ADIGRAT UNIVERSITY

College

COLLEGE OFENGINEERING AND TECHNOLOGY

DEPARTMENT OFELECTRICAL AND COMPUTER
ENGINEERING
STREAM OF INDUSTRIAL CONTROL
INTERNSHIP REPORT
ADDIS PHARMACEUTICAL FACTORY PLC

PREPARED BY : YONAS ALEMAYEHU

ID NO. : RET 1668/06
ADVISOR :FIKADU G.

DURATION OF INTERNSHIP OCT 20 – JAN 20/2010E.C

DATE OF SUBMISSION JAN 28/ 2010E.C

Declaration
I declare that the presented report of internship is prepared by me after the completion of four
months.The report was conducted in the department of electrical & computer engineering,
Adigrat university,Under the guidance of lecturer Fikadu G. The report contains necessary
information what I have gained from my internship program.I here by state and verify by my
signature that the report is prepared by me.

Date:

Name student: Yonas Alemayehu

Signature___

Mentor:Mr.Fikadu G.

Signature___

Supervisor: Mr.Amanuel_________

Signature___
Acknowledgement
Firstly glory to God who help me in all aspects in my internship program. For his protection and
givingpower in order to accomplish my tasks effectively. Next I would like to thank my
advisorFikadu who helps me by showing the procedures how to write the report and supporting
me.

I am also thankful for Adigrat university department of electrical and computer engineering for
letting me to joinAddis pharmaceutical factory(APF) to understand the practical world and gain
all the practical knowledge’s the university have been teaching me four years.

I want to express heartfelt thanks to Addis pharmaceutical factory for accepting me and
allowing me to learn practical world what I have learned in theory. Finally I want to say especial
thanks to electrical engineering department members of the company specially,Amanuel,
Birhane, Haftom, T/mariam and other operators.
Executive Summary
This report outlines that the activities that I was studied in Addis Pharmaceutical FactoryPLC.
Internship was very important to fulfill therequirements for the degree of Bachelor of Electrical
and Computer Engineering.The report is conducted by observation, oral discussion, and refering
other materials.My internship started on 20 October 2010 and lasted on 20 January, 2010 E.C.
List of Tables
Table 1 computer service for the company ................................................................................... 14

Table 2 input and output devices ...................................................Error! Bookmark not defined.

Table 3 Truth table Error! Bookmark not defined.

Figure 2Work task executing flow chart ........................................Error! Bookmark not defined.
Table of Contents

Declaration........................................................................................Error! Bookmark not defined.

Acknowledgment ..............................................................................Error! Bookmark not defined.

Executive Summary ..........................................................................Error! Bookmark not defined.

Abbreviation .................................................................................................................................. 4

List of Tables ................................................................................................................................. 5

List of Figures ...................................................................................Error! Bookmark not defined.

Table of Contents .......................................................................................................................... 7

Chapter One .....................................................................................Error! Bookmark not defined.

Background of the company APF ............................................................................................. 13

1.1. Its brief history .................................................................................................................................. 13

1.2. Mission of the APF .......................................................................................................................... 13

1.3 Vission of APF ......................................................................................................................................... 13

1.4. Objectives of APF ............................................................................................................................ 14

1.5. Computer and software services .....................................Error! Bookmark not defined.

1.6. APF production and the end users of the product .............................................................. 14

1.7. Its main customers and end users .............................................................................................. 15

1.8. Its overall organization and work flow.................................................................................... 17

Overall internship experience .................................................................................................... 20

2.1. How I got into the Company........................................................................................................ 20

2.2. Section of the Company I were work in .................................................................................. 20

2.3. Work follow section ..............................................................Error! Bookmark not defined.

2.4. Work task I have been executin ................................................................................................. 26

 2.5. Procedure and methods used....................................................................................................... 26

2.6. Challenges I have been facing ..................................................................................................... 27

2.7. Measurements I take ....................................................................................................................... 27

Chapter Three--------------------------------------------------------------------------------------------11
 Chapter One
Background of the company APF

1.1. Its brief history

Addis pharmaceutical factory PLC (APF) is the largest pharmaceutical manufacturing company.
It is established in June 1992.The company is located in northern part Ethiopia ,in the town of
Adigrat,Tigray region 898Km distance far away from Addis Abeba. The manufacturing plant
and the head office are sited in Adigrat Tigray regional state of Ethiopia and commercial office is
situated at Addis Ababa.

At the company there are around 1250 workers. The company has a laboratory equipped for
chemical analysis, microbiological testing and which serves to control the quality of raw
materials, intermediates and finished products.

The company has around ten departments such as production department, maintenance and
engineering department, warehouse and material planning department, quality control
department, purchasing and supply department, quality assurance department, research and
development department, human resource managing department, finance and budgeting
department, and marketing and selling department.

1.2 Mission of the APF

The mission of the company is :

 To satisfy our customer’s needs by providing quality and effective drug at

affordable price.
 To distribute product to the nation and national at the time.
 To produce safe, effective and quality products.
 To competitive products supply medicine drugs for our nation and
national.

1.3. Vision of APF

The vision of the company is:

 To be country’s most valued company to patients,customers,employees and investors.

  Leader inquality sales, price and stake holders satisfaction in five years.
 To be an exemplary corporate citizen able to continuously and successful compete in the
global market and involved in sustainable and progressive development

1.4 Objectives of APF

To reach 90% capacity utilization based on the existing 30% on the single shift worth in the
coming three years.

1. Understanding and write each and every process of organization routine works (based on the
value chain).

2. Strengtheners and expands knowledge relevant to academic background.

 Types of learn working methods.

 Participation in major works of the company.
 Work on one project of the company.

3. Acquires hands on training in practical in one or several of specific

4. Other experience should be learn.

1.5 Core Values Of The Comoany

 Innovative and resourcefulness

 learning organization
 promptness in solving problems
 Focus on the end users of APF products.
 Inculcating companywide quality culture
 Honesty and integrity.

1.6 APF production and the end users of the product

 APF has more than nineproduction lines and fully equiped laboratories as well as utilities
capable of producing Tablets, Capsules, Vial, Ampoules, Creams, Syrups and Ointments. Its
current and potential capacity is able to produce 91 types of drugs. Generally those lines are
grouped in to two. The first one is non-lactam products such as Tablets, Capsules, Syrups,
Topical Ointments, Creams and Gels. The second one is Lactam products namely Vials, Steriles
and Dry powders for reconstitution.

1.7.Its main customers and end users

The main customers of the company are pharmed (which is governmental pharmaceutical
market), different wholesales, pharmacies, and drug shops. The company provides 90% of its
products to pharmed and 10% its products to different wholesales, drug shops and pharmacies
located in overall towns and rural areas of the country.

1.8Its Products and Production Capacity

APF is able to produce 91 products – Tablets, Capsules, Vials, Ampoules, Syrups, Suspensions, and
Elixir and Dermatological preparations. The efficiency of the high – tech machineries and the
skilled man – power play important role to the production capacity.

The production capacity by product line is:-

Tablets:

Wet line – 1 70000 – 210000 Tablets/hr

Wet line – 2 70000 – 210000 Tablets/hr

Dry line 70000 –210000 Tablets/hr

Table 1 Amount of Tablets produced inAPF

 Capsules:

General capsules 252000capsule/hr

B –Lactum capsules 138000capsules/hr

Table 2 Amount of capsules produced in APF

Vials:

7cc 9000vials/hr

20cc

3200vials/hr

Table 3 Amount of Vials produced in APF

Syrups and suspensions:

30ml 6000 Bottles/hr

60ml 6000 Bottles/hr

100ml 5800 Bottles/hr

125ml 5800 Bottles/hr

Table 3 Amount of syrups produced in APF

Ampoules:

1ml 12000 Ampoules/hr

 2ml 12000 Ampoules/hr

5ml 9960 Ampoules/hr

10ml 4020 Ampoules/hr

Table 4 Amount of Ampoules produced in APF

Dermatological preparations:1500 – 3600 Tube/hr

1.9 Its overall organization and work flow

The company APF facilitates its work by dividing all its activities in to different departments.
Each department has its own role to speed up the productivity of the company.Those department
are

 purchasing department
 Warehouse department
 Quality control department
 Quality assurance department
 Production department
 Marketing department
 Maintenance and engineering department
 Managing department
 Research and Development department
 Rejected raw materials

THE GENERAL STRUCTURAL WORK FLOW OF THE COMPANY IS AS

FOLLOWS
 Figure
1organizational
structure of APF
until division
head line GM

SECRETARY

QCM HRM MP
PM MED FM
&WHM

PRODCUT ELECTRICAL TRAINIG GENERAL

Rand D
DIVISION I AND AND ACCOUNTANT
DISTRIBUTIO DEVELOPME DIVISION HEAD WH
NON- ELEECTRONIC
N NT HEAD DIVISION
BETALACTIMI SDIVISION
HEAD HEAD
C HR, PRP DISBURSMENT
MICROBIOLO SECTION MECHANICAL DIVISION AND
GY MAINTENANC HEAD COLLECTION PRODUC
DIVISION E T AND
PACKING
DIVISION DIVISION GENERAL COSTING MP
HEAD HEAD SERVICE AND DIVISION
PHSIICO HEAD
DIVISION DIVISION
CHEMIST
UTILITIES HEAD HEAD
ANALYSIS
DIVISION PRODUCT I DIVISION
HEAD BUDGET
BETALACTUM AND
SECTION PLANNING
WORK SHOP DIVISION
DIVISION HEAD
HEAD

Fig 1 Work Flow Of APF

EEPC
O
Distribution
generator
 PC-01 PFC

Compressor Chiller Boiler Workshop Water PC-02

treatment

Tablet
Head LPC Tablet weight 2 Tablet G.C Syrup Ampoule BC
office weight 1 drying

Cafe Clinic Administr

ation

Blisterin Cleaning Coating

g
Sterlin Y-cone Compress
machine machin granulator Vial
machine g ors Vial Vial Vial
e washing labelin
machin fillin cappin
g
e g g

Dry Blisterin Cap Cap Drum Double Granulato Cap

suspension g& inspection 1 inspection 2 mixer cone r fillin
chiller mixer gs

Belt Bottle Capping Filling Labeling

derive cleaning machine machine machine

Fig 2 Electrical Work Flow of APF

 Chapter Two

Overall internship experience

2.1. How I get into the APF

After the department of Electrical and computer Engineering give me a letter to find company, I
asked them wethere they accept or not.But the company’s rules and regulations, which search the
internship students accepted only agreement with university industry linkage director. Because of
this I did not get any chance to have acceptance paper from any company. Finally through
Industrial Linkage Director of Adigrat University I get an opportunity to join this adorable
company.

2.2. Section of the Company I were work in

The company APF has around ten departments. When I am working in this company, I have
been working in the technical and product section especially in the electrical parts. The company
has many sections like mechanical, electrical, chemists and daily workers.

The workshop of the company contains many electrical materials I can make studies and that
help us identify the practical system of the material that I only know theoretically. I have been
time looking to industrial materials that needs maintenances and the materials I use in the
process of the systems like relays, contactors,overload relays, timers, motors and etc . Working
in every section of the company where a problem or an electrical fault but the workshop is the
main head for the maintenance area so I spend my and I have been working in this section or
department for last four months of my internship time.

2.2.1Programmable Logic Control(PLC):-Is a specialized computer used to control

machines and process. It uses a programmable memory to store instructions and specific
functions that include on/off control, timing, counting, sequencing, arithmetic and data
handling.To develop an automatic bottle, filling and capping system with a deduction mechanism using
sensors. Automatic filling process for all the bottles simultaneously with a user defined selection for
volume to be filled.The PLC is designed for multiple inputs and outputs arrangement.
Figure 3 The Operation of PLC

2.2.2 Solenoid Valve:- It is an electromagnetic valve used to control various types of

liquids by opening and closing automatically.If the solenoid valve is normally closed when the coil is
nergized,the valve gets lifted open by the electromagnetic force produced by the coil.

Figure 4 Solenoid Valve

2.2.3 Proximity Sensor

Proximity sensor is a sensing device which sense objects nearby without any physical contact
up to nominal range or sensor’s vicinity. In brief we can also say that Sensorswhich convert
information on the movement or presence of an object into an electrical signal.The empty
bottles sent in to the filling unit by the conveyor.

Figure 5 proximity sensor

The proximity sensor senses the bottle whereas position sensor check whether the bottle is at
perfect position to fill itAfter getting signal form the proximity and position sensor the solenoid
valve operate for time period that mentioned in the programming.

Fig.6 Automatic filling control system

2.2.4 Position Sensor

Position sensors are basically sensors for measuring the distance travelled by the body starting
from its reference position. How far the body has moved from its reference or initial position is
sensed by the position sensors and often the output is given as a fed back to the control system
which takes the appropriate action.

Figure 7 Automatic Filling Process

Fig 8 . Process flow chart

2.2.5 Blistering Machine

Blister packs are commonly used as unit-dose packaging for pharmaceutical tablets, capsules
or lozenges.
Fig 9 Blistering Machine

2.3. Work follow section

Work flow in the maintenance work shop is super amazing that it contains many experienced and
hardworking electrical engineers and electricians. These engineers and electricians work by shift
so that I was getting full help from them whenever I needed too.

Work flow in this maintenance area is major and outstanding in the way that whenever a fault or
any failure in any system of the company exists. The work flow in this section especially because
it gives me more knowledge about the theoretical knowledge I have gained in my schooling life.

The purpose of each production line is converting the approved raw materials into a product and
the purpose of each packing line is packing the product and sending to finished product
warehouse. In each production line there are seven work stations and in each work stations there
are two machines needed to convert the raw materials into a product.

The number of operators in each machine is limited per shift. But manual working system
performs in each packing line and the number of each operator in each packing line is not
limited. Also in each packing line the work performs without any standard time.Each machine
produces about 91 types of drugs which are generally known as tablets, capsules, ampoules,
syrups and ointments. Each production line produces the products based on the customer’s
orderbecause the company’s production system is 80% make by order and the rest 20%is for
those products having longest expire dates.
 2.4. Work task I have been executing
The work task that I have been execute is finding problems which can affect to the company
based on productivity on each packing line and finding solutions to each problems through. From
these working section the tasks I have been executing is like whenever a fault in any electrical
system exists in the industrial machine. I joined the team of electrical engineers and I try to solve
the problem, if the problem is not easy to solve I ask the operators who are professional.

2.5 Procedure and methods used

Working in this company I have follow many electrical methods and procedures to solve the
problems that are disturbing the process of the company. Some of the methods and procedures
that I use are.

 Direct observation and attending in the whole processes and activities of

each production area.
 Finding the problems faced in each production line using millimeters, trial
and error systems and exchanging materials.
 Meanwhile after finding the problem of the system I try to give the possible
solution I think is best but if that failed so I look back in to the theoretical
knowledge I have gained from my previous studies and with more
knowledge I get I try to solve the problem again.
 Finding the best solution of this problem and solving and modify using plc.
systems the main procedures and methods were:-
 Selecting the problem
 Finding the elements of the problem
 Preparing a schedule to observe the problem
 Recording the time and rating the performance of the operators
 Determining manual diagram
2.6. Challenges I have been facing
In the APF I have seen some problems in the section I have been working and in the
company as a whole.
Some these are:
 Whenever there is any fault with the power coming from the EEPCO, the production will
stop for some time. This is because the generator used in the company is not
automatic
 There is no power line to the company they take power from the Adigrat city
because of this any fault happen the power stops coming from the EPCO, the
production will stop for some time.
 The company doesn’t have enough internet access to search what I want to know.
2.7. Measurements I take
 Even though it’s hard but by following the companies protection
instructions like wearing gowns and safety shoes properly I have try to
solve the contamination problems I have been facing in the company.
 By using an internet access outside the company and browsing the major
knowledge I have to gain from the outside world I solve the problem that I
can’t access internet access inside the company
 I commented the company to replace the control of the generator by the automatic one.
.
Chapter Three
Overall Benefits The Internship
The overall benefits I got from the internship program include:-
 Helps me improve my practical skills.
 Helps me upgrade my theoretical knowledge.
 Helps me improve my interpersonal communicational skills.
 Helps me develop team-playing skills.
 Helps me develop costume of leadership skills.
 Helps me understand work ethics related issues.
 Helps me develop entrepreneurship skills.

3.1 Improving my practical skill

Each and every activity is performed practically which allow me to memorize and change what I
know theoretically in to practical. In practical skill I improve in maintenance part how can read
the manual of the company wiring diagram and maintenance would be continuing by checking
and testing the machines. And also I know different structures, different names, different
functions, different structures with the same name and the same function.

3.2 Upgrading theoretical knowledge

Whenever theoretical knowledge’s are realized practically it can be developed and bounded
further. I therefore realize and upgrade my theoretical knowledge through
practice.Theoretical knowledge is a knowledge that I get from different sources,

For example:

 By reading written things

 By reading drawing and
 By listening from other person who is professional.

3.3 Interpersonal communication Skill

I were communicating with some workers within the company and some outside the company
when necessary through some questions. This skill up punctuality which means being on time. In
general I have seen how to communicate engineer’s with other daily workers. Therefore by
looking them and communicating with them, I develop my communication.

3.4 Improving Team playing skills

I have learnt from the design departmentwhere the final complete work is the output of team
work. Team member has equal role and important to the output. If one of the team members lag
behind the whole work is incomplete.

3.5 Improving Leadership skills

The leader ship has made the team free to do the given task in a given tasks a given time being
innovative.During the internship, I have observed some important things in team playing.

Those are:

 discuss openly about problems

 cooperative work
 Opened mind and flexible
 awareness of member ship & commitment
 transparency

 politeness
3.6 Understanding work ethics
I know all work ethics is the most needed criteria in every work place that everybody should
have in all his/her job activities that he/she gave to the society by respecting the rules and
obligations like:-

 Panctuality
 Responsibility
 Transparency

3.7 Entrepreneurship skill

APF works design and supervision enterprise is governmental organization, which is responsible
for providing safe the food supplies of human beings by the company of APF. The basic
principle of this organization is increase product of medical drug factory. The success of work is
done in the company through the display of the excellent works performed by the company and
the good workers.

Chapter Four

Conclusion and Recommendation

4.1 Conclusion of the Report
During my internship time in Addis Pharmaceutical Factory (APF) Company I have observed the
real world of the work and industrial linkage atmosphere. . I gathered a lot of data’s that are
usefulfor my profession like, upgrading my theoretical knowledge, improving my practical skills,
developing the habit of communication skills, grasp the custom of professional ethics, toidentify
the problems of the company, trying to solve the problems I faced which are professional related
problems and develop the custom of entrepreneurships that can help me for the future life, as
well as I develop the culture of independent as well as team work.Working in this company
help me to experience more knowledge about the systems, methods and industrial control
technologies that I only know theoretically in my campus life.

4.2Recommendation

Internship a great chance, choice and method of creating true, efficient, competitive ,skilled
person and means of identifying and solving different problems. But in my stay in the
company for the internship program, the implementation was very poor because of the
interconnection of the university and the company. So the university should have strong
interconnection with the company to allow the students to attach the program with no
difficulties.
Some electrical equipment requires modification for example making a generator to start
automatically. Also most of the machines are out of use it is better those machines are
maintained in short period of time.
References:
1. www.ijergs.org
2. Mallaradhya H M, K R Prakash,
3. Hemant Ahuja, Arika Singh, Saubhagya Tandon, Shreya Srivatsava, Sandeep Pal, ‘Automatic
Filling Management System for Industries', International Journal of Emerging Technology and
Advanced Engineering, Volume 4, Special Issue 1, February 2014
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