Professional Documents
Culture Documents
The Ethiopian iron and steel factory is the first industry opened in Ethiopia on iron industries.
It was installed during the time of emperor haile selase in 1952 e.c. initially it was installed by
Mr. Riso Sporando, an Italian as a major shareholder with the emperor family with an initial
capital of birr 500,000. But during the Derg military government time all big manufacturing
companies was in the hand of gov’t. Due to this, the Ethiopian iron and steel factory changed
to the hand of the regime. During this time, the company was nationalized by the Derg regime
and become the part of the National Metal Works Conformation. It is located 11km south of
Addis Ababa in the direction of assab road, woreda 27, kebele 3, akakibeseka.
In 1992, Ethiopian Iron and Steel Factory re-established as a public enterprise by the FDRE
minister in accordance with the provisions of public enterprise proclamation. In 03/28/2010
the Privatization and Public Enterprises Supervising Agency (PPESA) has put 12 public
enterprises up for sale. This is because the gov’t of Ethiopia plans to give full ownership of
these enterprises and businesses to investors who are ready and capable of operating and
developing the companies without violating the rights of the existing employees. From those
planed enterprises, Ethiopian iron and steel factory was one of them. It was sold by 1.4
million ETB in December 2003.
From the start, it was installed to manufacture only reinforcement bares, nails and bedsprings.
But through time, it expands its manufacturing ability of different products. The site location
of the company makes itself easily get the customers and suppliers. Initially the site was
selected to import the raw materials especially refractory materials and processing chemicals
such as dolomite, manganese and silicate from different countries specially Italy and China
and easily export the products back to all aver the world. Those imported or export raw
materials and products has the only way to be transported through the port of Djibouti. They
are heavy and cannot be transported by an airplane. So the only site, which is near to the
costumers, was akaki beseka 11km from Addis. But due to different constraints like;
Manufacturing method is not automated. That means their material handling system;
rolling process need human involvement. Which was the main constrain that pulling
back the company and make it not to reach its big goal of satisfying the customers of
all over the world.
The bottleneck manufacturing system; i.e. the department’s productivity variations.
By this and different reasons the company cannot export the products. For all this 52
years, the company depends on local customers.
1.1 Introduction
1.2 Vision of the Factory
To be center of excellence in providing quality of product at every once door and be
competitive manufacturing products.
To pay leading role in metal sector by manufacturing quality metal products,
equipment and machineries and export a broad in addition to satisfying the local
demand.
1.3 Mission of the Factory
EISF aspires to become the leading enterprise by providing its customers
high quality construction materials at a competitive price with the sense of
responsibility to support the national economy.
To provide adequate and quality of products distribution and sales service
through continues improvement of quality management practice
responsible to the socio-economic development and environmental
protection need of the public.
1.4 values and Principles
Customer is the king
Every minute has a price
We are all equal partners with one common goal
Both the effort and the result are collectively ours
We are judged not by our actions but by the results
Quality makes us unique
We are always learning
1.5 Objectives of the Factory
To satisfy the customers demand.
To produce quality product.
To compute all of the country market.
The existing organization structure of the factory shows that there are four services divisions under the
general manager namely legal service, quality & research development, internal audit and scrape
purchasing, collection, and preparation service divisions.
Moreover, there are four functional departments namely production & technique, finance,
administration & human resource and procurement &sales under which functional divisions and
sections are structured.
Accordingly, the production and technical department is structured further with two divisions support
namely production and technique in which production sections such as rolling & melting, nail making,
wire galvanizing and wire drawing.
Similarly, the technical section has auto shop, mechanical shop, and electric shop and machine shop
sections are structured under. The existing organizational structure of the factory is presented below:
GENERAL
MANAGER
DEPUTY GENERAL
MANAGER
SCRAPE PURCHASING ,
LEGAL SERVICE
COLLECTION AND
PREPARTION SERVICE
QUALITY ASSURANCE,
RESEARCH AND
INTERNAL AUDIT
DEVELOPMENT SERVICE SERVICE
COST GENERAL
GENERAL
ACCOUNTS SERVICE INVENTERY
ACCOUNTS
TECHNIQUE AND BUDGET MANAGEMENT
PRODUCTION DEVISION DIVISION HUMAN AND WHARE
DIVISION RESOURCE
DIVISION HOUS E
HEALTH SALES
AND PURCHASING
DIVISION DIVISION
SAFETY
PUBLIC
REALTION
The total man power of the factory including all the service and functional departments’ reaches to 295
out of which 26 are female and 269 as of the year 2015 male in permanent basis, the age, educational
level and number of employee’s distribution is presented below:
Table 3.3: Age distribution
1.8.1Major services
Mechanical property test
Chemical property test
Heat treatment
In five-decade history of the Ethiopian iron and steel factory, there was a lot of products was
produced in order to satisfy the customers. But because of the product type they produced, the
customers are local peoples and local construction companies. The products are the following.
1.8.2.1 Reinforcement Bar
Reinforcement bars also known as reinforcement steel commonly used as a tensional device
in reinforced concrete and reinforced big structures holding the concrete in compression. It is
usually formed from carbon steel, and is given ribs for better mechanical anchoring into the
concrete.
Concrete is a material that is very strong in compression, but relatively weak in tension. To
compensate for this imbalance in concrete’s behavior, rebar is cast into it to carry the tensile
loads.
Steel has an expansion coefficient nearly equal to that of modern concrete. If this were not so,
it would cause problems through additional longitudinal and perpendicular stress at
temperatures different from the temperature of the setting.
The re-bar in Ethiopian Iron and Steel Factory available in different grades and specifications
vary in yield strength, chemical composition, and percentage of elongation. Nevertheless, as I
tried to indicate that the company has no a chemical composition testing machine on the
melting department, they cannot differentiate the compositions of each product. Usually they
know the composition of grade 16 (by human judgment) and almost they manufacture this
product. Generally, if they have no any constrain they can produce the following types of re-
bars. The re-bars have average tensile strength of reaching from 250n/m² to 500n/m².
Dimensions, Mass Per Unit Length and Permissible Deviations
Standard dimensions, mass per length and permissible deviations are given on the table. By
the agreement between the manufacturer and purchaser, ribbed bars whose nominal diameters
are other than those shown in the table may be used.
Table 1- dimensions, mass per unit length and permissible deviations.
nominal bar nominal cross sectional area mass/length
An mm²
(diameter in d=
mm) permissible
requirement deviation %
kg/m kg/bar
6 28.3 0.222 ±8
Where
An = 0.7854xd²
Mass per unit length (kg/m) = 0.7854 x An
Permissible deviation shows for a single bar
The delivery length is subject to agreement between the manufacturer and purchaser.
Common delivery lengths of the straight bars are 6m, 9m, 12m and 18m.
Requirements for Ribs
There shall be rows of transverse ribs equally distributed around the perimeter of the bar. The
transverse ribs within each row shall be distributed uniformly over the entire length of the bar,
except in the area of marking. Ribs shall confirm to the requirements shown on the table.
Table 2 – requirement for ribs
mm
minimum
0.5d<=c<=0.8d
maximum
-Rib height (h):- distance from one point on the rib to the surface of the core, to be measured
normal to the axis of the bar
-Rib spacing(c):- distance b/n the centers of two consecutive ribs measured parallel to the axis
of the bar
-Transverse-rib inclination (β):- angle b/n the rib and the longitudinal axis of the bar
-Transverse-rib flank inclination (α):- angle b/n the flank of a transverse rib and the core
surface of a bar measured perpendicular to the longitudinal axis of the transverse rib
-Rib less perimeter (∑fi):- sum of the distance along the surface of the core between the ends
of the transverse ribs of adjacent rows measured as the projection on a plane perpendicular to
the axis of the bar.
Fig 1 reinforcement bar side view
KEY
1 longitudinal rib
2 transverse rib
tolerance % ±6
Quality min max
mechanical property yield strength (N/MM²) 276 414
The chemical and mechanical property testing is taken outside the company. Except the size
of 5 all types of nails are currently manufactured. But H5 nail manufacturing is stopped
because the machine breaking out.
1.8.2.3 Barbed Wire
Barbed wire is a fencing material consisting of a metal cable with regularly spaced sharp
projections. The cable usually consists of two wires twisted around each other to add strength
and to allow the cable to expand and contract with temperature changes without breaking.
Fig 4 side view of barbed wire
The sharp points, called barbs, usually consists of short pieces of wires twisted a round one or
both of the cables wires. The company manufactures the barbed wire from the steel wires.
This is an alloy of iron and a small amount of carbon.
It is a type of fencing wire constructed with sharp edges or points arranged at intervals along
the strands. It is used to construct inexpensive fences and is used a top walls surrounding
secured property. A person or animal trying to pass through or over barbed wire will suffer
discomfort and possibly get injury. Barbed wire fencing requires only fence posts, wire, and
fixing devices such as staples. Since constructions in Ethiopia are currently growing up the
security fences needs of the society is also grown up. So Ethiopian Iron and Steel Factory
started to manufacture barbed as soon as the customer requisition arises.
1.8.2.4 black Tying wire
This is a wire commonly formed by drawn the metal through a hole in a die with sizes of
Ø0.15. it is often reduced to the desired diameter and properties by repeated drawing through
progressively smaller dies, after a number of passes the wire annealed to facilitate more
drawing and maximize ductility. During drawing to the final stage the drawing mechanism is
helped by soap like lubricants.
The black annealed wire is used to hold together different products for example blanket
factory cotton factory are the main customers of this products.
1.8.2.5 Fencing Net
As a barbed wire fencing net wires are netted wires for fencing. They are manufactured from
the galvanized wires imported from local manufacturing companies. In order to make fencing
net it is needed around 2.2mm diameter wire. The company manufactures 2m by 25m fencing
net from galvanized wires. One roll of manufactured fencing net weights 80kg.
1.8.2.5 Bed Sprig
The manufactured system of bed-spring is the same as the fencing. In order to manufacture
the bedspring, they use the galvanized wire with diameter of 0.75mm. The dimension of the
manufactured bedspring is 1.20m wide by 10m length. But the wires in the bedspring are
doubling not single like fencing net.
1.9 company’s Stakeholders
1.10 The Main Customers of the Company
As the type of product the company manufactures, the main customers of the company are
construction companies; small business enterprises. Since the company has different
manufacturing constrains it cannot sell its product outside the country. It depends on the local
customers. In order to satisfy the customer, the company applies the quality management
systems to run in the ISO requirements. The processes needed for the quality management
system that includes, service realization, management, measurement, analysis and
improvement, and resource provision process, and their application throughout the scope of
implementation are identified in the quality management system. the following graph show
the EISF product realization process.
The company main customers are listed below: -
Construction sectors
Contractors of house sector
Demand of house hold
Fig 6 customer-company relationship chart
1.11 The Over All Organizational Structure Of the Company
Fig 7 over all organizational chart of the company
CHAPTER TWO
2. Departments
2.1 departments of draw bench room and nail making room
2.1.1 draw bench
a draw bench is machine used to do cold work on a metal such as changing the shape of the metal
without applying heat and applying only pressure.
2.2.1.1 machine construction
It consists of a chain drive driven by a motor and a set of gears. The other end of the machine consists
of the die mounted on a thick steel plate. the work piece is inserted through the die and clamped on
trolley which then is hooked on the chain for pulling across.
Die
The die is usually made of tungsten carbide with a steel housing .and it can be made to any desired
shape like round, square, rectangular, triangle, half round, L shape, oval etc.
Drawing
Drawing is a metal working process which uses tensile force to stretch metal. As the metal is drawn it
stretches thinner in to a desired shape and thickness.
Drawing is classified in to two types: -
1. sheet metal drawing: - the specific definition for sheet metal drawing is that It involves
plastic deformation over a curved axis.
2. Wire, bar and tube drawing: - for wire, bar and tube drawing the starting stock is drawn
through a die to reduce its diameter and increase its length. Drawing is usually done at
room temperature thus classified a cold working process however it can be performed at
elevated. Temperatures to hot work large wires rods or hollow sections in order to reduce
forces. Drawing is one type of extrusion. Drawing different from rolling in that the
pressure of drawing is not transmitted through the turning action of the mill but instead
depend on force applied locally near the area of completion. This means the amount of
possible drawing force is limited by the tensile strength of material.
Fig draw bench wire..
2.1.2 Nails
The history of the nail is divided roughly in to three distinct periods
1. Hand-wrought (forged) nail, until 19th century. To make forged nail ore is heated with carbon
and shaped in to square rods.
2. Cut nail, Roughly 1800 to 1941. Originally nail was handmade and the nail making process
was slow so that they were relatively few and expensive.
3. Wire nail, 1860 to the present. This nail produced in Ethiopian iron and steel factory there for
we can discussed deeply about wire nail.as the name implies wire nails are formed from wire.
Usually coils of wires are drawn through a series of dies to reach a specific diameter then cut
in to nail. The nail tip is usually cut by a blade; the end is formed by reshaping the other end of
the rod under high pressure. other dies are used to cut groves and ridges. Wire nails were also
known as “French nail” for their country of origin. Belgian wire nails began to complete in
England in 1863. Joseph Henry Nettelefold was making wire nails at Smethwick by 1875. the
over the following decades the nail making process was almost completely automated
eventually the industry had machine capable of quickly producing huge number of inexpensive
nail with little or no human intervention. With the introduction of chip wire nails the use of
wrought iron for nail making quickly declined as more slowly did the production of cut nail.
Formerly wire nail was made of bronze or wrought iron todays nails are typically made of steel
often dipped or coated to prevent corrosion in harsh to improve adhesion. Basically there are
different types of nail: - roofing nail, umbrella head roofing nail, brass escutcheon pin, finish
nail, concrete nail, spiral nail, ring shank nail.
2.2 department of barbed wire, fencing net, bed spring production
2.2.1 barbed wire
-background
Barbed wire is a fencing material consisting of a metal cable with regularly spaced
sharp projections. The cable usually consists of two wires twisted around each other
to add strength and to allow the cable to expand and contract with temperature
changes without breaking. The sharp points, called barbs, usually consist of short
pieces of wire twisted around one or both of the cable wires. Most barbed wire is
made of steel.
Fences have been around since people began living in settlements and needed to
keep things in or keep things out. Fences have been made from many types of
material. Before the introduction of barbed wire, early American farmers tried
different types of materials to make fences: rocks, logs, plants, or simple smooth
wire fences. Eventually most fences were replaced by barbed wire and there are a
number of reasons why barbed wire became so prevalent:
Because barbed wire could contain cattle and it was cheap and widely available, it
made it affordable to fence areas much larger than had ever been fenced before.
Barbed wire made possible the huge cattle ranches of the American west.
Although it is a deceptively simple invention, barbed wire changed the American
landscape forever. The wide open spaces of the west were more open before the
invention of barbed wire. Some historians refer to barbed wire as “the wire that
won the west,” and that it literally changed the face and economy of America’s
Great Plains.
Metal was not used for fencing until steel wire became easily available in the 19th
century. By 1870, improvements in steelmaking made it possible to produce large
amounts of steel wire and barbed wire for the first time. Joseph Farwell Glidden of
DeKalb, Illinois, patented the first commercially successful barbed wire in 1874.
Glidden is considered the “inventor” of barbed wire. There were many barbed wire
manufacturing plants in Illinois, Roseville and Bushnell each had barbed wire
making plants.
Raw materials
Barbed wire is usually made of steel which is an alloy of iron and small amount of
carbon. The raw material used to manufacture steel are iron ore, coke (a carbon rich
substance of air) and lime stone. To prevent rusting the steel wire are usually coated
with zinc. Sometimes the steel is coated with aluminum and occasionally the barbed
wire itself is made of aluminum.
Manufacturing process
The steel billet from continuous casting machine is heated again and roll until it
changed in to round bar 5.6 mm diameter known as wire rod. The wire rod is rolled
in to a coil weighing as much as 3969 pound or 1800 kg which is prepared by
Shimeelis Mezgebu and then the wire is coated with galvanized zinc to protect
corrosion. The wire must be perfectly cleaned and dry. To galvanize properly it is
cleaned in a hot dilute hydrochloric acid bath and then rinsed with hot water. Then
it passes through in the solution of hot zinc chloride or aluminum chloride. then it
will dry, after dried the wire pass through a bath of molten zinc. Excess zink is
wiped of and the coated wire is allowed to cool
Steel is one of the basic building blocks of the modern world. Modern bridges; buildings etc
all needs steel made products. From the tart, these departments produce steel by melting scrap
metal and other additives in the furnaces. The molten metal output is then solidified into the
semi-finished shapes before it is rolled into the reinforcement bar. As a backup, the
department manufactures finished steel products directly from the purchased steel billet.
These departments are using least cost method of making steel uses scrap metal as its base.
Steel scrap from many sources- such as old bridges, household appliances, and automobile
sand other additives are placed in an electric arc furnace, where the intense heat produced by
graphite electrodes and chemical reactions melts the scrap, converting it into molten steel.
The department that uses this method of producing steel by using the furnace called electric
arc furnace. It can melt 5tones at a time. The growth of the department has been driven by the
technology’s that require smaller initial capital investment and lower operating costs.
Moreover, scrap metal is found in all parts of the country, so electric arc furnace is not tied as
closely to raw material deposits as are integrated mills and thus can be placed closer to the
customers. There are a lot of problems that are identified in this department and the
recommendations are given as soon as the solution is fined.
-Work Environment
Steel melting furnace and the rolling machine evoke strenuous, hot, and potentially dangerous work.
Large machinery and molten metal can be hazardous unless safety procedures are taken. Hardhats,
safety shoes, protective glasses, earplugs, and protective clothing are required in most production
areas. But some of the company workers take all these protective devices.
The production begins when material-moving workers use over hade cranes to load scraps into the top
of electric arc furnace. During the production, process testers’ routinely take samples to be analyzed.
Based on this analysis, operators determine how much longer they must process the steel or what
materials they must add to meet specifications. Operators also pay close attention to conditions within
the furnace and correct any problems that arise during the production process.
Metal pourers and casters tend machine that release the molten steel from the ladle at a controlled rate
into molds, where it solidifies into semi-finished shapes.
Workers entering into the production process as lower skilled operators and maintenance personnel
generally assist more experienced workers, beginning with relatively simple tasks. As workers acquire
experience, they specialize in a particular process and acquire greater skill in that area. The time
required to become a skilled worker depends upon individual abilities, acquired skills, and available
job openings. It generally takes 2 to5 years, and sometimes longer, to advance to a skilled position.
CHAPTER THREE
The main objective of the internship semester is to get acquaintance. To be familiar with the work
environment which I will face after graduation. This is equivalent to the practical implementation of
the theoretical knowledge earned through years of schooling.
In that case I have benefited a lot clarifying my perception towards the meaning of all the hard work I
did learning and studying.
3.2 Why I Selected the Company
WHY I selected the host company?
Choosing the right internship company can be difficult. There’s rarely going to be one that
meets your exact requirement. so you are going to need to make a decision between multi
opportunities which may quite similar.
Picking an internship at random may be tempting, but don’t forget that choosing the right
internship has the potential to affect your future career trajectory. You should try and find one
that you would both enjoy and looks great on your CV for future job applications.so we have
narrow some of the key criteria choose the host company.
1. Career relevance
The most important factor in choosing an internship is how it will affect you when the time comes
to start applying for jobs. You want to be in an internship that will help you to gain valuable
experience that you can use on your first job interview. Don’t accept an internship just for the sake
of accepting it. It might not be easy to find a program, but your efforts will be well worth the
effort. And Ethiopian steel and iron factory have a vast production capability and experienced
workers so it is a good opportunity for us to gain enough knowledge.
2. Location
This is something you should consider on a couple of levels. First, taking an internship can
give you the opportunity to work somewhere completely new, whether it’s a new city or new
country. You can find international internship opportunities on Going Global, which current
students have access to through LSE.
Secondly, make sure you know where it is in terms of how long your commute is going to be,
what transport you’ll need to take, and the cost of the journey so that you can identify whether
getting there will be feasible every day.
So since Ethiopian steel and iron factory is located in Adiss Ababa and it have transport
service we select the company for internship so it meets our criteria.
3. Networking
The whole point of an internship is to immerse yourself in opportunities. You want an internship
that will introduce you to various people who can be your ticket to a job later on—not something
that will keep you sequestered, filing documents all day. Since Ethiopian steel and iron factory
have many customers there is opportunity to contact with different sectors including governmental
and non-governmental factory.
4. Environment
It can be easy to forget just how important the environment of where you’ll be working can be.
You’ll potentially be there five days a week for most of your day, so make sure that the
company seems to have the right atmosphere for you. And Ethiopian steel and iron factory is
found in akaki beseka the area is not crowded too much.