ACKNOWLEDGEMENT

This report would not have been possible without the support of many

people. I wish to express my sincere gratitude to my supervisor instructor Dawit

Kebede who was abundantly help full and offered valuable assistance, support and guidance as well. Deepest gratitude also due to the members of DDFCS staffs, without whose knowledge and assistance this report would not have been successful. Our departments staff members like instructor Samson who guided me through the process of internship are also have to be appreciated. I thank them

all.

 This report documents the work done during the internship better time at Image understanding the overall process of Dire Dawa Food Complex S.C & the rank of technology the company used, maintenance work performed under the supervision of my mentor, supervisor and manager of maintenance Department. From my first day in the company on wards I could honestly say that I was trying to see everything from my heart. I did that all because I made up my Mind before I got there to learn what

EXECUTIVE SUMMERY

so ever I came across during these four Month of internship practice. I believe that I met my goal.
Fortunately, from my first day of entrance of factory I got my friend who I learned together during high school level which are now the member of the company workers and he invite me as I visit all part of factory with explaining for me about machine one by one and next day after the

manager of maintenance section told me advisor also my advisor visiting me same as yesterday.
Also He told me how to communicate industrial community. So, I was not troubled to communicate with staff members even more they are easy going community.

SHORT PROFILE OF DIRE DAWA FOOD COMPLEX S.C Dire Dawa Food Complex S.C is located in Dire Dawa town in the eastern part of
the country which is around 515kms from Addis Ababa. The company stated its
operation in 1995 GC and it is one of the modern Food processing plants in East Africa. The company had played a leading role in the food processing industry of Ethiopia with respect to introducing new system of production and packaging as well as it is the pioneer in having international systems certificates like FSMS (Food Safety Management System) and ISO 22000:2005 ISO 14001:2004 (Environment Management System) certification.

Its High quality standard products have got a good reputation among our customers all over the country.

cont.
DIRE DAWA FOOD COMPLEX AS A PROJECT: The

Dire Dawa

Food Complex Project was conceived as an expansion program of

the ex-Dire Dawa flour mill located at Dire Dawa town in the Eastern region of the country. The feasibility study of the project

was finalized in 1972 GC with the main objective of establishing a

food complex consisting of a wheat flour mill with 120 tons/day grinding capacity, long and short cut past plant lines with total

production capacity of 44 tons/day and biscuit production lines

with a capacity of 10 tons/day.

Cont.
According to the feasibility study, the project cost was estimated to be 34.5 Birr million. The source of finance was planned to be: Foreign loan for 21 Million Birr Government equity for 7.4 Million Birr and Domestic bank loan for 6.1 Million But to complete the project cost has been reached 53.21 Million Birr due to the following major reasons;

cont.
Expansion After the above mentioned main machinery erecting time one additional Galleta (high energy biscuit) line with a capacity of 100 quintals/day is erected in the first half-year of 1988 GC and entered in to operation. The investment cost of this line was 1.6 Million Birr. And in December 1989 GC flour line milling capacity is expanded from 1200 quintals to 2000 quintals per day and finalized with 9.2 Million Birr. The pasta and macaroni production lines expansion erection are finalized in March 1990 GC with about 55 Million Birr cost and their production capacity are about290 quintals and 380 quintals per day respectively. The bread production line is also installed with about 4.9 Million and start operation in October 1991 GC. It has production capacity of 80 quintals per day.

Vision

The vision of the company is to be a famous pasta producer with the known brand VERA in East Africa and COMESA member countries, fulfilling the internationally accepted standards.
Mission

CONT.

The organization mission of the company is to produce

quality flour and flour based products to the best satisfaction of the customers based on FOOD SAFETY

MANAGEMENT SYSTEM (FSMS), ISO 22000:2005 and

ISO 14001:2000 Environment system requirements.

CONT.
2000 Quintal/day Wheat Flour 450 Quintal/Day Pasta

620 Quintal/Day Macaroni

130 Quintal/Day Biscuit 130 Quintal/Day Bread

Cont. OBJECTIVES IN GENERAL

The objective of the company is to produce & sell flour & flour related products profitably. The company has been already playing the role of substituting the import and this will be kept in the planning year. The company strives to produce quality products and keep its reputation by maintaining the implemented management systems. The company tries to stabilize the food price escalation by distributing products to the government institutes, market corporatizes and to the public at large with reasonable price.

CONT.
Major Products Of The Company Wheat Flour Vera Spaghetti Vera Tegletelli Vera Bucatini Vera Macaroni(Various Shapes) Vera Pastini High Energy Zebib Biscuit Fruit Biscuit

Bread
Animal Feed

How I get in to the company According to Jimma university Jimma institute of Technology Mechanical Engineering curriculum in our four year mechanical engineering experience we began to realize that this world is only can go far in innovation and creating things that uses to provide for humans best need to achieve their needs energy is must. Especially, mechanical energy. In the study of mechanical engineering many problems are solved and if the study widens its horizon students are able to solve many problems related to industries in the future. In our world food is the first need of human being. So, I decided to practice in food factory which is Dire Dawa Food Complex SC and tell to JUIL. The letters that asks for internees to do my internship program in the DDFCSC is given to me from JUIL. The latter is accepted by the company managers and they allow me as joining the DDFCSC staffs and Workers after 6 month of application and after that on 4th year 2nd semester I went to DDFCSC start practice.

There are many section of factory which I have been working in the following Flour mill section Pasta production section

T H E S E C T I O N I H AV E B E E N W O R K I N G

Macaroni production section

Biscuit production section Animal feed section Garage section

HOW DOES THE WORK FLOW IN THE SECTION I WORK LOOKS LIKE?

T H E T H I N G S I H AV E A C C O M P L I S H E D I N DDFCSC I have engaged myself in a lot of duties just not to sit and watch the four months gone by in idle and in vain. I do not under estimate rather I have been taking my hands to help the workers. Some of the works I have been undertaking were the following:-

I have been substituting the worned bearing of flour mill machine I have helped in disengaging motors which are prone for random damages. I have Searching a problem in factory I have designed and made load cart for pasta transportation. I gave them suggestion for different problem. I have helped them during repair of screw conveyor. I have saw all over part and mechanism of CNC machine also manual.

REPLACING OF BEARING

PROJECT
Load Cart Design
Specification
Load capacity 30 packet each 10Kg = 300Kg Height 730mm Length 1000mm Width 820mm Weld construction Wheeel is bolted with chases of cart.

This a single cart can reduces the human labour power with is working daily
labour of loading & unloading section by 14.00% of 107 workers.

 The time consumed by one worker to take two packets of pasta from production size to store is takes an average time of 3 minutes. This implies, when a

CONT.

single worker goes 15 round the consumption of time reach 45 minutes. Whereas
this design cart reduce the time that the worker rounds once at a time. To make the packet Safe the packed past must be setted as up Side.

This Cart Is:Maintainable Reliable Appropriate Minimizes cost Minimizes Workers Have & long Life Non environmental pollution

DESIGN CONSTRUCTION
Designing a part for expected life of the Cart. For rolling surface. Factors of safety & allowable stress. Selecting bolt diameter Design of welding part in each joint. Design of load carrying capacity. Design of load carrying capacity. Material selection.

Cart analysis

WHAT MAKES THIS CART DIFFERENT?

From all structure of the cart the two size of the cart can be disassembled to simplify the loading and unloading press from to the cart easy. In the same procedure this can be applied and we can carry motors or other parts of machine with are below 300kg from one place to another. The size of the cart is filled with size of pasta packet to make the

transportation of pasta safe.

It is only design for DDFC S.C.

Future
Inserting brake Motor and batter

MATERIAL SELECTION
A range of load cart is constructed from a variety of materials depending on the industry or the product in which they are being used for. Finest quality materials are used to manufacture load cart for ensuring reliability, ease of maintenance and long life. The specialty load cart materials undergo vibration and endurance test to ensure that the end product is of premium quality. The factors which should be considered while selecting the material for a machine component are as follows:
Availability, Cost, Mechanical properties and Manufacturing considerations Depending up on above criteria I select the following material for cart construction. Steel angle RH steel Wheel Wood block

Bolt and Nut design

D E S I G N A N D A NA LY S I S O F C A RT L OA D

Wheel of the cart is attached by the bolt and nut because of the fastening is having long life than welding, also the bolt can absorb vibration than welding. Therefore, we should have design bolt. Points of stress con-centration of bolt are at the fillet, at the start of the threads (run out), and at the thread-root fillet in the plane of the nut when it is present. The diameter of the washer face is the same as the width across the flats of the hexagon. The thread length for metric bolts is 2 + 6 = 2 + 12 2 + 25 diameter 125 48 125 < 200 Where d is the nominal > 200

The ideal bolt length is one in which only one or two threads project from the nut after it is tightened. Bolt holes may have burrs or sharp edges after drilling. These could bite into the fillet and increase stress concentration. Therefore, washers must always be used under the bolt head to prevent this. They should be of hardened steel and loaded onto the bolt so that the rounded edge of the stamped hole faces the washer face of the bolt. Sometimes it is necessary to use washers under the nut too. The clamping load stretches or elongates the bolt; the load is obtained by twisting the nut until the bolt has elongated almost to the elastic limit. If the nut does not loosen, this bolt tension remains as the preload or clamping force.

We get the dimension of Bolt and Nut from the Table of Limiting

Dimensions of Standard Series Threads for Commercial Screws, Bolts, and Nuts (1) For Bolt
Nominal size diameter = 5mm Pitch P = 0.8 Basic thread designation = M5 Tolerance class = 6g Allowance = 0.024 Major diameter Maximum = 4.976 Minimum = 4.826 Pitch diameter Maximum = 4.456 Minimum = 4.361 Tolerance = 0.095

Minor diameter Maximum = 3.994 Minimum = 3.841

For Nut
Nominal size diameter = 5mm Tolerance class = 6H Minor diameter Maximum = 4.334mm Minimum = 4.134mm Pitch diameter Minimum = 4.480 Maximum = 4.605 Tolerance = 0.125 Major diameter Minimum = 5.000 Therefore, the thread length = 16 Nominal Nut Dia. And Thread Pitch = M5x0.8

CONT.

Width across flats of nut, S Maximum = 8.00 Minimum = 7.78 Width across corner, E Maximum = 9.24 Minimum = 8.79 Thickness, M Maximum = 4.70mm Minimum = 4.40mm Bearing face dia, Minimum = 7.0mm

American National Standard Metric Plain Washers ANSI B18.22M-1981,

Washer

R1990 Nominal Washer Size = 5mm Nominal washer sizes are intended for use with comparable screw and bolt sizes. Washer Series is narrow. Inside Diameter, A Max. = 5.78 Min. = 5.50 Outside Diameter, B Max. = 11.00 Min. = 10.57 Thickness, C Max. = 1.40 Min. = 1.00

 Fastener length: > + = 16.40 + 4.70 = 21.10 Length of useful unthreaded portion: = = 21.10 16 = 7.10 Length of threaded portion: = = 21.10 7.10 = 14
2 Area of unthreaded portion: = 4= 4 = 19.635 Area of threaded portion: = 14.22 from table 8-1 of shigleys Mechanical Engineering Design 2 (5)2

C O N T.

Fastener stiffness: =

153/ Where = tensile-stress area = length of threaded portion of grip =major-diameter area of fastener =length of unthreaded portion in grip

19.6352 14.22 207 19.6352 14:14.22 7.10

EFFECTIVE GRIP

2 + 2 , 2 < = + 2 , 2 = 5, 2 = 5 Then = 1 + = 10 + 1.40 = 11.40 5 = 11.40 + = 13.90 2

Fastener length: > + 1.5 = 11.40 + 1.5 5 = 18.9 Length of useful unthreaded portion: = = 18.9 16 = 2.90 Length of useful threaded portion: = = 13.90 2.90 = 11 Diameter of the washer face is about 5% greater than the fastener diameter for standard hexagonhead bolts & cap screws.

Assume the column as a cantilever beam which is up side and performing an adequacy assessment statically loaded cantilever carrying 367.9N deflected in the following figure and the cantilever is made of AISL1018HR steel and weld as shown in figure. AnE6013 electrode was used and design factor was 1.

D E S I G N F O R W E L D I N G PA R T

h = 5mm, b = 40mm, d = 60mm A = 1.44h (b + d) = 1.44*5 (40 + 60) = 7202 40 60 = = = 20 , = = = 30 2 2 2 2 The unit second moment of Area is: = 3 + = 3 40 + 60 = 1080003 6 6 The Second moment of Area is based on weld throat area is: = 0.707 = 0.707 5 108000 = 3817804 The nominal throat shear stress is now found to be 2943 Primary shear = = = 4.088
720 2 (60)2

WELDING SHAPE

 Diagram showing the weld geometry; all dimensions in mm. Note that V and M represent loads applied by the welds to the plate.

welding diag ram

FIND THE DISTANCE = = = = 60/2

2

+ 40/2

= 36.06

The secondary shear stress is M = 650*2.943N = 1912.95 N.m

= = = =

1912.95(10)3 36.06 3817804

= 180.68

Factor of safety = 0.577 0.40 = 1.44

The minimum weld metal properties is E6013 which is = 427 = 345 From Table9.3

cont

The stress permitted by the AISC code for weld metal with applied force of load for shear on fillet permissible stress = 0.03 = 0.03 427 = 1282 , = 1

From the Table A-6

Properties of structural steel Angle: ALSI1018HR = 400 , = 220

The shear magnitude is the Pythagorean combination

180.68

+ 4.088

= 180.73

C O N T.
Therefore the factor of safety based on a minimum strength and the distortion-energy criterion is =

0.577

0.577427 180.73

= 1.36

Since > , that is, 1.36 > 1, the weld metal has satisfactorystrength From the above = 180.73, For an E6013 electrode 9.6 gives the allowable shear stress = 1282 Since < , the weld is satisfactory

load force on the base on the car t beam

cont.
1 = 2 = @ = 0,
2

2.943900 2 2

= 2648.7
2

=
2

2.943900

2.9430 = 1324.35

@ = /2,
@ = , =

=
2

=
2

2.943900 2

2.943450 = 0

2.943900

2.943900 = 1324.35

The bending momentum on the difference distance is @ = 0, = =

2 2

= 0
2 2

@ = /2, = @ = , =

2.943450

900 450 = 595957.52 900 900 = 0

2.943450

C O N T.

And solving for deflection and slope result in

@ = 0, = 24 2 2 3 3 = 0

@ = /2,
= 24 2 2 3 3 = 2.943900 (2 900 (450)2 ) (450)3 (900)3 = 24.5 24

@ = ,

= 2.943900 2 900 (900)2 (900)3 (900)3 = 0 24

For the slope at the left end, substituting x=0 yields

the slope is Negative =0

And at = the slope is positive At the midspan, substituting = /2 gives slope = 0, as earlier suspected. The maximum deflection occurs where slope = 0. Substituting = /2
5 = 384 4

E is the modulus elasticity of AISI1018 steel angle and we get from standard table

cost analysis

3 D D R AW I N G O F L OA D C A RT

D E T A I L D R AW I N G O F C A R T

T H E P R O C E D U R E S I H AV E B E E N U S I N G W H I L E
I PERFORM MY WORK

I have list down some of the procedures as follows:-

Visiting all section of factory with the mechanics and technicians.

I ask my supervisor, some mechanics, technicians and my friends about the ideas I have not understand. I write down some points while people brief me with new terms. I have tried to discuss a lot of issues with my friends Refer manuals Try to take caution while I work on different machines in the workshop. Take a heed not to transgress any forbidden laws.

HOW GOOD I PERFORM MY WORK IN THE C O M PA N Y

I have been in good condition while performing my task since I have covered almost all theoretical knowledge.so, it becomes suitable for me to upgrade into practical aspect.

All of our team members are hard workers and have good motivations so this makes my task
easy to perform in a good manner. Beside this most of the workers in the factory are ready to assist me. Even though there were a lot of challenges and unsuitable conditions, I tried my best to

struggle against those harsh conditions to achieve ultimate goal.

I realize and even begin to think and wonder about the things I have come across in beating my wishful mind. So, now I am very amused over my understanding of my working environments which have made me very curious about my prospects.

Finally, as of me I could say that I have measured my performances to be very satisfactory

since they have equipped me with the appropriate knowledge

During my project work there was different challenges exist to decline my readiness & moral to minimum point, some of these are; The general manager of company cant understand design project (not engineer), The company government system, The unwillingness of some formance to help me, Over work of the manager in each department, guards who those keep the inside & outside entrance gate of the company, Non voluntary body(department managers)to give data & make an interview, Lack of library, internet access & some reference about the operation machines. No office, no pocket money,

C H A L L E N G E S I H AV E B E E N FA C I N G D U R I N G M Y PROJECT WORK.

At least no one mechanical engineer in the technical staff.

The weather condition is very hot and humid temperature.

M E A S U R E S I H AV E TA K E N TO OV E RC O M E T H E S E C H A L L E N G E S

To make my project successful or to lead it to the completion, I did my best as much as possible. Some of those are:
Make close relationship with each of worker & operator of the company, Being patient to get something what I want Asking them repeatedly without saying it is boring, By telling the problem to my advisor & to the general manager of maintenance department , By following the companys official rule to ask something. To get reference material I used Internet by money on evening.

CHAPTER THREE

OBJECTIVES

To identify the major benefit that can be gained from an

internship program,
To relate theoretical knowledge with the practical one, To show to the interns what interface is there when they conduct in such area after graduation, To relate the interns with the common obstacles who

those must straggle

IMPROVING PRACTICAL SKILLS

Over the last four months, I can say that I have improved my previous skills and I even developed new practical skills. Without a doubt internship program ideas is the most basic and necessary, because the following critical elements.
Broad technical knowledge of mechanical elements. Outstanding project skills. I learned how to motor winding is done. A sophisticated appreciation for the flexibility and innovation required in our next business world and to my final project. I improved my welding skill. I know how to cut materials using different kinds of grinders and cutters. I advanced the talent of working in noisy work shop. In addition to the above critical elements we understand how many different mechanical elements are closely connected and work together successfully. I can develop my skill by participating myself into different part as I had learned theoretically in my department course. Among them:

UPGRADING THEORETICAL KNOWLEDGE

Today as we are mechanical engineering students and at the future we are a professional mechanical engineers we need to develop our problem solving skills,

project making ability, creativity and energy to make sure that all of the mechanical
engineering issues should be handled in a way that would support our business objectives without compromising our strong commitment to our world. This set of skills made the engineers a critical problem solver in every phase of his progression. Therefore this internship program may develop our theoretical knowledge through what we call it and also my way of way of writing daily report may also increase of theoretical knowledge because I interpret what I seen in our real eyes and work practically into theoretical knowledge to this I am daily worked depending upon the manuals which was I obtained from the factory this may increase because all the manuals I had in place was graphically prepared this may increase my way of visualization.

IMPROVING INTERPERSONAL COMMUNICATION SKILLS

I was develop the following characteristic Communication skill.

Problem solving
Motivation Negotiation & conflict control-to reach an agreement

Politeness
Being openness Self confidence

Honesty
Personal right & obligation

I M P R OV I N G T E A M P L AY I N G S K I L L S

I can develop very interesting behavior that is never happened before. I can improve How can be patient Giving respect for other

How can Make Close relation with the community of my

environment Develop listening skill Problem solving together.

I M P R OV I N G L E A D E R S H I P S K I L L S I have got the following progress:

How can establishing direction as a leader of a team Aligning people Motivating & inspiring Focus on team & overall goals Communication with each people under my control To be a leader not to be a boss .this slogan looks simple but it is a backbone to the whole process. To update oneself if anybody wants to be a leader. This is gone left the Leader with charismatic characteristics. To built and believe that leadership is dynamic.

UNDERSTANDING ABOUT WORK ETHIC RELATED ISSUES

The followings are some personal and professional ethics Personal ethics:

Fairness
Compliant to the law Benevolence (doing good) Refusing to take unfair advantage Professionals ethics Punctuality Office disciplines Impartiality Transparency. Accountability and openness Integrity Due diligences

ENTREPRENEURSHIP SKILLS:
As Entrepreneurship is the process of creating something new with value by devoting the necessary time & effort, assuming the necessary risks, & expecting rewards for undertaking, from this internship Program I gained different ideas to: Make myself free from the limit of standardized pay for standardized work(profit) Freedom from supervision & rules of bureaucratic organizations(independence) Freedom from routine, boring & unchallenging jobs(satisfying way ) And it makes me interested in: High need for achievement Willingness to take risks A need to exercise leadership Self-confidence Creativity

R E C O MME N DA T I O N
The company should have to use schedule maintenance to minimized high downtime, Safety materials for all the welding types, sanding, and grinding such as gloves, goggles

and others are not enough.

The rigidity of the company is not limited but extended to not to provide resource and facilities such as library, internet access and other reference materials for the staff reference and for the intern students to progress for any type of intended project for further insight

should be fulfilled.
On the other hand, neither no pocket money is given by the company nor the pocket money given by the university to the internship students is enough. It may be difficult to survive for students from poor background. The serious of sense of punctuality and team

working in the company should be admired and promoted for further success.
Lastly, I believe that this internship has to be continued since it has got lot of virtues.

CONCLUSION
The internship semester makes the new curriculum. So good to give real practical skills and make the students familiar to the outside world. Generally I get the following

benefits:
Allow me to both make and develop professional contacts, for my future job search. Assist me in developing greater understanding of my own strength and weakness. I know the companys workflow. Upgrade my theoretical knowledge. Knowing the local design standards. I Progress leadership skills.

I identify working standards.

I recognize time management

REFERENCES JIT Outline internship reports http://www.brightonk12.com/webpages/mjourden/general.cfm?subpage=13 05723 Shigleys Mechanical Engineering Design, Eighth Edition 26th Edition Machinerys Handbook BY ERIK OBERG , FRANKLIN D. J

ONES , H OLBROOK L. HORTON , AND HENRY H. RYFFEL.

Marks Standard Handbook for Mechanical Engineers. Different internship report