COLLEGE OF ELECTRICAL & MECHANICAL

ENGINEERING

DEPARTMENT OF ELECTROMECHANICAL ENGINEERING

SECTION B

TITLE OF PAPER: INTERNSHIP PROGRAM AT

YETEBABERUT FOOD COMPLEX

NAME OF INTERN: THOMAS TEREFE

ID. NO.: ETS0632/12

UNIVERSITY ADVISOR: MR. MITIKU B.

COMPANY SUPERVISOR:

- ENGINEER TEWODROS BIRHANU

- ENGINEER ALEMAYEW SHAWEL

Addis Ababa, Ethiopia

August 16, 2023
DECELERATION

I am a 5th-year Electromechanical Engineering student at Addis Ababa Science and Technology

University (AASTU). I completed a three-month internship at Yetebaberut Food Complex
Company under the guidance of my supervisors, Engineer Tewodros Birhanu and Engineer
Alemayew Shawel. Additionally, I received valuable support and advice from my advisor, Mr.
Mitiku B. My name is Thomas Terefe, and this document signifies the substantial effort I dedicated
to merging my theoretical knowledge with practical experience as I ventured into the professional
world.

Name of Student Date Signature

Thomas Terefe -------------- -------------

Approval of advisors Date: Signature:

Mr. Mitiku B. ------------- ------------

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Abstract

This report documents my internship at Yetebaberut Food Complex Company, which took place
from July 1 to September 30, 2023. It offers an in-depth exploration of the company's background,
mission, vision, main products, organizational structure, and my personal experience during this
period.

Yetebaberut Food Complex Company is a renowned name in the food production industry,
committed to delivering high-quality and nutritious food products. The company's mission is to
meet the diverse demands of consumers, while their vision is to establish themselves as a
recognized national and international brand known for quality and innovation.

The report delves into the company's primary product offerings, the production flow, and the
intricate machinery and technology used. This was not just an observational experience; I had the
privilege of gaining hands-on exposure to various aspects of the production process.

My internship involved interaction with personnel at various levels within the organization,
providing me with insights into the industry's dynamics and enriching my perspective.

During my internship, I faced challenges related to outdated methods and manual power control
systems. To address these issues, I worked on implementing a modern power control system using
Programmable Logic Controllers (PLCs) to improve efficiency and safety within the organization.

The report concludes with recommendations for further technological advancements within the
company and expresses my gratitude to the entire team at Yetebaberut Food Complex for their
support and guidance during this transformative internship. It emphasizes the invaluable
experience gained, skill enhancement, and my readiness to apply these learnings in my future
endeavors.

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Acknowledgement

First and foremost, I extend my heartfelt gratitude to the Almighty God for guiding and enabling
me to successfully complete this internship program.

I would like to express my sincere appreciation to my advisor, Mr. Mitiku B., for his invaluable
assistance in preparing my report and for providing me with guidance throughout the program. His
support has been instrumental in my journey.

I would also like to extend special thanks to Mr. Mitiku B. for his significant contributions and
mentorship during this internship. His insights and advice have been a cornerstone of my
experience.

My deepest appreciation goes to my supervisors, Engineer Tewodros and Engineer Alemayew,

who dedicated their time to guide me in all aspects of my internship. Their expertise and support
have been instrumental in my professional development.

I am grateful to Engineer Alelign, the head of the mechanical department at the company, for his
unwavering support and for encouraging me to tackle challenges within his field. His mentorship
has been invaluable.

I extend my thanks to my colleague and staff member, Engineer Gosa, for his consistent support
and assistance in various aspects of our work.

Last but not least, I want to express my sincere gratitude to all the staff members of the company.
Their cooperation and willingness to share their knowledge and experiences have enriched my
internship journey.

In conclusion, I appreciate the unwavering support and guidance I have received from my advisors,
supervisors, colleagues, and the entire staff of the company. This internship has been a
transformative experience, and I am deeply grateful for the opportunity to learn and grow within
this professional environment.

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Table of Contents
DECELERATION ............................................................................................................................................... i
Abstract ......................................................................................................................................................... ii
Acknowledgement ....................................................................................................................................... iii
Table of Figures and Tables.......................................................................................................................... vi
Chapter 1: Introduction ................................................................................................................................ 1
1.1 Abstract ......................................................................................................................................... 1
1.2 Background and Overview of the Company ....................................................................................... 1
1.3 Main products ..................................................................................................................................... 1
1.4 Customers of the product ................................................................................................................... 2
1.5 Overall organization and work flow .................................................................................................... 2
1.6 The Company Mine Division ............................................................................................................... 4
1.6.1 Store section ................................................................................................................................ 4
1.6.2 Wheat flour production room...................................................................................................... 4
1.6.3 Corn flour production room ......................................................................................................... 5
1.6.4 Macaroni production room.......................................................................................................... 6
1.6.5 Biscuit Production Room.............................................................................................................. 8
1.6.6 Technician workshop ................................................................................................................. 11
1.7 Power distribution of the company .................................................................................................. 12
1.8 Company unique rules and regulation.............................................................................................. 12
Chapter 2: Internship Experience ............................................................................................................... 13
2.1 Abstract ............................................................................................................................................. 13
2.2 Section of the internship ................................................................................................................... 13
2.3 Work flow of section ......................................................................................................................... 13
2.4 Tasks .................................................................................................................................................. 14
2.5 Procedures of Task preforming......................................................................................................... 15
Chapter 3: Overall benefit of the internship ............................................................................................... 17
3.1 Abstract ............................................................................................................................................. 17
3.2 Introduction ...................................................................................................................................... 17
3.3 General objective of internship ........................................................................................................ 17
3.4 Knowledge and Acquaintances Acquired ......................................................................................... 18
3.4.1 Practical skills ............................................................................................................................. 18
3.4.2Team player skill ......................................................................................................................... 18
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 3.4.3 Work ethics ................................................................................................................................ 19
3.4.4 Personal ethics ........................................................................................................................... 19
3.4.5 Professional ethics ..................................................................................................................... 19
3.4.6 Interpersonal communication skill ............................................................................................ 19
3.4.7 Theoretical skill vs. practical skill ............................................................................................... 20
3.4.8Management skill........................................................................................................................ 20
3.4.9 Acquaintances acquired ............................................................................................................. 21
Chapter 4: Problem Solving ........................................................................................................................ 22
4.1 Abstract ............................................................................................................................................. 22
4.2 Statement of the problem ................................................................................................................ 22
4.3 Objectives of the project................................................................................................................... 22
4.4 Scope and significant of the project ................................................................................................. 23
4.4.1 Scope: ......................................................................................................................................... 24
4.4.2 Significance: ............................................................................................................................... 24
4.5 Literature view .................................................................................................................................. 25
4.6 Material and Methods ...................................................................................................................... 26
4.6.1 Material used ............................................................................................................................. 26
4.6.2 Method Used ............................................................................................................................. 27
4.7 Challenges ......................................................................................................................................... 29
4.8 Result and discussion ........................................................................................................................ 30
4.9 Conclusion and Recommendations................................................................................................... 31
References .................................................................................................................................................. 33

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Table of Figures and Tables
Figure 1 : Work flow of Campany ................................................................................................................. 3

Figure 2: Flour factory machine .................................................................................................................... 5

Figure 3:- Macaroni production machine ..................................................................................................... 6

Figure 4: blue print of macaroni machine..................................................................................................... 7

Figure 5: biscuit Producing machine ............................................................................................................. 8

Figure 6:Biscuit manufacturing flow chart .................................................................................................. 10

Table 1: Power distribution of company..................................................................................................... 12

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 Chapter 1: Introduction
1.1Abstract

This chapter introduces Yetebaberut Food Complex, a privately owned food manufacturing facility
located in Bale Robe, Ethiopia. Established in 2010, the complex produces a range of high-quality
products, including wheat and corn-based items like flour, macaroni, and biscuits under the brand
"SELAM." The chapter highlights the company's strategic location in a wheat-rich region and its
commitment to local economic development. Key features include the company's mission, goals,
management structure, and power distribution setup. Additionally, unique company rules and
regulations are outlined to ensure a safe and productive work environment. This chapter serves as
a foundation for understanding the complex's operations, product offerings, and organizational
structure.

1.2 Background and Overview of the Company

Established in November 2010, the Yetebaberut Food Complex is a privately owned factory
located on a 2,000 square meter plot of land provided by the Bale Robe City Administration. An
investment permit was received from the Oromia Regional Estate in early 2010, and following
this, high-quality flour and a variety of macaroni under the brand name "SELAM" were swiftly
initiated for production. Today, their products are widely distributed in markets across the nation.

Located in Bale Zone - Robe, a region renowned for producing some of the highest quality wheat
and corn in the country, the complex is strategically positioned approximately 430 kilometers from
Addis Ababa, the capital city. The success of the Yetebaberut Food Complex is attributed to the
dedication of around 800 permanent employees and 200 seasonal workers.

In this year, through the collective efforts of many employees and the owners, a biscuit factory
was established. On Augst 24, 2023, the production of two types of biscuits commenced, with
expectations for the production of nearly 10 types of biscuits in the future. Additionally, a spaghetti
factory is in the process of being established, further expanding the complex's offerings.

Their commitment to aiding national growth and contributing to the success of the national
Economic, Development & Transformation Plan underscores their role in the broader economic
landscape. The complex's vision and dedication to enhancing food production and economic
development are truly commendable, and they are well-positioned to continue their positive impact
on the local community and the nation as a whole.

1.3 Main products

The main product of the company is

➢ Wheat flour
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 ➢ Corn flour
➢ Macaroni
➢ Biscuit
➢ Spaghetti in the coming year

1.4 Customers of the product

The company's main customers typically include distributors, retailers, and consumers. Products
are purchased in bulk by distributors, who then distribute them to retailers, which can include
grocery stores and supermarkets. Retailers, in turn, sell the products to individual consumers.
Furthermore, various businesses and institutions, such as restaurants, hotels, and catering services,
are also customers as they use flour and macaroni as ingredients in their food preparation.

The company's flour finds a significant customer base in local bread factories. Robe town, in
particular, hosts nearly 30 bread factories, with approximately half of them relying on the
company's flour for their day-to-day operations. Additionally, the company's macaroni dominates
the local market, with no other brand in the area.

1.5 Overall organization and work flow

➢ Mission

The production and distribution of high-quality products to our customers is guided by a

sustainable operational philosophy that focuses on strengthening our value and supply chain.

➢ Vision

Their vision is to herald economic, social, and cultural prosperity in the lives of wheat suppliers
by promoting vibrant, self-sustaining, and holistic cooperative wheat farm development in the Bale
Region.

➢ Goals
✓ Continuously focus on producing high-quality products
✓ Involve in a continuous expansion of our plant so that we could create more jobs to
the community,
✓ Be a quality leader in the industry and win the hearts of existing and new customers,
✓ Contribute to the economy of the country and help realize the national vision of
being a middle-income country.
➢ Site selection

The town of Bale Robe is situated 430 km from the capital city, Addis Ababa. The factory's power
supply is sourced from the national grid, and it is equipped with digital telecommunication

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facilities, including fax services. The selection of the town of Bale Robe as the location for the
food processing facility was based on the following reasons.

✓ Proximity of the town to the source of wheat (Bale zone is the most wheat
productive area in the country)
✓ Availability of water, electric power and other infrastructural facilities.
✓ The nature of the land is suitable.
✓ Availability of labor
➢ Management System

Management can be defined as all the activities and tasks undertaken by one or more individuals
for the purpose of planning and controlling the activities of others to achieve a specific objective
or complete a task that could potentially be accomplished by individuals acting independently. In
the context of the Yetebaberut Food Complex (YFC), which comprises various working sections,
each section is equipped with both a mechanic and an operator responsible for repairing
malfunctioning machinery and operating equipment.

The primary responsibilities of production officers encompass the entire production process. Once
they receive an order from upper management, the production officers collaborate with operators,
assistants, mechanics, quality controllers, and other team members to ensure the timely completion
of production. Additionally, production officers are responsible for identifying and addressing any
hazards or issues that may arise during production. If any production-related problems occur, it is
their duty to communicate and explain these challenges to the manager. Therefore, the success of
all production activities hinges on the effectiveness of the production officers within YFC.

➢ Work Flow Structure of the Company

General manager

Production and Human resource

technical manager manager

Security and ICT

Store keeper
cordinirator

Marketing and
Finance
department

Figure 1 : Work flow of Campany

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 ➢ Organization structure
As per the current organizational structure, the company comprises four departments and four
service sectors. These include:
1. Administration Department
2. Finance Department
3. Commercial Department
4. Production and Technical Department
In addition to the departments, the company has service sectors, which are:
1. Planning and Information Service
2. Quality Control Service
3. Store and Property Administration Service
4. Audit Service

1.6 The Company Mine Division

Yetebaberut Food Complex is a company specializing in the production of high-quality wheat
flour and macaroni. Within this establishment, a variety of machines are employed to perform
diverse tasks, each utilizing distinct operation mechanisms to facilitate the production processes.
Generally, the working section of YFC is the following
Store section
Wheat flour production room
Corn flour production room
Macaroni production room
Biscuit Production Room
Technician workshop
Work flow of section is discussed as the follow.

1.6.1 Store section

In this section, the primary raw materials of the company, namely wheat and corn, are stored.
Additionally, a weighing machine is present in this area. The stored wheat and corn are transferred
to their respective processing machines, the wheat flour making machine and corn flour machine,
without intermixing. This transfer is facilitated through an online system using air pressure. The
storage section comprises three storage units, each with a capacity of 75 tons for wheat, and two
storage units, each with a 50-ton capacity for corn.

1.6.2 Wheat flour production room

It has four unit of production (four different machine are there). This section is dedicated to the
production of wheat flour, and the entire process is fully automated from start to finish. Various
machines perform different functions in the production line, following this flow:

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1. Cleaning: In this initial stage, the wheat is meticulously cleaned to remove any impurities such
as sticks, stones, and other coarse and fine materials. After cleaning, the pure wheat is then moved
to the conditioning bins for further processing.

2. Tempering and Conditioning: The wheat undergoes soaking in water during this phase to
facilitate the easier removal of the bran. Conditioning is a critical step that ensures the moisture
content is consistent throughout the grain. Maintaining proper moisture levels prevents the bran
(the outer layer) from breaking during milling.

3. Gristing: Gristing involves the blending of conditioned and cleaned wheat. Different batches of
wheat are mixed to achieve the specific kind and quality of flour required for production.

4. Separating: The grist, now prepared, passes through a series of rolls that rotate at various speeds.
These rolls specifically split open the wheat grain, separating the inner white portion from the bran.

Figure 2: Flour factory machine

5. Milling: The wheat is ground by a flour mill machine, crushing it into smaller pieces. As the
process continues, the meal obtained starts out coarse. Through repeated grinding and sifting, the
meal is refined into fine flour, wheat germ, and wheat bran. These components can be sold
separately or combined to produce whole meal flour.

6. Blending: In the final step, different constituents are mixed together to create various types of
flours. For example, blending wheat bran with white flour produces whole wheat flour, offering a
versatile range of flour products.

1.6.3 Corn flour production room

Its process is the same as with the wheat flour production. But it has only one unit of production.
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1.6.4 Macaroni production room
The macaroni production facility is organized into four distinct sections, each contributing to the
macaroni-making process:
1st Section (Trabato Section): This initial section is dedicated to macaroni processing. It involves
the following subsections:

Figure 3:- Macaroni production machine

• Flour Receiver
• Pre-Mixer
• Main Mixer
• Vacuum Lamper
• Shaper & Cutter

Macaroni processing here involves the mixing of wheat flour with water, kneading the mixture
through an auger extruder equipped with mixing paddles and kneading blades to achieve a
homogeneous mass. Subsequently, the mass is extruded through variously shaped dies to create
the macaroni shapes.

2nd Section (Dryer Section): Drying is a critical phase in macaroni production. It's divided into
two parts:

• Pre-Dryer (4 layers)
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 • Main Dryer (Middle and Final Dryer) (9 layers)
• Boiler: used for providing hot water
• Fan Motor: Inside the dryer section, the fan motor is responsible for distributing hot air to
dry the macaroni.

Proper drying is crucial to achieve the desired macaroni quality. Precise control of temperature
and relative humidity ensures that the outer surface hardens while the interior remains soft and
plastic. Incorrect drying can lead to poor appearance, low mechanical strength, cracking, or
spoilage.

3rd Section (Cooler Section): This section is designed to dissipate heat from the macaroni before
it advances to the storage and packing area. It includes the following components:

• Chiller
• Compressor
• Water Tank
• Fan Motor

4th Section (Store and Packing Section): In this final section, macaroni is stored and packed.
Sensing technology is used in the macaroni room, including load sensors to monitor machine
activities. Load sensors are electronic devices that convert tension and compression forces into
corresponding electrical signals. They are employed to determine the weight of objects, such as
the weight of flour used in the macaroni production process.

Figure 4: blue print of macaroni machine

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Overall, the macaroni production workflow is a well-coordinated process involving these sections,
ensuring the production of high-quality macaroni products.

1.6.5 Biscuit Production Room

Figure 5: biscuit Producing machine

The biscuit manufacturing process comprises several key stages: mixing, forming, baking, and
packing. Here is a detailed overview of these stages and various aspects of the biscuit production
process:
Mixing:
• Mixing involves combining ingredients like flour, fat, sugar, and others in the right
proportions to create the biscuit dough.
• Mixing can occur in one stage, two stages, or three stages.
• Three-stage mixing involves creaming in the first stage, adding flour with chemicals in the
second stage, and combining flour with water in the third stage.
• Mixing time typically ranges from 15 to 25 minutes, depending on factors like mixer speed,
flour properties, and required dough temperatures.
• In biscuit production, vertical mixers are commonly used.

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Baking:
• Biscuit baking consists of various temperature zones.
• Key zones include the heating zone (for chemical reactions and ammonia removal), baking
zones (for the actual baking process), and coloring zones (partial and complete coloring).
• Proper temperature control is crucial for successful biscuit production.
• Bottom temperatures are typically higher than top temperatures in the oven.
• Conveyor systems must be synchronized to prevent production failures.
Chemical Changes:
• Various chemical changes occur during baking, including gas formation, starch
gelatinization, protein changes, caramelization of sugar, and dextrinization.

Cooling:

• After baking, biscuits exit the oven at high temperatures.

• Cooling is vital to bring biscuits to room temperature for handling and packing.
• Cooling conveyors may need to be 1.5 times the length of the oven to ensure proper
cooling.
• Forced cooling may be used in some cases due to space constraints or specific
requirements.

Packaging:

• Packaging is essential to protect biscuits and meet legal requirements.

• Major functions of packaging include protection from mechanical damage, loss of
moisture, foreign odors, and foreign body infestation.
• Packaging also communicates product details and serves as a means of advertisement.
• Biscuits are wrapped using packing machines, and wrappers are sealed.
• Various packaging materials, such as laminates, wax paper, and BOPP films, are used.
• Different pack sizes and shapes, like pillow packs and family packs, are popular.
• Packs are placed into cartons and sealed using carton taping machines.
Ingredients (Raw Material):
• Ingredients like sugar, salt, and sodium bicarbonate play critical roles in biscuit production.
• Sugar provides sweetness, color, and activates yeast during manufacturing.
• Salt contributes to taste and helps control wild yeast activity.
• Sodium bicarbonate, also known as a smoother, retains softness in biscuit products and
delays staling.

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Biscuit Plant Layout:

• The plant layout for biscuit production typically includes double-storied mixing areas for
ingredient mixing on the first floor.
• Provision for goods elevators is necessary to move ingredients to the upper floor.
• Natural ventilation in the roof helps control temperatures in the baking hall.
• Packing halls can be located on the same floor or on the first floor, depending on the
specific requirements.
• Basements may be designated for raw material storage.

This comprehensive overview provides valuable insights into the biscuit production process, from
mixing to packaging and plant layout considerations.

Figure 6:Biscuit manufacturing flow chart

Energy Conservation:

1. Ensure that machinery and equipment parts that have rotating and reciprocating movements
are adequately lubricated with suitable lubricating oil at regular intervals.
2. Organize the unit's layout to minimize material backtracking, thereby improving the
efficiency of material flow.
3. Switch off all electrical equipment when not in use to prevent unnecessary energy
consumption.
4. Before starting work, ensure that all transmission belts are properly tightened where
applicable to reduce energy wastage due to slippage.

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Pollution Control:

• Acknowledge that this industry may generate some level of pollution, and collaborate with
the State Pollution Control Board to address and mitigate these concerns.
• Maintain a minimum shed height and consider installing exhaust fans to facilitate proper
ventilation, reduce congestion, and remove harmful fumes like coke fumes from the
working environment.

1.6.6 Technician workshop

A workshop department is a setting where a group of individuals come together for a session of
discussion or practical work focused on a specific subject. Participants typically share their
knowledge and experiences during these sessions. Additionally, a workshop can refer to a physical
building equipped with tools or machinery used for the creation or repair of objects, particularly
those made from materials like wood, plastics, or metals.

Here are some of the key machines and equipment commonly found in a workshop:

1. Lathe Machine:
• A lathe machine is used for various operations, including cutting, drilling, and knurling.
• It can create three-dimensional surfaces.
• Lathe machines find applications in metalworking, metal spinning, wood turning, and
glass working.
2. Bearing Remover Machine:
• This machine is designed to remove bearings from their housings and shafts, especially
in cases where they are press-fitted or attached with keyways.
3. Grinding Machine:
• Grinding machines, often referred to as grinders, are power tools or machine tools used
for grinding operations.
• They employ abrasive wheels to cut small chips from workpieces through shear forces.
• Grinding is essential for achieving high surface quality and precise shape and
dimension in workpieces.
4. Arc Welder:
• Arc welding is a welding process that joins metal to metal by using electricity to
generate sufficient heat to melt the metal.
• It involves creating an electric arc between a metal stick (electrode) and the base
material, leading to the fusion of metals upon cooling.
• Arc welders can use either direct current (DC) or alternating current (AC) and are
compatible with consumable or non-consumable electrodes.

These machines and tools play vital roles in various workshop settings, enabling a wide range of
operations and tasks related to cutting, shaping, joining, and more.

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1.7 Power distribution of the company

In the facility, there are 5 high-voltage transformers and 2 backup generators. These transformers
are strategically allocated for specific purposes within the complex:

• One transformer is dedicated to powering the biscuit production area.

• Another transformer is assigned to the macaroni production section.
• The remaining transformers serve various functions, including supplying power to the flour
production room and supporting maintenance and utility requirements.
No Power in KVA Power in KW Section
1 1200 960 Biscuit
2 1200 960 Wheat Flour
3 630 504 Macaroni
4 315 252 Corn Flour
5 315 252 Other

Table 1: Power distribution of company

The presence of backup generators ensures uninterrupted power in the event of an electric power
outage, helping to maintain the continuous operation of the complex and safeguard against
production disruptions. These transformers and backup generators play a crucial role in the overall
functioning of the Yetebaberut Food Complex.

1.8 Company unique rules and regulation

The company has established specific rules and regulations to ensure a safe and productive
working environment. Some of the unique rules and regulations include:

✓ Prohibition of Photography and Mobile Phone Use: Employees are strictly forbidden from
taking photographs or using mobile phones within the company premises. This policy helps
maintain privacy and security.
✓ Mandatory Weighing on Beam Balance: Every individual and vehicle must undergo
weighing on a beam balance to prevent any form of cheating or unauthorized weight
discrepancies.
✓ No Unauthorized Departures without Reason: Leaving the company premises without a
valid reason is not permitted, as it can pose safety and operational risks.
✓ Zero Tolerance for Insults and Fights: Engaging in any form of insults or physical
altercations with fellow workers is strictly prohibited. Violation of this rule can result in
termination from the company.

These unique rules and regulations are in place to uphold the company's values, safety standards,
and operational efficiency while maintaining a respectful and harmonious work environment.

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 Chapter 2: Internship Experience
2.1 Abstract

This chapter describes the intern's experience at Yetebaberut Food Complex in the absence of an
electromechanical department. The technical department is divided into Mechanical and Electrical
departments, each with distinct workflows. The intern, possessing expertise in both areas,
primarily works within the Electrical Department. Tasks encompass various projects related to
electromechanical work, including the assembly of machines, developing an elevator, motor
winding, powering machines, training preparation, generator assembly, maintenance, and muffler
construction. Procedures for task performance involve issue identification, root cause analysis,
thorough analysis and study, information gathering, problem resolution, and understanding
machine parts. This chapter outlines the intern's active involvement in addressing
electromechanical challenges within the company.

2.2 Section of the internship

At the company, there is a notable absence of an electromechanical department. Instead, the

technical department is structured into two primary branches:

1. Mechanical Department: This department focuses on handling mechanical aspects of the

company's operations, including maintaining and repairing machinery and equipment used
in production.
2. Electrical Department: The electrical department specializes in electrical systems,
managing the installation, maintenance, and repair of electrical components and ensuring
the seamless operation of electrical machinery.

I play a pivotal role within the company, as I am involved in both the mechanical and electrical
departments. While my expertise extends to both areas, I predominantly work in the electrical
section due to my comprehensive knowledge of electrical systems. This dual capability enables a
wide range of issues to be addressed and contributes to the efficient functioning of the Yetebaberut
Food Complex.

2.3 Work flow of section

The workflow in both the mechanical and electrical departments varies according to their specific
functions:

Workflow in the Mechanical Department: The mechanical department is divided into two main
sections:

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 1. Operation Section: In this section, engineers are responsible for operating the machines
used in manufacturing and monitoring the production processes in each manufacturing
unit. They ensure that the manufacturing processes are running smoothly and efficiently.
2. Maintenance Section: In the maintenance section, the focus is on addressing any
malfunctions that occur in the machinery across all units. The team also plays a crucial role
in developing new mechanical components when necessary. This may include the
fabrication of new parts and even the construction of new machines like elevators. Welding
is a common task in this section, and the team is involved in both assembling and modifying
machines, whether they are old or new.

Workflow in the Electrical Department: The primary responsibilities of the electrical department
include:

✓ Maintenance of electrical components and systems within the company after they
informed.
✓ Installation and configuration of new electrical lines for various purposes.
✓ Participation in the assembly and modification of machines, whether they are old or new,
with a focus on the electrical aspects.

Both departments work together to ensure that the machinery and systems within the company are
well-maintained, efficient, and in good working order. The mechanical department takes care of
the physical aspects, while the electrical department handles the electrical components and
systems, contributing to the overall success of the company.

2.4 Tasks
During my internship at the company, I was involved in various projects and tasks related to
mechanical and electrical work. Here's a summary of my experiences:

1. Assembly of Biscuit Machine: When I first joined the company, the team was working on
assembling a biscuit machine. I assisted the mechanical and electrical teams by observing
their work, offering help with minor tasks, and providing tools when needed. Occasionally,
I was even invited to perform specific tasks.
2. Developing Elevator: Since the biscuit machine was located on the first floor, the team
needed to create an elevator to transport materials. I assisted in designing the elevator and
played the role of an observer during the preparation of crucial mechanical components. I
also contributed my electromechanical knowledge to resolve issues, such as limiting the
motor's rotation.
3. Winding and Starting of Motor: When the main assembler of the biscuit machine traveled
to China, the head of the electrical department, Engineer Tewodros, trained me and my co-
interns on motor winding and starting. I attended the training and applied the knowledge
learned.

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 4. Powering the Machine: Alongside my fellow interns, the electrical head assigned us the
task of powering the biscuit machine. Under the guidance of Engineer Alemayew, I placed
wires in their correct positions and utilized proper splicing methods.
5. Preparing Training: Engineer Alelign, the head of the mechanical department, tasked me
with preparing a training session about the working principles of refrigeration for
graduating members of the mechanical department. I delivered the training with his
guidance.
6. Assembly of Generators: During my internship, I participated in the assembly and
installation of two company generators. The old generator was replaced due to aging. My
role included stretching the necessary wires during the installation process.
7. Maintenance of Macaroni Machine: When two fan motors of the macaroni machines
malfunctioned, the head of the mechanical department instructed us to solve the problem.
I disassembled the motors from the drier part, checked for issues, and found that the motor
winding was problematic. After our supervisor rewound the motor, I reassembled it
correctly. The task involved both mechanical and electrical aspects.
8. Assembly of Transformer: As part of the preparations for a new spaghetti machine, the
company ordered the assembly of a transformer. I observed the assembly process and
provided necessary tools when needed.
9. Muffler Making: The new generator that replaced the old one had a noise issue that
disrupted the company and the surrounding area. I worked with Engineer Gosa, who had
prior experience working with me in the garage. Together, we constructed a muffler to
reduce the generator's noise.

These experiences allowed me to gain valuable insights into both mechanical and electrical work
and provided me with practical knowledge and skills in electromechanical tasks.

2.5 Procedures of Task preforming

All of my tasks are assigned by Engineer Tewodros, the head of the electrical department, and
Engineer Alelign, the head of the mechanical department. A significant portion of my
responsibilities involves electromechanical tasks. The procedures for my tasks typically follow
these steps:

1. Identifying Machine Issues: I begin by identifying the primary problems or malfunctions

in the machines or equipment.
2. Root Cause Analysis: Once the issues are identified, I delve into determining the root
causes behind these problems.
3. Analysis and Study: After selecting the potential causes, I analyze and study them
thoroughly to gain a deeper understanding.
4. Information Gathering: I collect information from various workers and employees who
have insights into the machine issues and the potential causes.
5. Problem Resolution: Finally, based on the gathered information and analysis, I provide
solutions to address and resolve the identified problems.

15
6. Understanding Machine Parts: To ensure effective troubleshooting, I often inquire about
different machine parts and their working principles to enhance my knowledge and
expertise in addressing electromechanical challenges.

16
 Chapter 3: Overall benefit of the internship
3.1 Abstract

This chapter discusses the overall benefits of the internship experience at Yetebaberut Food
Complex (YFC) in the context of the food production industry. The intern actively participated in
various technical aspects of the company's operations, resulting in the acquisition of practical
skills, team player skills, and enhanced work ethics. This chapter outlines how the internship not
only facilitated the development of theoretical knowledge into practical skills but also emphasized
personal and professional ethics. The intern also highlights the importance of interpersonal
communication skills and the knowledge gained from colleagues and mentors, shedding light on
the management and leadership skills acquired during the internship. Furthermore, the chapter
emphasizes the role of practical contributions to the host company and underscores the mutual
exchange of knowledge for personal and professional growth.

3.2 Introduction

During my internship period at YFC (Yetebaberut Food Complex), I was exposed to various
technical aspects of the food production industry. YFC is dedicated to manufacturing a range of
food products that cater to customer needs, achieved through the use of different machines in
various production lines.

Throughout my internship program, I wasn't just an observer; I was actively involved in the
operations, with workers guiding me through the process of operating several machines. This
active participation contributed significantly to the enhancement of my technical skills. Practical
knowledge was gained, and a deeper understanding of the complexities within the food industry
was developed.

YFC provided me with an opportunity to witness the inner workings of the industry, emphasizing
the crucial role played by technology and machinery. The experience has not only enriched my
technical capabilities but has also broadened my perspective on the dynamic world of food
production.

3.3 General objective of internship

The primary aim of the internship was to acquire practical skills.

➢ Specific objectives of internship

✓ The internship had several specific objectives, including:
✓ Resolving issues encountered in the hoisting company.
✓ Determining the advantages of practical skills.
✓ Identifying problems within various machine components.
✓ Gaining insight into the overall challenges faced within the field.
17
 ✓ Acquiring practical experience relevant to my department or field of study.

3.4 Knowledge and Acquaintances Acquired

During the internship, knowledge and acquaintances were acquired. In essence, an internship is a
form of job training, involving the exchange of services for experience between the student and an
organization. This period allowed me to assess my interest in a specific career, build a network of
contacts, and earn school credit. The experience and skills gained from the internship have made
me a more attractive candidate to businesses when I am in the process of hiring new employees.

3.4.1 Practical skills

Practical skills were gained during the internship, providing an opportunity to apply engineering
knowledge and collaborate effectively with others. The skills acquired include:

✓ Creativity and an innovative problem-solving approach.

✓ The ability to analyze and interpret diverse, complex data.
✓ Critical thinking and the capacity to assess designs, plans, and projects.
✓ Clear written and oral communication skills.
✓ Proficiency in operating various machines, including macaroni and wheat flour packing
equipment, among others.

3.4.2Team player skill

Team player skills were improved during the internship, emphasizing the importance of
collaboration, especially when working toward common goals to enhance company productivity.
Key points in enhancing team player skills include reaching consensus on tasks and fostering a
shared understanding of the objectives.

To facilitate teamwork, active listening is crucial. Actively listening to the ideas and input of
colleagues allows for more informed and productive discussions. After attentive listening,
providing constructive ideas and suggestions for the tasks at hand is vital.

In general, individuals with strong team player skills possess the following qualities:

✓ Actively listen to others.

✓ Demonstrate reliability and consistency.
✓ Cooperate and offer assistance to colleagues.
✓ Share openly and willingly, fostering transparent communication.
✓ Act as a problem-solver to address challenges collaboratively.
✓ Communicate constructively and positively.
✓ Exhibit commitment to the team's objectives.
✓ Engage as an active participant in team activities.
✓ Treat others respectfully and supportively.
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3.4.3 Work ethics

In the contemporary and intricate professional landscape, the ethical behavior of employees plays
a pivotal role in fostering a healthy work environment and enhancing overall productivity. Ethical
work conduct empowers me to exhibit appropriate behavior within the workplace, allowing for the
development of positive relationships with colleagues. This, in turn, contributes to the creation of
a productive and harmonious working atmosphere that is grounded in both personal and
professional ethics.

3.4.4 Personal ethics

These principles of personal ethics represent values that are anticipated from all individuals in their
lives. They play a crucial role in promoting harmonious interactions and peaceful coexistence
within a society. During my time at the company, I embraced and further developed principles of
personal ethics, including:

✓ Fairness
✓ Compliance with the law
✓ Benevolence (doing good)
✓ Refusal to take unfair advantage

3.4.5 Professional ethics

Professional ethics encompasses the standards and moral principles that regulate the behavior of
individuals within specific defined professions. To be considered a profession, an activity should
be carried out by those with advanced education, knowledge, and skills. Throughout my internship
period, I acquired an understanding of various professional ethical principles, including:

✓ Honesty
✓ Reliability
✓ Impartiality
✓ Punctuality
✓ Cooperation
✓ Accountability
✓ Office discipline
✓ Transparency and openness

3.4.6 Interpersonal communication skill

During my time in the company, I collaborated with all the team members and colleagues
harmoniously. It's common for individuals to acquire various insights from their peers through
communication. Communication serves as a vital means of learning for individuals. Formal
communication is defined as the act, process, or experience of acquiring knowledge or skills.
19
Effective communication encompasses various forms such as speaking, writing, and listening, and
it offers several advantages, including:

✓ Managing and conveying information effectively.

✓ Persuading and influencing people.
✓ Enhancing relationships with others.

3.4.7 Theoretical skill vs. practical skill

The internship program provided me with the opportunity to apply my theoretical knowledge in
real-world settings, thereby enhancing my practical skills. This hands-on experience allowed me
to gain a deeper and more comprehensive understanding of several courses that I had previously
only learned theoretically. Some of the courses that I was able to further comprehend through
practical application during my internship include:

✓ Machine
✓ Instrument
✓ Installation
✓ Workshop Practice
✓ Entrepreneurship
✓ Manufacturing

These fields were explored in more detail during my internship, enabling me to bridge the gap
between theory and practical application and gain insights into their real-world applications.

3.4.8Management skill

During my months of internship, I had the opportunity to develop leadership skills by observing
and learning from various leaders within the organizational hierarchy. I realized that effective
leadership requires a set of key skills, including:

✓ Good communication skills

✓ Active listening ability
✓ Decisiveness
✓ Strong management skills
✓ Efficient resource management and utilization
✓ Effective staffing and team management

In this company, every staff member is responsible for their specific role, and they take their
responsibilities seriously. For example, the finance administration oversees all monetary activities,
the human resources department manages the workforce, and each staff member contributes to the
company's overall effectiveness and success by fulfilling their respective duties. This experience
helped me understand the importance of leadership and effective management in the workplace.

20
3.4.9 Acquaintances acquired

During my internship, I had the privilege of learning from individuals with various ranks and roles
within the company, particularly my advisor. From the very first day, he provided me with
guidance and training, ensuring I gained a comprehensive understanding of the company's
operations. Some of the essential knowledge and skills I acquired include:

Machinery Operation: Initially, I had no prior experience operating machinery, and I was
unfamiliar with the various types of equipment. However, through effective communication and
mentorship, I gained practical experience and knowledge in operating machines such as the
packing machine and macaroni machine. I also learned how to set up and install industrial
machines, as was the case with the biscuit machine during its installation.

Contributions: Internships are not only about gaining knowledge but also about sharing knowledge
and contributing to the host company. I identified several issues during my internship, some of
which the workers had not recognized as problems, and others that they had not perceived as
having potential risks or negative consequences on individuals and their property. As part of my
contributions, I addressed some of these problems and provided insights into managerial issues
and employee compliments. This allowed me to actively participate in the improvement of the
company's operations.

My internship experience was enriched by the knowledge exchange between myself and the
company, making it a valuable and educational period for personal and professional growth.

21
 Chapter 4: Problem Solving
4.1 Abstract

This chapter discusses the installation of a PLC-based power control system at Yebetaberut Food
Complex, addressing various challenges and opportunities associated with this transformative
project. The objectives of the system include improved efficiency, enhanced safety, reduced
downtime, flexibility, remote monitoring, cost savings, compliance, integration with other
systems, and enhanced reliability. The chapter details the materials and methods used in the
installation process and outlines the challenges specific to the company's context. It highlights the
anticipated results of the system, emphasizing precision process control, real-time empowerment,
safety and reliability, minimized downtime, sustainable energy efficiency, and scalability for
future growth. The chapter concludes with recommendations for the successful implementation
and ongoing management of the PLC-based power control system.

4.2 Statement of the problem

During my internship, I encountered several challenges in the company's operations. Firstly, the
company primarily relies on outdated methods, and the adoption of modern technologies is
minimal. Most of the manufacturing units operate manually, with the exception of the biscuit
machine. In the event of an issue in these units, cutting off the power supply relies on human
intervention, which can be time-consuming and lead to machine failures.

Secondly, the manual control of the power system across all sections of the company poses a
significant problem. In cases of emergencies, such as a fire in one unit, the process of cutting off
power can be cumbersome. It involves reporting the issue to technicians who must then physically
disconnect the power supply from the main board or transformer room. This delay can potentially
result in severe damage to the company.

To address these challenges, it is essential to implement a modern power control system in the
company. While a SCADA (Supervisory Control and Data Acquisition) system is an optimal
solution, it may come with a substantial cost that the company might be hesitant to accept. An
alternative approach is to utilize PLCs (Programmable Logic Controllers) to automate the power
control system. This would significantly improve the efficiency and safety of the company's
operations without incurring the high costs associated with a full SCADA system.

4.3 Objectives of the project

The objective of implementing a PLC-based power control system in the compay is to achieve the
following goals:

22
 1. Improved Efficiency: The system aims to enhance the overall efficiency of power
distribution within the complex. Through automation, it will optimize energy
consumption, reduce wastage, and increase productivity in the various production units.
2. Enhanced Safety: Safety is a top priority. The system will provide rapid responses to
emergency situations and faults, helping to isolate problematic sections of the power grid
and thereby minimizing the risk of electrical accidents or fires.
3. Reduced Downtime: The automated power control system will contribute to reduced
downtime. It will promptly detect and address issues, minimizing interruptions caused by
power failures, equipment breakdowns, or human errors.
4. Flexibility: The PLC-based system will be highly adaptable, capable of accommodating
changing power needs as the complex's operations evolve. It will respond to varying
power demands efficiently.
5. Remote Monitoring and Control: Remote monitoring and control will be a key feature of
the system. It will enable operators to manage power distribution from a centralized
location, which is particularly advantageous for a complex of this scale.
6. Data Logging and Analysis: The system will collect and store data related to power
consumption, quality, and performance. This data will be analyzed to identify trends,
anomalies, or areas for improvement in power management within the complex.
7. Cost Savings: Through efficient power utilization, reduction in downtime, and improved
maintenance practices, the PLC-based system will lead to cost savings over time,
contributing to the complex's financial well-being.
8. Compliance and Regulation: Compliance with industry-specific regulations and standards
for power control and management will be a priority. The system will help ensure that
company adheres to these requirements.
9. Integration with Other Systems: The PLC-based system will seamlessly integrate with
other automation and control systems within the complex, providing a comprehensive
approach to facility management.
10. Reliability: PLCs are known for their reliability and robustness. Implementing this system
will increase the overall reliability of the power infrastructure within Company.

In summary, the objective of implementing a PLC-based power control system at the company is
to optimize power distribution, enhance safety, minimize downtime, and improve the overall
efficiency and reliability of the power infrastructure within the complex, ultimately supporting its
mission of providing quality food products.

4.4 Scope and significant of the project

The scope and significance of implementing a PLC-based power control system for Company are
extensive and crucial for the efficient and safe operation of the facility. Below are the key aspects
of the system's scope and significance:

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4.4.1 Scope:

1. Comprehensive Power Control: The PLC-based system will cover the entire power
distribution network within the company, including the control of transformers, generators,
electrical panels, and distribution lines.
2. Multi-Unit Integration: It will integrate with various production units, including the biscuit,
macaroni, and flour processing units, as well as maintenance and utility areas.
3. Real-time Monitoring: The system will provide real-time monitoring and control of the
power infrastructure, allowing operators to access critical data from a central location.
4. Remote Control: Remote access to the system will be available, enabling off-site
monitoring and intervention if necessary.
5. Emergency Response: The system will have a built-in mechanism to respond swiftly to
emergencies, such as electrical faults, power overloads, or fire hazards.
6. Data Logging: It will record and store data related to power consumption, voltage levels,
current loads, and system performance, offering valuable insights.
7. User-friendly Interface: The user interface will be intuitive, ensuring that operators can
easily manage and monitor the power control system.

4.4.2 Significance:

1. Improved Efficiency: The PLC-based power control system will significantly enhance the
efficiency of power distribution, minimizing energy wastage and optimizing consumption.
2. Enhanced Safety: Safety is paramount in the company. The system's ability to detect and
mitigate electrical hazards promptly will protect both personnel and property.
3. Reduced Downtime: By promptly addressing issues, the system will minimize downtime,
ensuring uninterrupted production processes.
4. Cost Savings: The efficiency improvements will lead to cost savings in energy
consumption and maintenance costs, contributing to the profitability of the company.
5. Environmental Impact: The reduced energy wastage aligns with environmental
sustainability goals, reducing the company's carbon footprint.
6. Scalability: The system is scalable, accommodating the company's growth and evolving
power needs.
7. Regulatory Compliance: Ensuring adherence to industry regulations and safety standards
is vital for the company's operations and reputation.
8. Data-Driven Decision-Making: The data collected by the system will enable informed
decision-making, performance analysis, and predictive maintenance.
9. Competitive Advantage: the company can gain a competitive edge through more efficient,
reliable, and safe operations.
10. Operational Excellence: The system will contribute to overall operational excellence,
aligning with the company's mission to produce quality food products.

In summary, the scope and significance of implementing a PLC-based power control system for
the company encompass comprehensive power control, remote monitoring, and real-time

24
management to improve efficiency, safety, and overall operational excellence. This system will
help ensure the long-term success of the company in the food production industry.

4.5 Literature view

PLC-based power control systems have a rich history, evolving over time to meet the changing
needs of industries. Here's a brief overview of their historical development:

• Early Automation and Relay Logic (Late 19th Century - Early 20th Century):

The history of PLC-based power control systems can be traced back to the late 19th century when
industries started using electrical control systems. Initially, these systems relied on relay logic and
hardwired connections to control machinery and manage power distribution. Engineers used
panels of relays and timers to create rudimentary automation.

• Introduction of Digital Computers (1940s - 1950s):

The development of digital computers in the mid-20th century marked a significant milestone.
These computers introduced the idea of programmable control. Engineers began to explore the
possibilities of using computers to control industrial processes, including power distribution.

• Birth of the PLC (1960s):

The modern PLC, as we know it today, was born in the 1960s. Richard E. Morley is often credited
with creating the first programmable logic controller. His invention, known as the Modicon 084,
aimed to replace complex relay-based systems with a more flexible and reprogrammable solution.

• Rapid Advancements (1970s - 1980s):

PLC technology advanced rapidly in the following decades. PLCs became more powerful,
compact, and affordable. They started to gain widespread acceptance in various industries. Early
PLCs used ladder logic diagrams for programming, a method that mirrored the earlier relay-based
control systems.

• Integration with Power Control (Late 20th Century):

By the late 20th century, PLCs had evolved to handle power control tasks efficiently. They became
integral components of power distribution systems, capable of monitoring and controlling
electrical equipment, such as transformers, generators, and circuit breakers.

• Digital Communication and Networking (1990s - 2000s):

25
The integration of digital communication protocols and networking capabilities further enhanced
the capabilities of PLC-based power control systems. These systems could now communicate with
other devices, central control stations, and even with remote locations.

• Modern PLC-Based Power Control Systems (21st Century):

In the 21st century, PLC-based power control systems have continued to evolve. They are now
part of the broader industrial automation landscape, often integrated with supervisory control and
data acquisition (SCADA) systems and the Industrial Internet of Things (IoT). These
advancements have brought real-time monitoring, predictive maintenance, and data analytics to
power control.

Today, PLC-based power control systems are essential for industries aiming to optimize energy
usage, ensure operational safety, and minimize downtime. They have a rich history of
development, and their future holds the promise of even greater integration and automation
capabilities.

4.6 Material and Methods

4.6.1 Material used

There are many materials for this project but the important ones are the following.

1. PLC (Programmable Logic Controller): The core component of the system, responsible for
controlling various processes and machinery.
2. Enclosure: A protective housing for the PLC and other components, usually made from
materials like mild steel, stainless steel, or aluminum.
3. Power Supply Unit (PSU): Provides a stable power source for the PLC and associated
devices.
4. Terminal Blocks and Connectors: Used for organizing and connecting wires and cables
within the control system.
5. Relays: Electromagnetic or solid-state relays for switching high-power loads on and off.
6. Circuit Breakers and Fuses: These protect the system from overcurrent or short-circuits.
7. Surge Protectors: Safeguard sensitive electronic components from voltage spikes.
8. Wiring and Cables: Copper or aluminum conductors to connect components and devices.
9. Busbars: Copper or aluminum bars for distributing power within the control panel.
10. Indicators (LEDs): Lights to display the status of the system or specific components.
11. Communication Modules: Enable communication between the PLC and other systems,
often using protocols like Ethernet or serial communication.
12. Sensors: Various types of sensors to detect parameters like temperature, pressure, or
proximity.
13. Actuators: Devices that perform a specific action, such as motors or solenoids.
14. PLC Programming Software: Used to write and upload the control program to the PLC.

26
 15. Tools and Instrumentation: Tools for installation and maintenance, as well as instruments
for testing and measurement.
16. Panel Mounting Hardware: Bolts, nuts, washers, and other hardware for securing
components to the control panel.
17. Terminal Lugs and Ferrules: Attach to the ends of wires for secure connections.
18. Cable Glands: Used to seal and secure cables entering the enclosure.
19. Insulating Materials: Heat-shrink tubing, insulating barriers, and other materials for
electrical safety.
20. Labeling and Identification Tags: Tags and markers for labeling wires, components, and
terminals.
21. Seals and Gaskets: Rubber or silicone seals for maintaining the enclosure's environmental
protection.
22. Protective Covers and Guards: Shield certain components or areas for safety and security.
23. Alarm: inform if accident happened in the company.

Each of these materials and components serves a specific role in the installation and operation of
a PLC-based power control system.

4.6.2 Method Used

The installation of a PLC-based power control system follows a systematic method to ensure
efficiency and safety. Here's a typical procedure for installing such a system:

Project Planning:

• Define the project scope, objectives, and requirements.

• Create a detailed project plan, including timelines and milestones.
• Allocate resources, budget, and personnel for the installation.

System Design:

• Develop a comprehensive system design, including the PLC hardware and software
requirements.
• Specify the type and location of sensors, actuators, and other field devices.
• Design the control panel layout and select the enclosure.
• Plan for power distribution and grounding.

PLC Selection:

• Choose a suitable PLC based on the system's complexity and requirements.

• Ensure the PLC is compatible with communication protocols and expansion options.

Panel Assembly:
27
 • Assemble the control panel with the necessary components and devices.
• Ensure proper wiring, cable management, and labeling.
• Follow safety guidelines for panel assembly.

Wiring and Connection:

• Connect sensors, switches, and actuators to the input and output modules.
• Follow a standardized color-coding scheme for wiring.
• Use terminal blocks and connectors for secure connections.

PLC Programming:

• Develop the PLC program according to the control logic required.

• Test the program in a simulation environment if possible.
• Download the program to the PLC.

Power Supply and Distribution:

• Install the power supply unit (PSU) and ensure a stable power source.
• Set up circuit protection, including breakers and fuses.

Communication Setup:

• Configure communication modules for data exchange with other systems.

• Ensure proper network settings and protocols.

Testing and Commissioning:

• Test the entire system for functionality, safety, and reliability.

• Debug and troubleshoot any issues in the program or connections.
• Verify that sensors, actuators, and alarms work as expected.

Documentation:

• Create detailed documentation, including wiring diagrams, schematics, and program

backups.
• Ensure all labeling and identification tags are in place.

Training:

• Provide training to operators and maintenance personnel.

• Ensure they understand the system's operation, troubleshooting, and safety procedures.

28
Final System Check:

• Perform a final system check to ensure all components are working as intended.
• Address any remaining issues or adjustments.
• Handover and Maintenance:
• Hand over the system to the end-users.
• Establish a maintenance plan for regular system checks and updates.

Post-Installation Support:

• Provide ongoing technical support and troubleshooting assistance.

This methodical approach ensures a successful installation of a PLC-based power control system,
with a focus on functionality, safety, and long-term reliability.

4.7 Challenges

When considering the installation of a PLC-based power control system for Yebetaberut Food
Complex, several distinctive challenges must be addressed to ensure its successful
implementation:

• Integration into Legacy Machinery: Yebetaberut Food Complex has a variety of legacy
machinery, each with its own set of controls and interfaces. Integrating the new PLC
system with these diverse components is a unique challenge, demanding meticulous
planning and adaptation.
• Customization for Varied Processes: The company's production processes are quite
diverse, covering biscuit, macaroni, and flour production. Tailoring the PLC system to
harmonize with each of these processes while preserving their uniqueness is a specialized
task.
• Localized Skills and Training: Acquiring and training local personnel to operate and
maintain the system can be more challenging due to the specific technical skills required.
• Variable Power Supply: Dealing with fluctuating power supply conditions, which can be
prevalent in some regions, requires unique solutions to ensure the PLC system's stability.
• Language and Cultural Adaptation: Effective communication with the local workforce and
adapting to the cultural context present unique challenges in a company like Yebetaberut
Food Complex.
• Limited Supplier Options: The availability of reliable suppliers for PLC components might
be limited in certain regions. Identifying trustworthy suppliers is essential.

Addressing these unique challenges will be essential in the successful implementation of the PLC-
based power control system at Yebetaberut Food Complex. It requires a tailored approach and a
deep understanding of the company's specific needs and operating environment.

29
4.8 Result and discussion

The PLC-based power control system, once installed at Yebetaberut Food Complex, is poised to
revolutionize the company's operations and usher in a new era of advanced power management.
The forthcoming results of this innovative technology deployment promise a host of distinctive
advantages and significant transformations. Below is a comprehensive discussion of the distinctive
expected outcomes:

1. Precision Process Control: The introduction of the PLC-based power control system will
instigate a remarkable enhancement in process control throughout the company's diverse
production units. This technology empowers the precise and automated regulation of critical
parameters, such as temperature, pressure, and power consumption. This level of control will usher
in a new era of process consistency and efficiency, resulting in products of unparalleled quality.
By reducing variations in the manufacturing process, the company will achieve heightened
efficiency and maintain uncompromising product quality.

2. Real-Time Empowerment: The PLC-based system offers real-time empowerment through

comprehensive monitoring of the entire power distribution network. The company can expect to
have continuous access to vital data on power consumption, voltage levels, and other electrical
parameters. This invaluable real-time data will serve as the bedrock for informed energy
management decisions. Furthermore, the system's predictive maintenance capabilities will enable
the proactive detection and resolution of power quality issues. This real-time insight will equip the
company to address potential problems swiftly and ensure seamless production processes.

3. Safety and Reliability Beyond Compare: Safety and reliability will be the cornerstones of the
company's operations with the implementation of the PLC-based power control system.
Automation will be the ultimate safeguard against human errors in power control, significantly
reducing the risk of accidents and equipment damage. This system's ability to identify electrical
faults or irregularities promptly will be pivotal in preventing electrical fires or machinery
breakdowns. The PLC system's capacity for efficient load management will guarantee the
equitable distribution of power throughout the facility, reducing the likelihood of disruptive
overloads.

4. Minimized Downtime: The PLC-based system will be a formidable tool for minimizing
downtime, a critical component of the company's pursuit of maximum profitability and operational
efficiency. With predictive maintenance data at its disposal, the company can schedule
maintenance activities during non-production hours, mitigating unscheduled downtime. This
forward-looking approach to maintenance will ensure that production lines remain unceasingly
operational, translating into substantial financial savings.

5. Sustainable Energy Efficiency: A commitment to sustainable energy efficiency will be a

hallmark of the company's operations with the PLC-based system in place. This technology will
facilitate the optimization of energy consumption, fostering intelligent power management

30
strategies. Reduced energy wastage and the mitigation of peak loads will lead to substantial long-
term energy cost savings.

6. Agile Scalability and Future Growth: The PLC system's built-in scalability ensures that it will
evolve in step with the company's expansion. The system's adaptability will accommodate
additional machinery or production units as the company grows, positioning it for enduring success
in the ever-evolving food production industry.

In summary, the PLC-based power control system is poised to deliver an array of distinctive
benefits that will redefine the way Yebetaberut Food Complex operates. The outcomes include
precision process control, real-time empowerment, unparalleled safety and reliability, minimized
downtime, sustainable energy efficiency, and unparalleled scalability for future growth. This
innovative technology will set the company on an exceptional path towards success and distinction
in the food production industry.

4.9 Conclusion and Recommendations

Conclusion: The implementation of a PLC-based power control system at Yebetaberut Food

Complex holds the promise of transforming the company's operations by introducing precision,
real-time empowerment, safety, and efficiency. This innovative technology, which will become
the cornerstone of power management, is set to make a significant impact. It is expected to enhance
the company's operations, minimize downtime, improve safety, and promote sustainable energy
efficiency, while also ensuring scalability for future growth.

Recommendations: As this project progresses, the following recommendations should be

considered:

1. Comprehensive Training: It is essential to provide thorough training to the company's

personnel who will operate and maintain the PLC-based system. Ensuring that they are
well-versed in its use and capable of troubleshooting will be critical for the system's long-
term success.
2. Integration with Legacy Systems: The integration of the new PLC system with existing
legacy machinery is a complex task. It is recommended to work closely with experienced
integrators who can facilitate a smooth transition.
3. Continuous Monitoring and Maintenance: Establish a robust system for continuous
monitoring and maintenance of the PLC-based power control system. Regular checks,
software updates, and hardware maintenance are essential to ensure its ongoing efficiency.
4. Local Support: Given the unique challenges and contextual factors, consider establishing
local support and partnerships with suppliers who can provide prompt assistance and
resources.
5. Sustainability Efforts: Leverage the PLC system to monitor and reduce energy
consumption actively. This aligns with sustainability goals and can lead to long-term cost
savings.

31
 6. Regulatory Compliance: Ensure that the system remains in compliance with industry-
specific regulations and standards. Regular audits and assessments can help in this regard.
7. Scalability Planning: As the company grows, the PLC-based system should be able to adapt
to increased power demands. Plan for scalability as part of the long-term strategy.
8. Data Utilization: Maximize the use of data collected by the system. Harness it for
performance analysis, predictive maintenance, and strategic decision-making.

In conclusion, the introduction of the PLC-based power control system is an exciting step for
Yebetaberut Food Complex. It has the potential to enhance operations, bolster safety, minimize
downtime, and promote sustainability, all of which contribute to the company's long-term success
and competitiveness in the food production industry. By carefully addressing the unique challenges
and opportunities associated with this project, the company can maximize the benefits of this
innovative technology.

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References
✓ Petruzella, F. D. (2019). Programmable Logic Controllers. McGraw-Hill Education.
✓ Beater, S. (2017). Industrial Automation and Process Control. Prentice Hall.
✓ Bolton, W. (2016). Programmable Logic Controllers. Routledge.
✓ Chapman, S. J. (2017). Electric Machinery Fundamentals. McGraw-Hill Education.
✓ O'Donnell, J. (2019). Practical Troubleshooting of Electrical Equipment and Control
Circuits. Newnes.
✓ Dorf, R. C., & Bishop, R. H. (2016). Modern Control Systems. Pearson.
✓ Ogata, K. (2019). Modern Control Engineering. Pearson.

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