COLLEGE OF

ENGINEERING
DPARTEMENT OF MECHANICAL ENGINEERING

INTRNENTSHIP PROGRAM
IN METEC REPORT

NAME: ID NO
1.BELETE GETACHEW ------------------------1357/06
2.DEREJE GETU --------------------------------360/06
 INTRODUCTION

-Metals and engineering corporation (METEC) inaugurated construction

machinery assembly and manufacturing factory at debre birhane town. Industry
general manager major kahsay kahshn of METEC said that at the inaugurated
ceremony debre birhane construction machinery industry is aimed at supporting
the construction sectors and also METEC has created job opportunity i,e for
thousands of people in debre birhan and is going to save millions of foreign
currency.
The industry is producing locality designed and manufactured machinery supplied
to mega projects including the Grand Ethiopian renaissance dam and sugar
factories and building construction.
Metal and engineering corporation (METEC) is construction engineering
machinery industry located at debre birhane is contributing its share in stabliting
the market price for construction machinery through supporting machinery at fair
price and high quality.
The main duty of this industry assembly of heavy duty machinery ,maintance and
reman facturing of parts that has been damaged the main source of heavy duty
parts are importing from other countries and buying damaged machinery from
internal campany inside the country most of the workers found in this industry
from poly tecchinic college of different parts of the country this industry works on
the machineries are listed below
 BACK GROUND OF THE COMPANY
The infrastructure machinery Engineering industry found in Debre birhan. The construction
machinery industry is one of the most famous and hugs company that is governed by METEC.
This company have a great role for working heavy duty machinery with standard and modernize
specification of the parts of all heavy load machines and also have some light vehicles that
transport the workers of the company. In the company there are 467 workers.

Under the operation there are six factories. For each factories one team leader and many labors
(workers).Those are

In our hosting company generally due to the job divided into two:

1. Assembly
2. Maintenance
1. Assembly
In general vehicles in the company done in workshop
1(wheel assembly), workshop
2 (chain assembly), and Engineering tools (e.g. crane, surface rig, stone crasher etc.)
A. Workshop1 (wheel assembly shop): Assemblies excavator (with wheel), grader and loader.
B. Workshope2 (chain assembly shop): assemblys excavator and dozer.
2. Maintenance
In maintenance the main one is re-manufacturing workshop ,and maintain every engine present in
the industry by using different machines such as lath machines, vertical drill machines, plasma arc
and Arc welding machines ,CNC machines (for feature)
Engineering tool: In these factory mainly assemble and maintain excavator, crane, surface
rig, loader, mini loader, water drill etc. In the manufacturing tool there is manufacturing of
stone which is called stone crasher it produces 0, 1and 2 number sands.

Our hosting company working on; Dozer ,Grader ,Excavator ,Crane, Loader ,Roller ,Fork Lift
,Surface rig, Stone crasher, Water drill , Asphalt fever, Asphalt distributer, Dumper
 BRIEF HISTORY OF THE COMPANY
By a letter issued from Ministry of Defense of the federal democratic republic of Ethiopia on
March 15, 2007G.C it was decided that the industry shall be structured independently by the name
DEFENCE INDUSTRY SECTOR It had been leading sixteen military Engineering complexes
and development enterprises. And after the decision of the federal democratic republic of
Ethiopian government, the Metals and Engineering Corporation (METEC) has been stablished by
the council of Ministers Regulation No.183/2010, since June 09, 2010, and Metal and Engineering
Corporation took over all responsibilities from defense industry sector to its side.

Figure 1.1 shows entrance to the industry

STRATEGIES THAT ARE FOLLOWED BY METEC

Jointly working with Domestic small and micro industry enterprises,
jointly working along with foreign partners,
Participating Educational and research institutes,
direct foreign investment on prospective economic sectors,
manufacturing fully accessible machineries
METEC ENGINEERING COMPLEXES THAT HAD BEEN
ORGANIZED UNDER THIS INDUSTRY
DEJEN Aviation Engineering complex
BISHEFTU Motorization Engineering complex
HOMICHO Ammunition Engineering complex
GAFAT Armament Engineering complex
NAZRET Canvas and Tailoring factory
NAZIRET Tractor industry
DEBRE BRIHAN infrastructure machinery engineering industry
ETHIO PLASTIC Industry
ETHIO POWER ENGENERING

THE MAIN PRODUCTS AND SERVICES

Most of the products at construction machinery industry are spare parts for industrial machine
components with simple and complex shapes. These machines are includes:

Figure1.3: Loader Figure1.2: Excavator

Figure 1.4: Bulldozer Figure 1.5: Grass grip excavator

Figure 1.6 Roller Figure 1.7 Asphalt smoother

Figure1.9: Mini Loader Figure1.9: Surface Rig

Figure1.10: Asphalt distributer Figure1.11: Water drill

Figure1.12: Grass grip Figure1.13: Crasher

Figure1.14: Fork Lift figure 1.15 grader

 Objective
-In F.D.R.E metals and engineering corporation infrastructure machinery
engineering industry which is located at Debre Birhan aimed at supporting the
construction sector due to the following parameters; the first one is to reduce forign
currency how to reduce foreign currency in the previous years METEC can have
done the assembling process. All body parts can be import from outside country and
assemble the part each other and selling for the customers ,but today METEC can
be manufacture some body parts like front frame,cabin,pin ,main frame,etc and
assemble together.

CURRENT CAPABILITIES METEC

Designing of Machines and equipments.
Manufacturing of Deferent Military and Civilian Equipments, chines, Metal
Structures.
Industrial designing, Manufacturing, erecting commissioning and transferring
Conducting Research and development activities
Conducting engineering capacity building Training
To design, manufacture, erect and commission manufacturing industries;
To engage in maintenance and overhauling of manufacturing industries;
To manufacture industrial machineries, capital goods and industrial spare parts.
To expand and enhance engineering and technological capabilities through crating
partnership for the integration and interfacing resources.
To undertake production, manufacturing maintenance, overhauling and upgrading
of weapons equipment and parts useful to defense security forces for combat and
war operations;
To sell its product of weapons equipments and parts to domestic and overseas
buyers in conformity with law.
 To build technological capabilities of the countries defense forces by capabilities of the
countries defense forces by identifying existing and potential needs through research and
development.
In the line with directives and policy guidelines issued by the ministry of finance and economic
development aimed at insuring macroeconomic stability, to sell and pledge bonds and to negotiate
sign loan agreements with local and international financial sources.

To engage in any other activities necessary for attainment of its purpose.

Now at this time METEC is authorized with a capital of 10 billion birr

The final aim of the METEC in the future all body parts will be manufacture
in our county and assemble the parts, due to this it will be fully reduce foreign
currency of our country and METEC also fully supporting the construction
sectors.

OVER ALL ORGANIZATION AND WORK FLOW

F.D.R.E Metals & engineering corporation infrastracture machinery engineering industry
production is managed by a General Manager accountable to the Ministry of National Defense.
 GENERAL
MANAGER

RESEARCH AND
DEVELOPEMENT MIS CORPORT

SAFETY AND QUALITY

SECURITY ASSURANCE

EQUIPMENT PROPERTI
ADMINSTRATION ADMINSTRATION

HUMAN RESOURCE
FINANCE MARKETING ADMINISTRATION
OPERATION

Factories

Loader Factory

grader Factory Excavator Factory Dozer Factory

Figure 1.16 OVER ALL ORGANIZATION AND WORK FLOW

 Overall internship experience

How we get into the company

We got in to the company as we are assigned by the request of the university industry linkage
officer Mr. Abebe to the company & accepted. When we entered to the company by the month of
March the head office and administration of the company gives as an orientation about the
company and also gives to follow the rules and regulations of the company.

In which section of the company you have been working in?

There are six factories in the company. These are

1. Grader

2. Excavator

3. Loader

4. Dozer

5. Engineering tools

6. Remanufacturing

From the above six departments, we work grader loader and excavator department especially in
Grader and Loder. Here some information about these;
 GRADER

figure 1.17 Grader

GRADER STREERING SYSTEM

Front wheel streering angle 45 , turning radius 10.9m at tilted wheel 10.4m at
non-tilted.
HYDRAULIC WORKING SYSTEM
Control system hydraulic drive system hydraulic pump high pressure gear pump
,hyounted on the out put shap of the gear box.
AIR CONDITIONING :-provided an user request ,special air conditioner with both
cold and heat for construction equipment.
ELECTRICAL SYSTEM:-rated voltage =24v
Battery= 12v2 165AMP/Hr
Lamp=two working lamps are on the both side of front frame , two front working
lamps and two rear working lamps are on the cabin one streering lamp ,one braking
lamp and tail lamp are at the left side of cabin and one streering lamp ,one braking
lamp and one tail lamp are at the right side of cabin.
GENERAL DESCRIPTION
-Engine and gear box are mounted on the rear front .The working device is
mounted on the front frame .front push plate and rear ripper have enlarged the
usage scop of the motor grsder.
The motor grader is equipped with a water coole 6 cylinder ,4 strock inlet turbo-
charged diesel engine .The engine power is transmmited to the rear axle to the rear
axle via torque converter , gear box and drive axle.And the power will drive the
four rear wheel via balance box chain.
Hydraulic front wheel streering together with articulated joints makes the mator
grader turning radius decrease (minimum)

GRADER ENGINE
-All the power driven devise (engine-gear box) are fixed on the rear frame via 6
pieces of rubber buffers.
When watch the crank shaft at the direction of the engine for the crank axle works
clockwise.
The air will go in to air filter and the engine bearing lubrication and the cooling of
some revolving parts depend on the oil supply pressure the oil of the lubrication
system came from the oil pan via oil pump , the engine oil cooling depends on the
water cooler which is mounted in the engine . PLEASE READ THE DIESEL
ENGINE MANUAL

HYDRAULIC TORQUE CONVERTER

-The machine is equipped with hydraulic torque converter this device include a
torque converter and a fixed shaft gear box . The gear box can shift speed at six
forward gear and three reverse gear.

ABOUT GRADER
A motor grader in load construction machine depend with in long blade to creat a
flar road surface .Sinomach road grader manufacture with heavy duty blade which
conze with 50% larger device like that ordinary one additionaly we can also offer
optional acceciries such as dozer blade front and rear ripper splash gard to the
application range of the construction equipment.
 WE OBSERVE FROM DEBRE BIRHAN METEC IN
THE FIRST TWO WEEKS IN GRADER FACTORY :-
COMPONENTS OF GRADER
Power device (cortelo)
Two battery
Two tandem, with 90 OIL for lubrication
Diferential located between in the two tandem
Transmission 15/40 OIL for operating
Propeller shaft
Control valve (hydraulic pump )
Hydraulic tanker
Circle drive:-used to for the machine rotating 360 in all direction
Front frame
Main frame
Axle:- consists universal joints, pistons , tyre road etc.
Indicators
Tslode
Tilting cylinder :- used to up and down the direction
Side lifting cylinder:-used to lift circle drive with out lifting other
device
Scarbata by pin at 90
Ripper piston :-used to lift ripper at the back of the machine
Acmmulator:- used to control the sudden moment of machine as a
safety
Torque converter :-used to multiply torque
Cooling system :- used to 1.for transmission 2.for hydraulic 3.for
engine
AC generator :- used to air conditioning in the cabin
Solonoid :- located on the engine used to transmit fuel
Starter motor:-used to convert electrical energy to mechanical energy
and used to start power
Solenoid on starter:-control power and there are 3 terminals
1.terminal 30- used to receive power from the ready battery
2.terminal C-used to transmit power from terminal 30 to the motor
3.terminal 50-used to control by ignition key by operator Then the
solenoid opened the spool mesh to fly wheel the engine will start.
 ELECTRICAL SYSTEM
Battery
Switch
Cortelo:-two battery can be connected in series because to
increase voltage
MAIN COMPONENTS OF BATTERY
o Sulpheric acid (H2SO4)
o Electrolyte
o Road
In battery there is a process regarding with chemical energy convertes to
electrical energy

- +
Battery 1 battery 2

GROUND

SYSTEM

4. start:-terminal 50,engine, starter,motor etc

1.read battery IGNITION KEY 3.accessories :-sensor,lights

-key switch ,alarm
2. ON
 CHARGING SYSTEM

GENERATOR/DYNAMO:-works when after starting of engine power can gets

from crank shaft by belt.
- It used to convert mechanical energy to electrical energy
- It also used to charge the battery and other accessories
- First generate altenative current (AC)
- Can be convert in to DC generator by using diod
- Generator generates high amount of voltage above 24v , so we can need or
using REGULATOR which regulate the excuss amount of voltage above
24v
- Produce accessories and start motor works only in 24v
 LAY OUT OF GRADER POWER
TRANSIMISSION
-WE HAVE SEEN FROM DEBRE BIRHAN METEC GRADER POWER
TRANISMISSION

Starter
Power device Accessories: -
Battery like -
OR cortelo sensor ,lights, Motor
al arms etc

Engine Gear box Torque converter

Propeller Tandem
differential Wheel
shaft - 1 . Gear drive

- 2 .Chain drive
Loader
A loader is heavy equipment machine used in construction to move a
side or load materials such as asphalt demolition debris, dirt, snow, feed,
gravel, logs, row materials, recycled material, rock, sand, wood chips, etc.
into or onto another types of machinery. Loader is a kind of earthwork self-
loading & unloading machine which is widely used in construction projects
of highway, railway, building, water and electricity systems, port, mine, etc.;
it is mainly used for loading materials such as soil, sand, lime, coal, and so
on.
Re-Manufacturing
In the manufacturing the company used the following machines Electric Arc welding machine,
Oxy-acetylene welding machine, Gas cutting Machine, Circular Gas cutting Machine, vertical
drill Machine, Mini vertical drill Machine , Lathe Machine and CNC Machine(Temporarily not
work).

Arc welding (AW). Arc welding refers to a group of welding processes in which heating of the
metals is accomplished by an electric arc or Arc welding (AW) is a fusion-welding process in
which coalescence of the metals is achieved by the heat of an electric arc between an electrode and
the work. The same basic process is also used in arc cutting

a) Vertical drill machine in CEMI b) Electric Arc welding

 OUR ability in performing OUR work tasks
During our internship since we have been working in the company, we were trying
to be active when every things going to be done every day. Especially, when our
assistants who was a mechanic worked there was tried to find out what problem was
the car made to be serviced or repaired. if today he fixed some part of the car, so we
were sure that we can fix the same problem for the next day by our own self holding
this activity in touch, eventually this practice made us to upgrade our
skills.Therefore using this skills, we were good by and then observing our
environment and surrounding point out the solutions for the problems around the
company, and also if there was anything that we couldnt under stood we was
keeping asked the mechanic who works indifferent sections. we also discussed with
our friends about what measures should taken for the difficulties especially about the
work flow of company to we make easy the way they do their tasks. Or things by
holding this we making helped producing new idea and plans which would then be
checked by our senior mechanics among the team.

we spent the two month in the company by assisting or helping them by providing
the material beside we learning and upgrading experiences skills. But the rest of the
two months the third and the last month, we were good by performing the activities
solving the problems of the car as repair are maintenance beyond assisting them.

our aim and expectation were exceeded in all possible ways. Not only did we learn
about the work and the problems. But also about the solutions and changing the way
in which the mechanics and the company works. Which leads the existence of bad
work flow in the company?

Towards the end of our internship, we did expect to solve at least one problem say
we have responsible that way given for engineer and for this purpose we always have
definitely improved our practical skills and also theoretical skills. This all tells how
good were during having the short-term position.
 problem identification
Since we began working in this company, we have seen a lot of challenges as problems of
the company as well as regarding to the machine parts which are mostly repaired. Those
common problems are listed below.

Presence of some bad work flow in the company

when see the work flow of the company, in different sections; we could see some
problems as result of bad managing systems of the consumed office manager.

For example, un proper setting of tools, including bolts, nuts, hammer, washers,
gaskets and also different tool sets. Makes the technician cannot find out easily
when they are needed. In addition to un proper placement of tools, there is also a
problem of active work flow between the technicians and the manager of stocking
shop materials during replacement. This means during disassemble or
assembling, the mechanic needs some new materials or parts for replacement
purpose, they cant get that component easily from the storing shop because of
absence of active work flow. This leads to make the problem takes extra time until
it will get fixed or it kills time as wastage.

Absence of engine and differential stands during

disassembling and assembling of an engine;

as we know, it is too difficult to move an engine or differential from place to turn it

upside down because of their weight. But in this company, after these parts come to their
shop where they are being repaired we have disassembled Them manually without
engine stand or any automatic mechanism.
 Wastage of usage material or components.
The materials or the components which were replaced by the new one all are
troughed to any place because of all the resources are passes to government which
is bad attitude.

Absence of convenient are for car wash.

This problem raised because of the washing machine is still doesnt work, and
doesnt get repaired which is called liavago

Un willingness and loose of motivation of the labor to be and

stay working in company;

Due to very law payment which made them unlade to fun fill their needs, almost all the
labors are not satisfied to work in their position within the company.

Absence of any entertainment places for the labor before and

after work and also during break time:

All the labors needs to refresh themselves and to be entertained by any situations, but
nothings can fun fill and satisfy their needs due to absence of such kinds of places in the this
company.