INDUSTRIAL ATTACHMENT REPORT

INSTITUTION: KAIBOI TECHNICAL TRAINING INSTITUTE

STUDENT NAME: MERCY JEMURGOR

ADM NO: K11909

COURSE: DIPLOMA IN MECHANICAL ENGINEERING

(PLANT OPTION)

PLACE OF ATTACHMENT: KIAMOKAMA TEA FACTORY LTD.CO

PERIOD: FROM: 09TH MARCH 2021 TO 13TH MAY 2021

PRESENTED TO: MR.SAYA JULIUS

DATE OF PRESENTATION: 04TH JUNE 2021

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ACKNOWLEDGEMENT
I began my attachment at Kiamokama Tea Factory on 09th March 2021 to 13th May 2021.

It is with great honor that I am writing this document and having been given the
opportunity to undertake my attachment at Kiamokama Tea Factory Co. Ltd for my course of
three terms cannot be complete without the industrial attachment.

I thank Mr. Mogi Bernard; my supervisor, Mr. Marucha Danvas my instructor for guiding
me through my whole attachment.

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OBJECTIVES
Industrial attachment is a mandatory exercise for learner to undergo for the mechanical
engineering course to be rightfully termed as completed to be awarded a certificate.

 The objectives of the industrial attachment are;

 To equip the learner with practical knowledge of the theory learned in class.
 To motivate the learner to embrace the right working attitudes.
 To give the learner a wider scope in the diverse fields of potential employment.

Table of Contents
INDUSTRIAL ATTACHMENT REPORT........................................................................................................i

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ACKNOWLEDGEMENT............................................................................................................................ii
OBJECTIVES...................................................................................................................................iii
Table of Contents..................................................................................................................................iv
INTRODUCTION.............................................................................................................................2
ORGANISATIONAL STRUCTURE..............................................................................................................3
HEALTH AND SAFETY RULES.....................................................................................................4
WELDING AND FABRICATION.............................................................................................................5
Types of welding...........................................................................................................................5
Multipurpose lathe machine...............................................................................................................5
Operation of lathe machine...........................................................................................................5
CTC ROLLER SHARPENING AND CHANGING..........................................................................6
Roller changing.................................................................................................................................6
GENERAL FACTORY MAINTENANCE OF MACHINERY.........................................................6
SAFE METALLIC WASTE DISPOSAL...........................................................................................7
PREVENTIVE MAINTENANCE PLANNING................................................................................8
Ways of making facilities stay on top of preventive maintenance..................................................8
Key measures for preventive maintenance.....................................................................................8
Benefits of preventive maintenance...................................................................................................8
Challenges incurred on attachment........................................................................................................9
MAINTENANCE OF THE WORKSHOP, CLEANLINESS AND WORKSHOP SAFETY............9
Maintenance..........................................................................................................................................9
CONCLUSION...................................................................................................................................10
REFERENCE......................................................................................................................................11

INTRODUCTION
Kiamokama Tea Factory was established in the year 1976 and since then it has been running.
It is established in Kisii County along the Keumbu Gesusu Street .it is about 400km from
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Nairobi and 18 km off Kisii Sotik road. The factory is in Masaba South District, Kiamokama
Division and Sub location.

It serves about 23000 registered active growers who bring their leaf to the existing 82 coded
buying centers.

Its role

 The factory was established to provide the small tea growers (the farmers) with
market for their tea.
 It conserves the water catchment areas of the neighboring community
 It provides employment opportunities to the locals and all people across the country
 Has improved the living standards of the people around it by providing social
amenities
 Has provided market for wood fuel growers; fuel used as energy source
 It has conserved the indigenous trees and forests from destruction and from extinction
 Has led to growth of the Kiamokama town centre
 Saves Kenya foreign exchange.
 Earns Kenya foreign exchange
 Has led to growth of other industries like those that use fluff from the tea to make
ceiling boards and leather for sue making
 Has led to the opening of that interior part of Kenya through road network

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ORGANISATIONAL STRUCTURE

BOARD OF DIRECTORS

REGIONAL MANAGER

PRODUTION MANAGER FACTORY UNIT MANAGER

HUMAN RESOURCE MANAGER

UNIT SUPERVISORS

WORKSHOP AND PACKAGING STAFFS

TRANSPORT STAFFS

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HEALTH AND SAFETY RULES

During the industrial attachment exercise I learned safety measures to be observed while I
work with a variety of machines in the tea processing plant. They all had one purpose in their
observance that I may be: Safe, secure and healthy to perform all my duties as expected and
also for the security of other workers, machines and to prevent down time and reduce
expenditure and maximize the profits to the company.

These safety rules and regulations include:

 Wearing proper protective equipment including; helmets, goggles, ear muffs,

overalls and dust coats, safety boots and hand gloves.
 Ensuring that all motor fans are guarded to prevent getting caught up with the
fans in motion.
 Making sure that all gang ways are cleared to prevent obstruction while
passing.
 Ensuring that all machines are in a proper working condition before using them.
 Asking on every direction or operation that you are not sure of while using a
machine.
 Switching off machines when you have finished working on them.
 Ensure that there is sufficient light in the working environment.
 All hoisting machines should be inspected before use.
 Ensuring that all power switches and sockets are in a proper w3orking condition
before using them.
 Ensuring that all chain and sprocket guard guards are in place and many other
safety precautions.

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 WELDING AND FABRICATION
Welding is the process of fastening two pieces of metal together by softening with heat and
applied pressure.

Fabrication is the process of constructing a piece of machinery.

Types of welding
 Arc welding
 Gas welding

Arc welding is the process of joining two pieces of metal together by use of welding rod.

Gas welding is the process of joining two pieces of metal together of oxyacetylene gas.

Multipurpose lathe machine

Operation of lathe machine

This machine is versatile, placed in this section to perform various operations which include;

i. Turning
ii. Boring
iii. Threading
iv. Chasing
v. Milling
vi. Cutting
vii. Centering

Turning; operation of removing excess material from the surface of the work piece.

Types of turning

a. Plain turning
b. Step turning
c. Taper turning

Boring operation of enlarging a hole already made on a work piece.

Threading is the operation of cutting helical grooves on a work piece.

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CTC ROLLER SHARPENING AND CHANGING
Operations in Roller Sharpening

a. Chasing
b. Threading

Chasing is the process of cutting parallel grooves on the roller.

Threading is the process of cutting helical grooves on the roller.

Roller changing
Is the process of replacing blunt or worn-out CTC ROLLER

It is done by removing safety plates then hoisting the rollers by use of a chain block.

Note: chasing and threading processes are done on the lathe machine

GENERAL FACTORY MAINTENANCE OF MACHINERY

Troubleshooting; is the process of identifying a problem and finding a proper solution
especially problems of technical nature.

Diagnosis; is the identification of the nature and the cause of a problem

Maintenance

 Fastening loose guards

 cleaning machines after use
 Replacing worn out conveyor belts
 Regular lubrication
 Welding rusted withering trough beds
 Switching off machines when not in use
 Welding broken conveyor supporting stands
 Replacing worn out conveyor brushes
 Replacing worn out water supply pipes to machines
 Sharpening blunt cutting edges of rollers
 Sealing leakages in machines
 Ensuring that the machine is used for its rightful purpose

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SAFE METALLIC WASTE DISPOSAL
Metal waste especially from the lathe machine is properly collected with caution and care to
prevent injury to the collector.

The different types of metal wastes are collected according to their type: cast iron, aluminum
and mild steels. They are sorted and placed in bins at the scrape yard ready to be taken for
recycling.

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PREVENTIVE MAINTENANCE PLANNING
This is a systematic approach to building operations that aims at predicting and preventing
catastrophic equipment failures before they occur.

To accomplish this goal, facilities personnel conduct routine inspections, maintenance and repairs on
assets to ensure they work as the manufacturer intended.

Functional facilities allows for the staff members to focus less on reactive maintenance and more on
upcoming maintenance tasks or time sensitive work orders

Ways of making facilities stay on top of preventive maintenance

 Schedule and perform regular cleaning of machines
 Lubricating moving parts of machines tore duce wear and tear
 Adjust controls for optimal performance and energy efficiency
 Repairing and replacing any defective machine or machine parts

Key measures for preventive maintenance

1. Inspection
2. Detection
3. Correction

Benefits of preventive maintenance

1. Save money by extending the useful life of the machinery
2. Eliminating unnecessary inspections and maintenance tasks
3. Prepare and prevent future breakdowns from happening
4. Prevent untimely breakdowns of critical equipments

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Challenges incurred on attachment

 Allotment of trivial work

 Inadequacy of proper protective equipment
 Unnoticed work

MAINTENANCE OF THE WORKSHOP, CLEANLINESS AND WORKSHOP

SAFETY

Maintenance
 The workshop is regularly cleaned to provide a safe working environment. This ensures that
accidents resulting from untidy working environment are done away with.

 Machines are also cleaned after done away with work; this is to provide for their highest
working efficiency and preventing down time that result from poor maintenance of
machines.
 The gangways are kept free from obstruction to prevent toppling over resulting in accidents
that could be avoided.
 The workshop should be properly arranged so that no large amount of time is wasted in
searching of an appliance or stored machine –parts urgently needed.
 The workshop machines should be used for the proper work that they are meant for to
increase or maintain its maintenance costs.
 Spilt grease is cleaned from the workshop floor to prevent slipping.
 Ensure that all power supply switches are in proper working conditions and replacing or
repairing the worn out ones.
 Insulate all naked power cables that may lead to fires.

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CONCLUSION
It was a wonderful learning experience at The Kiamokama Tea Factory Co. Ltd for the period
of two months that I was attached. I gained the practical equivalent of what I had learned in
class and more. I appreciate the warmly welcome of the company staff and their calmly lead
and guidance through the practical skill acquisition which I happily put into practice into the
prospect field of employment.

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REFERENCE
Personal experience

The internet

The company journals and booklets

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