COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

INTERNSHIP REPORT AND PROJECT

HOSTING COMPANY: WUSH-WUSH TEA DEVELOPMENT FACTORY

 DECLARATION

We are fourth year mechanical engineering students, under the leadership of Mr Mulubarhan
Tateos and Mr Andualem Tasho (Factory Consultant) and we have carried out our program
by providing practical training from March 1, 2024 to June 30, 2024.

We would like to announce the successful completion of a four-month operational program at

the Wush Wush Tea Development Factory. And we declare that this work experience report
is our own work and we have compiled this work according to the list of the university.

ACKNOWLEDGEMENT

First of all, thanks be to God Almighty. We are grateful to them for giving us the ability to
carry out this action program and to complete the series of work to carry out this action report
effectively, and to our families for supporting us in our work. Because they don't hesitate to
give us everything we want from them.

Secondly, we would like to thank the company's advisor Mr. Mulubrhan, Mr. Dawit, Mr.
Andualem and all the workers of the Wush Wush Tea Development Factory.

Finally, we would like to thank the Department of Mechanical Engineering for giving us this
opportunity to see and learn what we have been thinking about in the classroom, as well as
gain hands-on experience.
 PART-ONE

CHAPTER ONE

1. BACKGROUND OF THE COMPANY

1.1 INTRODUCTION
WUSH-WUSH tea development is one project under ETHIO AGRI-CEFT PLC endowed
with ideal ecology for the production of good quality highland tea. Tea planting at Wush-
wush plantation started as a trial in 1973. Then tea development expansion continued by the
government in 1981 till it reached its present size of 1253 hectares.

ETHIO-AGRI CEFT, one of the largest private companies in the agricultural and agro -
processing industries in the Federal Democratic Republic of Ethiopia established in January
1, 1998 under MIDROC Ethiopia Investment group company engaged in the production and
processing of various agricultural crop.

The common product of ETHIO-AGRI CEFT plc are washed and sundried coffee, black
made tea or (loose packed) green tea, food crops, (cereals, pulses oil medicinal and bio
pesticides e.g., Indod) herbal and aromatic plants, spices, honey and cut flowers for the
country & export for other country. The company has put together smaller farms tea out
scheme from year 2004 around Gumaro and wush-wush tea states when tea plant is ready for
plucking. The green leaf will be plucked and delivered to the respective the states at agreed
prefaces.

Ethio- Agri Ceft plc produces and exports best quality Ethio high land coffee and tea are one
of its export items Gemadro coffee has been certified by UTZ kapen and rain forest alliances
furthermore it has been foreign market. Wush-Wush tea factory was made from different type
of mechanical and electrical system. These mechanical and electrical systems were operated
by the manual and automatic mode to give good product. This tea processing factory contain
different sized mechanical device from small size up to the larger one. Those mechanical
components were maintained in scheduled maintenance time classified component and also
according to the failure of component in the work.

The company was awarded winner in the recognition of its excellent agricultural products
export performance of 2004/05 and 2005/06 from the minister of agricultural and rural
development as well as from regional administration. It uses the latest agricultural techniques
in producing light quality products which means international standards in coffee, tea and cut
flower plantation.

Wush-Wush Tea Plantation-460km South West of Addis Ababa, Kaffa Zone, formerly state-
owned bought by Ethio Agri-CEFT in 2000.

The largest commercial tea for inside country and export purpose in Ethiopia are that wush-
wush tea plantation is endowed with ideal ecology for the production of high-quality high
land tea. Tea plantation at wush-wush was started in 1973 then tea development expansion
continued by the government in 1981 fill it reached or its present size are 1249 hectares of tea
plant and 977 hectares of eucalyptus trees were planted as a power source for the boiler in the
tea factories and process. These much hectare tea were processed in two factories (factory 1
& 2) or in PIU factory and WONGI factory.

Among the sectors that will see an expansion include tea production. MIDROC's Ethio
Agric-CEFT produces a total of 5,700 tons of tea leaves annually from the 1,249-hectare
Wush-Wush plantation and the 860-hectare Gumaro, and expects production to rise to 7,000
tons in the next few years.

Wush-wush and Wongi factory (factory 1 & factory 2) work 6 days per week and 8 hours per

day during winter season and during summer season they work day and night.

1.2 VISION AND MISSION

1.2.1 Vision

The visions of Wush-wush tea Development Company are:

 By producing and supply standard quality made tea, for both domestic and foreign
market, with an affordable price and attractive brands depend on tests and preference
of customers, ensure that Wush-wush tea development agro-industry it is profitable
business organization in the country.
 Manage food safety as an integral part of our business process and practices right
from the field operations through factory processing up to delivery to the ware house
distributor.
  Maintain due to product safety laws and regulation of Ethiopia that are relevant to our
product tea and other internal law Appling to food safety and agreed food safety
requirements of customers.

 To create smooth relationship with society, live in company and around company.

1.2.2 Missions

The missions of wush-wush tea development Company are:

 To Produce and supply made quality tea for both domestic and foreign market.
 To conduct marketing researches so as to produce quality made tea with attractive
brands depend on tests and a preference of customer.
 To protect environmental pollution and degradation so as to maintain ecological
balances of the area’s living things.

 To achieve this, we will invest in our people training the health & safety in the
technology Equipment that will enable us to produce a satiety product that meets
customers’ requirements.

1.3 SERVICES AND PRODUCT OF THE COMPANY

The company has different services for the society and country those are: -

 open school
 helping the health institute
 providing pure water service
 And other infrastructures for society like giving home for workers.

The main product of the company is tea and wood. Those processed tea products different
level or grading for export and internal market.

1.4 COMPANY'S CUSTOMERS

The company has many customers. And many companies and people want it because the
product is of high quality and the product is more preferred.
 There are a lot of external countries by the products mainly Kenyans are the number
one customer for wush-wush tea and also a lot of Arab countries accepts the product.
 Bonga University is one customer it takes the tea product for student serves.
  All Ethiopians who drinking tea
 Also, there are many individual customers from this Solomon Birhanu. He lives at
Bonga town distribute local level tea at the zone. Not only this there so many
customers.

1.5 AVAILABLE MACHINES AND THEIR FUNCTION INSIDE THE FACTORY

Chain conveyor
A chain conveyor transports the tea leaves from the weathering room to the folding machine.
This machine is powered by a 3-phase electric motor and the speed is converted into torque
through a gearbox. The length of this transporter is 50 meters and it has a 20 cm long metal
hanger.

Sifter machine
Linear motion vibrating screens are used to process bulk materials in production streams.
They use a filter pad to remove large particles or separate small particles from the next
product flow. The machine uses vibration to move the material or the leaf forward, which
allows small particles, such as soil and sand mixed with the leaf, to fall through the filter
surface, and further places the tea leaf on a conveyor and sends it to the rotor vane.

rotor vane
The main tea grinding process is done by a rotor vane three phase squirrel cage induction
motor and these induction motors have a gearbox that reduces the speed of the motor and
converts it into power.
CTC roller
CTC rollers are used to cut the twisting process. There are 8 CTC rollers used for continuous
cutting and twisting process, which are assembled in pairs and each rotates at different speed
using gearbox and driven by three phase squirrel cage induction motors. CTC rollers are
available in two types; there are four grinds in total, the first two uses 8 TPI - 8 teeth per inch
CTC rollers, the next two uses 10 TPI - 10 teeth per inch CTC rollers.

Continuous fermenting machine

The oxidation process is called fermentation. Although the fermentation process begins when
the tea leaves are broken. But normally, the fermentation process is taken after the tea leaves
are processed, that is crushing, tearing and folding. The process is not only useful but also
very important and critical and directly responsible for the quality of tea. Chemical reactions
and changes in colour and smell - all this happens in this process. Temperature, humidity, air
changes and hygiene conditions determine the conditions for good quality. This fermentation
machine conveyor has two conveyors, which are designed to let air (oxygen) in, so when the
air is hot, cold air (oxygen) enters the fermentation conveyors using the fan.

This fermentation machine conveyor has two conveyors, the first conveyor takes 80 minutes
to complete one round and the second conveyor takes 70 minutes. As soon as the tea leaves
leave the first conveyor, they enter the second conveyor. When it comes out of the second
conveyor, it goes directly into the dryer.

dryer
This dryer means that the heat coming in the form of steam is transferred to the dryer by
drying the tea leaves using the radiator (spread floor) and wind. This dryer has three levels,
the first is 150-180. The second from 125-150. The third and last is 80-125. But we use a
wood fired boiler to get this steam.

Boiler
This boiler holds 4000 liters of water and is a wood burning boiler. This boiler can generate
180 steam and 5 bar pressure.
Sorting Machine

it is a machine that is used to separate the waxy substance or dirt from tea product and there
is a magnetic roller that is used to extract magnetic materials.

Vibrio-Screening
As the name implies it works with the principle of vibrating and gives different grades for tea
from export standard up to the local market
For export: -
-Pf it passes through mesh 10

-Bp, it passes through mesh 14

-Pd, it has last 3 mesh collection of mesh 24, 30, 40, except mesh 60 because it is dust.

Conveyor
Conveyors are often used for moving in high-volume industries. They constantly transport tea
leaves from one place to another.

Wush-Wush is one of the mechanical parts used in a tea factory and is used to transport tea
from one processing unit to another. Conveyors transport the tea leaves from the rotor vane to
the final process. The type of conveyor used in Wush-Wush Tea Factory is Belt Conveyor and
Canvas Conveyor.
 1.6 ORGANIZATION STRUCTURE OF THE COMPANY

1.6.1 General Manager:

The general manager oversees the entire Ethio-Agri Safety Company and studies the plans
before they go into implementation. He calls the management department for a meeting to
improve the company's productivity and the like.

 Approving the quality policy;

 Ensuring communication and understanding of the quality policy in the company;
 Ensuring consistency of improvement objectives with the implemented quality policy.
1.6.2 Tea Development Manager:

The person who manages the entire department through the factory organization. According
to the general manager, he will also study the plans before moving to the factory.

When allocating resources, special attention is paid to avoid material wastage. Another task
of the factory manager is to organize meetings where the heads of different departments can
review schedules, evaluate performances, better understand problems and solutions, resource
memory, eliminate doubts, speed plans and more.

1.6.3 Technical Section Head:

This leads the technical system which in factory and also this section is vital role in
maintaining and repairing when machines are not operating and the head gives the direction
to the mechanics and operators how to replace and repair these machines according the
scientific method through planning. Organizing, staffing, directing, and controlling of the
overall process. If the machines are failed, he orders the spare part of that machine if it’s not
found in section based on its specification number.

1.6.4 Units Farm Forman's:

He controls and monitors the productivity of the farm. It plays an important role in the
company's production. The farm is the backbone of this company.
1.6.5 Secretary Division:

He/she works in the office. Types letters, answers the telephone, keeps records documents
and it is the vital section for the managers by helping their work.
Organizational structure of the company
 CHAPTER TWO

2. INTERNSHIP EXPERIENCE

2.2 HOW WE GET INTO THE COMPANY

The university and our department planned this program to create a good interaction between
universities and industries. And also helps the students to know about the nature of the
working environment. We were asked to find a company by ourselves. Once we took our
internship request paper at the end of the seven semesters, we went to a wush-wush tea
development company. we gave our request paper to the head office and the hosting company
accepted our request letter then after, we submitted the acceptance letter which was received
from the company to our department. After this, we submitted the necessary document to
Wush-wush Tea Development that we received from our university. Then we met the
company administrator who told us to meet the factory technical and engineering head Mr.
Mulubirhan and supervisor Mr. Andualem.

Mr. Andualem told us the rules and regulations of the company and told us to stay and work
with Mr. Dawit who is a chemical engineer and serves the company in the position of quality
control department.

2.3 DEPARTMENT OF THE COMPANY WE HAVE BEEN WORKING

Tea manufacturing has a wide application area in manufacturing companies, we have been
working mainly in the company's maintenance department and production and quality control
department for a few weeks.

Since we are mechanical students, the maintenance course is very useful for us, so we usually
worked in the maintenance department for production and quality control department for a
few weeks. Based on the problems listed below

Preventive maintenance

Product maintenance

Corrective maintenance

2.5 The work we have been doing

As a member of the production department and maintenance department, the following job
duties were performed by us.
1. Confirmation of green tea leaf which is the raw material for the black tea produced by the
host company; This includes measuring plucking, checking moisture content and also
distinguishing the type of tea as export or domestic grade.

2. Check if the green leaf provided is sufficient and if the dryer is followed or not; This
includes checking the relative humidity, determining whether natural or artificial drying is
needed, and controlling the steam supply to the drying bed.

3. Controlling initiation of value addition to tea as the process starts with curling and tearing
(CTC) cutting.

4. Controlling the fermentation process and the correct air supply to the fermentation
machine.

5. Controlling the temperature of the cyclones to dry the tea as the tea passes through three
cyclones, these are wet end, medium and dry end.

6. In the repair room, the rotor teeth are fitted.

7. Change conveyer.

8. Changing CTC.

2.6 PROCEDURES WE HAVE BEEN USING WHILE PERFORMING A

TASK

 Observation
 Problem identification
 Questioning
 Understand the work, how in the company and which process performs in which parts
of the work task
 Measuring problem parameters
 Decide the solution and discus with my company supervisor
 Decide how to perform the job
 Asking experienced people how can I solve when it is confusing

2.7 Engineering methods, tools and techniques

Methods, tools, and techniques are critical to the success of any project.

A method is a systematic way of doing something. "Strategic" here refers to an orderly,

logical sequence of steps or actions.

A technique is a different approach to performing a task in an immediately obvious way.

In this department, all work activities are carried out according to the standard guidelines
prepared by the company. And these instructions contain many methods of mechanical
engineering. Some Mechanical Engineering Techniques-Standardization, Experiment Design,
Employee Involvement, Instrumentation, Flow Design, Information and Data Flow Design,
Interviewing for Data, Modeling and Testing, Process Auditing, Plant and Equipment Layout,
Project Management, Strategic Planning Theory, Time Study, Work Sampling

Tools: - Some of the tools I used are:

 Calliper
 Meter
 Adjustable wrench
 Open wrench
 Hand tool

2.9 CHALLENGES WE HAVE BEEN FACING WHILE PERFORMING WE WORK TASKS

While working everyone may face many challenges which may be work related or not work
related. Our tasks were the challenges we faced while working. Some of them are explained
below.

In the first week, it was difficult for us to get to know and communicate with the operators, ie
they use Italian language, for example, the name of the gearbox is Cambio, and they use
different names for carrying Cushinetta and keys such as Stella, Fascia.

Most of the operators perform their job duties with their long experience. That is, they do not
know the principles of work and do not want to use scientific methods. Some workers or
operators are willing to share their knowledge, but they do not allow us to work, and there is
a lack of clean water for drinking in the factory.

Another challenge is that although we try to get into the work activities, because each
workplace has its own person for each task, they do not give us the opportunity to practice,
but they allow us to work with them from time to time. Most of the operators operate the
machine with long experience and have no idea about the operation of the machine, it is
difficult to get complete information about a machine. Some machine manuals are not written
in a common language, which makes it a bit challenging to get complete and reliable
information about that machine.

2.10 MEASURES WE HAVE TAKEN TO OVERCOME THE CHALLENGES

In the first week, most things were not clear. We asked supervisors, foremen, operators and
other interested workers to get more information and knowledge about the work flow in the
factory. We try to see and practice how things are done in each part until we understand the
working methods and the related parts. We always try to find instructions for each operation
and workflow to get complete information about that process. We advise you to meet
graduate students who have done internships in the company and they will share their
experiences and tell us some information about the company.

At work, we are always polite. We consider ourselves as one of the responsible employees in
the company and we accept all work ethics and factory rules. We ourselves try to be friendly
with the engineers who work in the factory, and we try to do what they do with them. Most of
their work is related to production flow, quality control, and maintenance and repair
department.

Also, based on what we have learned before, we will try to share our thoughts on certain
operational mistakes, which will help us develop our interpersonal skills and develop
teamwork spirit.

These are the most common measurements we have used during our practice.

 Establish a close relationship with the employee.

 We wait patiently and calmly until we get answers to questions.
 Being punctual
 Compliance with the rules and regulations of the organization

3. OVERALL BENEFITS GAINED FROM INTERNSHIP

3.1 IN TERMS OF IMPROVING OUR PRACTICAL SKILLS

At first, we thought we had no idea about the internship, our job was to look around the
company's process, but over time we realized that being an engineer means doing a job
combining practical skills and scientific knowledge.

This experience has helped us to develop our practical skills in both professional departments
and industrial systems, because there are various machines in the factory, from common
types of machines to huge and complex systems, and the company has its own maintenance
department, so it provides a lot of experience. We have the opportunity to repair machines
and machine parts like tea cutting machine, motors, fans, conveyors, various racking
machines and also factory boilers, cyclones. So we had the opportunity to see different
machine methods and working principles in relation to what we learned in theory. For
example, we looked at machining processes such as boilers, gearboxes, engine oil changes,
lubrication in various mechanical parts and also face turning, grinding, drilling and welding
on lathe machines.

And we also had a chance to look at electric motors and what attention should be paid to
them because the main drivers of the industry are these electric motors. The most commonly
used motors in the factory are three-phase squirrel cage induction motors from fractional
horsepower to large depending on their load.

3.2 IN TERMS OF UPGRADING THEORETICAL KNOWLEDGE’S

Before entering the Wush-Wush tea factory, we learned safety courses. Previously, when we
were at the campus, we learned how to use a fire hose in a basic workshop practice course.
After finishing the work, we can control the work equipment. As we know in the design
processes, the technological processes to produce the part must be written according to the
company's format and then approved and given to the machinery and quality control teams.
So this did the same during our project and helped us develop technology process writing
skills. In the company's work shop department, there was installation for the factory machines
that produced bolts and nuts. Therefore, we have acquired the knowledge of how to transport,
assemble, install and consider the machines for economical, safe and high production speed.
During the internship, we worked with the mechanics in shipping, installing roller CTC
machines and in the factory maintenance shop.

For the most part, we understand that there are similar and different machines in different
processing plants, so we understand the working principles of the same machines and how to
fix them if they are out of order or not working properly.

3.3 IN TERMS OF IMPROVING OUR INTERPERSONAL COMMUNICATION SKILLS

Communication skills are the processes used by individuals to express their thoughts and
feelings effectively and efficiently to others. Interpersonal skills are qualities that can be
improved through practice. Developing interpersonal skills is very important everywhere. It
is very important for individuals to communicate and express their ideas freely in the
workplace. So we realized that it is very important to communicate effectively with
employees or anyone. We try to overcome our fear of developing interpersonal
communication skills and always try to share their knowledge and ideas.

Since we meet many people in different departments in the company, this has helped us to
express and share ideas and to receive the knowledge of many people. Employees in the
factory and various departments are willing to share their knowledge. They invite us to talk
more with them and our cooperation with all of them is friendly.

Based on our practical experience, interpersonal communication skills are one of the most
important and critical factors that help us to be good at working and sharing knowledge,
ideas, thoughts and experiences with different colleagues. And the professional engineer
derives the aforementioned benefits from interpersonal skills.
As we mentioned above, we understand that good employee relations play an important role
not only in the employee but also in the organization's interaction and development with
others.

3.4 IN TERMS OF IMPROVING TEAM PLAYING SKILL

During our internship, we realized that there are many big problems that cannot be solved
individually, so we realized that it is very important to work collaboratively with other
people. We also understand how important it is to work collaboratively. Co-working skills
are an essential requirement for a proper job in a good company.

Regardless of work level, gender and genetic inheritance. In this four-month internship
program

We have developed good communication skills with operators, quality inspectors, and
maintenance

We learned a lot about how to communicate with planners, product managers and other
internal staff. We have found that rationality and accuracy are always better when activities
are done in a group than when done individually. in order to

We truly understand the importance of teamwork to strengthen efforts to accomplish the task.

Ideas that arise in group work help us to see something from different angles and reason.

Teamwork has a significant impact on an organization's performance. We understand that

teamwork is essential to solving problems and nothing is impossible when we work together,
teamwork helps us to strengthen and enhance our communication skills Generating different
ideas to solve different challenging problems.

In general, the ability to work in a group helps to improve the following qualities.

 Communicate in a constructive way

 To be an active participant
 Cooperate and help others
 Tolerance of differences
 Showing commitment to the team
 To overcome difficult problems

3.5 IN TERMS OF IMPROVING LEADERSHIP SKILL

Leadership skills are critical management skills and are the ability to motivate a group of
people toward a common goal. Always trying to communicate your ideas clearly to
employees is a key way to achieve the goal and make the workplace more productive, and
sharing ideas with employees as a friend always keeps employees motivated and engaged.
The leadership skills we developed during the internship came from observing and learning
from senior engineers, managers, supervisors, and each department's key tasks. There are
good qualities that a leader should have in order to work successfully and be a role model for
other employees and create good conditions for the growth and profit of the factory. This skill
will help us to know and develop the qualities of a good leader which will be one of our jobs
in the future. I have observed such skills from our consultant who is head of production and
quality department and we think he has good qualities as a leader.

Following are the good qualities we learned from him as a leader.

 Starting work with a plan

 Completion works on time
 Motivation for work
 Being willing to serve others
 Ability and desire to learn
 Understanding people
 Ability to withstand stress
 Ability to solve problems
 Self-control
 Giving encouragement

So, these are the good qualities that we have identified and we will follow his path in our
future.

3.6 IN TERMS OF UNDERSTANDING ABOUT WORK ETHICS RELATED ISSUES

A strong work ethic is an essential part of being successful in our work. Work ethic is a set of
values based on the concept of discipline and hard work. Building a strong work ethic allows
one to train oneself so that hard work becomes automatic. Forming good habits like paying
attention, being motivated, completing tasks promptly and more can help create a good work
ethic that will attract employers.

People with a good work ethic have the ability to focus on tasks as long as necessary to get
their job done. Building endurance essentially allows us to train ourselves to work longer and
harder. Balancing endurance with adequate rest is important to reduce the risk of burnout.
Focus is just as important as persistence when it comes to work ethic. It allows us to complete
tasks efficiently while avoiding distractions. So understanding the above mentioned factors
will help you become a professional.

In addition to getting right to work, good work ethic involves getting things done right.
Employers don't want to see shoddy work and may question the work ethic of people who
produce poor quality work. According to us, performing tasks correctly is a critical
requirement for professionalism.

To make a good impression, we should always be punctual for work or appointments. Some
people have trouble getting out the door, so setting the clock a few minutes earlier or
planning to leave the house can help. Being late to work can signal to employers that you are
not dedicated to your work and that you are punctual.

A person shows proper dress, grooming, cleanliness, and manners because he is prepared for
the job, where he may be criticized by colleagues.
As a student intern, generally the following ethical considerations are required of a
professional employee:

 Honesty, integrity, credibility, credibility, initiative and self-discipline

 Positive attitude, self-confidence and true self-confidence
 One who follows safety procedures, conserves resources and follows instructions
 Someone who respects the rights of others, likes to work together, likes to help, is
self-confident, has a good attitude towards customer service and wants continuous
learning.

In our internship program, we understand that the above ethical issues are required and
severely limit employees from being the best in their professional lives.