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PRACTICUM ATTACHMENT REPORT FOR BATA SHOES COMPANY LTD

Presented by;

Joseph Njuguna Kamau J75/2340/2009
Institution
Kenyatta University School of Engineering and Technology Department of Mechanical and Manufacturing Engineering

Assessed by: MR. KARIUKI IKINYA

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Table of Content CHAPTER 1 0 Introduction………………………………………………………………………………...….3 1.1 Historical background of Bata Shoes Company……………………………............................3 1.1 Production Processes at Bata Shoes Company………………………………………….…….4 1.3 Organization Structure of Bata Shoes Company………………………………………...……6 1.3.1 Management organization structure…………………………………………………………6 1.4 Bata Environmental and Corporate Social Responsibility…………………………………….8 1.4.1 Manufacturing and the Workplace………………………………………..…………8 1.4.2 1.4.3 1.4.4 Eco-Efficiency and Environment………………………………………………….8 Eco-Innovation and Development……………………………………………..….9 Community Involvement & Social Development…………………………...…….9

1.5 General Outlook of Bata Shoes Company………………………………………………...…10 CHAPTER II 2.1 Attachment Goals and Objectives……………………………………………………………12 2.2 Safety at the Factory Premises……………………………………………………………….13 2.3 Potential Risks & Accidents at Bata Shoes Company……………………………………….14 CHAPTER III 3.1 Assignments at the Company………………………………………………………..……….19 3.1.1 Workshop Practices………………………………………………………………………..19 3.1.2 Installation, Maintenance and Repairing of Motors………………………………….……20 3.1.3 Making Safe Working Procedures of Various Machines…………………………….……22 3.1.4 Making and Documentation of LOTO Procedures……………………………………...…23 3.1.5 Maintenance and Repairing of Machines……………………………………………….…24 3.1.7 Maintenance and Repairing Steam Boilers……………………………………………...…26 3.1.8 Maintenance of Water Pumps and Aerating Pumps…………………………………….…28 CHAPTER IV 4.0 Conclusion and Recommendation………………………………………………………...…31 4.1 Recommendations………………………………………………………………………..…..31 4.2 Conclusion……………………………………………………………………………...……31

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CHAPTER 1

0 Introduction This industrial attachment report gives an outline of the skills and experiences gained while I was at Bata shoes Company, Limuru from 5th July 2012 to 5th September 2012. The main object of this paper is to examine the nature of the production operations of Bata Shoes Company including designing of shoes, their production, and maintenance of machines including other activities. The report gives a general overview and background information of Bata Shoes Company, specific activities I was involved in while on attachment, the skills and knowledge acquired during the attachment period. I have also included the activities I undertook in benefit to the company. The report also includes a summary of all the report and some recommendations of the changes that should be made in various sections in order to maximize the output and at the same time catering for the workers and the customers.

1.1 Historical background of Bata Shoes Company The Bata shoes company originated from what is now Czechoslovakia. In its early stage of development, the company received a substantial boost in the form large contracts for military boots and shoes, which were placed by the imperial Government. After the 1st world war, the company expanded overseas from its national base and set up production units in many parts of the world. By 1930, it had established itself as a major international shoes firm with distribution and production units located in several different continents. In 1935, the Bata Shoes Company opened a distribution branch in Mombasa, on the Kenyan Coast. This was a strategic position to capture the expanding market for shoes in east

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Bata’s Mission Statement To provide world-class products to our valued Customers. This was from the order of the colonial government.and central Africa. the company was manufacturing over 8 million pairs of shoes per year. Maintaining high Ethical Standard business. which were then marketed along with other Bata products imported from Czechoslovakia. In 1939. A site was offered by the government 20 miles north of Nairobi. Bata is a multinational company with more than one hundred companies in the world. the Mombasa branch began to manufacture low cost rubber shoes for the African market. There was a rapid expansion of the production capacity of the Bata plant in Kenya and by 1975. In 1939. in the east African region. a rubber factory and a bicycle tyre plant were added to the existing complex. 1950’s. which was concerned about the threat of invasion along the east African coast. It was located in what is now known as Limuru. the headquarters of the Bata Shoes Company had to be moved from Czechoslavakia to Canada. tannery and leather factory. where there was an ample supply of running water for the setting up of a tannery. commenced out between 1940 and 1950. Today. In the mid. 1. The Kenyan subsidiary was also moved upcountry from Mombasa during the second world war. As with many other 4 .1 Production Processes at Bata Shoes Company The structure of Bata Shoes Company was clearly determined from the onset of the overall pattern of operations of the Bata organization throughout the world. The construction of the factory. There was a branch of a railway line which run through the factory to ease transportation of shoes.

The company uses sophisticated production techniques to manufacture synthetic shoes.large multinational corporations. although the technology employed in the Kenyan Subsidiary is not much advanced in comparison to Bata’s European and north American branches. The form of production adopted by the Bata shoes company reflects the technical sophistication common to major industries operating in a world-wide scale. To give an idea of the world-wide integration of this processes. All the Bata Shoes company products are distributed through Bata’s own sales networks spread all over the country. Virtually. 5 . the company owns estates in West Africa on which rubber is grown to supply Bata Shoes Factories in other parts of the world. the form of production utilized is of a capital intensive nature. all the leather used by the Bata Shoes Factory comes from their tannery. This method requires the use of machinery such as injection moulding machines. Bata’s operations are highly interpreted and carefully controlled from start to finish of the production process. Thus.

1 Management organization structure Below is an illustration of the organization structure of the Bata shoes Company. Chief Electrical Eng.1. Advertising Manager 6 . Information Technology Chain Store managers Chief Mechanical Eng. Board of Directors Managing Director Chief Finance Officer Secretary Production manager Chief Plant Engineer Assurance Manager Tannery Manager Sandak Internal Audit HRM Public Relation Manager Manager Thongs Chief Chemist Manager DIP Manager Palletizin g Chief Manager.3 Organization Structure of Bata Shoes Company 1. Procurement Chain Store managers Marketing Manager Manager.3.

7 . The managing director is the overall head of the company.   The Human Resource manager is the overall head of all employees of the company Chief Finance Officer deals with planning of how funds will be used. He receives orders from the headquarters of Bata Companies in Canada. The production manager manages all production processes. financing the buying of items and accounting of the financial records. funding of the various activities running in the company for example the paying of workers’ salaries. Procurement department headed by the procurement officer is involved in the purchasing and distributing items used by various departments and making records for those items.    Chief plant engineer is the overall manger heading the engineering department.

Bata has a sustainability program.  Bata employs more than 2. while simultaneously protecting the environment for the current generation and the generations to come. clean and stimulating workplace for all its employees. suppliers and communities in the developed as well as in the developing world. which is an ongoing consultative process throughout its global operations and includes activities in four key areas: 1.4. The common goal of the company is to continue improving the lives of all their customers. 8 . thus helping the company conduct business in accordance to this philosophy of service and corporate responsibility. Some examples of current Bata good practice includes:  Bata Code of Ethics and Values and Beliefs that guides the employees in day to day work.4 Bata Environmental and Corporate Social Responsibility Driving a dynamic enterprise that serves its customers and its community has been at the heart of Bata’s culture and vision since 1894.1.000 people from all over Kenya manufacturing quality shoes for the local people’s taste and needs. health & safety days to raise awareness among the workers.  At Bata. The company has a tradition of responsibility towards its workforce and offers working conditions that protect each employee's health and dignity. learning is a priority: The company has an E-learning induction program that trains all new employees in Bata culture and skills.  Bata organize routinely environment. employees.1 Manufacturing and the Workplace Bata is committed to the development of operational excellence that leads to the production of footwear in a safe.

materials and products that cause the least harm to the environment and to the people.   BATA has introduced water-based adhesive in its shoe production.000 mature pine trees over the period of one year. This saving would be the equivalent to the carbon sequestration from the atmosphere of about 80. and to conserve fresh water resources in its tannery with wastewater treatment plants. environmentally conscious materials like 9 .  BATA is committed to minimize the use of water in its operations with water harvesting systems. Recycle. In doing so.3 Eco-Innovation and Development Bata strives to identify and utilize processes. to ensure protection of the environment.  BATA has introduced translucent sheeting on roofs.4. For instance.2 Eco-Efficiency and Environment The Bata shoes company has always played a leadership role in the communities in which it operates. Bata aims to reduce the climate impact of its manufacturing facilities by taking every precaution to prevent or lessen any adverse effect on the environment that may result from its operations.4. Reuse. 1. LED lamps.1. photocell control in the manufacturing facilities that help reduce energy consumption. The translucent sheeting reduced the carbon footprint by approximately 490 tons of CO2. Some examples of current BATA good practice:  The BATA’s Environmental Mission Statement supports its pledge to uncompromising environmental stewardship and supports the principle of the three Rs: Reduce. BATA supports the development of materials and manufacturing innovation. BATA has a long tradition of planting trees in and around its production sites.

10 . stitched and embedded to the sole after some other intermediary processes. charitable contributions and by spearheading social ventures.4 Community Involvement & Social Development BATA supports and empowers local communities wherever it operates by being involved with the communities through employees’ participation. buffing. leather and canvas footwear. The factory is incorporated with various machinery used in process of fleshing. 1.5 General Outlook of Bata Shoes Company The Bata shoes company produces various types of footwear ranging from sandak. Various chemicals are weighed depending on the intended colour and hardness of the product. embossing and other finishing operations. water-based adhesive and natural materials like cork are being utilized in shoes manufacturing. Finished leather from the tannery factory is cut into various patterns. 1. chromium-free leather.recyclable and partly recycled TPE.4.  Tannery factory This is where raw hides and skins are converted to leather ready for shoe making. which produce specific type of shoes. They include:  Palletizing factory This is where the PVC resin used in the manufacrure of Sandak and Soles is converted to PVC granules. The plant is divided into subsections. spraying. tanning. splitting. The company has a program called Bata children’s Program which conducts initiatives with the help of Bata volunteers.  Leather factory This is where leather shoes are made.

The factory is incorporated with automated injection machines.  D. 11 . which are fed with pre-warmed PVC granules from the palletizing factory.P Factory This is where canvas shoes such as ngoma and bullets are made.I.  Thongs Factory This is where EVA sheets used in making slippers are made. Sandak Factory This is where PVC footwear is made mainly gumboots. The factory is incorporated with machines for hardening and cutting the canvas material and also injections machines for injecting soles into the uppers.

applying the knowledge learned in the classroom to the work environment. In order to achieve the above goals and objectives. I did set measurable objectives which could help me achieve my goals.1 Attachment Goals and Objectives The attachment program was meant to help me experience and appreciate what it is really like working in an engineering department of a manufacturing company. I analyzed my technical skills (what I was capable of doing).gaining decision-making and critical thinking skills as well as increased confidence and self-esteem in my profession as an engineer. which acted like a benchmark in which I assessed my achievements and my personal development. Before starting my attachment at the Bata shoes company. I did reflect on my own abilities which gave me a direction in search for a productive and worthwhile attachment program. The attachment would also help me apply the theory and skills that I have learnt at school for my professional development as an engineer to be.  Personal development. 12 .  career development-developing knowledge in engineering field in order to pursuemy particular interest in engineering. my professional skills (what I knew) and my personal skills (how well I can get things done). First.  skill development-gaining an understanding of the technical skills and knowledge required in the workplace. I did a SWOT analysis on myself. I did set my own goals and objectives. The goals and objectives were as follows:  academic learning.  Develop an attitude conducive to effective interpersonal relationships.CHAPTER II 2.

therefore. and supervision for ensuring safety and health. instruction.  making arrangement for ensuring safety and health in connection with the use.   providing and maintaining safe access to and egress from the workplaces.  Bata management contributes to safety and health in the workplace by:  providing and maintaining plant and work systems that do not endanger safety or health. training. Ask questions in case of anything unclear. Therefore. the working environment can have a major impact on their heath.  the premises. 2. most of the employees spend about a third of the day at work premises. Under these regulations. everyone has a role to play in creating a safe and healthy workplace.    Be cooperative with the fellow engineers in order to learn. storage or transport of plant or substances. 13 . Always follow instructions from my supervisor. handling.2 Safety at the Factory Premises At Bata shoes Factory. finds it necessary to put up regulations to the interest of its employees’ safety and health. Always avail myself at any time of need. The company. and providing and maintaining a safe and healthy work environment  The supervisors and managers take responsibility for ensuring that.  providing all necessary information.

and using any equipment or following any system or work practices provided by their employers. LOTO (lock out/Tag out) procedure is a safety procedure. in case of a machine breakdown.    Undertaking tasks and duties carefully considering personal safety and that of others. They can be avoided if safe working practices and procedures are observed. Complying with all safe operating procedures and practices provided by the company.  Working hand in hand with the safety appointed representatives and committees to help create and maintain a safe working environment. In Bata Shoes Company. incidents or injuries that may occur during the course of work. everyone in the factory premises has the following safety responsibilities. machine injuries are not common but they do occur occasionally. the engineer working on the machine should isolate the machine using the LOTO standards.3 Potential Risks & Accidents at Bata Shoes Company An accident is an unexpected or unintentional event in which injury or damage occurs.  Employees also contribute to safety and health in the workplaces by :   taking care for the safety and health of persons at the workplace. the means of access to and egress from the premises. which is used in industry and research settings to ensure that dangerous machines are properly shut off and not started up 14 . 2. For instance. even if they do not directly employ that person on the premises. In addition to the above mention responsibilities. and any plant or substance kept at the premises are safe and without risks to health to any person working on the premises. Reporting to team leaders on any potential workplace hazards or any mishaps. The company has some strict regulations in order to avoid such mishaps.

and placing it in such a position that no hazardous power sources can be turned on. When working on a stopped machine. It requires that hazardous power sources be "isolated and rendered inoperative" before any repair procedure is started. Power e. Before starting up.1 Cuts/ Amputation Many machines in the factory have blades and knives which could cause severe injury to an individual. Take care not to distract the attention of anyone working on a machine.again prior to the completion of maintenance or servicing work. "Lock and tag" works in conjunction with a lock usually locking the device or the power source with the hasp. The machinery should always be operated by trained and qualified personnel. To avoid such cases employees are advised to avoid cleaning machinery while in motion or is powered. Dimension b. Capacity f. for instance ones mate on the machine. Manufacturer Specifications a. 2.560(W) x 2.100 prs/8 hrs 6 bar Fig.7 kw 1. Machine Name Model No. is in a position to get hurt. Air pressure : Two Hot And Cold Counter Moulding Machine : YL-ALFA684 CF2HP : YILI TECHNOLOGY : : : : : : 850(L) x 1. Net weight c. make sure that the power is cut off in such a way that it cannot start itself or be started accidentally.000(H) mm 571 kgs 220 v 2. Voltage d. The procedure requires that a tag be affixed to the locked device indicating that it should not be turned on.3. see that everything is as it should be and that no one. Counter moulding machine 15 . Never work or operate a machine without its guard on.

watching for traffic. as serious injury may result. Welding jobs are to be screened off to protect other people’s eyes from flash. Some of the workers are exposed to hot work where flames. flammable liquids. Spillages should be wiped and fallen objects picked up regardless of who dropped them. Gas storage. Fig. To avoid such accidents a hot work permit must be issued for all tasks involving gas welding. Looking to ones footing. One should use the walkways and gangways provided. L.3 Slip/ fall/ Trip To avoid the occurrence of this accident every individual is expected to watch his/her steps while in the factory premises.2 Burns Burns may occur due to contact to hot surfaces. Employees are advised to keep off dangerous zones such as near the high pressure vessels. solvent and fuel stores. dust chambers. Drying and reactivation machine 2. Other sources of industries injuries include.P. cutting or other concentrated heat sources near such places as: paint. vessels containing flammable or combustible liquid or materials.3. One should not look directly at a welder’s arc.2. fluid bed coolers. heat or sparks may be generated. 2.3. Spilled liquids such as oil can cause falls.3. Team leaders are to be 16 . crane loads and men working overhead. Ensuring roadways or rail tracks are clear before crossing is important.4 Confined Spaces Safe work procedures are to be followed when entering confined spaces such as generator stators.

7 Clothing Loose parts of clothing.3. Use a suitable ladder whenever climbing about. pumps. but will take one with it into the machine or round the shaft. wheels and drums. loose clothing should be avoided because the material won’t tear if it caught by the moving part of a machine. 2. 2. elevators.3. are as dangerous as in-running gear wheels.5 Moving Process Equipment One should not work on moving equipment such as conveyors. Wear good safety boots or shoes at work and keep them in good repair. 17 . Examine ladders and planks every time and mark defective materials. They are to be adequately guarded at all times and isolated before any work is done on them. and open coats. One should never walk into the plant without a helmet. It pays in the long run because one will get less tired.informed before one enters confined spaces and specific procedures are to be followed in addition to using the necessary safety gear.3. ties. bows and scarves are always dangerous near machinery. as well a less liable to foot injuries and falls. Protective clothing provided for specific areas should be worn when in those areas. 2.6 Falls Pile material so that it is stable and steady at all times. Put tools and other equipment where they cannot possibly fall or be knocked onto someone below. flapping cuffs. Do not stand under suspended loads. despite their innocent appearance. Smooth shafts.

3. 2.2. files.9 Fires Fire fighting equipment is for use in sudden emergencies. So does the misuse of tools because it damages them. chisels with burred or mushroomed heads. 18 . crackxed split and splintery. these lead to injuries. Cutting tools should be carried with the edges protected. carry them so as to be safe to one’s self and others.3.8 Hand tools Hand tools should be kept in order. screwdrivers and saw on without handles. Spanners with splayed jaws. When carrying tools or goods. They should be kept clear of any obstructions for quick access. The same applies to fire doors and exits. any tools with handles that are warped.

Maintenance and repairing of motors Installation. Other activities I undertook at the workshop include welding and fabrication where the worn out molds were repaired through filling out the worn out parts. the blades of granulating machine used in recycling injected PVC materials is sharpened regularly using the surface grinders.CHAPTER III 3. the hydraulic press etc. 19 . For instance. Also. surface grinder.1. I was exposed to various tools used in engineering field including the lathe machines. fabrication. lathe machine. During my one week stay at the engineering workshop I did various activities using this machines. etc.  Workshop practices. hydraulic press.1 Workshop Practices The Bata Shoes Company engineering department has a wide range of tools. mould making. I helped in making both internal and external threads of bolts and nuts using the lathe machine. the surface grinders.         Installation. Maintenance and repairing of generators Making safe working procedures of various machines Maintenance and Repairing steam boilers Maintenance of water pumps and aerating pumps Making safety precaution for various machines Maintenance and repairing of injection machines Making and documentation of LOTO procedures 3.1 Assignments at the Company During the three months period at the Bata shoes company I involved myself in both mechanical and electrical engineering practices. The major assignments include the following.

000 feet per minute unless otherwise specified. The motors will operate (but with characteristics somewhat different from nameplate values) on line voltages within ±10% of nameplate value and frequency within ±5%. Keep the motor cleaned and the ventilation openings clear. sprockets and gears on motor shafts are common.3. depending on service. belt drives.The power supply must agree with the nameplate voltage and frequency. The bearings furnished with these motors are not designed to take any external axial thrust load unless otherwise specified.2 Installation. it is recommended that a general inspection routine be set up to periodically check the following items:  General Cleanliness 20 . and most outdoor conditions while severe-duty enclosed motors are used in highly corrosive or excessively moist areas. The applications of pulleys. the belts should be allowed to slip during acceleration to prevent the possibility of overloading the motor bearings. flat base. On drives of this type. If necessary. sheaves. The standard transition and/or sliding bases are suitable for floor mounting. grout in larger motors. Maintenance and Repairing of Motors Standard enclosed motors are used where they are exposed to dirt. Usually the belt speeds should not exceed 6. and a combined variation not to exceed ±10%. The axial position of the motor frame with respect to the load is important. In addition to the daily observation of the overall condition. Motors should be mounted securely on a firm. Align the sheaves carefully to avoid axial thrust on the bearings.1. Belt tension should just prevent slippage when the motor is running at full load. Inspection of motors should be done at regular intervals. Excessive belt tension causes unnecessary load on the bearings. This may be especially true on high-inertia loads where belts may be tightened to prevent squealing and slipping during acceleration. moisture.

and other contaminants. metal particles. it is not possible to accurately predetermine when new grease must be added. paper. This lubricant must always be present to avoid rapid wear and bearing failure. availability of equipment. grease and conducting dust. Suction should be used to remove dirt and dust particles from windings to avoid driving particles into the windings and damaging the coils. oil. However. A variety of satisfactory and acceptable methods are available for keeping equipment clean. vacuum and/or compressed air cleaning with nonmetallic hose tips should precede cleaning with water and detergent or solvents. excessive or too frequent lubrication may damage the motor. the speed at which the bearing operates. Any of these contaminants can lead to early motor failure. The grease used as a lubricant in grease lubricated anti-friction ball bearings loses its lubricating ability over a period of time. The choice of method will depend greatly on time. Oily vapor.  Insulation and Windings Lubrication and Bearings The interior and exterior of the machine should be kept free from dirt. good results can be obtained if the general recommendations as stated in the instruction book are followed. and on the insulation system. they should be kept clean from dirt. But. The primary function of grease is to supply the essential lubricating oil from the sponge-like reservoir of its soap structure. To obtain long life and satisfactory operation of insulated windings. oil. and the severity of operating conditions. For a given bearing construction and assembly. As a result. Ball bearing motors are 21 . the size of the bearing. However. or textile dusts may build up and block off ventilation. the lubricating ability of a grease with age depends primarily on the type of grease. Tight adhering dirt will require agitation by gentle brushing or wiping. Compressed air should be used to remove loose dirt and dust from air passages such as air ducts. Grease-lubricated anti-friction ball bearings consume only a small amount of lubricant.

I engaged in developing Save Work Procedures (SWP) of all the machines in the company.650(L) X 2.1.400(L) X 2. Slicing thickness f. Motors with grease fittings should be relubricated in accordance with these instructions to provide maximum bearing life. one of the most important safety issues at work is machine safety.500 kgs : EVA.34 kw : 1~10 mm 5. While there are various ways to ensure personal safety.TAIW b. Machine safety is promoted through a set of general guidelines to protect workers from personal injury by a wide variety of machines. of cooling rollers : : : Water Cooling Auto MC-969 MC-967 MC-965 TEN SHEEG .500 kgs 3.200(L) X 2.95 kw 6. Machine weight 3. 22 .42 kw : 8. They also assist in the training and orientation of new employees/students in job hazards. Power e. These guidelines provide information necessary to assist all workers and supervisory staff in performing their various tasks safely. PVC. Safety at work is one of the most crucial aspects of any job.000(W) 5. as well as providing them with the rules and procedures necessary to ensure that they can perform their work in a safe and hazard free manner. Output 9 units : 7 units 5 units : 965.000(W) : 4. EVA blank making machine g. Applicable material i.500 kgs : 4. All faculty. Rubber : Depends on speed of While at the Bata Shoes Company.000(W) 3.adequately lubricated at the factory. Everyone is expected to follow these general rules when engaged in any machine operation. staff and students are expected to familiarize themselves with these requirements. Cutter width PICTURE d. Machine size Fig.3 Making Safe Working Procedures of Various Machines h. Cooling roller width c. Manufacturer Specifications a. The management of Bata Shoes Company recognizes that written safe work procedures [SWP] or supplementary instructions are extremely important to ensure a safe work environment and form an essential part of the overall Occupational Health and Safety Program.2 & 1270 mm : 850 & 1150 mm 13. No. Machine Name Model No.

2) Shut off the power source(s) at the control devices(s) 3) Apply personal lock(s) to lock-out loop or alternate locking device 4) Where more than one person will be applying locks.4 Making and Documentation of LOTO Procedures I was also involved in making Lockout and Tag Out procedures of various machines at the company. clear away all tools and personnel. This is achieved by pressing the start button to ensure the machine does not start. 3. Lockout and Tag Out occurs during the machine repair process. The following procedure is a general example of the how Lockout and Tag Out is done for all machinery or equipments where maintenance is required to be performed. use a multiple lock attachment.People engaged in any activity involving a machine should familiarize themselves with the specific SWP for the task they are involved in. 5) Test control buttons to be sure that the power sources has been disconnected. but a very important one. Lockout and Tag Out is a common and simple procedure in machine safety. 6) Perform repairs and /or maintenance. from the moment the machine either breaks or is designated for repair until the moment the machine is deemed "working.1." The process involves disconnecting the machine from its power source and using a Lockout device to prevent it from being reconnected. 7) Upon completion. 1) Shut off the machinery or equipment. This procedure prevents accidental activation of the machine while it is being repaired. 23 . then applying tags to the machine explaining its required repairs. 8) Replace all guards and protective devices. And then pressing the stop button twice.

Before the material is fed into the machine. working pressure : Hydraulic Press (Steam circulates k. The following maintenance practices are commonly performed in the injection machine. the PVC material to be injected is fed into the hopper by an autoloader. Machine Name Model No. Speed of opening : j.9) All employees working on a machine are to remove their lock(s) as soon as they have completed their maintenance. 10) Ensure that everyone is clear of the machine.1.350 x 1. Manufacturer PICTURE : : DTEA-32 : DAHTYAN 1100 Ton Hydraulic Press With 1 Unit Hydraulic Pow Fig. As shown in the diagram above. Distance of heating plate : e. Size of heating plate : f. The injection machine requires regular maintenance in order to ensure they are in a good condition. 11) Person who originally shut off the power then removes his lock last and turns the power back on and tests the equipment or machine.  Hydraulic cylinder repair 24 . Daylight dimension : d. The screw pushes the molten material through a nozzle into the mold.350 x 1.495 kg/cm² 812. it is first pre-warmed to reduce its heating time in the barrel. Power : l. Speed of closing : i.5 Maintenance and Repairing of Machines Injection machines are used in making gumboots and injecting soles into the uppers.5-2sec 175 kgs/cm² to make EVA 25 + 15 hp Full automatic bumping syste 3.8 mm 1.500 mm 150 mm 1. T ype of heating : h. T otal pressure : b. The machine has a rotating screw surrounded by several heating elements. Ram diameter : c. sheets) Specifications a.500 mm 900MM Steam / Oil / Electric 900ST /38-24sec 900ST /1. Operation : 1. Stroke : g. Max.

There are three heating elements whose temperatures are set depending on the injection material being used. clamping device is a key component of the injection molding machine. At the same time. The temperature of the screw and barrel is controlled by heating elements aligned along its length. The injection machines can be operated manually or switched to automatic operation. Thus. The molds are pressed/clamped by a hydraulic press during injection and releases the mold when the injection is complete. 25 . and to meet the requirements of molding. the molds must be sufficiently clamped. and thus require to be heated to different temperatures.         Linkage repair Realignment for parallelism Mold alignment for uneven platens Extrusion screws repair and replacement Extrusion barrels repair and replacement Bent Tie Bars repair and replacement Toggle and toggle pin repair and replacement Adjustment of the quantity injected Platen adjusting screw repair and replacement In order to ensure proper molding and achieve the quality required. Different materials have different densities. injection must be done with enough pressure. due to the high injection pressure.

Manufacture Fig. Heater f.1850C 1700C . Power cons h. Mould dime b.170-1750C 1750C .1750C Zone 1 Zone 2 Zone 3 Zone 4 Every injection machine has a control panel where the temperatures at the four sections are set. Working safely is the first thing the user or operator should learn because the safe way is the correct way. Machine Nam Model No. Machine we 3. A person learning to operate machine tools must first learn the safety regulations and precautions for each tool or machine.1800C 1800C .6 Making Safety Precaution for Various Machines All tools are dangerous if used improperly or carelessly. Most accidents are caused by not following prescribed procedures. other settings such as the injection quantity and the speed of rotation of the machine are also done. Electric mo g. In order to avoid accidents in Bata Shoes Company. Machine siz i.1. In addition. we developed safety precautions of machines in the company. Injection ca e. Mould clam d. Mould stati c. Mixing Neader and PVC Injection Machine Specificatio a. Some of the general safety practices include: 26 .

safety shoes or a solid leather shoe must be worn at all times. ear plugs. and heavy stock may be dropped on the feet. is often covered with razor-sharp metal chips. Safety glasses must be worn when working with hand cutting tools.6. hearing loss is avoidable with ear muffs. since most hand cutting tools are made of hardened steel and can break or shatter when used improperly.2 Hazardous Noise Protection Noise hazards are very common in the workshop. 27 . 3.1. Calendering Mill 3.1.Fig.3 Foot Protection The floor.6. Although noise hazards cannot always be eliminated.6.1 Eye Protection Using eye protection in the machine shop is the most important safety rule of all. Therefore. or both. The shoes have a steel plate located over the toe and are designed to resist impact. especially in workshop. 3.1. High intensity noise can cause permanent loss of hearing. Metal chips and shavings can fly at great speeds and distances and cause serious eye injury.

The temperature of the boiler is checked and regulated depending on the required levels.1. The boiler is designed to generate high quality steam for plant use. When operating a grinder without a vacuum. In Bata Shoes Company there are three boilers used to generate steam. In the boiler furnace. The relative percentage of each is dependent upon the type of boiler and the designed heat transfer surface. and it is the function of the boiler to transfer this heat to the contained water in the most efficient manner. conduction and convection. the chemical energy in the fuel is converted into heat.6.3.4 Grinding Dust and Hazardous Fumes Grinding dust from abrasive wheels is made up of extremely fine particles of the metal and the wheel. Some grinding machines are equipped with a vacuum dust collector. the operator is required to wear an approved respirator to avoid inhaling the dust. The fumes produced from lead and mercury are very harmful. Inhaling these fumes may cause temporary sickness. as their effect is cumulative in the body and can cause irreversible damage. or death.7 Maintenance and Repairing Steam Boilers A boiler is a closed vessel in which water under pressure is transformed into steam by the application of heat. This heat is transferred to the boiler water through radiation.1. 28 . Metals such as zinc give off toxic fumes when heated above their boiling point. 3. The steam is used in the factory for heating soles and EVA sheets used to make slippers. The figure below shows a flow diagram for a typical boiler plant. A boiler must be designed to absorb the maximum amount of heat released from the heaters.

8 Maintenance of Water Pumps and Aerating Pumps The Bata shoes company has a wastewater treatment plant where the water from the tannery is treated before being discharged to the municipal council. acid or caustic in the water and a high temperature   Embrittlement of boiler metal Steam leakages 3.Some of the potential problems in the boilers that needed regular check up included:   Boiler deposits resulting from hardness salts. The aeration systems are 29 . In order to ensure full chemical action and deposition of products after the reaction. Various chemicals are added into the wastewater as the water passes through the treatment stages. Boiler waterside corrosion due to dissolved oxygen. every process has water pumps and aerating pumps which adds oxygen into the water. The wastewater contains some toxic chemicals such as chrome which when released to the environment can cause harm. metallic oxides.1. The wastewater passes through several stages before it can be discharged. silica etc.

30 . The diffuser provides finer bubbles covering more surface area with the water than larger bubbles and improves water circulation. moving oxygen-rich water from the top to the bottom. increasing the dissolved oxygen levels at the bottom.designed to circulate large volumes of water. Usually. Pure Power also provides a fine bubble membrane diffuser to dramatically improve aeration efficiency. the water pumps and aerators could block and thus needed regular maintenance.

31 . the molding equipment should be well insulated to reduce heat loss. The company should adopt the use of efficient equipments in order to conserve energy. air compressors. Creating Energy Conservation Awareness. the management should encourages employees to turn off or shut down idle processing equipment. Energy conservation can be done by using many conservation in an aim to reduce energy consumption. The company should have workshops regularly where the machine operators are reminded and practical demonstrations done about safety in the industry.CHAPTER IV 4. For example. In addition. high-intensity discharge lighting should always be used. Steam leakages on pipes should be avoided at all costs to reduce heat losses. lights. fans. the use of energy-efficient fluorescent lighting that consumes only about half the power used by standard.1 Recommendations The following recommendations can be adopted by the company to maximize and improve its efficiency while ensuring customer satisfaction. Safety. the company would realize a rise in its net profit. The company should create awareness to the employees on the importance of conserving energy. Accident management is so critical in the growth of any company in today’s world. The company spends millions of money on energy every month. Therefore. For instance. This can be done by performing a all-inclusive training to newly employed employees regarding their personal safety and those of others.0 Conclusion and Recommendation 4. By conserving energy. and other types of energyconsuming equipment when they are not in use. Bata Shoes Company should ensure its environs are free from injuries. Using Energy-Efficient Equipment.

The attachment program build a strong skill set that extends beyond the classroom into an industrial engineering job. 32 .Maintenance. This would be particularly important to those spare parts that need importation. which I acted as a valuable asset. allowed me to learn and grasp many engineering processes and maintenance of machines. Bata Shoes Company gave me a variety of skills and experiences that would enable me pursue the avenues that would fit me best. I understood the work ethics necessary for an engineer. I would recommend that instead of having an overhaul annually. A timetable should be made where every week overhaul of a particular machine is done. Being at a manufacturing company was one of the most rewarding and enlightening opportunities I have ever experienced in engineering. help an individual learn whether he/she and that industry is a good match. I was able to be a part of the creation of safety working instructions of machines. This would be a very effective method to reduce wastage of time and also the worn out parts are noted and bought in advance prior to the machine breakdown. the team orientated working style at the company and one-on-one relationships with the company’s engineers. the company should adopt a system where preventive maintenance is done on every machine. In collaboration with the company employees. which broadened my mind on the importance of safety in an industry. To avoid wastage of time and resources due to constant breakdown of machines.2 Conclusion One of the few ways to get engineering experience outside the class is to experience an engineering attachment. I also learned the importance of networking and building strong relationships with colleagues in the field. 4. In addition. Attachments give you on-the-job experience. There were many functions in the Bata Shoes Company that needed oversight.

The attachment taught me the importance of communication in any engineering environment and how asking questions can help you succeed. 33 . In addition. being a busy company. Throughout the attachment. Bata shoes company taught me the importance of safety especially when working around locomotives each day. In conclusion. I learnt from my fellow engineers who did not hesitate to contribute their intellectual creativity and physical force to perform their duties. I had the opportunity to apply multiple skills that I had learned in the classroom. Overall. My supervisor and engineers at the company in the engineering department did mentor me throughout my attachment program and I will always be grateful to the lessons I have learned from the Industrial Engineering department at Bata Shoes Company. For instance. I also learned the importance of diversity as an engineer. I believe the learning that took place in and out of the classroom has prepared me for my future life as a Mechanical Engineer. I believe the industrial attachment at Bata Shoes Company has given me countless opportunities to thrive as both a student and as a professional. the attachment was very successful and I was able to achieve my goals and objectives. I learnt basic entrepreneurial skills such as looking at ways to minimize costs for the company while optimizing the supply chain.