put some rough dates to project milestones and even discuss some of the finer points of the project.  I'm beginning to feel better about the competition knowing that we have a training plan and some milestones in place.  The water activities were the highlight of the camp and it was good to see the team experts getting involved in the rafting and canoeing activities along with all of the competitors. Even though we're all from different trades and backgrounds we all seemed to make the most of the training camp and have some fun.  

Matthew Nunn, 2007 Competitor