INDUSTRIAL TRAINING FINAL PRESENTATION

INDUSTRIAL AND MANUFACTURING

ENGINEERING
KESEGO LUCKY
15000353
INTRODUCTION

 Industrial training is a program which aims to provide supervised practical

training within a specified timeframe. Its an initiative used to bridge the gap
in academic curriculum and the industry.
 Productive Industrial Trainings help students make informed decisions and
improve their marketability after graduation.
 It also provide students with the opportunity to apply their theoretical
knowledge in solving real engineering problems by applying their design and
analytical skills.
OBJECTIVES

 Understand the organization of business and the functions of the various

departments with a view to developing an appreciation of the complexity of a
successful engineering firm.
 Appreciate real world engineering problems as they arise in practice.
 Integrate engineering theory with practical applications.
 Gain and apply practical skills in design, manufacture, fabrication, assembling
and maintenance.
 Appreciate the deployment of engineering plant and equipment.
BACKGROUND INFORMATION OF BOKOMO
BOTSWANA

 Bokomo Botswana (Pty) Ltd is a wheat, sorghum and maize milling company
that was established in 2003 as a joint venture between PF Brink (Pty) Ltd, a
Botswana registered company and pioneer foods (Pty) Ltd of South Africa.
 The company operational activities are mainly focused on milling, packaging,
warehousing and distribution.
 The company strives to boost value for its customers, shareholders,
employees and suppliers by unceasingly aspiring to be the best fast moving
consumer goods sales (FMCGS) and distribution company within the country.
SUMMARY OF DUTIES

OPERATION OF A SORGHUM MILLING PLANT

 Engaging Aspiration. Industrial aspiration channel machine is particularly suited to
separate husks, chaff, small seeds, insect fragments, broken and hollow kernels.
 Pneumatic Conveying. Bulk product conveying with pressurized air.
 Cleaning
 Dehulling. A process of removing the external husk of sorghum grains without
damaging the kernel using dehuller.
 Coarse Milling. Crushing and grinding of sorghum grains using Selis Fortimus roller
mills (B1 and B2)
 Fine Milling. SMH 845 Hammer mills is used for large volume fine product milling
 Packaging
CONT’
LABORATORY EXPERIMENTAL WORK
 Ring test
 Alveograph test
 The Mixograph and farinograph test
 Fortification test
 Sieve Analysis
CONT’
PACKAGING
 Packaging of refined sugar
 Packaging of maize meal
 Packaging of flour
 Packaging of samp and maize rice
 Packaging of sorghum meal
CONT’
MAINTENANCE OF MILLING PLANT MACHINES AND EQUIPMENT
 ROFF 800 Mono Sifters
A ratchet spanner was engaged in disassembly of the B1.1, B1.2, B2 sifters.
Novatens (sieve tensioning device) was used in repairement of sieves with the
help of QSS-BOND (cyanoacrylate adhesive and cyanoacrylate activator).
CONT’
 Dehuller.Different Allen keys were used to assemble and disassemble the
dehuller. The dehuller screen was then replaced with a new one.
 Selis Fortimus Roller Mill. The worn out rolls in the cylinder pack were placed
with better performance ones to increase the output of the processed
products. Cleaning was also undertaken to fully utilize the output power of
the roller mills.
CONT’
 Italpack (Simatic HMI) Packaging machinery. Re-adjustment of the transfer
line and the sachet holder was also carried out to ensure optimum
functionality for longer periods of time
 Assembling of extraction fan to the conveyor. Different hex keys were used in
an assembly of extraction fan 4 to the auger 16 conveyor running to the bran
bulk out loading storage tank.
CONT’
OPERATION OF THE MAIZE AND WHEAT PLANT
 Transfer. The grains are moved from the bottom of silos through conveyors to
the top floor of the mill where the cleaning process begins. Maize is stored in
silo 1 and silo 5 whereas wheat is in silo 2,3,4,6.
 Cleaning and separating. Accurate separation and cleaning of incoming maize
and wheat is important for final product quality. Equipment-• Magnetic
separator,Aspirators,Destoner,Scourer
 Conditioning or tempering. Moisture is added in precise amounts to toughen the
bran/chop and mellow the inner endosperm in the conditioning bins. The length
of soaking/lying time for wheat is 18-24 hours and for maize is 4-12 hours.
 Degermination. The degerminator separates bran, germ and endosperm to
achieve maximum yield and top-quality end products.
CONT’
 Roller mill grinding. Dolomit roller mills grind degerminated maize and wheat
grits into flour and maize meal.
 Sieving and grading
 Enrichment, blending and storage. Vitamins are added to the white and
brown bread flour, super maize meal and the flour improver into the white
and brown bread flour.
WORKING EXPERIENCES
Projects carried out
 Line balancing of automated sorghum milling plant
This project was undertaken as an investigation on the line balancing of an
automated sorghum milling transfer line (process) in order to reduce the total
cycle time and increase machine utilization in a milling plant.
In effective balancing the line the following disciplines were employed; Time
study (cycle time, flow rate), work sampling .This whole data was obtained from
the process weighers (raw material, Bran and fine and course final product
process weighers).
CONT’
 Plansifter Sirius MPAK Installation.
The project was executed to curb the company maintenance costs of the old
Sirius plansifters of which were underperforming.
CONT’
 Statistical process control chart
The parameter of interest is the granulation of the champion sorghum meal of
which was recorded into the quality control excel spreadsheet.
CONT’
 SUPERVISORY WORKS
 For the 20 weeks duration I have undertaken industrial attachment, I have
been exposed to different facilitators from various departments in the firm.
 Mr W. Ramantsima (head of maintenance department) was my overall
industrial supervisor by chain of command he was the last person to report to
whenever I had anything that demands his attention.
CONT’
 PROBLEMS ENCOUNTERED
• Danger in the plant. The milling plant was one area with plenty of potential
hazards.
• At times some of my facilitators forget that I am new in the field. They would
give me mini project but the directions don’t quite make sense and I have
trouble looking at the bigger picture.
• New lifestyle. Getting used to a new lifestyle was a quite jarring. Instead of
waking up at 0800hrs and going to few classes a day, now I had to be hands on
from 0730hrs to 1630hrs with only one hour and a half in between.
• Quarel with the millers. There were times when the final products were not
conforming to the specifications and they would take it on me doubting my
results.
CONT’

 PROBLEM SOLVING PROCESS, APPROACH

 Observation
 Research
 Oral interview
 Consultation
CONT’
 FEASIBLY PERMANENTOR TEMPORARY SOLUTIONS ARRIVED AT AND REASONS

o Observation of safety signs in place

o Reaching out to the supervisors either by email or phone call when
complications arises during project.
o Adoption and implementation of the 5’s (set in order, sort, and shine,
standardize and sustain)
o Scheduling socializing and adventurous activities.
RECOMMENDATIONS
TO THE UNIVERSITY (BIUST)
I. Inform students well in advance
where they will be undertaking
their industrial training
II. Research further on industrial
attachment firms prior to
deployment of students so that
students fully maximizes benefits
by going through various relevant
department to the career path of
their choice.
ORGANISATION (BOKOMO BOTSWANA)
I. Create more structured training
programs to ensure smooth
completion of industrial
attachment.
II. Offer small rewards to students to
motivate them further and make
them aspire to always unleash the
best out of their potential.
CONCLUSION
 The industrial training duration with different departments of Bokomo
Botswana was fruitful as it facilitated self learning , research, teamwork,
professionalism and solution based problem solving.
 The attachment gives students a real experience of what to expect in the
world of work and allows students to monitor their self and their performance
in a work setup.Its an experience which no students should be deprived of.
REFERENCES
Education.2011. Wheat Milling Process [Online]. Education. Available at:
https://www.namamillers.org/education/wheat-milling-process/[Accessed:09
September 2019].
Bokomo Company Overview.2018.Available at:
http://www.bokomobotswana.co.bw/about.html [Accessed: 08 September
2019].
Maize Milling.2019.Roff C-80. [Online].Maize Milling. Available at:
https://www.roff.co.za/maize-milling/c80 [Accessed 12 September 2019].
Industry Solutions.2019.Process Technologies[Online].Industry Solutions.
Available at: https://www.buhlergroup.com/global/en/industry-solutions.htm
[Accessed 17 September 2019].