AIR FORCE INSTITUTE OF TECHNOLOGY AIR FORCE BASE, KADUNA

TECHNOLOGY REPORT ON STUDENTS’ INDUSTRIAL WORK EXPERIENCE

SCHEME
(SIWES)

UNDERTAKEN AT:
De United Foods Industries Limited (DUFIL FOODS PRIMA LTD)

PRESENTED BY:
NAME: CLARK ABDUL-AZIM OGEIN
COMPANY: DUFIL PRIMA FOODS PLC.
MATRIC NO: AFIT/MEN/18/0032
DEPARTMENT: MECHANICAL ENGINEERING
FACULTY OF GROUND & COMMUNICATION
ENGINEERING.
AIR FORCE INSTITUTE OF TECHNOLOGY,
KADUNA.
DATE: SEPTEMBER 20TH 2022 - FEBRUARY 27TH, 2023

IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE

AWARD OF A BACHELOR OF ENGINEERING (B.ENG) DEGREE IN
MECHANICAL ENGINEERING SEPTEMBER 20th 2022 - FEBRUARY
27th 2023

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 DECLARATION
I, CLARK ABDUL-AZIM OGEIN (AFIT/MEN/18/0032), hereby declare
that this project work carried out and submitted in partial fulfilment of the
requirements for the award of Bachelor of Engineering (B.Eng.) Degree
in Mechanical Engineering is my original work and has not been
presented for any degree elsewhere, to the best of my knowledge.

………………………………… …………………………….

CLARK, Abdul-Azim Ogein Date

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 DEDICATION

I dedicate this report to my parents, Barrister Alhaji Isa.E.Clark and Mrs

Regina Clark for their interminable support, my brother Abdul-Karim
Clark for helping guide me through the report writing process and last
but not least, Almighty Allah for his never-ending grace and
unconditional love.

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 ACKNOWLEDGEMENT
I want to use this opportunity to acknowledge my coordinator Engr.
Soretire IK for his guidance and patience he exercised in putting us
through this experience.

Special thanks to the Human Resources Department at DUFIL FOODS

PRIMA LTD for enabling and giving me the opportunity to undertake my
IT at the company, my supervisors at the Engineering Department of the
company for guiding me patiently and helping me through my whole
duration at the company and Chinedu; the company welder who helped
teach me a very vital engineering skill.

I would also like to thank Engr. Ayo, Engr. Prakash, Engr.Vijay, Engr.
Rakesh and my brother Karim Clark for their support and guidance in
making this report.

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 ABSTRACT
The Students’ Work Experience Program (SIWES) was established by
the Industrial Training Fund (ITF) and serves as a link that compliments
the theoretical aspect of engineering studies through practical
applications.

Work experience provides many benefits, giving students skills and

experience that will allow us stand out to potential employers as well as
helping you choose a sector you excel in.

Work experience is an important part of becoming ‘workplace-ready’,

building useful skills that cannot be taught in the classroom as well as
contacts students otherwise would not be exposed to.

My student Work Experience Program (SIWES) was undertaken at DE

UNITED FOODS INDUSTRIES LIMITED, KM 4 Idiroko Road, Ota, Ogun
State, Nigeria. The training took place over a period of six months. This
report illustrates all my experience and practical knowledge that I gained
during this period.

The DE UNITED FOODS INDUSTRIES LIMITED is a company with a

vision to build capacities and capabilities in Nigeria’s Food
Manufacturing Industry through the development of human capacities,
institutional capacity development as well as the promotion of research
and acquisition of relevant technologies. DUFIL serves as a vessel for
the development of indigenous manpower and technology transfer
acquisition in the Food Manufacturing Industry.

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TABLE OF CONTENTS
DECLARATION .....................................................................................................................................2
iDEDICATION........................................................................................................................................3
ACKNOWLEDGEMENT ........................................................................................................................4
ABSTRACT ...........................................................................................................................................5
TABLE OF CONTENTS ..........................................................................................................................6

CHAPTER ONE

1.0 Introduction to SIWES ....................................................................................................................7

1.1 Brief History of SIWES ....................................................................................................................8
1.2 Scope, Aim & Objective of SIWES ..................................................................................................8
1.3 History of The Company ................................................................................................................ 9
1.4 Vision, Mission & Statement of Company....................................................................................11
1.5 Organizational Chart of the Factory .............................................................................................14

CHAPTER TWO

2.0 Production Process for Instant Noodles Creation ........................................................................15

2.1 Safety Precautions…......................................................................................................................35
2.2 Emergency in the Company...........................................................................................................40

CHAPTER THREE

3.0 Personal Experiences and activities performed………....................................................................42

3.1 Machines Used and Operated.......................................................................................................42

CHAPTER FOIUR

4.0 Challenges Encountered and Experience Gained..........................................................................60

4.1 Challenges Encountered during SIWES .........................................................................................60
4.2 Experience Gained during SIWES...................................................................................................61

CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDTION…………..............................................................................62

5.1 Conclusion…………………………………………..........................................................................................62
5.2 Recommendation……………………....................................................................................................63.

REFERENCES ........................................................................................................................................64

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 CHAPTER ONE

1.0 SIWES INTRODUCTION

The Students Industrial Work Experience Scheme (SIWES) is a skills

training programme designed to expose and prepare students of

universities and other tertiary institutions for the Industrial Work situation

they are likely to meet after graduation. It is also a planned and

structured programme based on stated and specific career objectives

which are geared towards developing the occupational competencies of

participants (Mafe, 2009). Consequently, the SIWES programme is a

compulsory graduation requirement for all Nigerian university students

offering certain courses.

The Students Industrial Work Experience Scheme (SIWES), is the

accepted training programme, which is part of the approved Minimum

Academic Standard in the various degree programmes for all Nigerian

Universities. The scheme is aimed at bridging the existing gap between

theory and practice of Sciences, Agriculture, Medical Sciences (including

Nursing), Engineering and Technology, Management, and Information

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and Communication Technology and other professional educational

programmes in the Nigerian tertiary institutions. It is aimed at exposing

students to machines and equipment, professional work methods and

ways of safeguarding the work areas and workers in industries, offices,

laboratories, hospitals and other organizations.

1.1 BRIEF HISTORY

Prior to establishing the Scheme, industrialists and other employers of

labour felt concerned that graduates of Nigeria Universities were

deficient in practical background studies preparatory for employment in

Industries and other organizations. The employers thus concluded that

the theoretical education being received in our higher institutions was

not responsive to the needs of the employers of labour. Consequently,

the rationale for initiating and designing the scheme by the Industrial

Training Funds ITF, in 1973.

The scheme is a tripartite programme involving the students, the

universities and the employers of labour. It is funded by the Federal

Government and jointly coordinated by the Industrial Training Fund (ITF)

and the National Universities Commission (NUC).

1.2 SCOPE, AIM & OBJECTIVES OF SIWES

l To provide an avenue for students in the Nigerian universities to

acquire industrial skills and experience during their course of study;

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l To prepare students for the work situation they are likely to meet

after graduation;

l To expose the students to work methods and techniques in handling

equipment and machinery that may not be available in their

universities;

l To allow the transition phase from school to the world of working

environment easier and facilitate students’ contact for later job

placements;

l To provide students with an opportunity to apply their theoretical

knowledge in real work situation thereby bridging the gap between

theory and practice.

1.4 History Of My Workplace

De United Foods Industries Limited, Noodle Division, started its

operation in year 1996 at Ota, Ogun State, is the first instant noodles

manufacturing plant in Nigeria and the largest in Africa at that time.

DUFIL PRIMA FOODS PLC was incorporated in 2001 as a private

limited liability company at Choba, Port Harcourt, Rivers State. Upon

completion of a restructuring exercise the company was converted to

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Public limited company and became the holding company of the group in

year 2008.

The existence of the facility arises due to the growing demand for the

product from the consumers of the region and the nation. The objective

is to provide fresh and quality product to the consumers.

De United Foods Industries Limited (DUFIL PRIMA FOODS LTD.) as

indicated above is the largest instant noodle manufacturer. Over the past

25 years in the Nigerian market, Dufil Group has had a remarkable

impact on the Nigerian culinary Landscape. Their Product, Indomie

Instant Noodles which appeals to several demographic groups has

grown to become a household name across the country. The group,

which is a joint venture between Tolaram Group of Singapore and Salim

Group of Indonesia, currently has 3 factories.

l The First; De United Foods Industries limited which was

commissioned in 1995 in Ota Ogun State, is the First Instant Noodles

Manufacturing Plant in Nigeria and the Largest in Africa.

l The second Factory; Dufil Prima Foods Plc which was commissioned

in 2001 is located in Choba, Port Harcourt, Rivers State.

l The third and most recent state of the art automation factory was

commissioned in Kaduna on the 29th of May 2012.

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Website http://www.dufil.com

Industries Food and Beverage Services

Company size

Company Size 1,001-5,000 employees

Headquarters Surulere, Lagos

Type Privately Held

Founded 1995

Specialties Noodles Manufacturing and

Vegetable Oil Production

1.3 VISION. MISSION & VALUES

The Dufil Family is guided by a clear and simple vision statement. We

believe in making the well being and satisfaction of our customers the

apex of every decision. The quality of our products and the loyalty of our

customers are a testimony to the above statement

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Trust
To build and retain Trust, we need to:
l Be honest and direct in our dealings
l Always. always act with transparency
l Say what you mean, and mean what you say
l And keep our promises

Respect
Because it’s a shared journey, we will always seek a Win-Win outcome
as asign of Mutual Respect.

Commitment
With Commitment, there should be focus and depth in everything we do
for it to be sustainable over the Long Term.

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Courage
We want to surround ourselves with brave people who:
l Are not quitters
l Can make tough decisions
l Have conviction in thought and action
l Are prepared to take smart risks
l Speak their mind

Humility
We look for those who think of themselves less:
l To build a company of givers rather than takers, multipliers not
diminishers
l To create cadre of leaders who serve
l To appreciate that everyone we interact with has a contribution to
make to our wellbeing and

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l To recognize that while we control what we do, the outcome is not
entirely ours.

1.5 ORGANIZATIONAL CHART OF FACTORY

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CHAPTER TWO

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 DUFIL PRIMA FOODS PLC PRODUCTION PROCESS

2.0 PRODUCTION PROCESS FOR INSTANT NOODLE CREATION

Produ Product
Sequen
Product Image ct Descriptio
ce
Name n

Water mixed
with additive
such as salt,
Alkal alkali.
i
body,shaft,m
liqui
1 d ixing device
syste stainless
m steel304，
water
measuring
automatically

Flour and
water
Flour combined
2 mixer and mixed
full,mixing
tank made of

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 stainless steel
304，mixing
shaft,water
injection
pipe,safety
head,cover
made of
stainless
steel.
supporter,dri
ving
shaft,driving
fitting,fasten
er made of
carbon steel

Dough aging,
improve the
elasticity of
Aging
the flour.
3 machi
ne tray,rod
made of
stainless steel
304 driving

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 fitting,suppor
ter made of
carbon steel

feeder,cover
made of
stainless
steel.roller
side,supporte
r,driving
fitting made
of carbon
Rolli steel.
ng scrapper:
4 machi copper ,guar
ne
d board for
roller:nylon ,
noodle press
roller: solid
alloy ,dough
sheet
conveying
belt: food
grade

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 To make
slitted and
waved
noodle
mushy and
shaped.
steaming
groove,cover
,spray
Steam pipe,conveyi
ing ng chain,net
5 machi belt,orbit,exh
ne
aust
pipe,exhaust
cover, net
belt washing
tank made of
stainless
steel304.
supporter:ma
de of
stainless steel

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 Cutting,
folding,
dividing,
forming the
dough pieces
and entering
boxes, it can
form square
Cutti
ng or circular
and dough pieces
6 Divid from
ing different
machi
molds.
ne
made of
stainless
steel,dividing
plate:silica
gel,include
centralized
oil supply
device

Fryin Dehydrated
7 g by frying,

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 machi fixing the
ne
shape of
dough
pieces,
making
dough crispy
to taste good.
heating
system,temp
control
automatically
,oil pot up
and down by
manual and
automatically
.
oil
pot:carbon
steel,the
cover of oil
pot:stainless
steel,chain
and
orbit :carbon

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 steel

Lower the
temperature
of dough
pieces to
meet the
demand of
packing,conv
Cooli eying net belt
ng made of
8 machi stainless steel
ne 304.
conveying
chain: made
of carbon
steel,outer
guard plate
made of
stainless steel

SILO

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A silo is a structure for storing bulk materials. Silos are used in
agriculture to store fermented feed known as silage, not to be confused
with a grain bin, which is used to store grains. The silo is used to store
Cassava & Flour, used in the production of the noodles. There are two
silos located in the factory.
l The first silo has a storage capacity is 100,000 cubic meters and is
used to store flour.
l The second silo is smaller with a capacity of 40,000 cubic meters and
this is used to store cassava.
A Tri Axle 50 Ton Dry Flour Tank Truck (Bulk Truck) containing flour is
used to fill up the silo. A conveyor system is used to load the flour into
the hopper mounted at the top of the silo. This is the easiest and most
efficient way of loading a silo, and the system can deal with immense
loads, which makes it ideal for storing large quantities of flour. A pump
is used to suck in thee flour from the bulk truck to enable it have a high
enough velocity to get to the silo, also in the silo we have 2 other pumps
which also support in the conveying of the flour from the bulk truck to the
top of the silo.

MIXER
The mixer area consists of 12 mixers, 6 hoppers. The mixer area is
where the flour is conveyed to from the silo. There is a control room
which has an indication of the level of flour in the hopper (A container for
a loose bulk material; in the case flour, typically one that tapers
downward and is able to discharge its contents at the bottom). When the
level of flour in the hopper is low, there is a red indicator which pops up
on the software in the control room and the operator then releases flour
from the silo until reaches the required or designated amount of flour
which should be in the hopper.

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The amount of flour in the hopper varies from Line to Line. (The Lines
are the combinations of machines and workers in the factory where the
product moves along while it is being processed. In this case from the
silo to the warehouse.)

Line 1
Hopper contains 225kg Flour and 35kg Cassava
Line 2
Hopper contains 315kg Flour and 35kg Cassava
Line 3
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Hopper contains 400kg Flour and 35kg Cassava
Line 4
Hopper contains 315kg Flour and 35kg Cassava
Line 5
Hopper contains 225kg Flour and 35kg Cassava
Line 6
Hopper contains 315kg Flour and 35kg Cassava

The Flour in the hopper is the dropped into the mixer (A machine with
two; 2.3m shafts with blades on them used for mixing the flour to turn it
into dough). It is mixed with water and an alkaline solution. The amount
of water and alkaline solution depends on several factors, hence they
are not fixed. Every Line has a specific mixing time, where the flour,
water and alkaline are allowed to mix to a perfect consistency and they
are as follows:

LINE CASSAVA(KG) FLOUR(KG) LIQUID(L) TIME (S)

1 35 225 70 780
2 35 315 98 660
3 35 400 112 780
4 35 315 98 660
5 35 225 70 660
6 35 315 98 660
PRESSER
After undergoing the process of mixing, the dough is dropped into a
hopper which is connected to the presser also known as Aging Machine

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(A machine powered by high power motors used to compress the dough.
Dough aging, improve the elasticity of the flour; tray, rod made of
stainless steel 304 driving fitting, supporter made of carbon steel) this is
then passed onto the rollers ( A cylindrical shaped metallic structure
used to press the dough and turn it into a flat shaped dough. feeder,
cover made of stainless steel, roller side, supporter, driving fitting made
of carbon steel.

scrapper: copper, guard board for roller: nylon, noodle press roller: solid
alloy, dough sheet), for every line, there are three rollers, the dough
passes through this roller and flattens and is then conveyed into the
slitter (A form of rewinder that contains rotatory cutting blades to slit the
jumbo roll into specific roll widths as specified by the company which is
usually slitted and waved noodle mushy and shaped.) The slitter cuts the
dough into the strand-like shape and its conveyed on a metallic net and
the passed into the next stage of production.

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STEAMER
The already slit dough goes into a metal compartment which boils the
strands of noodles at a particular temperature usually at about <90℃,
this softens the dough just enough that its almost edible, using the
steam coming form the boiler the the dough softens and boils and is
then conveyed on a tray which has fans to drain away the excess liquid
from the noodles then it is dropped into a basket (This is a metallic tray
which the noodles is folded and divided forming dough pieces and and
entering the basket boxes. It forms square dough pieces from different
molds.) It is then conveyed to the next production process. The size of
the basket varies from Line to Line. The sizes are listed below

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.

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LINE TYPE SKU IMAGE

1 Indomie Belle 305g/280g

Full/ 200g
Relish

2 Indomie 180g
Noodles
Hungry Man

3 Indomie 120g
Noodles Super
Pack

4 Indomie 100g
Instant
Noodles
Standard Pack

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 5 Indomitable 70g

6 Minimie 100g
Noodles

As there are varieties of products to be produced, the type of noodles to

be produced during a particular production week depends on the
corporate office and the lines are limited hence a process called
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CONVERSION takes place. This process involves removing the basket
in the fryer, steaming machine and the plates in the cutting and dividing
machine to fit the specified noodle size to be produced. The noodles is
then conveyed in to the cutting and dividing machine which as indicated
above involves dividing, forming the dough pieces and entering boxes, it
forms a square dough piece from different molds. It is made of stainless
steel, dividing plate: silica gel, include centralized oil supply device. It
also contains holes which enables the liquid to drip off just before it gets
into the fryer.

FRYER
The noodle is conveyed into the fryer and the fryer contains processed
palm oil which sits in the metallic tray which is connected to a
temperature regulator and this is what is used to commence the
dehydrating process by frying, fixing the shape of dough pieces, making
dough crispy to taste good. Every noodle stays in the fryer for roughly 2
minutes to turn it golden yellow and then it is conveyed to the cooling
region shortly after frying.

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COOLING
This consist of an air tight sealed passage which has fans to reduce the
temperature of the noodles by using cooling fans. It goes through the
process for about 60 seconds. The cooling process is done to ensure
the noodle is at the right temperature before it gets to the packaging
region in order not to melt the nylon-like material which is used to pack
the noodle.

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After the noodles are moved from the cooling region, a conveyor belt
carries them and move them to 4 different conveyors which take them to
the to the packaging and sealing region. There are several machines
with the noodles passes through before it is wrapped and the machines
are indicated in the images below.

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The complete packaging machines

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WAREHOUSE
After the products have been packaged and have been given their SKU
and then put into their various cartons by either manual means (factory
workers) or automatically using the (carton caser) which automatically
put the noodle in the cartons and is used in only Line 3. The cartons are
then moved to a tape sealer which is connected to a conveyor which
then conveys it to the warehouse where they store the various type of
noodles and then load it in a truck for distribution. .

2.1 SAFETY PRECAUTIONS

Safety is a vital workplace consideration in almost every industry.
Staying safe on the job supports team member well-being, regulation
compliance and production efficiency. This can be particularly relevant
for industries such as manufacturing that involve heavy machinery or
equipment. In this article, we discuss the importance of safety in a
manufacturing setting and share 14 safety tips, to help you stay
accident- and injury-free.

1. Support a culture of safety

A culture of safety is one in which every individual feels responsible for
behaving safely and encourages team members to work safely. Leaders
in a manufacturing setting can cultivate a culture of safety by
communicating the importance of safety procedures and demonstrate
them by following safety regulations. Programs such as safety incentives
can also help build a company culture that prioritizes safe workplace
behaviors.

2. Implement and attend safety training

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Providing safety training to employees can be a valuable way to ensure
every member of your team has the information they need to stay safe. If
you are in a leadership position, be sure to provide ample opportunity for
safety education. If you are a team member, be sure to attend safety
trainings when they are offered and be mindful of the important
information they provide. Other types of training such as manufacturing
best practices and equipment use can also support safety in the
workplace.

3. Hold regular safety meetings

Safety meetings can reinforce and reiterate important topics covered at
safety trainings in the manufacturing environment. Consider holding
safety meetings on a regular schedule such as weekly, biweekly or
monthly. You might use these meetings to emphasize a particular safety
topic, discuss observable safety hazards and interact with team
members to engage their commitment to safe work practices.

4. Communicate effectively
Clear communication between colleagues, between team members and
supervisors and between an organization and the public can help ensure
favorable safety outcomes. If you notice a safety issue in your
manufacturing role, be sure to inform your supervisor as soon as
possible so they can mitigate it. Communicate with teammates regarding
safety and maintain clear communication channels with the public to
prevent safety risks to visitors such as customers and clients.

5. Prioritize organization
An organized workplace is often a safer workplace because it's easier to
navigate physical spaces and find safety equipment efficiently in a tidy

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environment. Prioritize organization and a neat workspace by taking time
to tidy before leaving a work area. If you are in a leadership position, try
allocating specific time in each day or shift for cleaning and organizing
work areas in the manufacturing space.

6. Follow important safety procedures

Following established safety rules is a key practice for maintaining safety
in a manufacturing setting. The time invested in doing so every time you
complete a task can help achieve your organization's safety goals.

7. Use equipment correctly

Manufacturing work environments often involve specialized tools,
equipment and facilities that must be used correctly in order to ensure
operator safety. Be sure you and your team members, if applicable,
receive appropriate training in correct equipment use. If you are in a
position to do so, be sure to mandate and reinforce correct equipment
procedures for your team members as well.

8. Wear personal protective equipment

Those who operate manufacturing equipment or work in the same area
as manufacturing equipment must often wear personal protective
equipment, or PPE, to stay safe on the job. Examples of PPE include
hard hats, safety goggles, respirators and any other items that are
required for personal safety in the work environment. Wearing PPE is
often required by the workplace as well as external regulating
organizations, in addition to being considered a best safety practice.

9. Monitor your environment

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Pay close attention to your area to identify and mitigate safety risks
before an accident can occur. For example, you might check the floor for
moisture and dry any spills to prevent slips and falls. If a potential hazard
requires a supervisor's attention, be sure to communicate that hazard to
others before leaving the area to prevent injury.

10. Prevent falls

Slips and falls can be a safety consideration in manufacturing work
environments. Watch for slipping and tripping hazards such as wet floors
or objects underfoot. Addressing them promptly can help keep you and
others safe.

11. Practice fire prevention

Be sure to learn everything you can about fire prevention in a
manufacturing environment. These specific hazards are usually specific
to the environment, so familiarize yourself with your own facility's
nuances and regulations. Follow fire safety protocol accurately and
consistently to help prevent accidents.

12. Be aware of hazardous materials

Some manufacturing environments may incorporate hazardous
materials. Be mindful of these specific hazards in your environment and
take any necessary precautions mandated by your facility's policies. Try
to learn all you can about the hazardous materials you might encounter,
how to prevent accidents and how to address them if they occur.

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13. Lift appropriately
Lifting incorrectly can sometimes cause injury, so lift correctly at all times.
Look for industry-specific training or information regarding how to lift
heavy or awkward items, and follow those procedures as indicated by
your organization and relevant authorities. Ask a safety leader or
supervisor for more information regarding safe lifting to help you prevent
injury.

14. Take breaks when necessary

Preventing fatigue can also help prevent workplace injuries and
accidents. Take breaks when necessary and try stretching or changing
positions during breaks if it makes sense for your situation. Try to get
ample rest before a manufacturing shift whenever possible so you are
able to respond to environmental hazards quickly if necessary.

As an engineer working in the factory, we were exposed to a lot of

hazards and to protect ourselves the best way possible, we always had
our personal protective equipment (PPE). Below is an image of the full
PPE of an engineer

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2.2 EMERGENCY IN THE COMPANY
In case of a fire, we were given a training on how to protect ourselves
and others in the vicinity in case we are first witnesses to a fire outbreak.
This training is called fire drill and we were taught how to use fire
extinguishers depending on the type of fire or the source. The instructor
made us practicalize and extinguish fires we started using some wood.
We made use of the PASS method.

P - Pull the pin

A - Aim at the base of the fire
S - Squeeze the handle
S- Sweep the nozzle from side to side

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Page 42 of 65
 CHAPTER THREE
SECTIONS/UNITS & VARIOUS ACTIVITIES PERFORMED

3.0 PERSONAL EXPERIENCE AND ACTIVITIES PERFORMED

At the inception of my IT at DUFIL, I was firstly assigned to the workshop
where we had various machines which would be listed and explained in
details below. I was assigned by Mr. Fulani; My Supervisor at the
company to Mr. B. Suga who is the Chief Machine Operator, he guided
me and showed me how to make use of the machines in the workshop
and i was given many tasks to create various things using the machines
at the workshop e.g Sprocket, Gear, Metallic Cylinder with an internal
diameter etc.

3.1 MACHINES USED AND OPERATED

The machines which were present at the workshop include;
l Lathe Machine
l Milling Machine
l Drilling Machine
l Sawing Machine
l Welding Machines - Arc Welding Machine
- Argon Welding Machine
- Oxygen Welding Machine
l Bench Grinder

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3.1.1 LATHE MACHINE
A lathe uses rotational force and a stationary cutting tool to shape a
workpiece, which is typically made of metal or wood.

Removing material from a workpiece is the lathe's primary function. As

the piece rotates, the cutting tool is pressed against it. This can create
threads, holes, faces, and other designs.

Their versatility has earned the lathe the nickname of the "Mother of All
Machine Tools."

A lathe machine operates on a simple principle, but it has many complex

moving parts. Most lathes contain a headstock, tailstock, spindle, motor,
chuck, and an assortment of cutting tools.

First, the workpiece is fastened to the chuck. This is the part of the
machine that holds the piece in place. The chuck usually grips the
outside of the workpiece.

The spindle, which is attached to the chuck, is connected to the engine

that rotates the workpiece. This is the part that allows the workpiece to
rotate. Once the piece is spinning, it's ready for cutting.

Then, the machinist attaches a cutting tool to the tool holder. The tool
holder keeps the cutting tool firmly in place and allows the tool to travel
the length of the piece as it spins.

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Cutting tools come in a wide variety of sizes, each with its own purpose.

Turning tools can cut material off of the workpiece. These flat blades are
the most common kind of cutting tool used in lathe work.

Other cutting tools include boring bars to make holes larger, chamfering
tools to create bevels, and parting tools to cut the workpiece in half.

A PICTURE OF ME OPERATING THE LATHE MACHINE

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3.1.2 MILLING MACHINE

A milling machine removes material from a work piece by rotating a

cutting tool (cutter) and moving it into the work piece. Milling machines,

either vertical or horizontal, are usually used to machine flat and

irregularly shaped surfaces and can be used to drill, bore, and cut gears,

threads, and slots.

The vertical mill, or “column and knee” mill, is the most common milling

machine found in machine shops today.

The general construction of this mill includes the quill,

which moves vertically in the head and contains the

spindle and cutting tools. The knee moves up and down

by sliding parallel to the column. The column holds the

turret, which allows the milling head to be positioned

anywhere above the table. Hand wheels move the work

table to the left and right (X axis), in and out (Y axis), in addition to

moving the knee, saddle, and worktable up and down (Z axis

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THE MILLING MACHINE USED IN THE WORKSHOP
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3.1.3 DRILLING MACHINE

The type of drilling machine which was used in the workshop is called a

Pillar Drilling Machine.

Also known as an upright drilling machine, a pillar drill machine is an

advanced drill machine used for making 20mm to 40mm holes in metal

and wood. It looks similar to a bench drill machine. But it has a more

powerful motor and more drilling capacity compared to a bench drill

machine.

This machine is primarily used by professional woodworkers and

manufacturing industries. Pillar Drilling Machine is suitable for drilling,

reaming, reaming, tapping screws, spot-facing machining, and batch

production.

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DRILLING OPERATION TAKING PLACE IN THE WORKSHOP

THE DIAGRAM OF THE DRILLING MACHINE

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3.1.4 SAWING MACHINE

Sawing machine, device for cutting up bars of material or for cutting out

shapes in plates of raw material. The cutting tools of sawing machines

may be thin metallic disks with teeth on their edges, thin metal blades or

flexible bands with teeth on one edge, or thin grinding wheels. The tools

may use any of three actions in sawing: true cutting, grinding, or friction-

created melting.

The power hacksaw machine provides a vise for clamping the work and

means for reciprocating a U-shaped frame on which is mounted a

straight steel hacksaw blade that cuts when moving in one direction only.

The saw presses down on the work during the cutting stroke but is

raised clear of the work during the return stroke.

The band saw employs an endless flexible steel band with teeth on one

edge; the band is carried on two large-diameter rotating wheels mounted

on parallel axes some distance apart. Band saws that cut vertically are

particularly suitable for cutting out shapes in thin, flat plates from

workpieces that lie on horizontal tables.

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Cold-sawing machines with toothed disk cutters are used extensively in

steel-rolling mills and in places where large quantities of bars are cut. A

V-shaped clamping vise enables bundles of bars to be clamped and cut

at one time.

Friction-sawing machines are used largely for cutting off steel structural

shapes such as I beam, channels, and angles. The cutting wheels, with

or without teeth, rotate at such high speeds that the heat from the friction

of contact is sufficient to remove the metal by melting it. Abrasive cutoff

saws, thin rubber or Bakelite-bonded abrasive wheels that are operated

at high peripheral speeds, are particularly suitable for cutting off thin

tubes and hardened steel bars.

The type of sawing machine used in the company was a power hacksaw

machine.

I used this machine to automatically precisely cut metallic shafts into

specified lengths which were later used to create spare parts for the

machines e.g. gears etc.

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3.1.5 WELDING MACHINE

A welding machine is a powerful tool used to fuse two pieces of metal

together. This machine holds the metal pieces in place, melts them, and

uses pressure to join them.

It is an essential tool for any construction-related job which requires

metalwork. Welding machines are used to create strong welds by

applying high temperatures, which is significantly greater than those

required for cooking or burning purposes.

The two most common types of welding machines include MIG welding

machines and wire feeders.

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 The company has 3 types of welding, they consisted of

I. Arc Welding

II. Argon Welding

III. Oygen Welding

ARC WELDING

Arc welding is a type of welding process using an electric arc to

create heat to melt and join metals. A power supply creates an

electric arc between a consumable or non-consumable electrode

and the base material using either direct (DC) or alternating (AC)

currents.

Arc welding is a fusion welding process used to join metals. An electric

arc from an AC or DC power supply creates an intense heat of around

6500°F which melts the metal at the join between two work pieces.

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ARGON WELDING

Welding is a process used in a number of industries, and there are

several different processes welders can use depending on what kind of

project they’re working on. If you like working with your hands and are

detail-oriented, you might consider a career in the field. Universal

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Technical Institute (UTI) teaches four major types of arc welding

processes, including gas metal arc welding (GMAW) and gas tungsten

arc welding (GTAW), which both use shielding gases to help protect

welds from contaminants.

Pure argon or an argon mix is often the choice when it comes to the

shielding gases used for these methods. Keep reading to find out more

about how argon works.

GMAW and GTAW

There are two primary welding methods that employ the use of a

shielding gas — GMAW, also known as metal inert gas (MIG) welding,

and GTAW, otherwise known as tungsten inert gas (TIG) welding.

GMAW

During the GMAW process, an electric arc is formed between the metal

being worked on and a wire electrode. As the wire electrode travels

through the welding gun, a shielding gas, commonly argon, is used to

protect the weld pool from contamination.

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GMAW can be utilized on a range of metals, including thick and thin

sheets and nonferrous (not containing iron) materials.

GTAW

The GTAW welding process works similarly to GMAW welding — an

electric arc is also formed during the process. However, with GTAW

welds a nonconsumable tungsten electrode is utilized instead of a

continuously fed wire.

The tungsten electrode works to heat objects enough so a bond can be

formed between the two, meaning no filler material or wire is needed like

with GMAW welds.

GTAW welds also use inert shielding gases, like argon, to help prevent

damage and pollution.

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Page 57 of 65
THE ARGON WELDING MACHINE IN THE WORKSHOP AND PROCESS OF
WELDING USING AN ELECTRODE WITH A TUNGSTEN

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OXYGEN WELDING MACHINE
Oxy-fuel welding, a welding torch is used to weld metals. Welding metal
results when two pieces are heated to a temperature that produces a
shared pool of molten metal. The molten pool is generally supplied with
additional metal called filler. Filler material selection depends upon the
metals to be welded.

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3.1.6 BENCH GRINDER
A bench grinder is a benchtop type of grinding machine used to drive
abrasive wheels. A pedestal grinder is a similar or larger version of
grinder that is mounted on a pedestal, which may be bolted to the floor
or may sit on rubber feet. These types of grinders are commonly used to
hand grind various cutting tools and perform other rough grinding.
Depending on the bond and grade of the grinding wheel, it may be used
for sharpening cutting tools such as tool bits, drill bits, chisels, and
gouges. Alternatively, it may be used to roughly shape metal prior to
welding or fitting.

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 CHAPTER FOUR
4.0 CHALLENGES ENCOUNTERED AND EXPERIENCE GAINED

4.1 CHALLENGES ENCOUNTERED DURING SIWES

As A student undergoing the industrial attachment program, I noticed

that the same amount of work which was carried out by contract workers
and staffs were assigned to me and I had to do a lot more because I still
went on errands for other workers, this was aside my normal work as an
intern. They also treated me like I already had previous experience on
the job and if I asked questions were reluctant to give answers or they
just gave sarcastic responses. Only the expatriates were reasonable
enough to explain in-depth when I had questions about the working
principles of these machines and/ or problems encountered on the line
e.g. The Auto Dispenser, Channelizer etc.
Other than this I would say the next challenge I encountered was
actually having to not just troubleshoot but also try to fix these problems
I encountered on my own with little or no assistance.
Finally, I live in Lagos State and I had my IT company situated in Ota,
Ogun State so I was spending so much money on just transporting
myself there and also feeding because I worked 8-5 from Sunday-
Sunday.

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4.2 EXPERIENCE GAINED DURING SIWES

At the conclusion of my SIWES program, I gained the following skills

• Operation of the Lathe Machine
• Operation of the Drilling Machine
• Operation of the Sawing Machine
• Cutting and polishing of Metallic Materials
• Coupling of chains with links
• Learn the technical application of some principles learnt in class.
• Arc and Argon Welding
• Adopt proper work ethics
• Refine my ability to think assertively and speak confidently

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 CHAPTER FIVE
5.0 CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
In review, this internship has been an excellent and rewarding
experience. I have been able to hone my skills to use these fundamental
machines to create necessary mechanical components e.g. gear,
sprocket etc. whilst networking with some amazing people.

My SIWES experience has indeed served its purpose as the initial idea
of SIWES programme was to not only expose the student to the real life
work environment but to enable us students to educate ourselves about
work ethics and ethos, mannerism and how to conduct ourselves in the
work environment. This invaluable knowledge would go a long way in
developing myself as a mechanical engineer. The practical knowledge is
what truly moulds students into competent engineers who are capable of
contributing sufficiently in a work setting.

The industrial training illustrates what life is really like after school. It has
really exposed me to what is obtainable in the industrial setting and I
believe the experience gained would be put to good use in the nearest
future. The training made me realize that there no limitation to what I can
achieve.

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5.2 Recommendation
I use this means to make the following recommendations concerning the
training of students in
Industrial Attachments
i. I would like to recommend that the Engineering curriculum in the
Airforce Institute Of Technology (AFIT) be adjusted such as would provide
going on industrial attachments for a longer period of time as opposed to 6
months or making the program to occur twice throughout an engineering
degree program.
ii. Allowances should be paid to students during their programme just like
NYSC and not after. This would help them a great deal to handle some
financial problems during their training course.

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 REFERENCES

I. De United Foods Industrial Limited (2023). ABOUT US, Retrieved March 20th
2023 from https://www.dufil.com/about-us/
II. Clark, A. (2023) TECHNICAL REPORT ON STUDENTS’ WORK
EXPERIENCE PROGRAMME II (SWEP II)
III. Gary Hou (2020) ASIAN NOODLE MANUFACTURING INGREDIENTS,
TECHNOLOGY AND QUALITY. Retrieved March 21st 2023 from
https://www.elsevier.com/books/asian-noodle-manufacturing/hou/978-0-12-
812873-2
IV. Indomie Instant Noodles (2019). OUR RANGE, Retrieved March 21st 2023
from https://www.elsevier.com/books/asian-noodle-manufacturing/hou/978-0-
12-812873-2
V. Er. Armit Kumar (2016) Lathe Machine: Definition, Parts, Types, Operation,
Specification, Advantages, Application
[Notes & PDF] from https://themechanicalengineering.com/lathe-machine/
VI. Biblus. (October 24, 2022). What is Facility Management?. Retrieved
March 3, 2023 from https://biblus.accasoftware.com/en/what-is-facility-
management/

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