TECHNICAL REPORT

ON
STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

HELD AT
MUBI GENERAL METAL WORKSHOP, GUSAU ZAMFARA STATE

BY

IBRAHIM ABDULJABBAR
ND/23/MET/00056

SUBMITTED TO THE DEPARTMENT

OF ELECTRICAL ELECTRONIC ENGINEERING TECHNOLOGY, SCHOOL OF
ENGINEERING TECHNOLOGY, FEDERAL POLYTECHNIC KAURA NAMODA
ZAMFARA STATE

IN PARTIAL FULFILLMENT TO THE REQUIREMENT FOR THE AWARD OF

NATIONAL DIPLOMA IN ELECTRICAL ELECTRONIC ENGINEERING
TECHNOLOGY

DECEMBER, 2024
 DEDICATION
I dedicate this report to Almighty God for making me to start this program safely and end it
safely.
 ACKNOWLEDGEMENT
I wish to register my profound gratitude to Allah Almighty for the guidance and grace
throughout my life
I'm grateful to the entire staff of Mubi General Metal Workshop, Gusau Zamfara State for
making my industrial training interesting, educative and worthwhile.
My regards to my amazing parents who financially support my educational pursuit, I say remain
blessed by Allah Almighty and to my beloved siblings I love you all you are the best.
 CHAPTER ONE
1.0 INTRODUCTION
There is a need to actualize what is theoretically learnt in the institution with the reality that
happens in the field/industry, the concept of training as a continuous process at all stages of a
workers active life and at all occupational levels for improved performance, is a key factor in
enhancing free mobility of the labour force. Based on the above, the effective development of
human resources is one of the best waysj of achieving economic growth and development.
Human resource development has been variously defined by many authors; however, in most of
the definition, the emphasis tends to be on manpower planning, training, retraining, productivity
and employee motivation.

Human resources development can also be said to embrace all the diverse processes which aim
at transforming people to enable them contribute more effectively to social and economic
development. A nation’s human resource can thus be improved through purposeful and result-
oriented education and training.

From the general introduction above, the student work experience programme which basically
prepares students for the world of practical work has become an innovative phenomenon in the
process of manpower development and training in Nigeria, Hence, the introduction of the
Students Industrial Work Experience Scheme (SIWES) into the educational system and training.
SIWES has reached wide dimensions in recent times and all industrial and commercial
establishments had made it operational by providing specific skills in the form of experience.
There is hardly any sizeable industrial and commercial establishment that is not involved in the
scheme. The SIWES was introduced in Nigeria by the Industrial Training Fund (ITF) 30 years
ago, but was then limited to students of technical schools. Today, it covers many disciplines and
has become a necessary precondition for the award of diploma and degree certificates in specific
disciplines in most institutions of higher learning in the country. The Students Industrial Work
Experience Scheme (SIWES) is a skill training programed, designed to expose and prepare
students of universities, polytechnics/colleges of technology and colleges of education to real
life work/ situation after graduation.
1.1 Historical Background
The fund in its policy statement No. 1 published in 1973, inserted a clause dealing with the issue
of practical skills among locally trained professionals. Section 15 of the policy statement states
inter-alia, that “Great emphasis will be placed on assisting certain products of post-secondary
school system to adopt or orientate easily to their possible post graduate job environment. The
scheme exposes students to industry based skills necessary for a smooth transition from
classroom to the world of work. It affords student of tertiary institutions the opportunity of
being familiarized to the needed experience in handling machinery and equipment which are not
available in the educational institute.
1.2 Importance of SIWES
SIWES have a lot of importance attached to it which includes;

It helps to improve the quality of skilled manpower of the students.

The scheme provides a forum for industries to evaluate prospective employers and gives
feedback to institutions.

The scheme gives students practical knowledge of course of study.

SIWES programme exposes students to real life situation, thus supplementing the theoretical
lesson.
SIWES programme establish a close collaboration between institutions and industries, a factor
which is essential for preparing people for the workforce.
1.3 Aim and Objectives of SIWES
Specifically, the objectives of students industrial work experience scheme (SIWES) are:
To provide an avenue for students in institution of higher learning to acquire industrial skills and
experience in their course of study.
To provide students opportunity to apply their knowledge in real work (situation thereby
bridging the gap between college work and actual practice).
To expose students to methods and techniques in handling equipment and machinery, that may
not be available in educational institutions.
To prepare students for real working situations after graduation.
1.4 DESCRIPTION OF THE ORGANIZATION
 Name and Address: [Mubi General Metal Work, Unguwar Gwaza, Gusau Zamfara Sate]
 History of the Organization:
Mubi General metal work was establish on 17th March, 1996 at Kaura Namoda, later
relocated to Gusau in the year 2021 establish by Engr. Muhammad Yushau Mubi
 Core Operations:
The company specializes in welding, fabrication of metal gates, tanks, pipes, and repairs
of metal structures.
 CHAPTER TWO
2.1 ACTIVITIES CARRIED OUT
During my SIWES program Mubi Metal work, I participated in various metalworking tasks that
exposed me to practical applications of engineering principles. These activities are detailed
below:
1. Orientation and Tool Familiarization
 Introduced to workshop tools and equipment such as welding machines, grinding
machines, cutting torches, hammers, and measuring tools.
 Learned proper handling and maintenance of tools.
 Attended safety briefings on the use of Personal Protective Equipment (PPE) such as
gloves, safety boots, goggles, and welding helmets.
2. Metal Cutting and Preparation
 Practiced measuring and marking metal sheets and bars using rulers, tape measures, and
chalk.
 Performed metal cutting using:
o Hand tools such as hacksaws for small tasks.
o Power tools like angle grinders and plasma cutting machines for precision
cutting.
 Smoothed and cleaned cut edges to prepare materials for welding or fabrication.
3. Welding Operations
 Participated in different welding techniques, including:
o Arc Welding: Fused metal parts together using an electric arc.
o Gas Welding: Used oxy-acetylene equipment for welding and brazing operations.
 Prepared welding joints by cleaning and aligning metal components.
 Learned techniques to control the welding arc, manage heat input, and ensure strong,
clean welds.
4. Fabrication of Metal Structures
 Assisted in the fabrication of metal gates, windows, railings, water tanks, and storage
racks.
  Used clamps and jigs to hold components in position during assembly.
 Worked on both small-scale repairs and large fabrication projects, ensuring accuracy in
dimensions.
5. Grinding and Finishing
 Operated grinding machines to smooth welded joints and cut edges for a polished finish.
 Applied anti-rust coatings and paint on fabricated structures to improve durability and
appearance.
6. Maintenance and Repairs
 Diagnosed and repaired damaged metal components, such as cracked gates, bent pipes,
and broken tools.
 Reinforced weakened structures using welding and additional supports.
 Replaced worn-out machine parts, such as grinder discs and cutting blades.
7. Interpretation of Technical Drawings
 Studied and interpreted technical drawings and blueprints to understand project
requirements.
 Measured and marked materials accurately based on design specifications.
 Assisted in planning layouts for fabrication projects.
8. Workplace Safety Practices
 Ensured compliance with safety standards, including proper ventilation during welding
and grinding.
 Participated in periodic checks of workshop tools and machinery to maintain safety and
efficiency.
9. Team Collaboration
 Worked alongside senior technicians and other interns to complete tasks within deadlines.
 Learned effective communication and teamwork skills in a workshop environment.

2.2 WELDING SAFETY TIPS THAT ALL WELDERS SHOULD FOLLOW TO

REMAIN SAFE
Some of the common hazards during welding are impact, penetration, smoke, harmful dust,
heat, light, and fumes. Welding smoke is a mixture of fumes and other gases, and most of the
substances in smoke are very toxic. The intense heat and sparks can cause severe burns.
 When metal chips and hot slag come into contact with eyes, they can cause injury and in
severe cases lead to loss of sight.
The intense light can also cause eye damage. If there are flammable materials near the
welding area, the heat and sparks can cause fires and explosions. There is also the high risk
of electric shock. To avoid these common safety hazards, it is important to know the
necessary precautions that you should take. Below are three ways you can improve welding
safety.
 Read and understand the instructions: A welders’ operating manual contains
information on procedures that help maximize the machines potential and safety
information. Ensure that all employees operating the machine are familiar with its
contents. In case you lose the manual, or it gets damaged, call the manufacturer and
request for a replacement. Many manufacturers post manuals online, and you can
download them from their website.
 Wear the proper clothing: All welding jobs require proper safety clothing. From
welding safety glasses to a welding helmet and gloves, there are several things that
welders need before tackling welding tasks. You should never wear short-sleeved T-shirts
or shorts when welding no matter how small the job. Any exposed skin is vulnerable to
painful and harmful effects of infrared and ultraviolet rays. Sparks also catch in pant
cuffs, open pockets or shirts that aren’t well buttoned. Therefore, always button your shirt
collars and front pockets to cover your skin completely and prevent them from catching
painful sparks. Additionally, never leave butane lighters or match boxes in your pockets.
 Breathe freely: Welding fumes are difficult to avoid, especially in industrial
environments, and for this reason, you should improve the air quality for your workers.
Welding fumes cause some illnesses such as lung cancer, heart disease, kidney damage,
stomach disease, motor and neurological problems. Some specific materials may require
respirators when welding that’s why it’s important to provide employee safety training.

2.3 IMPORTANCE OF WELDER SAFETY

Both seasoned and new welders can easily get into the “comfort zone.” This is where one
becomes unworried about welding safety. If you drop your guard during welding, you or
your workers can be hurt, maimed, or even fatally injured. Welding safety guidelines
demand that all welders are always receiving safety training and staying alert.
2.4 TOOLS REQUIRED FOR WELDING AND IT USES
1. Auto-Darkening Welding Helmet
This first basic welding tool is a must-have for anyone welding. It’s a welding helmet.
Not all welding helmets are created equal, but you don’t have to spend $350 to get a good one.
The first piece of advice I would give you here is to choose an auto-darkening welding helmet.
A welding helmet is the most important welding workshop tool you have, so you want something
that’s user-friendly.
2. Welding Magnets
Welding magnets are an essential welding fabrication tool because they are so versatile.
3. Welding Framing Jig
A welding framing jig is NOT a required welding tool for beginners, but I put it in here because
it’s so effective at helping you create frames that are square.

4. Speed Square
The speed square is a necessary tool, and here’s why…
Let’s say you’re working with a long piece of square tubing, and you just want to cut off about
12 inches of it.
You set your speed square on the work piece, make your mark across the tubing, and now you
have a 90 degree cut ready to go.
5. Sheet Metal Gauge
This next tool is great if you want to find out how thick your metal is.
This is great because most welders will have a chart that says what setting you need to weld on
for different metal thicknesses. It’s hard to eyeball the thickness of a piece of metal, so that’s
where the sheet metal gauge comes in.
6. Metal File
You’ve probably used metal files before, if not on a welding project, then on your finger nails.
They’re great to use when finishing a project.
7. Welding Clamps
This next basic welding tool is an absolute must have.
In fact, you need to get at least 10 welding clamps. You will need them. Imagine that you start a
welding project, and you have to fit up the pieces tightly before tack welding them in place.
8. Welding Gloves
Obviously you have to have welding gloves, unless of course you already have nerve damage on
your fingers. In that case you won’t need them.
There are the really thick welding gloves (which I recommend for beginners) that you can pick
up hot pieces of metal with for a few seconds without getting burned.
9. Metal Brush
A metal brush is something you’ll need if you’re using a welding process that creates slag.
For example, if you’re welding with a stick welder or flux core arc welder you’ll have to scrape
off the slag coating to reveal the final weld.
Chipping hammers and metal brushes are great for this.
10. MIG Pliers
For those of you who are readers of my blog, you know that I recommend MIG welding as the
easiest process for beginners to learn.
12. Angle Grinder
Angle grinders are a necessity. Period.
I don’t think you can get by without having one. You can put a grinding disk on to smooth out
your projects, put a cut off wheel on to cut metal, put a wire brush on to remove paint, or put a
flap disk on for precise grinding.
13. Safety Glasses
When you’re using angle grinders, you need to have some safety glasses on.
Those sparks you see flying off the grinding disk are small pieces of metal, and if one hits you in
the eye, you’re done with.
14. Portable Band Saw
A portable band saw isn’t necessary as a welding workshop tool for beginners, but it’s a fantastic
piece of machinery.
Basically, it produces clean cuts that don’t need any rework.
15. Chipping Hammer
I mentioned earlier that if you’re MIG welding with flux core wire, or stick welding, you’ll have
to chip away at the slag coating to reveal the weld underneath.
 CHAPTER THREE
3.1 INTRODUCTION TO WELDING AND FABRICATION
Welding means the process of joining metals by causing coalescence due to heat. It happens by
melting the workpiece with weld pool. The joint gets stronger when it cools down. It’s heats
when the weld pool is used with the workpiece & produces weld in that time.
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to cool causing
fusion. Welding is distinct from lower temperature metal-joining techniques such as brazing and
soldering, which do not melt the base metal.
In addition to melting the base metal, a filler material is typically added to the joint to form a
pool of molten material (the weld pool) that cools to form a joint that, based on weld
configuration (butt, full penetration, fillet, etc.), can be stronger than the base material (parent
metal). Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.
Many different energy sources can be used for welding, including a gas flame (chemical), an
electric arc (electrical), a laser, an electron beam, friction, and ultrasound. While often an
industrial process, welding may be performed in many different environments, including in open
air, under water, and in outer space. Welding is a hazardous undertaking and precautions are
required to avoid burns, electric shock, vision damage, inhalation of poisonous gases and fumes,
and exposure to intense ultraviolet radiation.
3.2 How to Weld
Introduction: How to Weld - MIG Welding
This is a basic guide on how to weld using a metal inert gas (MIG) welder. MIG welding is the
awesome process of using electricity to melt and join pieces of metal together. MIG
welding is sometimes referred to as the "hot glue gun" of the welding world and is generally
regarded as one of the easiest type of welding to learn.
This Instructable is not intended to be THE definitive guide on MIG welding, for that you might
want to seek out a a more comprehensive guide from a professional. Think of this Instructable as
a guide to get you started MIG welding. Welding is a skill that needs to be developed over time,
with a piece of metal in front of you and with a welding gun/torch in your hands.
Step 1: Background

PLATE 2.1
MIG welding was developed in the 1940's and 60 years later the general principle is still very
much the same. MIG welding uses an arc of electricity to create a short circuit between a
continuously fed anode (+ the wire-fed welding gun) and a cathode ( - the metal being welded).
The heat produced by the short circuit, along with a non-reactive (hence inert) gas locally melts
the metal and allows them to mix together. Once the heat is removed, the metal begins to cool
and solidify, and forms a new piece of fused metal
A few years ago the full name - Metal Inert Gas (MIG) welding was changed to Gas Metal Arc
Welding (GMAW) but if you call it that most people won't know what the heck your talking
about - the name MIG welding has certainly stuck.
MIG welding is useful because you can use it to weld many different types of metals: carbon
steel, stainless steel, aluminum, magnesium, copper, nickel, silicon bronze and other alloys.
Here are some advantages to MIG welding:
 The ability to join a wide range of metals and thicknesses
 All-position welding capability
 A good weld bead
 A minimum of weld splatter
 Easy to learn
Here are some disadvantages of MIG welding:
i. MIG welding can only be used on thin to medium thick metals
 ii. The use of an inert gas makes this type of welding less portable than arc welding which
requires no external source of shielding gas
iii. Produces a somewhat sloppier and less controlled weld as compared to TIG (Tungsten
Inert Gas Welding)
iv. MIG welding can only be used on thin to medium thick metals
v. The use of an inert gas makes this type of welding less portable than arc welding which
requires no external source of shielding gas
vi. Produces a somewhat sloppier and less controlled weld as compared to TIG (Tungsten
Inert Gas Welding)

Step 2: How the Machine Works

A MIG welder has a couple of different parts. If you open one up you will be able to see something
that looks like what is pictured below.
The Welder
Inside the welder you will find a spool of wire and a series of rollers that pushes the wire out to the
welding gun. There isn't much going on inside this part of the welder, so it's worth it to take just a
minute and familiarize yourself with the different parts. If the wire feed jams up for any reason
(this does happen from time to time) you will want to check this part of the machine out.
The large spool of wire should be held on with a tension nut. The nut should be tight enough to
keep the spool from unraveling, but not so tight that the rollers can't pull the wire from the spool.
If you follow the wire from the spool you can see that it goes into a set of rollers that pull the wire
off of the big roll. This welder is set up to weld aluminum, so it has aluminum wire loaded into it.
The MIG welding I am going to describe in this instructable is for steel which uses a copper
colored wire.

The Welding Gun

The welding gun is the business end of things. It's where most of your attention will be directed
during the welding process. The gun consists of a trigger that controls the wire feed and the flow of
electricity. The wire is guided by a replaceable copper tip that is made for each specific welder.
Tips vary in size to fit whatever diameter wire you happen to be welding with. Most likely this part
of the welder will already be set up for you. The outside of the tip of gun is covered by a ceramic or
metal cup which protects the electrode and directs the flow of gas out the tip of the gun.
The Ground Clamp

The ground clamp is the cathode (-) in the circuit and completes the circuit between the welder, the
welding gun and the project. It should either be clipped directly to the piece of metal being welding
or onto a metal welding table like the one pictured below (we have two welders hence two clamps,
you only need one clamp from the welder attached to your piece to weld).
The clip must be making good contact with the piece being welded for it to work so be sure to
grind off any rust or paint that may be preventing it from making a connection with your work.

3.3 Impact of the Welding Industry

When we think about welding, we often don't realize how this industry impacts the world around
us. Welding is an essential component of many industries such as the automotive industry, the
construction industry, the aviation industry, and more. Without this form of metal work, so many
things, including many buildings, gates, and fences, small kitchen appliances, vehicles - and even
space travel - would not exist.
70 percent of all manufactured products are made with the skills of welders! This data in and of
itself is solid evidence of welding's importance to our country's economic health, keeping the
United States strong both domestically and internationally.
 CHAPTER FOUR

4.0 SKILLS ACQUIRED

 Practical skills in welding (arc and gas welding).
 Knowledge of operating metalwork tools like grinders, cutting torches, and drilling
machines.
 Understanding of workplace safety standards (e.g., use of PPE).
 Improved measurement and technical drawing interpretation skills.
 Time management and teamwork abilities.

4.1 IDENTIFICATION OF METAL

What is a Metal
A metal is an element that readily forms positive ions (cations) and has metallic bonds.

Metals are sometimes described as a lattice of positive ions surrounded by a cloud of

delocalized electrons.

The metals are one of the three groups of elements as distinguished by their ionization
and bonding properties, along with the metalloids and nonmetals.

On the periodic table, a diagonal line drawn from boron (B) to polonium (Po) separates
the metals from the nonmetals.

Properties of metal
 Malleability, the ability to be hammered out into a sheet...
 Ductility , the ability to be drawn out into a wire....
 Thermal conductivity, the ability to conduct heat....
 Electrical conductivity, the ability to conduct electricity....
 Chemical reactivity, metals tend to be good reducing agents.......

Different Types of Metals

In addition to ferrous metals, we have a large selection of non-ferrous ones. Each has certain
qualities that make them useful in different industries.
Aluminum
Aluminum derives primarily from its ore bauxite. It is light, strong, and functional. It is the
most widespread metal on Earth and its use has permeated applications everywhere. This is
because of its properties such as durability, light weight, corrosion resistance, electrical
conductivity and ability to form alloys with most metals. It also doesn’t magnetise and is easy
to machine.
Copper
When talking about different types of metals, copper and its alloys can not be overlooked. It
has a long history because it is easy to form. Even today, it is an important metal in the
industry. It does not occur in nature in its pure form. Thus, smelting and extracting from ore is
necessary.
Brass

PLATE
Brass is an alloy of copper and zinc. The amount of each of the metals may vary depending on
the electrical and mechanical properties sought of the metal. It also contains trace amounts of
other metallic elements such as aluminium, lead, and manganese. Brass is a great candidate
for low friction applications such as locks, bearings, plumbing, musical instruments, tools and
fittings. It is indispensable in intrinsically safe applications to prevent sparks and allow usage
in flammable environments.
Bronze
Bronze is also an alloy of copper. But instead of zinc, bronze contains tin. Adding other
elements such as phosphorus, manganese, silicon, and aluminium may improve its properties
and suitability for a particular application. Bronze is brittle, hard, and resists fatigue well. It
also has good electrical and thermal conductivity and corrosion resistance. Bronze finds
application in the manufacturing of mirrors and reflectors. It is used for electrical connectors.
Due to its corrosion resistance, it finds usage in submerged parts and ship fittings.
Titanium
Titanium is an important engineering metal due to being strong and lightweight. It also has
high thermal stability even at temperatures as high as 480 degrees Celsius. Due to these
properties, it finds application in the aerospace industry. Military equipment is one use-case
for this metal. Since titanium is also corrosion resistant, medical applications also use it.
Titanium is also used in the chemical and sporting goods industry.
 CHAPTER FIVE

5.0 Challenges Faced

 Limited availability of some modern tools and components.

 High frequency of outdated or poorly maintained equipment, increasing repair

complexity.

5.1 Conclusion

The SIWES experience at Mubi General Metal Work provided invaluable practical

exposure to real-world electronic engineering practices. It enhanced the students'

technical skills, built their confidence, and prepared them for future roles in the

electronics and broadcasting industry. The hands-on activities bridged the gap between

theoretical learning and professional application, ensuring a well-rounded engineering

education.

5.2 Recommendations

 Institutions should collaborate with more advanced technical departments to expose

students to modern technologies.

 The government and private sector should provide better tools and resources to support

students during their SIWES program.

 More emphasis should be placed on mentoring students to maximize learning outcomes

during the industrial attachment.