Industrial Training Report: College of Engineering and Technology (Cet)
Industrial Training Report: College of Engineering and Technology (Cet)
Industrial Training Report: College of Engineering and Technology (Cet)
STUDENT ID 15000353
The attachment is meant to allow students to learn more about their career, find out what
it’s like to work in their potential career, gain valuable experience to build their resume
and get to know employers and make a solid network. During a period of 20 weeks of
Industrial Training I have been through various departments which includes milling,
maintenance, packaging, warehousing and distribution. Throughout this industrial
training I’ve learnt to run all milling plants and maintenance of plant equipment and
machines and implement what I have learnt for the past three and half years. Some
different potential projects arisen as I progressed through the training period of which I
managed to execute some and others not due to time constraint.
ACKNOWLEDGEMENTS
I would first of all like to thank my God for each and every day that I was able to see
the sunrise and sunset , grateful for the fact that no harm occurred to me during the 20
weeks I undertaken industrial attachment though my life was at stake each time I
entered the facility.
Secondly I want to thank my parents for giving encouragement, enthusiasm and
invaluable assistance to me. Without all this I might not have completed this pivotal
industrial training properly.
Thirdly, I would like to express my deepest gratitude to Prof Totolo (Vice Chancellor,
BIUST) meticulously planning academic curriculum in such a way that students are not
only academically sound but also industry ready by inclusion of industrial attachment.
I express my immense pleasure and deep sense of gratitude to Mr. Edwin Petso (Head
Miller), Mr. M. Madimabe (Head of packaging department) in spite of being busy with
their duties, took time out to hear me out and provided guidance on the correct path.
Lastly l will like to give my thanks to those I might have forgot to mention for helping
with an effort to increase chances of successful completion of the industrial attachment.
Milling
The company attained Botswana Bureau of Standards BOS ISO 9001 in 2015 of which
drives the company to maintain high standards of quality and safety management in its
operations.
Packaging
In thriving to achieve efficiency and consistency, the company utilizes the fully
automated packaging machinery .In addition to maize and wheat products, the company
also packages refined sugar.
Warehousing
Abundantly spaced and sufficiently shelved warehouses maintained with high level of
housekeeping. Gaborone covers 7714 square meters and Francistown is 1600 square
meters.
Distribution
Gaborone operation has 30 and Francistown has 8 order picking staff to guarantee
accuracy and convenient execution of client orders. Transportation of products to
customers is outsource for empowerment of Batswana entrepreneurs and to ensure
access to all across the entire Botswana.
Administration
Bokomo Botswana Head office is located in Gaborone and houses all administrative
activities. To keep up with advancement and innovation the organization uses SAP ERP
systems which is interfaced with web based Business Intelligence portal for performance
monitoring and reporting. Inspection is carried out annually by KPMG to ensure the
company adhere to high accounting standards.
Sales and Marketing team is entrusted with the implementation of point of sale strategy,
working hand in hand with the customers to sell more and increase market share. From
expanding deals, to building, activating and invigorating brands, Bokomo sales team is
there to ensure the principal brands stand out from other contending brands, to guarantee
that the products are in stock, optimizing shelf health all the time.
Their course to advertise arrangements include;
Trade marketing
Dedicated, synergized and customized sales and merchandising services across all
channels and categories.
Bokomo Botswana also produces house brands for buying groups such as;
Eureka/Trident
Spar
Shoprite
Aspirational channel is used for removal of light weight particles such as immature
shriveled grain, dust etc. from all kinds of grains and pulses. Industrial aspiration
channel machine is particularly suited to separate husks, chaff, small seeds, insect
fragments, broken and hollow kernels.
2.1.2 Pneumatic Conveying
2.1.3 Cleaning
The pre-cleaners consists of an aspiration unit and a screening section with two screens.
2.1.4 Dehulling
A process of removing the external husk of sorghum grains without damaging the kernel
using dehuller. Dehuller performance of 1.8 to 2 ton/h @ 20% hulling degree.
SMH 845 Hammer mills is used for large volume fine product milling. Feeding rollers
are for precision load balancing and even spread.
Crushing and grinding of sorghum grains using Selis Fortimus roller mills (B1 and B2)
2.1.7 Packaging
Packaging of 5kg champion refined sorghum meal using the PMD packaging machinery
via a transfer line (auger 26) which draws from the four product storage tanks.
It measures and records the resistance of dough to mixing with pins. Measures two
parameters; peak time and mixing tolerance.
Experiment to determine presence and intensity of vitamins in flour and maize meal
products.
Measures protein content, moisture content and falling number in all flours (cake, white,
brown,), maize meal (super and special), wheat, sorghum, maize.
2.3 PACKAGING
Packaging of 1kg, 2.5kg, 5kg of white and brown refined sugar using Italpack (Simatic
HMI) packaging machinery. The pneumatic valve packer packages the 12.5kg brown
and white sugar.
2.3.2 Packaging of maize meal
Packaging of 1kg, 2,5kg, 5kg,10kg super (white star) and special ( Bokomo & lesedi)
maize meal using the premier tech chronos packaging machinery.
Fair Pak packaging machinery (PO5) and P186 packaging machinery are used to
package 1kg, 2.5kg, 5kg and 12.5kg of brown, white and cake flour. There is also
manual packaging of 50kg of all flours and brown and white bread flour mix back.
Champion samp is packaged in 1kg, 2.5kg, 5kg, 10kg and 50kg.The same applies for
maize rice.
The 19 kg bags of champion sorghum meal are manually packaged with the aid of
Buckle packaging bag closing system. Automated packaging of 5kg champion is carried
using the PMD packaging machinery.
2.4.2 Dehuller
A dehuller is a machine used to remove the external husk of various granular products
like wheat, sorghum without damaging the kernel. Dehulling takes place with the pair of
rolls by shearing action. Different Allen keys were used to assemble and disassemble the
dehuller. The dehuller screen was then replaced with a new one.
2.5.1 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.
Accurate separation and cleaning of incoming maize and wheat is important for final
product quality.
Magnetic separator- There are magnets at different points to remove metals from
the grains.
Separator-Vibrating drum separators remove bits of wood, straw and almost
anything too big or too small to be the desired grain.
Aspirators-Air currents act as a vacuum to remove dust and lighter impurities.
Destoner-Using gravity, the machine separates the heavy material from the
lighter material to remove the stones that may be the same size as the desired
grain.
Disc separator- It rejects anything longer, shorter, more round, more angular or
in any way a different shape.
Scourer- The scourer removes outer husks, dirt in the kernel crease and any
smaller impurities with an intense scouring action.
Impact Entoleter- Centrifugal force breaks apart any unsound kernels or insect
eggs and aspiration removes them from the mill flow.
2.5.3 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. The time and temperature depend on the
type of wheat, maize and their moisture level.
2.5.4 Degermination
A process where the grain kernels are crashed from the thin edges towards the center
while avoiding crashing of the relatively flat side surfaces. The degerminator
separates bran, germ and endosperm to achieve maximum yield and top-quality end
products.
The gradual reduction of the wheat and maize kernels through a process of grinding.
Dolomit roller mills grind degerminated maize and wheat grits into flour and maize
meal.
2.5.6 Sieving and grading
The broken particles of wheat and maize are elevated through pneumatic conveying
and then dropped into a huge, vibrating box-like sifters where they are shaken
through a series of Nova sieves to separate the larger from the smaller particles.
Vitamins are added to the white and brown bread flour, super maize meal and the
flour improver into the white and brown bread flour. Final products (maize meal,
flour, and samp) are then directed to storage tanks to ready them for packaging.
Methodology
Choose the appropriate control chart for the data.
Determine the appropriate time period for collecting and plotting data.
Collect data, construct your chart and analyze the data.
Look out for control signals on the control chart. When identified mark it on
the chart and investigate the cause.
Out of control signals are those that lie outside the control limits.
Continue to plot data as they are generated. As each new data is plotted
check for new out of control signals.
By the full utilization of the excel arithmetic functions the graphs auto updates whenever
there are changes made to the original data or incase false data was added at first.
Findings
When starting the control chart the process may be out of control. If so, the control
limits calculated from the first 20 points are conditional limits. When you have at least
20 sequential points for a period when the process is operating in control, recalculate
control limits.
This project was carried out because with the old ones kept on being maintained every
fortnight or less thereby costing the company resources hence leading to initiation of the
project of installation of the Sirius plansifters.
Purpose
The project was executed to curb the company maintenance costs of the old Sirius
plansifters of which were underperforming.
Methodology
It took a day and a half to assemble the Sirius plansifters. Ratchet spanners were used to
lock nuts and bolts during the erection of the plansifters. The 10compartmnet plansifter
with 25sieves per compartment was erected with stability from the holding lines from
the top floor I-beams. Insertion of sieves of different sizes (16-110 m2 net sieve area) and
attachment of the compartment doors. The installation was under guidance of the Buhler
Sirius plansifters installation manual.
Findings
There was a huge observable differences. In comparison with the old plansifters, the new
plansifters had; Top sanitation and product safety, high capacity in a minimum space,
flexibility due to its modularity and minimum maintenance. All this were observed with
time and there was consistency. It was also evident that the company was now beginning
to make profit and other projects which put on hold were kick starting.
Purpose
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.
Findings
Strategies of re- sequencing of existing operations and devices were utilized to decrease
the process duration of these critical operations and to balance the line. With reference to
the results obtained from the process weighers it was evident that that the transfer of the
raw materials was lagging hence allowing other transfer lines to run idle. This was
tackled by increasing the flow rate of the raw material process weighers.
3.2 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. For the 6 weeks I have
spent in the milling department in guidance of Mr E. Petso (Head of Milling department)
who assigned me to different millers (Mr W. Tebele, Mr T. Lekhane and Mr K. Sanoto)
of whom I worked closely with. This are the very individuals who taught all there is to
know about milling operations (both sorghum and maize and wheat plant).What they
would do is show me how something is done and later on they expected me to be
confident enough to do it on my own. Whenever I did something right on first attempt
they would give me credit and praise but whenever I failed they never gave up on me
they went on to be patient and gave me motivation by means of real life situations.
Still under milling, I worked with Mr T. Makgoeng (laboratory technician) in the quality
control laboratory. Mr T. Makgoeng shared with me the knowledge he had when it
comes to quality control, the equipment they had and how to operate them. After
sometimes when I had performed to his satisfaction, he would delegate all the work to
me when he had the serious matter to attend to. This built my confidence to extend that I
was able to make well informed decisions and work hand in hand with millers and
packaging team to take the firm forward. When Students from Botswana University of
Agriculture and Natural Resources arrived he gave me the floor to share with them the
information about the operations of the quality laboratory.
From Milling I went further to packaging department where I was under the wing of
Mr M. Madimabe who assigned me to Mr T.Kedikilwe (supervisor packaging) and Mr
T.Obakeng (supervisor packaging) the two gentlemen are the employees I reported to
and they report back to their head of department. They oversaw the workflow and
assigned different roles to the packaging team. They set targets and deadlines the team
had to execute. We had outside work chats about how to strive in this high demanding
and unfair world and in overall I can say I enjoyed working with them.
Danger in the plant. The milling plant was one area with plenty of potential
hazards. High noise area, equipment with moving pants, has an elevated
positioning and high dust presence to mention a few.
Underperformance of 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.
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.
My work not being used. My bosses would give me a project and it ends up
never being published and gets discarded. This is frustrating because it seems
like I wasted my time and effort and it makes me less motivated for projects in
the future.
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.
3.4 PROBLEM SOLVING PROCESS, APPROACH
Through observation I got to realize that there were measures put in place to help
address some of the problems such as use of safety signs to make employees aware of
this potential dangers. An oral interview was also conducted with the SHE officer Mrs.
Kgosidintsi who confirmed that over time there are some employees from milling plant
who developed respiratory problems and hearing impairment.
Consultation of the involved parties’ for better understanding. It is with this consultation
that yielded alternative approach to this encountered problems.
Research was also conducted to further my knowledge on some issues and concepts I
had hard time to comprehend.
Adoption and implementation act (set in order, sort, and shine, standardize and sustain)
Sort: Removing all the items from the workplace that are not needed for current
production or electrical operations. The workplace becomes less crowded and an
easier, quicker, more efficient place to work.
Set on order: Arranging the items that are needed in the area and identify them
or label them so that anyone can find them or put them away. This ensures
adequate storage, eliminates clutter and keeps surfaces and walkways clear.
Shine: Defects are easier to see in a well-lit and clean environment and a clean
workspace is less likely to cause health or safety issues. Machines that are clean
and maintained work more efficiently.
Standardise: Creating a consistent way of implementing the tasks that are
performed on a daily basis including sort, set in order and shine. Dong the right
things the right way every time.
Sustain: Putting efforts to ensure sustainment until it becomes a habit. Benefits
can be truly be seen if it is maintained in the long term.
Reaching out to the supervisors either by email or phone call when complications arises
during project.
Keeping a list of tasks and projects I have accomplished to help me remember what kind
of experiences I have had gave me a sense of completion I need to push further.
Adoption of new conformance management systems (plan, do, check, act). A useful
quality tool that is key quality management system performance indicator.
CHAPTER 4 CONCLUSION
REFERENCES
Education.2011. Wheat Milling Process [Online]. Education. Available at:
https://www.namamillers.org/education/wheat-milling-process/[Accessed:09 September
2019].
https://www.youtube.com/watch?v=O7DWJODMDDU
APPENDIX
Appendix 1
Supplementary Pictures
Figure 12 Novatens sieve stretcher
Figure 15 Loubser bulk services horse and trailer raw material carriers
Figure 16 Sensor monitoring storage level of final product storage bin