PRACTICUM ATTACHMENT REPORT FOR BATA SHOES COMPANY LTD

Presented by;

Joseph Njuguna Kamau J75/2340/2009

Institution
Kenyatta University School of Engineering and Technology Department of Mechanical and Manufacturing Engineering

Assessed by: MR. KARIUKI IKINYA

Table of Content CHAPTER 1 0 Introduction....3 1.1 Historical background of Bata Shoes Company............................3 1.1 Production Processes at Bata Shoes Company..4 1.3 Organization Structure of Bata Shoes Company...6 1.3.1 Management organization structure6 1.4 Bata Environmental and Corporate Social Responsibility.8 1.4.1 Manufacturing and the Workplace..8 1.4.2 1.4.3 1.4.4 Eco-Efficiency and Environment.8 Eco-Innovation and Development...9 Community Involvement & Social Development....9

1.5 General Outlook of Bata Shoes Company...10 CHAPTER II 2.1 Attachment Goals and Objectives12 2.2 Safety at the Factory Premises.13 2.3 Potential Risks & Accidents at Bata Shoes Company.14 CHAPTER III 3.1 Assignments at the Company...19 3.1.1 Workshop Practices..19 3.1.2 Installation, Maintenance and Repairing of Motors.20 3.1.3 Making Safe Working Procedures of Various Machines.22 3.1.4 Making and Documentation of LOTO Procedures...23 3.1.5 Maintenance and Repairing of Machines.24 3.1.7 Maintenance and Repairing Steam Boilers...26 3.1.8 Maintenance of Water Pumps and Aerating Pumps.28 CHAPTER IV 4.0 Conclusion and Recommendation...31 4.1 Recommendations....31 4.2 Conclusion...31

CHAPTER 1

0 Introduction This industrial attachment report gives an outline of the skills and experiences gained while I was at Bata shoes Company, Limuru from 5th July 2012 to 5th September 2012. The main object of this paper is to examine the nature of the production operations of Bata Shoes Company including designing of shoes, their production, and maintenance of machines including other activities. The report gives a general overview and background information of Bata Shoes Company, specific activities I was involved in while on attachment, the skills and knowledge acquired during the attachment period. I have also included the activities I undertook in benefit to the company. The report also includes a summary of all the report and some recommendations of the changes that should be made in various sections in order to maximize the output and at the same time catering for the workers and the customers.

1.1 Historical background of Bata Shoes Company The Bata shoes company originated from what is now Czechoslovakia. In its early stage of development, the company received a substantial boost in the form large contracts for military boots and shoes, which were placed by the imperial Government. After the 1st world war, the company expanded overseas from its national base and set up production units in many parts of the world. By 1930, it had established itself as a major international shoes firm with distribution and production units located in several different continents. In 1935, the Bata Shoes Company opened a distribution branch in Mombasa, on the Kenyan Coast. This was a strategic position to capture the expanding market for shoes in east

and central Africa. In 1939, the Mombasa branch began to manufacture low cost rubber shoes for the African market, which were then marketed along with other Bata products imported from Czechoslovakia, in the east African region. Today, Bata is a multinational company with more than one hundred companies in the world. In 1939, the headquarters of the Bata Shoes Company had to be moved from Czechoslavakia to Canada. The Kenyan subsidiary was also moved upcountry from Mombasa during the second world war. This was from the order of the colonial government, which was concerned about the threat of invasion along the east African coast. A site was offered by the government 20 miles north of Nairobi, where there was an ample supply of running water for the setting up of a tannery. It was located in what is now known as Limuru. There was a branch of a railway line which run through the factory to ease transportation of shoes. The construction of the factory, tannery and leather factory, commenced out between 1940 and 1950. In the mid, 1950s, a rubber factory and a bicycle tyre plant were added to the existing complex. There was a rapid expansion of the production capacity of the Bata plant in Kenya and by 1975; the company was manufacturing over 8 million pairs of shoes per year.

Batas Mission Statement To provide world-class products to our valued Customers, Maintaining high Ethical Standard business.

1.1 Production Processes at Bata Shoes Company The structure of Bata Shoes Company was clearly determined from the onset of the overall pattern of operations of the Bata organization throughout the world. As with many other

large multinational corporations, Batas operations are highly interpreted and carefully controlled from start to finish of the production process. To give an idea of the world-wide integration of this processes, the company owns estates in West Africa on which rubber is grown to supply Bata Shoes Factories in other parts of the world. Virtually, all the leather used by the Bata Shoes Factory comes from their tannery. All the Bata Shoes company products are distributed through Batas own sales networks spread all over the country. The form of production adopted by the Bata shoes company reflects the technical sophistication common to major industries operating in a world-wide scale. Thus, although the technology employed in the Kenyan Subsidiary is not much advanced in comparison to Batas European and north American branches, the form of production utilized is of a capital intensive nature. The company uses sophisticated production techniques to manufacture synthetic shoes. This method requires the use of machinery such as injection moulding machines.

1.3 Organization Structure of Bata Shoes Company 1.3.1 Management organization structure Below is an illustration of the organization structure of the Bata shoes Company.

Board of Directors

Managing Director Chief Finance Officer Secretary Production manager Chief Plant Engineer Assurance Manager Tannery Manager Sandak

Internal Audit

HRM

Public Relation Manager

Manager Thongs

Chief Chemist

Manager DIP

Manager Palletizin g

Chief Manager, Procurement Chain Store managers

Marketing Manager

Manager, Information Technology Chain Store managers

Chief Mechanical Eng.

Chief Electrical Eng.

Advertising Manager

The managing director is the overall head of the company. He receives orders from the headquarters of Bata Companies in Canada.

The Human Resource manager is the overall head of all employees of the company Chief Finance Officer deals with planning of how funds will be used, funding of the various activities running in the company for example the paying of workers salaries, financing the buying of items and accounting of the financial records.

Chief plant engineer is the overall manger heading the engineering department. The production manager manages all production processes. Procurement department headed by the procurement officer is involved in the purchasing and distributing items used by various departments and making records for those items.

1.4 Bata Environmental and Corporate Social Responsibility Driving a dynamic enterprise that serves its customers and its community has been at the heart of Batas culture and vision since 1894. The common goal of the company is to continue improving the lives of all their customers, employees, suppliers and communities in the developed as well as in the developing world, while simultaneously protecting the environment for the current generation and the generations to come. Bata has a sustainability program, which is an ongoing consultative process throughout its global operations and includes activities in four key areas: 1.4.1 Manufacturing and the Workplace Bata is committed to the development of operational excellence that leads to the production of footwear in a safe, clean and stimulating workplace for all its employees. The company has a tradition of responsibility towards its workforce and offers working conditions that protect each employee's health and dignity. Some examples of current Bata good practice includes:

Bata Code of Ethics and Values and Beliefs that guides the employees in day to day work, thus helping the company conduct business in accordance to this philosophy of service and corporate responsibility;

Bata employs more than 2,000 people from all over Kenya manufacturing quality shoes for the local peoples taste and needs;

At Bata, learning is a priority: The company has an E-learning induction program that trains all new employees in Bata culture and skills;

Bata organize routinely environment, health & safety days to raise awareness among the workers. 8

1.4.2 Eco-Efficiency and Environment The Bata shoes company has always played a leadership role in the communities in which it operates, to ensure protection of the environment. Bata aims to reduce the climate impact of its manufacturing facilities by taking every precaution to prevent or lessen any adverse effect on the environment that may result from its operations. Some examples of current BATA good practice:

The BATAs Environmental Mission Statement supports its pledge to uncompromising environmental stewardship and supports the principle of the three Rs: Reduce, Reuse, Recycle;

BATA has introduced translucent sheeting on roofs, LED lamps, photocell control in the manufacturing facilities that help reduce energy consumption. The translucent sheeting reduced the carbon footprint by approximately 490 tons of CO2. This saving would be the equivalent to the carbon sequestration from the atmosphere of about 80,000 mature pine trees over the period of one year;

BATA is committed to minimize the use of water in its operations with water harvesting systems, and to conserve fresh water resources in its tannery with wastewater treatment plants;

BATA has introduced water-based adhesive in its shoe production; BATA has a long tradition of planting trees in and around its production sites. 1.4.3 Eco-Innovation and Development Bata strives to identify and utilize processes, materials and products that cause the least

harm to the environment and to the people. In doing so, BATA supports the development of materials and manufacturing innovation. For instance, environmentally conscious materials like 9

recyclable and partly recycled TPE, chromium-free leather, water-based adhesive and natural materials like cork are being utilized in shoes manufacturing. 1.4.4 Community Involvement & Social Development

BATA supports and empowers local communities wherever it operates by being involved with the communities through employees participation, charitable contributions and by spearheading social ventures. The company has a program called Bata childrens Program which conducts initiatives with the help of Bata volunteers. 1.5 General Outlook of Bata Shoes Company The Bata shoes company produces various types of footwear ranging from sandak, leather and canvas footwear. The plant is divided into subsections, which produce specific type of shoes. They include: Palletizing factory This is where the PVC resin used in the manufacrure of Sandak and Soles is converted to PVC granules. Various chemicals are weighed depending on the intended colour and hardness of the product. Tannery factory This is where raw hides and skins are converted to leather ready for shoe making. The factory is incorporated with various machinery used in process of fleshing, tanning, splitting, buffing, spraying, embossing and other finishing operations. Leather factory This is where leather shoes are made. Finished leather from the tannery factory is cut into various patterns, stitched and embedded to the sole after some other intermediary processes. 10

 Sandak Factory This is where PVC footwear is made mainly gumboots. The factory is incorporated with automated injection machines, which are fed with pre-warmed PVC granules from the palletizing factory. D.I.P Factory This is where canvas shoes such as ngoma and bullets are made. The factory is incorporated with machines for hardening and cutting the canvas material and also injections machines for injecting soles into the uppers. Thongs Factory This is where EVA sheets used in making slippers are made.

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CHAPTER II 2.1 Attachment Goals and Objectives The attachment program was meant to help me experience and appreciate what it is really like working in an engineering department of a manufacturing company. The attachment would also help me apply the theory and skills that I have learnt at school for my professional development as an engineer to be. Before starting my attachment at the Bata shoes company, I did set my own goals and objectives, which acted like a benchmark in which I assessed my achievements and my personal development. The goals and objectives were as follows:

academic learning- applying the knowledge learned in the classroom to the work environment;

career development-developing knowledge in engineering field in order to pursuemy particular interest in engineering;

skill development-gaining an understanding of the technical skills and knowledge required in the workplace;

Personal development- gaining decision-making and critical thinking skills as well as increased confidence and self-esteem in my profession as an engineer.

Develop an attitude conducive to effective interpersonal relationships.

In order to achieve the above goals and objectives, I did reflect on my own abilities which gave me a direction in search for a productive and worthwhile attachment program. I did a SWOT analysis on myself. First, I analyzed my technical skills (what I was capable of doing), my professional skills (what I knew) and my personal skills (how well I can get things done). I did set measurable objectives which could help me achieve my goals.

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Be cooperative with the fellow engineers in order to learn. Ask questions in case of anything unclear. Always follow instructions from my supervisor. Always avail myself at any time of need. 2.2 Safety at the Factory Premises

At Bata shoes Factory, most of the employees spend about a third of the day at work premises. Therefore, the working environment can have a major impact on their heath. The company, therefore, finds it necessary to put up regulations to the interest of its employees safety and health. Under these regulations, everyone has a role to play in creating a safe and healthy workplace; Bata management contributes to safety and health in the workplace by:

providing and maintaining plant and work systems that do not endanger safety or health;

making arrangement for ensuring safety and health in connection with the use, handling, storage or transport of plant or substances;

providing all necessary information, instruction, training, and supervision for ensuring safety and health;

providing and maintaining safe access to and egress from the workplaces; and providing and maintaining a safe and healthy work environment

The supervisors and managers take responsibility for ensuring that;

the premises;

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the means of access to and egress from the premises; and any plant or substance kept at the premises are safe and without risks to health to any person working on the premises, even if they do not directly employ that person on the premises.

Employees also contribute to safety and health in the workplaces by :

taking care for the safety and health of persons at the workplace; and using any equipment or following any system or work practices provided by their employers.

In addition to the above mention responsibilities, everyone in the factory premises has the following safety responsibilities; Undertaking tasks and duties carefully considering personal safety and that of others. Complying with all safe operating procedures and practices provided by the company. Reporting to team leaders on any potential workplace hazards or any mishaps, incidents or injuries that may occur during the course of work. Working hand in hand with the safety appointed representatives and committees to help create and maintain a safe working environment. 2.3 Potential Risks & Accidents at Bata Shoes Company An accident is an unexpected or unintentional event in which injury or damage occurs. They can be avoided if safe working practices and procedures are observed. In Bata Shoes Company, machine injuries are not common but they do occur occasionally. The company has some strict regulations in order to avoid such mishaps. For instance, in case of a machine breakdown, the engineer working on the machine should isolate the machine using the LOTO standards. LOTO (lock out/Tag out) procedure is a safety procedure, which is used in industry and research settings to ensure that dangerous machines are properly shut off and not started up

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again prior to the completion of maintenance or servicing work. It requires that hazardous power sources be "isolated and rendered inoperative" before any repair procedure is started. "Lock and tag" works in conjunction with a lock usually locking the device or the power source with the hasp, and placing it in such a position that no hazardous power sources can be turned on. The procedure requires that a tag be affixed to the locked device indicating that it should not be turned on. 2.3.1 Cuts/ Amputation Many machines in the factory have blades and knives which could cause severe injury to an individual. To avoid such cases employees are advised to avoid cleaning machinery while in motion or is powered. The machinery should always be operated by trained and qualified personnel. When working on a stopped machine, make sure that the power is cut off in such a way that it cannot start itself or be started accidentally. Before starting up, see that everything is as it should be and that no one, for instance ones mate on the machine, is in a position to get hurt. Take care not to distract the attention of anyone working on a machine. Never work or operate a machine without its guard on.
Machine Name Model No. Manufacturer Specifications a. Dimension b. Net weight c. Voltage d. Power e. Capacity f. Air pressure : Two Hot And Cold Counter Moulding Machine

: YL-ALFA684 CF2HP : YILI TECHNOLOGY : : : : : : 850(L) x 1,560(W) x 2,000(H) mm 571 kgs 220 v 2.7 kw 1,100 prs/8 hrs 6 bar

Fig. Counter moulding machine

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2.3.2 Burns Burns may occur due to contact to hot surfaces. Some of the workers are exposed to hot work where flames, heat or sparks may be generated. To avoid such accidents a hot work permit must be issued for all tasks involving gas welding, cutting or other concentrated heat sources near such places as: paint, solvent and fuel stores, L.P. Gas storage, flammable liquids, vessels containing flammable or combustible liquid or materials. Welding jobs are to be screened off to protect other peoples eyes from flash. One should not look directly at a welders arc.

Fig. Drying and reactivation machine 2.3.3 Slip/ fall/ Trip To avoid the occurrence of this accident every individual is expected to watch his/her steps while in the factory premises. Looking to ones footing, watching for traffic, crane loads and men working overhead. Spilled liquids such as oil can cause falls. Spillages should be wiped and fallen objects picked up regardless of who dropped them. One should use the walkways and gangways provided. Ensuring roadways or rail tracks are clear before crossing is important. Employees are advised to keep off dangerous zones such as near the high pressure vessels. Other sources of industries injuries include; 2.3.4 Confined Spaces Safe work procedures are to be followed when entering confined spaces such as generator stators, fluid bed coolers, dust chambers, as serious injury may result. Team leaders are to be

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informed before one enters confined spaces and specific procedures are to be followed in addition to using the necessary safety gear. 2.3.5 Moving Process Equipment One should not work on moving equipment such as conveyors, elevators, pumps, wheels and drums. They are to be adequately guarded at all times and isolated before any work is done on them. 2.3.6 Falls Pile material so that it is stable and steady at all times. Put tools and other equipment where they cannot possibly fall or be knocked onto someone below. Use a suitable ladder whenever climbing about. Examine ladders and planks every time and mark defective materials. Do not stand under suspended loads.

2.3.7 Clothing Loose parts of clothing, ties, and open coats, flapping cuffs, bows and scarves are always dangerous near machinery. Smooth shafts, despite their innocent appearance, are as dangerous as in-running gear wheels. loose clothing should be avoided because the material wont tear if it caught by the moving part of a machine, but will take one with it into the machine or round the shaft. Wear good safety boots or shoes at work and keep them in good repair. It pays in the long run because one will get less tired, as well a less liable to foot injuries and falls. One should never walk into the plant without a helmet. Protective clothing provided for specific areas should be worn when in those areas.

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2.3.8 Hand tools Hand tools should be kept in order. Spanners with splayed jaws, chisels with burred or mushroomed heads, files, screwdrivers and saw on without handles, any tools with handles that are warped, crackxed split and splintery, these lead to injuries. So does the misuse of tools because it damages them. When carrying tools or goods, carry them so as to be safe to ones self and others. Cutting tools should be carried with the edges protected. 2.3.9 Fires Fire fighting equipment is for use in sudden emergencies. They should be kept clear of any obstructions for quick access. The same applies to fire doors and exits.

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CHAPTER III 3.1 Assignments at the Company During the three months period at the Bata shoes company I involved myself in both mechanical and electrical engineering practices. The major assignments include the following; Workshop practices; mould making, fabrication, lathe machine, surface grinder, hydraulic press, etc. Installation, Maintenance and repairing of motors Installation, Maintenance and repairing of generators Making safe working procedures of various machines Maintenance and Repairing steam boilers Maintenance of water pumps and aerating pumps Making safety precaution for various machines Maintenance and repairing of injection machines Making and documentation of LOTO procedures 3.1.1 Workshop Practices The Bata Shoes Company engineering department has a wide range of tools. I was exposed to various tools used in engineering field including the lathe machines, the surface grinders, the hydraulic press etc. During my one week stay at the engineering workshop I did various activities using this machines. For instance, the blades of granulating machine used in recycling injected PVC materials is sharpened regularly using the surface grinders. Also, I helped in making both internal and external threads of bolts and nuts using the lathe machine. Other activities I undertook at the workshop include welding and fabrication where the worn out molds were repaired through filling out the worn out parts.

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3.1.2 Installation, Maintenance and Repairing of Motors Standard enclosed motors are used where they are exposed to dirt, moisture, and most outdoor conditions while severe-duty enclosed motors are used in highly corrosive or excessively moist areas. Motors should be mounted securely on a firm, flat base. If necessary, grout in larger motors. The standard transition and/or sliding bases are suitable for floor mounting. The axial position of the motor frame with respect to the load is important. The bearings furnished with these motors are not designed to take any external axial thrust load unless otherwise specified. The applications of pulleys, belt drives, sheaves, sprockets and gears on motor shafts are common. Align the sheaves carefully to avoid axial thrust on the bearings. Belt tension should just prevent slippage when the motor is running at full load. Excessive belt tension causes unnecessary load on the bearings. This may be especially true on high-inertia loads where belts may be tightened to prevent squealing and slipping during acceleration. On drives of this type, the belts should be allowed to slip during acceleration to prevent the possibility of overloading the motor bearings. Usually the belt speeds should not exceed 6,000 feet per minute unless otherwise specified.The power supply must agree with the nameplate voltage and frequency. The motors will operate (but with characteristics somewhat different from nameplate values) on line voltages within 10% of nameplate value and frequency within 5%, and a combined variation not to exceed 10%. Inspection of motors should be done at regular intervals, depending on service. Keep the motor cleaned and the ventilation openings clear. In addition to the daily observation of the overall condition, it is recommended that a general inspection routine be set up to periodically check the following items: General Cleanliness

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Insulation and Windings Lubrication and Bearings

The interior and exterior of the machine should be kept free from dirt, oil, grease and conducting dust. Oily vapor, paper, or textile dusts may build up and block off ventilation. Any of these contaminants can lead to early motor failure. To obtain long life and satisfactory operation of insulated windings, they should be kept clean from dirt, oil, metal particles, and other contaminants. A variety of satisfactory and acceptable methods are available for keeping equipment clean. The choice of method will depend greatly on time, availability of equipment, and on the insulation system. However, vacuum and/or compressed air cleaning with nonmetallic hose tips should precede cleaning with water and detergent or solvents. Tight adhering dirt will require agitation by gentle brushing or wiping. Compressed air should be used to remove loose dirt and dust from air passages such as air ducts. Suction should be used to remove dirt and dust particles from windings to avoid driving particles into the windings and damaging the coils. The grease used as a lubricant in grease lubricated anti-friction ball bearings loses its lubricating ability over a period of time. For a given bearing construction and assembly, the lubricating ability of a grease with age depends primarily on the type of grease, the size of the bearing, the speed at which the bearing operates, and the severity of operating conditions. As a result, it is not possible to accurately predetermine when new grease must be added. But, good results can be obtained if the general recommendations as stated in the instruction book are followed. The primary function of grease is to supply the essential lubricating oil from the sponge-like reservoir of its soap structure. Grease-lubricated anti-friction ball bearings consume only a small amount of lubricant. This lubricant must always be present to avoid rapid wear and bearing failure. However, excessive or too frequent lubrication may damage the motor. Ball bearing motors are

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adequately lubricated at the factory. Motors with grease fittings should be relubricated in accordance with these instructions to provide maximum bearing life. Machine Name
Model No. Manufacturer Specifications a. No. of cooling rollers : : :

Water Cooling Auto

MC-969 MC-967 MC-965

TEN SHEEG - TAIW

b. Cooling roller width c. Cutter width PICTURE d. Power e. Slicing thickness

f.

Machine size

Fig. EVA blank making machine g. Machine weight 3.1.3 Making Safe Working Procedures of Various Machines
h. Applicable material i. Output

9 units : 7 units 5 units : 965.2 & 1270 mm : 850 & 1150 mm 13.42 kw : 8.95 kw 6.34 kw : 1~10 mm 5,200(L) X 2,000(W) : 4,400(L) X 2,000(W) 3,650(L) X 2,000(W) 5,500 kgs : 4,500 kgs 3,500 kgs : EVA, PVC, Rubber : Depends on speed of

While at the Bata Shoes Company, I engaged in developing Save Work Procedures (SWP) of all the machines in the company. Safety at work is one of the most crucial aspects of any job. While there are various ways to ensure personal safety, one of the most important safety issues at work is machine safety. Machine safety is promoted through a set of general guidelines to protect workers from personal injury by a wide variety of machines. The management of Bata Shoes Company recognizes that written safe work procedures [SWP] or supplementary instructions are extremely important to ensure a safe work environment and form an essential part of the overall Occupational Health and Safety Program. These guidelines provide information necessary to assist all workers and supervisory staff in performing their various tasks safely. They also assist in the training and orientation of new employees/students in job hazards, as well as providing them with the rules and procedures necessary to ensure that they can perform their work in a safe and hazard free manner. All faculty, staff and students are expected to familiarize themselves with these requirements. Everyone is expected to follow these general rules when engaged in any machine operation.

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People engaged in any activity involving a machine should familiarize themselves with the specific SWP for the task they are involved in. 3.1.4 Making and Documentation of LOTO Procedures I was also involved in making Lockout and Tag Out procedures of various machines at the company. Lockout and Tag Out is a common and simple procedure in machine safety, but a very important one. Lockout and Tag Out occurs during the machine repair process, from the moment the machine either breaks or is designated for repair until the moment the machine is deemed "working." The process involves disconnecting the machine from its power source and using a Lockout device to prevent it from being reconnected, then applying tags to the machine explaining its required repairs. This procedure prevents accidental activation of the machine while it is being repaired. The following procedure is a general example of the how Lockout and Tag Out is done for all machinery or equipments where maintenance is required to be performed. 1) Shut off the machinery or equipment. 2) Shut off the power source(s) at the control devices(s) 3) Apply personal lock(s) to lock-out loop or alternate locking device 4) Where more than one person will be applying locks, use a multiple lock attachment. 5) Test control buttons to be sure that the power sources has been disconnected. This is achieved by pressing the start button to ensure the machine does not start. And then pressing the stop button twice. 6) Perform repairs and /or maintenance. 7) Upon completion, clear away all tools and personnel. 8) Replace all guards and protective devices.

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9) All employees working on a machine are to remove their lock(s) as soon as they have completed their maintenance. 10) Ensure that everyone is clear of the machine. 11) Person who originally shut off the power then removes his lock last and turns the power back on and tests the equipment or machine.
Machine Name Model No. Manufacturer PICTURE : : DTEA-32 : DAHTYAN

1100 Ton Hydraulic Press With 1 Unit Hydraulic Pow

Fig. sheets)

Specifications a. T otal pressure : b. Ram diameter : c. Daylight dimension : d. Distance of heating plate : e. Size of heating plate : f. Stroke : g. T ype of heating : h. Speed of closing : i. Speed of opening : j. Max. working pressure : Hydraulic Press (Steam circulates k. Power : l. Operation :

1.495 kg/cm 812.8 mm 1,350 x 1,500 mm 150 mm 1,350 x 1,500 mm 900MM Steam / Oil / Electric 900ST /38-24sec 900ST /1.5-2sec 175 kgs/cm to make EVA 25 + 15 hp Full automatic bumping syste

3.1.5 Maintenance and Repairing of Machines Injection machines are used in making gumboots and injecting soles into the uppers. As shown in the diagram above, the PVC material to be injected is fed into the hopper by an autoloader. Before the material is fed into the machine, it is first pre-warmed to reduce its heating time in the barrel. The machine has a rotating screw surrounded by several heating elements. The screw pushes the molten material through a nozzle into the mold. The injection machine requires regular maintenance in order to ensure they are in a good condition. The following maintenance practices are commonly performed in the injection machine. Hydraulic cylinder repair 24

Linkage repair Realignment for parallelism Mold alignment for uneven platens Extrusion screws repair and replacement Extrusion barrels repair and replacement Bent Tie Bars repair and replacement Toggle and toggle pin repair and replacement Adjustment of the quantity injected Platen adjusting screw repair and replacement In order to ensure proper molding and achieve the quality required, and to meet the

requirements of molding, injection must be done with enough pressure. At the same time, due to the high injection pressure, the molds must be sufficiently clamped. Thus, clamping device is a key component of the injection molding machine. The molds are pressed/clamped by a hydraulic press during injection and releases the mold when the injection is complete. The injection machines can be operated manually or switched to automatic operation.

The temperature of the screw and barrel is controlled by heating elements aligned along its length. There are three heating elements whose temperatures are set depending on the injection material being used. Different materials have different densities, and thus require to be heated to different temperatures.

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170-1750C

1750C - 1800C

1800C - 1850C

1700C - 1750C

Zone 1

Zone 2

Zone 3

Zone 4

Every injection machine has a control panel where the temperatures at the four sections are set. In addition, other settings such as the injection quantity and the speed of rotation of the machine are also done.

Machine Nam

Model No. Manufacture

Fig. Mixing Neader and PVC Injection Machine

Specificatio a. Mould dime b. Mould stati c. Mould clam d. Injection ca e. Heater f. Electric mo g. Power cons h. Machine siz i. Machine we

3.1.6 Making Safety Precaution for Various Machines

All tools are dangerous if used improperly or carelessly. Working safely is the first thing the user or operator should learn because the safe way is the correct way. A person learning to operate machine tools must first learn the safety regulations and precautions for each tool or machine. Most accidents are caused by not following prescribed procedures. In order to avoid accidents in Bata Shoes Company, we developed safety precautions of machines in the company. Some of the general safety practices include:

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Fig. Calendering Mill

3.1.6.1 Eye Protection

Using eye protection in the machine shop is the most important safety rule of all. Metal chips and shavings can fly at great speeds and distances and cause serious eye injury. Safety glasses must be worn when working with hand cutting tools, since most hand cutting tools are made of hardened steel and can break or shatter when used improperly.

3.1.6.2 Hazardous Noise Protection

Noise hazards are very common in the workshop. High intensity noise can cause permanent loss of hearing. Although noise hazards cannot always be eliminated, hearing loss is avoidable with ear muffs, ear plugs, or both.

3.1.6.3 Foot Protection

The floor, especially in workshop, is often covered with razor-sharp metal chips, and heavy stock may be dropped on the feet. Therefore, safety shoes or a solid leather shoe must be worn at all times. The shoes have a steel plate located over the toe and are designed to resist impact.

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3.1.6.4 Grinding Dust and Hazardous Fumes

Grinding dust from abrasive wheels is made up of extremely fine particles of the metal and the wheel. Some grinding machines are equipped with a vacuum dust collector. When operating a grinder without a vacuum, the operator is required to wear an approved respirator to avoid inhaling the dust. Metals such as zinc give off toxic fumes when heated above their boiling point. Inhaling these fumes may cause temporary sickness, or death. The fumes produced from lead and mercury are very harmful, as their effect is cumulative in the body and can cause irreversible damage.

3.1.7 Maintenance and Repairing Steam Boilers

A boiler is a closed vessel in which water under pressure is transformed into steam by the application of heat. In the boiler furnace, the chemical energy in the fuel is converted into heat, and it is the function of the boiler to transfer this heat to the contained water in the most efficient manner. The boiler is designed to generate high quality steam for plant use. A boiler must be designed to absorb the maximum amount of heat released from the heaters. This heat is transferred to the boiler water through radiation, conduction and convection. The relative percentage of each is dependent upon the type of boiler and the designed heat transfer surface. In Bata Shoes Company there are three boilers used to generate steam. The steam is used in the factory for heating soles and EVA sheets used to make slippers. The figure below shows a flow diagram for a typical boiler plant. The temperature of the boiler is checked and regulated depending on the required levels.

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Some of the potential problems in the boilers that needed regular check up included: Boiler deposits resulting from hardness salts, metallic oxides, silica etc. Boiler waterside corrosion due to dissolved oxygen, acid or caustic in the water and a high temperature Embrittlement of boiler metal Steam leakages

3.1.8 Maintenance of Water Pumps and Aerating Pumps The Bata shoes company has a wastewater treatment plant where the water from the tannery is treated before being discharged to the municipal council. The wastewater passes through several stages before it can be discharged. The wastewater contains some toxic chemicals such as chrome which when released to the environment can cause harm. Various chemicals are added into the wastewater as the water passes through the treatment stages. In order to ensure full chemical action and deposition of products after the reaction, every process has water pumps and aerating pumps which adds oxygen into the water. The aeration systems are 29

designed to circulate large volumes of water, moving oxygen-rich water from the top to the bottom, increasing the dissolved oxygen levels at the bottom. Pure Power also provides a fine bubble membrane diffuser to dramatically improve aeration efficiency. The diffuser provides finer bubbles covering more surface area with the water than larger bubbles and improves water circulation. Usually, the water pumps and aerators could block and thus needed regular maintenance.

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CHAPTER IV 4.0 Conclusion and Recommendation 4.1 Recommendations The following recommendations can be adopted by the company to maximize and improve its efficiency while ensuring customer satisfaction. Creating Energy Conservation Awareness. The company should create awareness to the employees on the importance of conserving energy. The company spends millions of money on energy every month. By conserving energy, the company would realize a rise in its net profit. Energy conservation can be done by using many conservation in an aim to reduce energy consumption. For example, the management should encourages employees to turn off or shut down idle processing equipment, lights, fans, air compressors, and other types of energyconsuming equipment when they are not in use. Using Energy-Efficient Equipment. The company should adopt the use of efficient equipments in order to conserve energy. For instance, the use of energy-efficient fluorescent lighting that consumes only about half the power used by standard, high-intensity discharge lighting should always be used. In addition, the molding equipment should be well insulated to reduce heat loss. Steam leakages on pipes should be avoided at all costs to reduce heat losses. Safety. Accident management is so critical in the growth of any company in todays world. Therefore, Bata Shoes Company should ensure its environs are free from injuries. This can be done by performing a all-inclusive training to newly employed employees regarding their personal safety and those of others. The company should have workshops regularly where the machine operators are reminded and practical demonstrations done about safety in the industry.

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Maintenance. To avoid wastage of time and resources due to constant breakdown of machines, I would recommend that instead of having an overhaul annually, the company should adopt a system where preventive maintenance is done on every machine. A timetable should be made where every week overhaul of a particular machine is done. This would be a very effective method to reduce wastage of time and also the worn out parts are noted and bought in advance prior to the machine breakdown. This would be particularly important to those spare parts that need importation. 4.2 Conclusion One of the few ways to get engineering experience outside the class is to experience an engineering attachment. Attachments give you on-the-job experience; help an individual learn whether he/she and that industry is a good match. Being at a manufacturing company was one of the most rewarding and enlightening opportunities I have ever experienced in engineering. There were many functions in the Bata Shoes Company that needed oversight, which I acted as a valuable asset. In collaboration with the company employees, I understood the work ethics necessary for an engineer. Bata Shoes Company gave me a variety of skills and experiences that would enable me pursue the avenues that would fit me best. The attachment program build a strong skill set that extends beyond the classroom into an industrial engineering job. In addition, the team orientated working style at the company and one-on-one relationships with the companys engineers, allowed me to learn and grasp many engineering processes and maintenance of machines. I also learned the importance of networking and building strong relationships with colleagues in the field. I was able to be a part of the creation of safety working instructions of machines, which broadened my mind on the importance of safety in an industry.

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The attachment taught me the importance of communication in any engineering environment and how asking questions can help you succeed. I had the opportunity to apply multiple skills that I had learned in the classroom. In addition, being a busy company, Bata shoes company taught me the importance of safety especially when working around locomotives each day. I also learned the importance of diversity as an engineer. For instance, I learnt basic entrepreneurial skills such as looking at ways to minimize costs for the company while optimizing the supply chain.

Overall, I believe the learning that took place in and out of the classroom has prepared me for my future life as a Mechanical Engineer. My supervisor and engineers at the company in the engineering department did mentor me throughout my attachment program and I will always be grateful to the lessons I have learned from the Industrial Engineering department at Bata Shoes Company. I believe the industrial attachment at Bata Shoes Company has given me countless opportunities to thrive as both a student and as a professional.

In conclusion, the attachment was very successful and I was able to achieve my goals and objectives. Throughout the attachment, I learnt from my fellow engineers who did not hesitate to contribute their intellectual creativity and physical force to perform their duties.

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