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CHAPTER 1: BACKGROUND OF THE

CAMPANY
1.1 Brief History

Meher Fiber Products Factory was first established in 1951 GC as Nicolas Papasinos

PLC in Akaki; located 20 kms southeast of Addis Ababa. It was primarily designed to produce

sacks made only from the locally available raw materials, processed from the fiber of false

banana. In 1965 GC, the company started to manufacture twine and ropes as well.

In 1973 GC, the ownership of the company has been changed from private limited

company to share company and the name to unifiber. The jute bags manufactured by the

company were used for flour, cotton, coffee, salt and pulses. Later in 1975 GC the ownership of

the company was completely transferred to the government and the name was changed to

Meher Fiber products Factory (MFPF) and organized under the national Fiber products

corporation. The company was then upgraded by installing 12 weaving and 3 sliver machines. In

general, the factory contains 70 weaving, 10 weft spinning, 4 twine and ropes spinning

machineries.

After the fall of the socialist regime the public development enterprise was

assigned to run the factory to curb the packing style of twines and enhance its competitiveness

in the market in terms of quality and to strengthen the capacity of the maintenance

department a spool binder and laze machines were bought in 2002. Furthermore, to overcome

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the quality problem associated with old sewing machines, 20 sewing machines were bought

and used in the factory starting from the year 1993 to 2004 GC.

At this time, the ownership of the factory is transferred from government to private

and owned by G- Seven Trading and Industry PLC. It has also a sister company called Ethiopia

Fiber Products Factory. The company has created employment opportunity for about 1300

employees.

1.2 Main Products

The major products of the company are made of 100% Jute. Currently it is the sole

manufacturer of twine and ropes from the fibers of sisal and false Banana in the country. It

supplies its products to local markets, at reasonable price striving to satisfy the requirements of

its customers.

Besides the fact that Meher Fiber Product Factory is a major Jute bag producer,

Twines and Ropes are also produced as a product by which the raw material is imported from

Brazil.

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Some of the main products of Meher Fiber Product Factory are listed below:-

 Grain Jute Bag (50 and 100 kg),  Salt Jute bag,

 Coffee jute Bag / 60 kg,  Can Jute bag,

 Coffee Jute bag (Alfoz) 50 kg,  Jute Fabric,

 Cotton Jute bag,  Sisal / 50 kg,

 Sand Jute bag,  Rope 8-32 mm , etc

 Flour Jute bag,

Fig.1 Coff ee jute

Bag

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Fig.2 Rope

1.3 Main Customers

G- Seven Trading and Industry PLC is a sole Jut bag producing factory. This makes all

grain, coffee and cotton distributors and exporters to be its customers. Among the many

customers, the top ones are:-

A. Coffee distributors and exporters:

Muluneh Kaka Coffee Export Anbessa Enterpise

Bashenfer Trading Mamo Cacha PLC

S.A. Bageresh Mulege PLC

Tracon Trading Ask International

Cabe PLC Oromia / Coffee Union

Alfoz PLC Kemal Abdela International

Bashewe Trading HelenG/Neguis Coffee Exporters.

Wondo Trading Hora Trading

SMS Trading Ethiopian Commodity

Abadir Coffee Ethio Agri Seft

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B. Grain distributors and exporters:

Ethiopian Seed Enterprise

Bale Agricultural Development Enterprise

Arsi Agricultural Development Enterprise etc.

C. Can packing distributor :

Elfora agro – Industry

D. Cotton distributors and exporters:

Ami bara Agricultural Development

Middle awash agriculture research

Upper awash agriculture research

E. Twine and ropes distributors:

Mehdin Hassen

Mussa Ahmed

Mekonnen Asmare

Zaki Hassen

Temam Muzein

F. Hessian cloth customers

National tobacco trading

Techno-serve/NGO.

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1.4 Organizational Structure

1.4.1 Function of Each Division

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A. Managing Director (MD)

- He is the head of all departments in the company.

- He has the power to control all financial issues.
- He has the power to control each domestic and foreign purchases and sales of
production.
- The company’s yearly budget is approved by the MD.
- He has the power for employee recruitment and discharge.
- Any rules and regulations are approved by the MD.

B. Managing Director Secretarial Office (MDSO)

- Acts as a Managing Director, when the MD is not in the company except for
financial issues.
- Has the power to control raw materials.
- Daily observe and give information about production for the Managing Director.
- Prepare yearly budget.
- Consult the MD about all company’s issues, problems and give the possible
suggestions, etc.

C. General Manger (GM)

- Mainly Controls Production and Technique, Administration and Quality Control

Departments.
- Outside interactions on behalf of the company is done through the General
Manger (GM).

D. Finance
- Controls the overall company’s cost and gives information for the MD.
- Collect insurance payments for the company.
- Pays employees’ salary.
- Allows Money (Cheques) for Purchase (Foreign and Domestic).
E. Project Research and Development
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- It helps the company to bring new technology which can help to increase
production.
- Research and Development and Human Resource Development are found under
this department.
- Helps to increase Machines’ efficiency and durability, etc…

F. Purchase and Supply Division

- It is the responsible department for any domestic and foreign purchases, which
are the raw materials, spare parts, etc…

G. Sales and Marketing Division

- Responsible for sales of finished goods (sacks, twine), etc…

- The department sales these products with cash and credit.
- Try to solve the complains raised from the different customers in collaboration
with the production department.
H. Production and Technique

- Controls the production of the company.

- Production Division and Technique division are under it.

I. Administration

- Personnel, Clinic and General Service are under this department.

- Employees’ health is held under Administration through Clinic.
- The company’s cars are under the department through General Service.
J. Quality Control Service

- Controls the overall quality of the raw materials before passing through different
processes, during processing and after the product is achieved. Different
measures are taken to minimize the defects etc…

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CHPETER 2: OVERALL INTERNSHIP

EXPERIENCE
2.1 Introduction

According to ECTS curriculum of Bahirdar University, Institute of Technology,

there are two ways of allocating students to industries for their internship program. One

of the ways was a chance given to students to find industries by their own and apply for

internship. The second way was choice of industries by the students from list given by

Bahirdar University, UIL office.

I have chosen G-seven Treading and Industry PLC from the list of companies given

by UIL office and been allocated to do my internship program. At G-seven Treading and

Industry PLC I have been working in Spare Part Engineering Consumption and Stock Control

Section Department.

2. 2 Spare Part Engineering Consumption and Stock Control

Section

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Spare Part Engineering Consumption and Stock Control Section Department is run

by senior mechanical engineers, who have long time experience in the company. Most

of the Fabrications in the Machine shop or repair of machines have to pass through

Spare Part Engineering Consumption and Stock Control Section Department. The senior

Mechanical Engineers give technical suggestions and solution to the problems pointed

out from mechanics.

The work flow of Spare Part Engineering Consumption and Stock Control Section

department is as follows:-

Production and Technical head

Technical Head Production

Spare Part Engineering

Workshop and Stock Control

On the first week of the internship program the Department together with other

department gave internship students a chance to be in group and point out problems according

to our specialization. We were required to do report on Problem identification and we did.

After we had well over view of the company Spare Part Engineering Consumption

and Stock Control Section Department set up four month Action plan for Mechanical

internship students and given us two projects to work on. The two projects given were

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Modification/Installation of stop motion in spinning machine and Design Die and punch

for conduction making.

2.3 Work Task

In my stay at the company I have done three complete projects. These projects are
listed below:-

1. Factory Problem Identification and solution

2. Modification/Installation of Stop Motion in Spinning Machine
3. Design Die and punch for conduction making

From all the projects I have given more attention to ‘Modification/Installation of Stop
Motion in Spinning Machine’ for the reason that the project mainly concentrate on
manufacturing.

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CHPETER 3: Modification/Installation of
Stop Motion in Spinning Machine
3.1 INTRODUCTION

Spinning machine is one of the most important and the bottle neck of the factory. And
its primary function is:

reduces the number of fiber strands per cross section area accordingly count
of the yarn
imparts twist to form yarn
Winds the yarn on bobbin case by maintaining yarn To twist the sliver to
yarn, this increases the strength of the yarn.
To change the sliver in to yarn.
To wind the yarn on the bobbin.
For drafting the sliver.

Fig.3 Spinning Machine

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Productivity of any manufacturing sector is enhancing whenever the deployed machineries

are functioning in proper way. Proper functionality can no longer exist if the machines are not

being maintained in a scientifically outlined scheduled.

Stop motion is a simplified geometrical mechanical element that is easy for maintenance

and handling. This element is installed at the spinning machine which is used to protect yarn

breakage by stopping the feed during operation of machine in irregular flow of sliver. The

working principle of the element is by weight balance mechanism that is it stops when the tip of

the element inserted in the spline.

Fig.4 Stop Motion

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3.2 PROBLEM IDENTIFICATION

In this stage we have dealt with the major hindering factors for lesser operation of

spinning machine stop motion spare part. In parallel there are other causative agents due to

human made sanctions. These and other related problems are listed below.

 Wear and wide groove of the element at the connecting link.

 Parallel angle with motion of spline.

 Wear out of stop motion spare parts.

 Lack of awareness of the mechanics’ about the machines

 Lack of scheduled maintenance on spinning machines

 Lack of available operators regarding on stop motion

 Supervise problem on spinning machine

3.3 OBJECTIVE

General Objective

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The main objective of this project is to modify and upgrade stop motion. Also,

suggesting solutions for related problems in Meher fiver products factory to increased

productivity of spinning machine.

Specific Objectives
 Introducing the handling of the stop motion mechanism while operation.

 To identify frequent problem of the stop motion mechanisms.

 To increase life time of stop motion

 Inspecting entire category of stop motion in the spare part

 Recommending to use instruction manual

 To develop fully working stop motion, having longer life span.

 To minimize (reduce) waste of sliver.

 Reducing work load of operators at spinning machine

 Creating good working environment in spinning machine

 Give training for spinning machine operators by research and development department.

Stop
Motion

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Fig.5 Stop Motion Wile Operation

3.4 GOAL

Past our objective and by reaching the aim of fully working stop motion this project will lead
to the following advantages to the company.

 Minimizing workload in mechanics and work shop workers

 Customer care of the company will be improving since the ordered product will be

available in speculated time.

 Increasing productivity of spinning machines

 Eradicate the waste of spinning machine

 Saving manual workers energy

 Solve the bottleneck problem of mill section

 Improving and increasing continuous yarn feed for winding machine.

3.5 METHODOLOGY
In the project of Modification of stop motion mechanism, to reach the objective and
goal we have passed through consecutive stage of operation.

The stage that we have started which was observing and following up the existing stop
motion lead us to realizing that some stop motions have their own problems which couldn’t be

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found on the other one. Hence we tried pointed out the most common and severe one that is
being an obstacle for the stop motion to operate properly.

The following are the uncommon problem found.

 Shortening of tip of the stop motion.

 Deformation of the straight structure of the stop motion due to improper
usage by operators.
 Previously modified stop motions but failed which changed the original
form of stop motion

The second stage is suggesting and designing different modifications for stop motion
mechanism the suggested designs can be manufactured easily and doesn’t damage the original
size of the spare part.

The last stage of our mechanism is trial and error; here modified elements are
manufactured and installed for taste at the machine. Since it operated well, we continued
modifying using the sample for mass production.

As a summary:

 Observation: - follow up of the stop motion to identify where the problem lies.

 Trial and error: - suggesting different solutions for the observed problem.

Implementing and testing modified products.

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 Experimentations:-analyzing the difference of waste before and after

implementation.

3.6 ANALYSIS

The first phase of the analysis is recording data, before installing the modified stop motion

element throughout the machine. This is done to know the waste present because of absence

of effective stop motion and to compare it to the waste of yarn after implementation of the

project.

Measure of yarn waste before Implementation of Modification:

Doff Waste by Kg
1 1.5
2 1.3
3 1.3
4 1.4

Table 1. Collected data of west before implementation of modification

The average waste per kg in each Doff ( single round spinning) is calculated
as follows:

Average waste (Wav) = X1 + X2 + X3 + X4

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4

1.5+1.3+1.3+1.4
W av = 4

5.5
Wav = 4

Wav = 1.375kg waste/Doff

Measure of yarn waste After Implementation of Modification:

Doff Waste by Kg
1 0.4
2 0.6
3 0.5
4 0.4

The average waste per kg in each Doff is calculated as follows:

Average waste (Wav) = X1 + X2 + X3 + X4

4

0.4+0.6 +0.5+0.4
Wav = 4

1.9
Wav = 4

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Wav = 0.475kg waste/Doff

 We can compare from the above numbers that after the modification the waste is highly

reduced with an amount of a difference 0.9 Kg waste, which is a great change on the

machine productivity.

3.7 RESULT

The result reached due to the implementation of the modified stop motion is
that the waste of yarn on spinning machine has decreased.

Graphical Presentation of Waste per Single Round(Doff)

Before Implimentation
1.55
1.5
1.45
1.4 Before

1.35
1.3
1.25
1.2
Doff 1 Doff 2 Doff 3 Doff 4

Fig. 5 waste before implementation of the modification

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 From the graph of waste before implementation of modified stop motion we can see
that that there is big amount of yarn waste. Also there is huge fluctuation of waste form
round to round.

After Implimentation
0.7 Fig. 6 waste after implementation of
0.6 the modification
0.5
0.4 After

0.3
0.2
0.1
0
Doff 1 Doff 2 Doff 3 Doff 4

The above graph of the
measured waste after the
implementation of the modified stop motion shows that there is a dramatic decrease of
yarn waste. Also the fluctuating waste has smoothed out. So this implies that the
modification has good result.

Comparison
1.6

1.4

1.2

1
Before
After
0.8

0.6

0.4

0.2

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Fig. 7 Comparison of waste before and after implimentation

 The above bar graphs also demonstrate or compare and contrast the waste of the

spinning machine per doff before and after making modifications.

3.8 SOLUTION

Mainly the testing of our different suggested designs (i.e. trial and error) had leaded us

to most suitable and reliable solution.

From the suggested designs the ones listed below are chosen to be best working modifications

for automatic stopping of yarn feed.

 Increasing the angle of the tip by 110 as presented on the technical drawing.

 Filling up the grove of the connecting link with thickness of 2mm. this is also

shown on the technical drawing.

The increasing of the angle can be done by heating the tip by the help of oxyacetylene torch

and then hammering the tip according to given angle.

The grove is filled up with arc weld, with thickness larger than 2mm. After that grinding the

filled grove to reach required thickness and to smooth the surface.

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3.9 CONCLUSION

From this project we have identified the most recognizable problems, collected data for

analysis and finally reach ground breaking solution on the modification of stop motion and

increasing productivity of spinning machine and eliminate the wastage.

By going through our methodology, step by step we have reached to best solutions on

modifying stop motions. Also from the analysis (i.e. comparison of waste per kilogram before

and after modification) it is clear that there is much difference of reduction of waste. This

reduction of waste will lead to a remarkable increase of productivity of spinning machines.

3.10 RECOMMENDATION

In this project we achieved a great result that we proved it practically which we got an

encouraging change to do the same for other spinning machines.

I recommend Meher Fiber Products Company to implement our project that is we

reached solution to the stop motion element modification. Hence, the company will be able to

productive more profitable better than ever.

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CHPETER 4: INTERNSHIP BENEFITS

4.1 Introduction
4.2 Practical skill
The main aim of this internship program is to make practicable and tangible

what we have learned theoretically for this to happen, we have done different kinds of

project works by which the different theoretical knowledge have been applied.

4.3 Theoretical skill

I have learned that there are different quality test methods and I have observed

and practiced all those tests including:-

Ü Moisture regain test for raw materials,

Ü Moisture regain test for yarn,

Ü Moisture Regain test for jute bag,

Ü Sliver count,

Ü Yarn count,

Ü Fiber length and strength (used for blending composition),

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Ü Yarn strength (to determine the appropriate twist on the yarn by changing the twist

gear).

Product Tests

 Actual bag weight,

 Actual bag length,

 Actual bag width,

 PPI and EPI etc…

In general, these all tests have been practiced and the equipments used for

testing are:-

 Balance,

 Meter,

 Jute Moisture Regain meter (%),

 Strength tester etc…

4.4 Communication skills

Developing interpersonal communication skill is vitally important in today’s

work place. Almost all kinds of work require communicating with your partners.

When we communicate, we don’t actually swap ideas, we swap symbols t stand for

ideas. Words are just symbols that do not have inherent meaning, we supply use

them in certain ways to convey an idea or give it a meaning and no two people use

the same word in the same sense at all instances.

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The symbols attached to these words are a function of which we are, our social up

bring and culture which will pretty much vary invite widely in today’s work

environment.

Any communication is based not just on words but also on body language, tonality,

situation etc. Using these techniques, we constantly communicate with others.

In the factory different kinds of professionals are working. These are:-

 Operators,

 Mechanics,

 Engineers,

 Top level Mangers etc…

Every day in my work I made contact with these people to help me know the

different kinds of things about their working environment. This makes me to have a wide

knowledge and can easily communicate with their relatives about the different problems

occurred and try to solve it together.

In general, I have observed that it is a must to create smooth relation amongst

different workers. This is because each and every department in the factory is dependent

one on the other. So to be fruitful there has to be good communication between each and

every members of the factory.

4.5 Team playing skills

Team building skills are one of the basic requirements for the proper working of

a good company, regardless of its size and service. A company with properly functioning

dedicated working team will always have a graph going up words. With different workers,
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working as different teams, such as management team, sales team and project team.

However, they contribute to a single goal, the progress of the company.

For the proper functioning of a team, each member must be sure of his mission,

vision, behavior, work style and goal. He must be personally professionally and

organizationally dedicated to the team.

Team members must believe in one another and must be ready to work hand in

hand in both adverse and favorable situations.

General skills such as good communication, concentration, fast decision making,

self –confidence and a well being feeling are important for all team members engaged.

Different project works have been conducted through research and development

department of the factory. The projects are made in group so that different kinds of

knowledge have been shared.

In our project works, different kinds of problems have been assessed from

different perspectives. I.e. I have made the project works in collaboration with an Industrial

Engineering Intern Student and this helped us to see things from industrial and textile

point of view. This makes the projects to be multi-dimensional.

In general this internship program had contributed a lot in making students work different

kind of projects in group. This helps to share different kinds of knowledge from different

perspectives.

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4.6 Leadership skills
“There are leaders and there are followers” as the saying goes and developing good

leadership skills can create the distinction between the two. Many people believe a strong

leader is born and not made. This is not necessarily the case.

A leader is a person who has strong principles, courage and dedication to a clear

vision. Developing a powerful vision, building a strong team and bringing out the best in

those you lead are key facts to experience success as a leader.

People follow a great leader because he is representative of the beliefs of a

group. This person is often a well-principles individual who is focused on a common goal

and eliminates excess fear and doubt.

For me to be a great leader I have to develop a deep understanding of what is

valuable to me. It is also essential for me to understand ethics. Great leaders will shoe case

their ethics and values in their behavior. A common problem that many leaders have is

trust from those that follow them.

One thing that all great leaders have in common is strong beliefs, once I

understand by believes I can next look at may group to determine if those beliefs are being

promoted.

To be a great leader I don’t want to waste to me worrying about things that are

not directly connected to may beliefs.

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One thing that all great leaders have in common is vision. If I want to improve my

leadership skills I will need to have a powerful vision. But is not just enough to retain it in

my head. I will need to design what is called a strategic plan.

The most top managerial position in the factory is Managing Director (MD). The person in

charge is the head of all departments in the company and so he is responsible for all the

things happened in the factory. Everything is ordered by the MD.

I have observed that during every meeting it is the Managing Director that:-

talks, shouts, screams and reflects his own ideas. I think this comes from his personal

behavior besides the fact that he is the head. Although such kind of behaviors are

necessary, it is invite fair that every issues have to be discussed with those mangers/

Managing Director secretarial Office (MDSO), General Mangers and Administrative Manger.

So, here I want to point out that before making any decision it is better for the

Managing Director to discuss issues with those middle level Mangers.

4.7 Work Ethics skills

Globally there is an enormous emphasis on education and skills preparation for

future employments. Many employers indicted that a strong work ethic ranks at the top of

the list along with proficiency in a chosen profession.

Instructions to develop strong work ethics:-

1. Arrive to work at least 15 minutes before the schedules start time this offers the

ability to mentally prepare for tasks. plan to work the time and days agreed up on.

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Schedule all appointments outside of the times ou have committed to your

employer. A great attendance record is an essential attribute of a strong work ethics.

2. Maintain a professional demeanor at all times. Be cordial and friendly to all staff in

the company. Refrain from allowing your home if to skill over into your employment

environment. Conversations should focus primarily on work related issues. Respect

yourself and others.

3. Put a positive spin on negative comments. A positive attitude is crucial to have a

strong work ethics. Bring a fresh perspective to problems at work.

4. Developing a strong work ethic involves taking initiative. Although to solve

problems at work independently. Use your taking materials to assist in locating a

solution. Be confident and self motivated in your ability to handle job

responsibilities.

5. Honor Your Commitments:-

Being dependable creates confidential in your capacity to handle more

responsibility. Seek to serve the interests of the company’s goals, objectives and

mission. Do your part to create a productive place to work.

6. Strive to do the job right the first time. Quality and Quantity of work is a direct

reflection of personal character and integrity. A productive worker with strong

work ethic takes the time to reproduce quality work. Take provide in your work.

7. Respect what others contribute to the work environment. Concentrate on your job

and commitment to a proactive attitude. Be a team player Help other at work

without being asked.

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8. Go the extra vile whenever necessary to ensure that your verbal and written

interaction switch others are productive. Communication skills are an indispensable

asset to any organization. Use empathy and self control when diffusing

disagreements.

 Find the good in every situation. Negativity is infections and ruins norale .

Enjoy the position you told in the company.

 Do not worry about non-productivity employees. Refrain from comparing

yourself to those who are not meeting he company standards.

“Work ethical employee is a key to productivity” this is to near for a factory to be

productive; all of the employees have to be disciplined and ethical in their working

environment.

An employee can be considered as work-ethical if he/she is:-

 Punctual/on time

 Not absent (except during special cases (death of family members, sickness etc…)

 Open enough to create smooth relation with partners

 Committed for his/her work

 Accountable and Responsible etc…

4.8 Entrepreneurship Skills

The state of being an entrepreneurship can be realized when on engages in

profitable risks and creates something of valve.

Entrepreneurship is defined by their habit of innovating and redefines market

trends and limits.

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Regardless of their heredity, their background, their exposures and what not;

entrepreneurs are people who are able to develop new business and affect the

overall condition of the global economy. Given this, it is obvious that being an

entrepreneur is no joke. Aside from the stress of creating and running business , the

additional responsibility of being able to contribute something significant to society

I given to them.

Nevertheless, entrepreneurs do have the advantage of inheriting and learning

entrepreneurship skill that would assists then in meeting those expectations.

These skill are abundant; some, more important than other. All of them , however

are needed for a person to fully nature as an entrepreneur. But there is no pressure

though for any a spring business man to learn everything before he starts his

venture. Most of these skills are not even developed without experience. So it is

expected that a stat up entrepreneur is half prepared when he decides to pursue his

files. But then again, there are abilities innate to human beings that can be very

helpful when starting out as entrepreneurs.

1. Self Awareness

This ability basically denotes having a sense of one’s self and knowing what

one’s strengths, weaknesses and biases are. This is pretty important for

entrepreneurs as this help them sort out through personal rubble and came up

with informed and reasonable decisions. Though this skill is inborn some

businessman difficulty to apply it n their lives. Usually, they are so overwhelmed

by other people’s influences that their own beliefs and preferences are forgotten.

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If I am able to invoice personal understanding and appreciation of own

tendencies, I can better myself , better my entrepreneurs ship approaches and

ultimately prepare myself for absorbing other essential entrepreneurship skills.

2. Ingenuity

Ingenuity here is not only the ability to think of out of the box. It also means

being able to work out one’s way to the achievement of a goal despite

limitations. Ingenuity is adapted by entrepreneurs when they create a unique

service or good and how they find alternative (feasible) ways to solve problems.

But entrepreneurs should not assume that ingenuity ends with them. Part of

learning and applying this skill is recording the ideas of others. This is how they

came about creating the best business solutions and ideas.

3. Love

Few consider this entrepreneurship skill important. But actually, this ensures a

more harmonious, accomplished and long lasting business. love means seeing

potential in people. It means being able to create a nurturing environment for

my employees and co-workers. Love means being able to bring out the best from

there around me.

Entrepreneurs, who are able to create worthwhile goods and services, give a

greater impact to society, have loyal and well-trained employees and finally,

keep devoted customers.

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2011
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CHPETER 5: CONCLUSTION

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2011
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CHPETER 6: RECOMMENDATIONS

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2011
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REPORT

References

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REPORT

ANNEX

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2011

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Fig.8 Stop Motion before modification

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2011

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Fig.9 Stop Motion after modification

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2011

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REPORT

Fig.10 grove before and after weld filling

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2011

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REPORT

Prepared By : Bona Tolosa

2011