FROM HAWASSA TABOR CERAMIC

PRODUCT SHARE COMPANY

TO WACHEMO UNIVERISTY
DEPARTMENT OF ELECTRICAL
AND COMPUTER ENGINEERING
 COME TO
OUR
PRESENTIO
Out line
1.Background of Hawassa Tabor Ceramics Product Share Factory.
2.Vision and Mission ,Main products , main customer input and output of the
company.
3.Overall Internship Experience.
4.Section we have been working in company.
5.Benift Gained From The Internship.
6.project of internship.
7.Conculision and Recommendation
 Background Of HAWASSA Tabor Ceramics PRODUCT SHARE
Factory

The company was established in 1987 E.C)by a capital of 240 million birr.
Tabor Ceramic Factory is directly financed by the government till the launch of
privatization policy in 1992. Hence, the beginning of privatization policy in Ethiopia,
the factory is transferred in to share company with a capital of 208,321,000 birr.
Ceramics products share company (TCPSC) is a public organization engaged in the
production of Table ware , sanitary ware, wall and floor tiles, Insulator.
 The company is Geographically located in the South Southern Nation Nationalities
Peoples Regional State HAWASSA City which is 270 km South of Addis Ababa.
This company manufacture many table wares, sanitary products, tiles and insulator.
In this company there are 1000 workers are working. Among them 200 workers are
skilled workers, the others are labor workers.
 VISION AND MISSION OF THE COMPANY

VISION
 To be perceived as an organization which banks on the quality and development of its
products, for its customer service and for respect of the environment.
By matching the properties of ceramic materials to client specification that we are able
to find the material that provide optimal performance in the finishing components.
MISSION
 Understand more successfully the needs of the consumer and the market
ambience through ethical business management, taking into consideration the
consumer’s interests.
The Tabor Ceramic Products we work closely with customers to develop and
manufacture products that meet exacting specifications.
 MAIN PRODUCTS OF COMPANY

Under four categories of production (Tiles, Table Ware, Sanitary and

Insulator) the factory manufactures many products .
1) Table Ware: -
 Tea and Coffee cup
Tea and Coffee pots
Dish plates
Bowls
Saucers
Sugar containers
2) SANITARY WARE PRODUCTS
Bidets
Hand wash
Soup dish and soft holders
Wash basins Urinals
Pedestals
 3) Tiles Plant Products
Wall and floor tiles.
 4) INSULATOR PRODUCT

15KV Line Tension Insulator.

15KV Pin types Insulator.
33KV Pin types Insulator.
Main customers/ users of the end product

 Consumed by the following users; Institutes, Peoples, Industries, EELPA,

Universities, etc.
INPUTS FOR COMPANY
Tableware Sanitary ware Tiles plant Insulators
Pure Feldspar Red silica Aarero Feldspar Fiber glass
Sand
Ball Clay Aarero Hosanna kaolin Silicon rubber
Feldspar
Pitcher Hosanna Talc Upper and lower
Kaolin fittings
Quartz Ball clay Mugher Clay  
Hosanna   Red silica Sand  
Kaolin
 OVERALL INTERNSHIP EXPERIENCE
Objectives of the internship
General Objective
The general objective of the internship is to develop skills in the application of
theory to practical knowledge
Specific objective
To interpret the theoretical knowledge practically.
To develop problem solving skills.
To develop communication and cooperative skill with the workers.
To develop practical experience.
 SECTION WE HAVE BEEN WORKING IN COMPANY
In Tabor Ceramics Product Share Company, there are four main production
sections i.e. sanitary section, table ware section, tiles section, and insulator
section. But most of electrical and computer engineering application are
available in tiles section and insulators sections.
Electrical power house section: the amout of power that facilitates all section
in the 15kv three phase line from EEPCO at power house
Compressor section.
Boiler section.
Tile section.
Insulator section.
WORK FLOW IN TILES SECTION
 DISCRIPTION OF MACHINE
Crushing machine: Materials are rarely found in the size range required, and it
is often necessary to decrease the particle size. It operates by using star-delta
motor starting.
Control mechanism of machine: it works automatically.
 BALL MILLING MACHINE:

After weighing the raw materials are transferred to the ball mill, where
water is added. And it rotates the balls inside grinds or mill the materials
inside.
It operates by using star-delta motor starting and controls automatically.
 BLUNGING/MIXING MACHINE:

It mixes together the various milled or dispersed constituents in the required
proportions.
The output of the blunging/mixing is a slip which is made to pass through a
double deck screen sieve with an electromagnet to separate the iron. it operates
by using direct online motor starting method.
 SPRAY DRYING MACHINE

  It is method of producing a dry powder from a liquid or slurry by rapidly
drying with a hot gas.
The basic principles of spray drying are simple; a suspension of particles
in a fluid medium is atomized in to fine spray which is projected in to
steam of hot air above 1100.
 POWDER STORAGE
The granules have to be kept in a storage bin for few days so that its
composition becomes even more homogenous.
This process makes the granule more pliable and less likely to stick to the
mold.
 PRESS MACHINE:
After storage the granule is conveyed to a shaping machine and to be molded
by squeeze with high pressure, the pressure throughout a closed system is
constant.
Hydraulic press (Alpha press) are a powerful machine tools, they drive the
energy they deliver through hydraulic pressure.
It operates automatically using PLC control system
 DRYING MACHINE

  Drying machine used for heating the products ready for kilning and the temperature up to
130.
Glazing
The glaze and decorating is applied by water fall glazing system. The glaze adds a shiny
protective top coats to the ceramic.
 FIRING OR KILNING

 
Is further heating step that can be done in one of two types oven or kiln.
 A biscuit kiln consist of a single refractory lined sealed chamber with burner ports and flues
or electric heating elements.
The maximum firing temperature is 1100- 1120.
Temperature sensor: senses the temperature of kilning and send the signal to programmable
logic control when the temperature is above limit.
 SIZING MACHINE
when the tiles out from kiln and sized in desired dimension with sizing machine.it
operates using direct online motor starting.
Insulator production section
Insulator is provide necessary insulation between line conductors and supports and thus
prevent any leakage current from conductors to earth. In general insulator should have the
following desirable properties.
1. High mechanical strength in order to withstand conductor load, wind load etc.
2. High electrical resistance of insulator material in order to avoid leakage currents to
earth.
WORK FLOW OF INSULATOR SECTION
THE WORK OR TASKS WE HAVE BEEN EXECUTING
As an Electrical and computer engineering student we have been working on the
following activities:
Identifying contactors, breakers, relay, timer, push button, etc.
Preparing drawing for Motor Starting method (power and control circuit).
Testing of insulator.
Control motor starter using plc.
Starting motors with different techniques.
CHALLENGES FACED AND MEASURES TAKENS
CHALLENGES
The first and main challenge was some machines are not working due to the
political issue.
The spread of corona virus, which limits the close relation with some Electricians
for example one of the electrician was attacked by corona virus.
 Lack of formal education of the factory workers.
The other challenge was when the machines are working the rooms are filled with
dust and over heat, especially in sanitary production section due to that difficult to
inter the room.
The financial problem was also one of the challenges we faced.
 MEASURES TAKENS
For the first challenge we communicated the operators and supervisors to
know the working of machines even if the production was stopped.
We also solved the problem of covid by using face mask and sanitizer.
For those questions we had that we couldn’t find answer from the operators we
asked the supervisors and other skilled workers.
In another side we solved our financial problem by oppressing families and
friends.
 BENEFITS GAINED FROM THE
INTERNSHIP

 Improved practical skills

 Improved theoretical knowledge
 Improved interpersonal communication
Improved team playing skills
Improved leadership skill
Understood work ethics and related issues
Planned to be a good entrepreneur
 PROJECT OF INTERNSHIP
u la t e s tem
S im n g s y
an d k a g i C
s i g n p a c g P L
De matic t u si n
to u c
Au le prod
of T i
 INTRODUCTION

Packaging machine is a machine which is used to pack the tiles products.

Packaging is the technology of using conveyor belts for enclosing or protecting
products (floor tiles, wall tiles) for storage, pack objects together into containers,
boxes, and use.
PLC uses program to control the machine.
 PROBLEM STATEMENT

The packing system of the product is working Manually, which needs a lot of
man power, it takes or consumes time and it is not well packed. This cause a
problem to company.

Objective of the project

General objective of project is converting manual operation of packaging

system in to automatic system operation.
 cont.
Specific objective of project
 Design block diagram of the system.
 Model of automatic packing machine.
 Design the ladder diagram of automatic packing machine.
 Simulate the ladder diagram.
 Raw Materials used for this project:
Three-Phase breaker: Mechanical switching device, capable of making,
carrying and breaking currents under normal circuit conditions, and also making,
carrying for a specified time and breaking currents under specified abnormal
circuit conditions such as those of short -circuit.
Contactor: has its own coil with two conditions as normally open and normally
close condition.
Timer: used to setting time to be count. We used count delay timer for this
project.
Relay: are simple switches operated both electrically and mechanically.
Motor (3phase induction motor): used to operate the machine and to derive
and rotate the conveyor belts.
Photo Sensor: used to detect absence or presence of object and send the signal
to controller.
 METHODOLOGY

Working of Methodology
BLOCK DIAGRAM OF SYSTEM
LADDER DIAGRAM OF SYSTEM
 Program Description

Rung 0000:- start/stop PB latched with memory B3:0/0

Rung 0001:- B3:0/0 enabled to turn on Conveyer motor (O: 0/0).
Rung 0002:- photo-sensor (I: 0/1) is connected to one shot to give one pulse
when a product crossing photo-sensor. The counter counts the number of the
product.
Rung 0003:- Counter done bit turns robotic arm for packing (O: 0/1) to turn
ON and conveyor motor to stop.
Rung 0004:- Packing complete sensor (I: 0/4) or manual counter reset (I: 0/4)
is used to reset the counter which will turn on conveyor motor to start the
process again.
Conveyor Motor (O: 0/0) is connected in the NC contact to give interlocking
with robotic arm for packing product.
 Conclusion AND Recommendation Of OUR PROJECT
Conclusion
This Automatic packaging control system will generally solve the problem
occurring due to manual operation.
This system will specially minimize time taken, labor force and also
increase quality of packing process.
Recommendation
Our project needs hardware materials like machine, motors, robot, sensors,
contactor, timer …etc. To become applicable for this company but we have
not enough money to install this machine.
 CONCLUSION AND RECOMMENDATION

CONCLUSION
 In Tabor ceramics product share Company we have seen different types of
machines that we didn’t seen before.
 By maintaining and knowing their operation, use and function of the machines,
Motor starters, Sensor, PLC system, fans; testing of insulator…etc.
 The internship was a good chance for us to have a confidence in the practical
world.
 The automatic Packaging system can generally remove the problems caused mainly
due to the manual operations.
 Generally, during the internship period we observe different machine, sensor, motor
starters those are facilitating the production of ceramics.
 RECOMMENDATION

Recommendation to Company
 Most of machines are old and slow working rate.
The working environment is not suitable for workers.
Most of the technicians and operators in the company work by experience and
they use try and error method.
Recommendation to University
The university tries to give necessary Practical courses before the internship
program such as course related to PLC, Sensor, instruments.
The university should arrange some practical visit in some courses before the
internship program.