Final Report

HIBRET MANUFACTURING AND MACHINE

BUILDING INDUSTRY

CONVECTIONAL SHOP

Internship Project

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

04-02-2006 to 28-05-2006
(Duration of Training period)

BAHIR DAR UNIVERSITY INSTITUTE OF

TECHNOLOGY
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ACKNOWLEDGMENT

First of all I would like to thanks the almighty GOD and my mentor zelalem who
recommended how to form the work in the company and thanks to my advisor
Mr.tamiru who is initiated me to solve minor problems that challenged the factory
working environment. And also to thanks the workers of convectional shop especially
design room workers.

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EXCUTIVE SUMMARY

Hibret Manufacturing and Machine Building Industry iS located in Addis Ababa

Lideta Kifle Ketema around Mexico and it covers an area of 97,025 square meter.

This industry has capable of by its demand amplifier or the product groups are: -
industrial machinery parts, construction machinery parts, bolt and nut, Gear box and
Spare parts are the main product of the company.

One of the objective HMMBI is to solve the technological problems through its in
charged mandate by producing industrial machinery’s machine tool and spare parts
with sufficient quality, competitive price and delivered on time as well as a role
model by enhancing the technological development and capacity building activity
through national industrial developing strategy.

In buildup of Engineering capacity this internship program is very important and

relevant for the students. The program helps me as follow:

 How theoretical parts converted in work practically in the company

 How the working condition is in the company concerning with the information
flow , communication to each other, the behavior of the work or culture of the
work and claim to assert the leadership, entrepreneur skill
 Understanding of the company’s production system
 The company’s working environment

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TABLE OF CONTENTS

CONTENTS PAGES

CHAPTER ONE................................................................................................................1
1 .INTRODUCTION..........................................................................................................1
1.1 HISTORICAL BACKGROUND OF THE COMPANY.......................................................1
1.2 METEC mission.........................................................................................................1
1.3 METEC vision.........................................................................................................2
1.5 Main products and services of HMMBI...................................................................4
1.6 Main customers of HMMBI.....................................................................................5
1.7 Organizational structure of HMMBI........................................................................6
1.8Work flow
CHAPTER TWO

2.Overall internship experience

2.1How I get in to the company

2.2 section I work in

2.2.1 convectional shop

2.2.2 lath machine room

2.2.3 Milling machine shop

2.2.4preciation shop

2.2.5 Machine building shop

2.3 work task

2.4 problem and challenge

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2.5 Measure taken to overcome this challeng

CHAPTER THREE...........................................................................................................27
3. THE OVERALL INTERNSHIP BENEFITS..........................................................27
3.1 Improving practical skill........................................................................................27
3.1 Upgrading theoretical knowledge skill..................................................................28
3.3 Improving industrial problem solving capability...................................................29
3.4 Improving team playing skill.................................................................................30
3.5 Improving leadership skill......................................................................................30
3.6 In understanding about work ethics issue, industrial psychology and related ......30
3.7 Gaining of entrepreneurship skill...........................................................................31
3.8 Improving interpersonal communication...............................................................31
CHAPTER FOUR......................................................................................................32
4. GENERAL CONCLUSION AND RECOMMANDATION...................................32
4.1 General conclusion.................................................................................................32
4.2 Recommendation....................................................................................................33
4.3 Reference................................................................................................................34
4.4 Appendix................................................................................................................35

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LIST OF FIGURES

figure 1 Organizational structure of HMMBI................................................................6

figure 2 Work flow the industry.....................................................................................7

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CHAPTER ONE

1. NTRODUCTION

1.1 HISTORICAL BACKGROUND OF THE COMPANY

Hibret Manufacturing And Machine Building Industry is located in Addis Ababa
Lidet Kifle Ketema Kebele 07, around Mexico Square and it covers an area of 97,025
square meters. This industry was established between the agreement of our country
and the Czechoslovakian government here at Addis in 1945 E.C at an estimated cost
of birr 2, 00,000.00 and invested capital of Birr 2,000,000.00.it was expanded in
1977E.C with the expense of Birr 82,000,000.00.

The reason for establishment of industry the major one is to occurrence of

foreign invention for different time and it is easy to image the importance of
establishing an ammunition Factory for the organization of modern army when
thinking of the establishment of Ammunition Factory in 1945 during Haileslassie
region.Among the ministers established by the proclamation issue during Emperor
Minilik II in 1900 was the established of a modern government system was ministry
of army and under the In 1928 the Italian fascist army used fighter are craft to invade
Ethiopian .It attempted to retailed the shame it sustained during the battle of Adwa it
was obvious that the major problem faced by our patriotic during the war happen
shortage of weapon and Ammunition ,when our patriotic returned after defeating the
enemy. They brought the idea of establishing an Ammunition industry. After Emperor
Haileslasie conclude contractual argument with Czechoslovakian to manufacture
ammunition for light weapons locally .The design work was finalized by an architect
name Mr.Mussa Huslar construction work commenced during the same year.The
FDRE defense industries coordination decides since 2000E.C.Coming out of this part
history, currently the complex was structured to industry. It is now given version and
direction from the Ethiopian government and restructures itself under the metal and
engineering corporation to meet the target it established for. The corporation is
established to:

To design manufacturing industries, installation and commissioning to mass

production. To produce industry machineries and industrial spare parts
Improvement of manufacturing industries and corporation to be sufficient also
production of capital materials and spare parts Developing Engineering and
technology in the industry. Production of military materials and spare parts for
defense and security for domestic and other countries.

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1.2 METEC mission

One of the objectives of metal and Engineering Corporation is to solve the
technological problems through its in charged mandate by producing industrial
machinery’s machine tool and spare parts with sufficient quality, competitive price
and delivered on time as well as a role model by enhancing the technological
development and capacity building activity through national industrial developing
strategy.

1.3 METEC vision

METEC harmonizes to full fill the following preconditions:-

To assure and address the national spare parts machine tools and industrial
machineries need as well as developing the country wise technology through
industries. And managing different manufacturing and assembling factories which are
Hibret manufacturing and machine building industry, Metals fabrication, Bishoftu
locomotive industry, Ethio plastic industry, power engineering, akaki spare parts etc.

Therefore this corporation contains 16 branches of sister company’s through the

country.

1.5 Main products and services of HMMBI

This industry has capable of by its demand amplifier or the product group therefore
the products produced are as follows:-

industrial machinery parts

construction machinery parts
bolt and nut
Gear box
Spare parts

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1.6 Main customers of HMMBI

The main customers or the end users of this company are:-

 The sugar factories like wonji, metehara etc

 Ethiopian electric power corporation
 Cement factories
 Ethiopian defense force
 Textile and tannery industries
 Private organization and individuals

The above listed are adopt and serviced under this company.

1.7 Organizational structure of HMMBI

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General manager

Design and Development

financial audit

safety and security Quality management

office administration and Contract and law service

MIS

Finance & logistic Operation Marketing HR &development

finance PMF contract &follow general service

U
material resource CMF HR administration
sales department

MBF
budget &planning market research supply department
&bossiness
MB MF development

BNMF CS and production HR development

purchasing
Figure 1 ORGANIZATIONAL STRUCTURE OF HMMBII

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1.8 Work flow of the Industry

customer need
Sales price

done by D&D

Design and development Done by outside

Yes

Seen by D& D

no
design & development
End

MBF BNMF MBMF PHMF/MT

CMF
F

need material
treatment

yes
mass production

no QC QC
store

no
end delivery & feed back

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Figure 2 WORK FLOW THE INDUSTRY

CHAPTER TWO

2. THE OVERALL INTERNSHIP EXPERIENCE

2.1 How I get in to the company

Like any other students, after university gives me the application paper for the
companies I was searching the company which can accept and which company is
change my theoretical knowledge in to practical. And I was thinking how I can get the
chance to tests myself. I applied for different companies in Addis Ababa for
internship then after I decided to be here I applied to Hibret Manufacturing and
Machine building industry and their response was positive.

Before proceeding to any of our activities we got our contacting person Mr.
Tamiru who was our supervisor on our intern time. We clearly talked on the coming
days, on what we are going to work and he introduced his workers member.

2.2 Section I work in

The company have four shops ,these are convectional shop ,machine building
,precision shop it consists of computer numerical control(CNC) and heat treatment
and the last material treatment shop.

I get the chance to join in convectional shop with my friends .it consists of different
room this are:-

 Design room
 Quality control room
 Material preparation room
 Grinding machine room
 Lath machine room
 Milling machine room

2.2.1 Convectional shop

As an introduction to the subsequent discussions of production systems of the

conventional manufacturing factory are capabilities of producing many different kinds

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of spare parts in a series of value adding manufacturing processes converting the raw
materials into more useful forms and eventually finished products. Let us see the
basic means of manufacturing systems model as value as adding process the process
transforms raw materials and semi manufacturing articles(inputs) to finished
products or goods of a higher value (output).concerning with the basic mechanisms
and tools used in carrying out this transformations are the production systems and
manufacturing and equipment involved in the physical flow and transformation of
materials the employees involved in the manufacturing operations.

Job O. Or Drawing No. Title of parts Cost Customer

No. d. Sheet No.
Qty
4-2-IC- 1 02409 Sleeve spacer OPRN MBI
/06 /06
Material Code blank size
Mat
erial
type
120 Ǿ60x36
50

Tool Meas Inspe

s . tool cted
Planned time Act by
perfor
S/ OP ual
Operation RP med by
N N. Feed time
description M Tot
Mac
Set up al
h.Ti
Time Ti
me
me
01 L Face and 1 200 20mi 1:00 1:2 HSS V.Cal
turn to 0 liper
Ǿ50+0.5x7
Drill a
holeØ42thro
ughtout
Make the
chamfer as
per the
drawing
02 GR Grind to Ø
R 50+0.05
0
Prepared by/on Checked by/on Approved Remark:
DEBEBE ABEBAW by/on
TAMIRU

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Table 1.sample of write technology

2.2.2 Lath machine room

Process performed on a lath machine which is turning and facing is common. The
principle of working in lath creating relative motions between work piece the tool in
which the work piece and the tool is make parallel to the axis of rotation of the work
piece.

Operation of lath

Operation of lath

 Turning
 Facing
 Parting and grooving
 Drilling
 Boring
 Tapering
 Screw thread

Fig 1. Lath machine

2.2.3 Milling machine shop

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There are three types of milling machine i.e vertical, horizontal and universal. In this
machine there are six type of motion i.e left right, up , down, horizontal and
vertical motion.

Fig 2. Milling machine

2.2.4 Precision shop

Consists of different CNC machines that do more complex precise works. Precise
work up to 0.001um, the products produced in this factory are:

 Vehicles and trucks spare parts

 Molds, dies, punches, jigs, and fixtures
 Farm machineries and other huge parts and the conventional accessories
finished

2.2.5 Machine building

Medals and badges are made along with different signs and writings. The products
are produced by engraving and pressing, heat treatment, and surface treatment.

Currently working on:

 A small scale building machineries vehicles and trucks spare

part, Construction and industrial machineries.

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 Upgrading of the machines to CNC (Computerized

Numerically Controlled) machines and others parts.

Work section and workflow of the CMF

Marketing

Operation PPC

CMF PPC received order

To design prepared technological drawing

PPC received technological drawing

PPC asks operational material (given blank size, material type & quantity

Operation back to PPC

lathe milling

to deliver work order by format for Forman to deliver work order by format for Forman

the Forman order the team leader the Forman order the team leader

the team leader arranges to deliver work pcs

the team leader arranges ro deliver worker
pcs

at the end of the work day

the workers take the work
the team leader
pcs to gate quality approval
report daily activity
within job ticket within format to the
Forman
at the end of the work
day the workers take the
work pcs to gate quality
approval within job ticket

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Work section and workflow of the CMF

quality approval

PPC PREPARE TRANSFER SHEET

2.3 Work task

The work task in which I have been performed or executed is by observation and the
assessment that I made and conducted as a project work is small induction melting
furnace.

The techniques and the tools that I used to perform or to accomplish the project work;
first of all I made a decision with my advisor. I made a proposal by means of a format.
As a mechanical Engineering student I preferred a solution for the problems of the
factory especially for the project work that I preferred.

Before design of small induction furnace ask permission to visit Basic Metal Industry
which helps for design of the project and the response was positive for visit the
industry.

Project selected and summary of the project

After I made an important observation in the company especially in conventional
manufacturing shop, the major workers are not skilled because of these no of rejection
is increase from day today. By considering this I prepared a proposal for design of
melting furnace which problems need a solution and then I focused on my project
work.

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2.4 Problems and challenges during my work task

During in my internship experience I faced or encountered many problems to
accomplish this work. These problems are:-

 no enough material and idea support during work

 not access the information ,lack of computer
 transportation
2.5Measures taken to overcome this challenge
 By referring different text book in company library to collect
information,
 By using the material wisely.

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CHAPTER THREE

3. THE OVERALL INTERNSHIP BENEFITS

During in my stay of this internship I have been gained the prominent things that used
for the student who is under graduate. Therefore the benefits that I gained or
improved are:-

3.1 Improving practical skill

Basically improving practical skills is made from participating in every of the
activities performed or done. In my stay in this company I have improved my
practical skill in terms of digging out the problems that company faced as well as
giving the solution for the problems that I gained from the company and also by
working together with factories workers and the production planning and control, the
quality control, the maintenance group, the store room, design and development with
them it made very confident. The activities naturally employed in the manufacturing
facilities in production process and the system design in order to obtain substantially
demand through system knowledge and practical skills. For efficient handling of
assigned work in the field of production planning or others like operational
managements as well as in producing products the practical skill is very important.

Besides the technical department I trained how the machines are upgraded to
computerized numerically controlled system and also with maintenance department
team and subordinates provided me with opportunities to understand and gate
experience how and when the maintenance activities done. In addition to this I gained
the relevant experience on the store room arrangements. And therefore I saw the
operational management system by itself worth knowing skills that shows the key
activities in the planning, scheduling, work initiation, work order generation,
prioritization, execution, recording, and demonstration, documentation, procedures
carried out on periodic basis.

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In general, it was an effective experience in improving my practical skills in varies

aspects during the internship program.

3.2 Upgrading theoretical knowledge skill

One of the aims of this internship program is to develop the theoretical knowledge in
to practical one also encourages the theory that I have learnt. Therefore in my stay in
the company I develop the knowledge that I know in theory with the participating in
operational system of the company as well as in the factory’s working condition of the
production planning, in design and development, in quality control, store system, and
also in maintenance activity besides this I gathered the relevant information which is
important to understand the theory for practical application.

In addition to this I improved the practical skill in theory that is I understood the
working environment of the company as well as the factory by facing the challenges
which is seen as technically and scientifically. And also I upgraded my theoretical
knowledge in different ways like in the operating system of the machines and the
upgrading of the CNC machines and how the raw material moves also how the
finished products inspected and arranged in the store. In the field of acquiring
applicable knowledge with regard to the theoretical knowledge along with the
employment and putting into effect of facilities at the industries, associated on
operational technical, and system manuals have been provided and kept in order for
reference and training purpose. These were the primary resources I referred to as a
new way to enhance and get acquainted with theoretical particularities of the specific
systems in addition to the discussions held with engineers on the underlying basic
principles.Basically the theoretical knowledge that I managed to exploit from the
available sources is considerable and determined through the background in the
system. Moreover, steps and techniques in planning and scheduling, applicable
procedure, and regulation in the manufacturing industry and such development have
been very crucial in maximizing my scope of knowledge in manufacturing industry
field and general outstanding knowledge of the company. Therefore generally I

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acquire to upgrade my theoretical skill in different ways of situations and participation

in the factory.

Identify the challenges seen in the industry. Dealing with the problem solving I
effectively offered the capability to identify the problems in every industries as well.
Fortunately this internship program made me a good listener and a problem identifier
in any situation to meet the problems in contact to reducing their consequences and
challenges for the bottleneck effect in production system. In conclusion I was an
effective experience in improving of my capability of solving the industrial problems
in varies aspects.

3.3 Improving interpersonal communication skill

When I was in the internship session I did too many formal and informal
communications with the company manager and the personnel’s and the workers of
the company, production managers, quality heads, shift leaders and as well as the
factory team leaders that could help me to develop my communication skills very
well.

Any duties and responsibilities assigned to performers in the research and

development in the conventional manufacturing factory core process are usually
accomplished in a crew or individual consisting of low level workers to highly
experienced technician. The tasks strongly demand to process appreciable
communication ability and cooperation is needed in order to meet goals and
satisfactory results. During the work order flow I saw from initiation to approval and
execution, the process incurs involvement of expertise from multiple sectors. Besides
this I improved my interpersonal communication skill and knowledge in my stay in
the company

3. 4 improving team playing skill

In my stay in the company I would collected the relevant information sharing and the
data from different areas of the company as well as on different experience
concerning to get a well background of how achieving a team playing skill which is

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open mindedness, sharing ideas and practical skill sharing or contribution it helps me
to increase the working environment experience on completion of this internship
program and finally I have capable of to increase the social understanding and
practical skill in the work environment of the company. Therefore the team playing
skill made me to integrate all the activities of planning, scheduling and controlling
materials from design through production and including delivery to customer. In
addition to this the team playing skill is important in participating and understanding
of the knowledge that I have learned to share the data that I collected indifferent areas
of the company.

3.5 Improving leadership skill

Leader ship is one of the important management systems in every organization so I
followed how the massive labor force can be controlled in a single purpose managing
of the overall coordination in the factory. And also I understood which area can be
controlled in order of more productive and reliable for easiness of the of the work
flow in the factory. Moreover I made contacts to the manager for to understand the
leading condition of one’s company. And I have learned mostly during the regulation
takes place in the industry. Generally it made me more confident whenever making a
leadership to the future in any organization or an industry.

3.6 In understanding about work ethics related issues

When I was in company I have been experienced the ethics of work, rules of
governing one’s self in the work place with briefly identifying the principles and
ethics of work like punctuality for the work and in the work place, tolerance with
concerning to every one in every where or in every jobs, and the capability being
committed for the work in any situation in the work place.

In addition to this I understood the how looks like the area of the industry and its
manufacturing area. And also I observed the industry location, its contribution and its
major application for this purpose this internship made me an experienced man for to
understand the overall industrial psychology in every aspects or situation.

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Dealing to the related issues it offered me a well trained man through which ideally
identifying the way of eliminating any problems and challenges made in any related
issues.

3.7 Gaining of entrepreneurship skill

When I have been doing my project work the potentials and how to reform once self
is designed out inside me to re habilitate in the future for job creation opportunities
being an entrepreneur person. And also I come up with the new ideas alternatives to
improve production and minimization of costs and avoidance of wastage happened
during production system. Therefore intermesh of gaining the entrepreneur skills this
internship program made me confident and prudent for the work.

3.8 Improving interpersonal communication

When I was in the internship session I did too many formal and informal
communications with the company manager and the personnel’s and the workers of
the company, production managers, quality heads, shift leaders and as well as the
factory team leaders that could help me to develop my communication skills very
well.

Any duties and responsibilities assigned to performers in the research and

development in the conventional manufacturing factory core process are usually
accomplished in a crew or individual consisting of low level workers to highly
experienced technician. The tasks strongly demand to process appreciable
communication ability and cooperation is needed in order to meet goals and
satisfactory results. During the work order flow I saw from initiation to approval Sand
execution, the process incurs involvement of expertise from multiple sectors. Besides
this I improved my interpersonal communication skiunderstanding ll and knowledge
in my stay in the company

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CHAPTER FOUR

4. 1 GENERAL CONCLUSION AND RECOMMANDATION

5.1 CONCULUSION

HMMBI is located in Addis Ababa, the invested capital is2, 000,000 birr. The reason
for establishment of industry the major one is to occurrence of foreign invention for
different time. The industry has four main shops i.e convectional, precision, machine
building and material treatment shop. Each shop makes different material. When I
was spend four month internship helps for how to improve practical skill,
understanding about work ethics, improving interpersonal communication skill,
gaining entrepreneurship skill.

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4.2 Recommendation

My recommendation is made for which the company faced the challenges and
the problems with respecting to assist and encompassed in to account for the
solution is: -
 The company should have avoids the design error as well as the finished
product rejection
 The company should use as a team cooperation for to make a system easy and
proper
 And also the company should use a proper inventory for raw material as well
as for the finished product
 Concerning to the conventional manufacturing factory there should be a
proper use of resources

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5.3 Reference
 The company web site that is www.metec.gov.et
 Document provided by METEC 2000 E.C A.A Ethiopia.

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4.4 Appendix

CMF-Conventional Manufacturing Factory

MBF-Machine Building Factory (Industry)

CNC-Computerized Numerical control

HMMBI-hibret Manufacturing and Machine Building Industry

METEC-metal engineering technology

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