Teachers’/Trainers’ Industrial Attachment Individual Report

Contents
Abbreviations..............................................................................................................................................2
Acknowledgement.......................................................................................................................................3
1. Introduction............................................................................................................................................4
2. Industry’s profile....................................................................................................................................7
3. Practical knowledge and skills gained....................................................................................................7
4. Tracer assessment result of previous TVET graduates at the industry....................................................8
5. Industry’s problems assessment result....................................................................................................9
6. Industry’s problems solutions Proposal..................................................................................................9
7. Lesson learnt.........................................................................................................................................17
8. Challenges and Remedial actions.........................................................................................................17
8.1 Challenges......................................................................................................................................17
8.2 Remedial actions.............................................................................................................................17
9. Conclusion and Recommendation........................................................................................................17
9.1 Conclusion.....................................................................................................................................17
9.2 Recommendation............................................................................................................................17

Abbreviations
DC Direct current

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EMS Environmental Management System
FSMS Food Safety Management System
GC Gregorian calendar
PLC Programmable logic controllers
SCADA Supervisory control and data acquisition

Acknowledgement

I would like to express my appreciation to EASTRIP, Dire Dawa Polytechnic College and Dire
Dawa Food Complex Share Company for offering me this chance, which helps to get a great
experience.
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1. Introduction
Dire Dawa polytechnic college was established in 1985 GC with five training disciplines,
namely:-

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 1. Auto Mechanics
2. General Mechanics
3. Wood Work Technology
4. Electricity
5. Electronics

Some of the trainees of Dire Dawa polytechnic college were found from the neighboring region
of Somali, Harar and Western Harargie.

The training programs and qualifications could be divided into two:

1. 1985-2001
Admitting students who completed grade 10 and graduating them with deploma of
technical education. And fields of training grew to 9.
Offering training courses in two different schools has not been found convenient.
Therefore in the year 2005 under the proclamation 16/1997 dire dawa comprehensive
secondary school merged and formed the dire dawa technical and vocational college.
2. 2001-2009
Based on education and training policy the college offered training at the levels of
10+1, 10+2 and 10+3 and graduated trainees with diploma and certificates.
The aim and present condition of the college, Ethiopia has embarked on a process of
reforming its TVET system.
Within the policies and strategies of the Ethiopian government, technology
transformation by using international standards and international best practices as the
basis and adopting, and verifying them in the Ethiopian context is a pivotal element.
TVET is given an important role with regard to technology transfer. The new
paradigm in the outcome-based TVET system is the orientation at the current and
anticipated future demand of the economy and the labor market.
The Ethiopian Occupational Standards (EOS) is a core element of the Ethiopian National TVET
strategy and an important factor within the context of the Ethiopian TVET-Qualification
Framework (ETQF). Currently the college started educating trainees based on the Ethiopian
Occupational Standards (EOS) and the new trading policy which is level-I, II, III and IV in
construction and industrial sectors.

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At dire dawa technical vocational and training college, the college committed to help men and
women to develop the skills and knowledge to pursue many opportunities in today’s fastest
growing career fields, including coble stone, electronics, metal fabrication, drafting, surveying,
hotel and tourism currently the college is grown to level 5.
The college has a total of 184 workers among them, 24 of them are A-level trainers, 78 are B-
level and 15 are C-level trainers and of 117 trainers females are 24 and males are 93. The college
also has 67 administrative staffs of which 31 are females and 36 are males totally there are 184
employees 124 males and 60 females.

Dire Dawa Food Complex Share Company is Located in Dire Dawa as Head office and the
Company has centered its production at the city of dire Dawa. In addition, as it is recognized as
the largest firm and leading suppliers of flour and flour-based food products nationwide in
Ethiopia that has been serving and providing for about three decades of time. Moreover, it is
involved in the manufacturing vendor in more than four manufacturing sectors. Which are
known as Pasta Factory, Macaroni Factory, Wheat Flour Factory, Zebib Biscuit Factory and
Bread Factory. The Pasta Factory is producing the major product of Dire Dawa Food Complex
S.Co, which is known as the brand Vera Pasta. This factory is capable of producing 500 Quintals
of Spaghetti Pasta per day and make supply to its valuable nationwide customers. In addition,
more similarly the macaroni and pastini products are the primary deliveries of the company in
which the Vera Macaroni factory is capable of producing 620 Quintal of Macaroni per Day and
respectively Vera Pastini delivers about the same amounts of pastini products from its root
factory. Further more our Company provides a Wheat Flour products with an overall production
capacity of 2000 Quintal per Day and also 200 Quintal per Day from the biscuit factory branded
as Zebib Biscuit and producing about 110 Quintal per Day of Daily Bread if the production goes
without difficulties.

The knowledge and skill gain from the industry attachment program on Dire Dawa food complex
share company was focused on instrumentation and control servicing which was about different
kinds of sensors, transducers, SCADA (Supervisory Control & Data Acquisition System )and
PLC (programmable logic controller). Systems and devices which are used to control, monitor
and regulate industrial processes and manage, design, and install the machines or control systems
used in highly technical fields.

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Every academic institution's goal is to produce competent and highly qualified graduates that can
eventually be competitive in a local and global ground. A graduate tracer study is a very
powerful tool that can provide valuable information for evaluating the where about and
performance of the graduates in the workplace. One of the aim of this program is to keep track of
the graduates in one of the industries in Dire Dawa. A structured interview and observation
served as an instrument to gather information. Most of the graduates are young and they are
doing their job properly with a great manner. Furthermore, the graduates have jobs related to
their respective study programs. However, the industry have the need to work with TVET
institutes to gain trainings to update the employees with new technologies emerging. Industrial
Instrumentation and Process Control involves, installation, repairing, calibrate, tuning those
measurement and control instruments that are used in industrial manufacturing processes but in
Dire Dawa food complex because of its financial problem the main performance is calibration
and tuning. There are different equipment’s that need to be replaced and riper but financially it is
not possible the spear parts are not available. The need of the industry from the trainer was to
maintain the washing machine, which used to wash the industries, employs uniform for this need
the program was developed and the document was prepared and ready to use whenever the
industry buy the hard ware to be replaced.

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2. Industry’s profile
Dire Dawa Food Complex S. Co. is one of the leading suppliers of flour and flour-based food
products nationwide in Ethiopia. Dire Dawa Food Complex S.Co. is located in Dire Dawa, 515
kms east of Addis Ababa. Having started its operation in 1995G.When it comes to producing
food supplies in mass-scale, safety comes first. This is the underlining reason our company has
taken the initiatives to be awarded international systems certificates like FSMS (Food Safety
Management System) ISO 22000:2005 and EMS (Environmental Management System)
certification ISO 14001:2004.
The company were the pioneer for these certificates in the country and this has helped other
company to build the success brand Vera Pasta. The company mission is to produce quality flour
and flour based products to the best satisfaction of the customers, totally complying with
international requirements for Food Safety and Environmental Management Standards.
The vision of the company is to supply Vera Pasta products with the internationally accepted
quality & safety standard, with the required amount, with affordable price and within the
required time to our customers.

3. Practical knowledge and skills gained

 Testing, evaluating, modifying and calibrating products and instruments

 Practical viewing of process in and out.
 Programmable logic controllers (PLC)
 Supervisory control and data acquisition (SCADA).
 Develop an understanding of the process control requirements.
 Analyzing data and presenting findings in written reports
 Managing operations
 Working collaboratively with other employees
 Project management within cost and time constrained environments
 Understanding and ensuring compliance with relevant health and safety regulations and
quality standards
 Providing advice and consultancy support
 How to Purchas equipment’s
 Writing computer software and test procedures

4. Assessment result of previous TVET graduates at the industry

 The work environment in Dire Dawa Food Complex S. Co. is encouraging. It is healthy
and safe, provides to both personal comforts, and facilitates doing a good job the working
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 condition is good the company have clean and attractive surroundings plus it is friendly
and supportive environment so the employees have good intention for the company on
this area, so the employees are satisfied.
 The employees are appreciated for a job well done this is creating higher satisfaction.
 Wages and salaries are recognized to be a important. In Dire Dawa Food Complex S. Co
the payment is good but it most of the time it have delay because of the company internal
problems this is making the employs uncomfortable.
 Older employees tend to report higher satisfaction, and younger employees say the lowest
job satisfaction rates because the company is not on its best performance level for the
time being.
 Promotional opportunities are available and performed in a proper manner
 The relationship between managers and employees is effective. The managers know their
employees need and communicate well with every employ.
 The salary is fair as the graduates said but it did not paid on a regular formal manner
 The graduates have well technical skill, life skill, management skill but they have the
need to get new updated trainings.
 They also have good work ethics. They respect their working hours and their work.

5. Industry’s problems assessment result

 The have different kinds of problems but it all involves finance.
 The core problems I assessed in the industry was maintenance of the washing machine
which is used to wash the industries, employs uniform

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Figure 1. The washing machine mark and defective components
6. Industry’s problems solutions Proposal
Changing The System And Repairing (ZODIAC L18ET) Automated Washing Machine By
Using Programming Logic Controller.

1. INTRODUCTION

This proposal shows changing the system and repairing (ZODIAC L18ET) Automated washing
machine by using programming logic controller. Hardware required PLC, solenoid valves, relays
and DC Motor. PLC will be used to control devices and functions such are timing, sequencing,
controlling, relaying and alarming. A DC Motor required because of its variation over a wide
range of speed. Solenoid for the control of water as an input and output valves of the machine.
All the devices are fully controlled on a few instructions once given by PLC.

2. SYSTEM BLOCK DIAGRAM

The main components are

1. Inlet valve
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 2. Motor control
3. Outlet valve,

3. WASH PROGRAMS

Start the washing machine by pressing the ‘START’ switch. Set the timer for the water level by
pressing the ‘LEVEL SWITCH’. The inlet valve is on for that particular time set by the timer.
Ensure that the ‘DOOR LOCK SWITCH’ is on.

STAGE 1:

Motor running

 Forward direction for 5sec.

 Reverse direction for 3sec.

(This occurs for 2min.)

 Forward direction for 60 sec.

Motor stops running

Outlet valve remains ‘ON’ for 60 sec.

STAGE 2:

 Again, inlet valve remains ON for time set by level switch.

 Motor starts running
-Forward direction for 60 sec
 Motor stops running
 Outlet valve remains ON for 60 sec

STAGE 3:

Motor running

 Forward direction for 120 sec

Motor stops running

Alarm starts ringing.

4. FLOW CHART:

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 4. LADDER DIAGRAM
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RSlogix Micro software is used for testing purpose

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 5. COMPONENTS FOR THE HARDWARE IMPLEMENTATION
 Allen Bradley PLC
 Solenoid Valve
 DC Motor
 Relay

6. CONCLUSION:

PLC is being widely used for various applications for automization. By using PLC and other
components, from the washing machine it is possible to make the washing machine perform
using the software program shown above.

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7. Lesson learnt
 It is good to be familiar with the industry it helps with the practical knowledge.
 It was a good opportunity to meet different peoples to shard different kinds of skill and
knowledge.
 The work ethics of our college and the industry is different was good experience to observe that.

8. Challenges and Remedial actions

8.1 Challenges
The only challenge that I have faced was the companies financial problem because of that it was difficult
to perform maintenance

8.2 Remedial actions

It is beyond our capacity to solve the company problem but since the PLC program was
performed using the software, it is possible to maintain the washing machine when the company
afford to buy the PLC hardware.

9. Conclusion and Recommendation

9.1 Conclusion
As I try to express above on the document the industry attachment program was a good opportunity to get
more knowledge that is practical and to assess the graduates of the college will help us to know the level
of their skill and knowledge. It a good way to know the standard of our teaching and learning process
whether it is on the right truck or not.

9.2 Recommendation
It was better if EASTRIP PIU select active and well-organized industries for the industry
attachment program and it was good if the report was performed ever weak in the last 45 days.

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