Chapter One

Introduction

1.1 Background/ Profile of Company

ABMI (Akaki basic metal industry) is one of among the defense industries which was

established manufacturing spare parts and hand tools. It was established in 1989 EC the

factory built in cooperation with the government of the republic of Italic was inautgurated

by comrade MENGISTU HAILEMARIAM and general sector of the FDRE and

commander in chief of revolutionary army force. Formerly the industry was named as

Akaki spare part and hand tools social corporation and producing a larger quantity of

hand tools like hammer, shower, roller and etc. ABMI is located in south east of Addis

Ababa in Akaki town it far away 25 km from Addis Ababa. Akaki basic metal industry is

one of the crucial industry in Ethiopia.

In October, 1999; the company has been re-established as a share company in according

with the proclamation No. 146/98 with a capital of birr 142,298,000 (One Hundred Forty

tow Million Tow Hundred Ninety eight Thousand birr) subscribed by the government and

change the name of Akaki Spare parts and Hand Tools Factory in to Akaki Basic Metal

Industry by using E.F.D.R state and minister of council No. 183/2002.

The industry is currently doing expansion work in the manufacturing quantity and quality

of machines to develop the manufacturing process and also spare part factory project

being implemented within the firm work of the economical scientific and technical

cooperation between the government of socialistic Ethiopia and the government of Italy.

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1.2. Objective, Vision, Mission, Core values of ABMI

1.2.1. Objective
By melting different types of metals and manufacture standard products to satisfy local
demand and generates profit.
To provide better quality, competitive price and suitable products for Ethiopian
industries.
To save foreign currency and export products to neighboring countries.

1.2.2. Vision
Enable the country as progressive and an industrialized nation through metals
fabrication engineering technology.
To develop our country to the highest stage and be competitive in the world market.

1.2.3. Mission
Developing the basic metals technology through enter relation with in

engineering knowledge that support the economic activities to achieve our

country’s goal.

By knowing the present and estimation the future need of basic metal products by
studying and analyzing the casting and metallurgical technology through a continuous
improvement to be the owner of regional invention.
By using past integrated experience to speed up the development of our country’s
basic metals need.
By giving priority to human resource development in order to obtain trained and skilled

professionals.

1.2.4. Core values of ABMI

Integrity, customer focus, hardworking, team work, and loyalty.
Professionalism,
Problem solving
Commitment

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 1.4. Main customers
i. Sugar Factories iii. Textile Industries
• Fincha Sugar Factory
• Addis Garment
• Metehara sugar factory
• Akaki garment
• Wenji sugar factory
ii. Cement Factories
• Abyssinia cement factory
• Mossobo cement factory
• Mugar cement factory

• National cement factory

1.5. Main products and Services

Table 1. 1 Some products of ABMI for different sectors

Product name Sector of product user

Construction sector
Different types id ripper tips, mixer, planet and pinion gear,
construction steel bar, etc.
Bend pipe, compressor, water pump parts, etc. Agricultural sector

Wheel disc, front hub, spoke wheel,, liner, U-bolt, etc. Transport sector

Cement ball, jaw plate, crusher hammer, armor plate, etc Cement sector

Sugar factories

Pinion gear, sprocket gear, sugar cane juice tranker, mill

roller, , T-Bar, Head stock, etc.
Flat bar, big and small collar, cross arm, different types of Ethiopian electric power
hooks and pins and Ethiopian electric utility
Different factories
Pulley, different type of gear, worm gear, kill care wheel,

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 ring gear, male and female coupling, different types of
bearing housing, eccentric cover, gear box housing

The main departments of in this manufacturing factory

• Design department
• Production planning and control department
• Machine shop
• Quality control department
• Cutter store
• Heat treatment(common for all manufacturing factories)
• Finished product ware house
• Water treatment and pump station
• Scrap and foundry raw material
• Forging and heat compressor station

Chapter Two

Details of working experience

2.1. How I got into the Company

In every University a student has to take internship practice before he/ she is qualified in his

or her University for graduation. This helps to know what he or she learns in the academy. I’m

3th Year Computer Science Department Student. The university gave me Internship asking paper

on June 2021. I tried to get the host company which is appropriate one for my profession. Then I

gave for ABMI by writing my full name, department, phone number. My friends also do the

same thing and distribute to different companies.

Then my paper got accepted by the ABMI. Then the company gives me acceptance paper. At the

beginning of second semester I went to ABMI main office and they grouped students into

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different shops. I was ordered to practice in Foundry shop. I started our practice in this shop and

for 7 days looking for inspection works.

2.2. Summary of Duties

The internship program was conducted from March 1, 2019 up to June 18 for about 100 days at
ABMI. The Company has different workshops. For the first one I worked in foundry shop which
is directly related to my stream and the remain days on the rest of the shop namely;
Machine shop,
Forging shop,
Heat treatment shop and
Marketing

2.3 Working flow of Akaki Basic Metal Industry

The working flows of Akaki Basic Metal Industry are the following
The piece which is going to be manufactured passes through the following steps.

1st step – customer - the customer must come with full drawing of the sample to be
manufactured or the sample itself but if the sample is available, it should not be severely
damaged so that exact measurement could be taken.

2nd step-Marketing –in the marketing department the whole of cost product is estimated if the
customer agrees with the cost, then must pay 50% of the total cost. The cost is estimated based
on the difficulty of production and the type of material.

3rd step – production - after the agreement is done the sample or the full drawing will be
forward to the design room
4th step Design Room - in the design room the sample piece will be converted in to 3D drawing
than back to 3rd angle projection view using CATIA-v5 software

 All dimensional measurements are taken from the sample piece using caliper and
other measuring tools
 In addition to drawing, Technological procedure is forwarded in the design room
Technological procedure: - It means he steps the machinist should follow to produce the
required object.

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  After each operation the piece will be checked by the quality control for its
dimensional accuracy.
 If any clear and visible error is detected on the piece, it is rejected.
 In the design room no mechanical design analysis takes place but sometimes the
engineers select material for new products.
 In this room there are mechanical engineers and draftsmen. They take the sample,
measure its dimension and convert it in to 3D drawing, and then in to projection
views, finally they print the views in three copies and give one for machinists, one
for PPC and one for the design room.
 They use a software called CATIA-v5 for making the drawings PPC (process plan
control) Room:
 In this room every piece will be followed starting from the blank raw material up

to the finished product.

2.4 Foundry shop

Foundry shop– is a shop which is equipped for sand preparation, pattern making section, core

making section, mold making section, melting of ferrous unit, melting of non-ferrous unit and

cleaning of the finished casting.

Workers who perform casting are called foundry men.

2.4.1. Casting
Casting is a process of shaping a metal by pouring a liquid/molten metal into mould

cavity.

Casted metal property

Density becomes less – due to level of porosity.

Porosity is high – due to entrapment of slag, oxygen. Hydrogen
etc. minimize conductivity – due to present of porosity
No variation for melting point of cased

Advantage of Casting

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  Complex shapes of materials can be done easily
 Huge (large ) objects can be done
 Allayment is easily possible if required
 Economically advantageous.
 Structural object can be obtained in one piece rather than joining pieces by
welding
2.4.3. Sand
2.4.3.1. Type of sand

Akaki Basic metal Industry uses silica sand (SiO2) which is applicable for molding and core

making. This sand came from Jema River which is found in Merhabete North Shewa in Ethiopia.

Advantage of silica sand (SiO2):

 It can be used repeatedly for

making molds. inexpensive

 The sands maintain their shape and other characteristics even at very high
temperatures while they are in contact with molten metals.
 After ramming the mold remains sufficiently porous to give vent to the gases

2.4.3.2. Sand preparation and system in foundry

The sand system in Akaki Basic metal Industry is comprises of new sand, mechanically

reclaimed sand (Reclaimed sand) and thermally reclaimed sand (Regenerated sand).

2.4.3.3. New sand preparation

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 Sand brought from Merehabete for Akaki Basic Metal Industry and at the time of our training

it was washed manually and deposited on concrete silos on the ground floor via a hopper vibrator

bucket elevator and belt conveyor. The sand from the concrete silos on the ground floor is

excavated using a shove hoper and feed to the drier via a hopper, the dried sand is finally
transported to the two steel silos of pneumatic propulsion. The new sand stored in silos can either
be transported to the HM, MM, core shop (CS). At the time of our intern they were not use the
drier machine since it was not work. They are simply spray the sand on the floor for allowing it
to dry.
2.4.3.4. Sand testing (laboratory)
When selection and testing of proper foundry sand, Sand test is done for quality and casting
.The following tests is conducted in the sand lab.

Clay content test – is used to determine the percentage of particles.

Moisture content test - this instrument can be used to accurately measure the
moisture content of green sand.
Permeability test – is used measure a condition of porosity and the passage of
gaseous materials through the sand.
Grain fineness test – this type of instrument is used to determine a grain size of sand.
At the time of our training we saw the above sand testing machines but they were not working.
Some machines of sand mixer and reclaimed machines are mentioned below.

2.4.3.5. Sand mixer machine

Sand mixer machine is a machine which is used to mix new sand or old sand with risen

and catalyst. This machine contain stirrer which consists of 90 teeth and these teeth are

rotated for mixing of sand with risen and catalyst. To mix sand, risen, and catalyst

together first the ratio of risen to catalyst should be calculated. It is one by half (1 :) ratio

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 Of risen and catalyst respectively and then sand is added to them based on the ratio of

risen to catalyst. In this mixture risen helps to bind sand particles and catalyst facilitate

the reaction to be carried out.

2.5. Mechanical workshop

Mechanical workshop is one of the shop on which different materials or products are

machined. In this shop different machining process is takes place also, it’s used for finishing of

casted materials for instance;

- Cutting - Boring
- Grinding - Turning

- Bending - Drilling …etc.

Akaki Basic Metal Industry uses pneumatic machine (a machine which works by air) and

hydraulic machine (a machine which works by oil) but widely pneumatic machine is used due to

their cost. Hydraulic machine is expensive than pneumatic machine.

2.5.1. Pneumatic machine

Pneumatic machine is uses air for its entire work. It consists of different machine elements like
pulley, clutch. Shaft, eccentric shaft, pinion gear and gear. Motor is also installed for the purpose
of supplying power to the machine.
Working principles of pneumatic machine

First the electric motor is switch on and motor makes the pulley to rotate. Until the
air valve is switched on, the pulley simply rotates and no action takes place.
Then the air valve is on and between plate and clutch is closed and clutch transfers

motion using shaft to pinion gear and the pinion gear in turn transfer motion to the

gear. There is an eccentric shaft on the top of the machine and it moves up and down.

The eccentricity of the shaft enables it to move up after it is pressed down.

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Pneumatic machine is used to change shape metal to the required shape and by changing its
die different products like; spoon is produced. The air used doesn’t recycled but its escape.
Economically it’s cheap as it uses air.
2.5.2. Hydraulic machine
All the function and working principle of hydraulic machine is similar to pneumatic machine but

oil is used instead of air and the oil used is reused.

Chapter THREE

Overall Benefits I Gained From Internship

3.1. In terms of improving my practical skill

Internship program gave me chance of working at a manufacturing and this program helped

me in many ways. Fortunately, the project I have been working for the last 4 months gave me an

opportunity to have a wider view of the industry world. During those months the shop offered

me a tremendous amount of practical skill regarding current way of on manufacturing structures.

These include how to transfer the data on paper in to the practical accurately.

The following benefits are gained in terms of improving our practical skills:
Creativity and an innovation approach to solving problems
Effective assessment and management of risk, resources and
time Highly developed numerically and computer literacy.
Clear written and oral communication skills.
I got a lot because there are different types of machines in factory from the conventional
types of machines. Therefore, I had access to see different machines mechanisms and working
principles by relating them with what I had been learnt theoretically.
The other basic thing I had learnt during the internship time was knowing the capacities of
different machines i.e what kind of products are produced on different machines, how to keep
surface finish, keep allowances, surface treatment, process and I was observing assemble and

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disassembling processes during maintenance and this helped me to know internal machine parts
and assembling order and vice versa
In addition to these I also become familiar with shop terminologies and technical terms used by
work group. I saw all manufacturing process we have learned on machining, foundry and
manufacturing system courses.

3.2 Interpersonal communication skill

Because I meet every day many people in the company from daily labors up to managers
at different sections. This helped me to develop skill to express myself, ask what I need,
give recommendations, and accept any suggestions from many people.
The workers in the company are interested to answer whatever questions I want to ask
and also their good facial expression which invite me to talk with them more and I also
help them what can do to increase their efficiency and make us more closer and increase
our cooperation &friendship.
Since manufacturing work is a team work by its nature you will face different individuals
with different professions and personality come up together and communicate with each
other to solve different problems and run the whole work. Through time I believed that
good relation and communication skill is the key for getting the experience and
knowledge I require for the internship program. Based on this I tried to change my
approach to the people at the work place. As time progresses I was able to see
improvement on myself. I can say that I have got good lesson regarding communication
skill while my stay in the company for the internship program.
3.3 Team Playing Skills
During the internship time I was working with my classmates which help us to discuss
problems we face in the company to adapt ourselves to the new environment fast. Also while we
observe different section of the company we discuss what we had seen in the section relating it
with what we have learnt before and we discuss on new ideas which may be raised between us.

Because each of us may have different understanding on what we observe. Also after we
identified problems and prepare our project personally we kept working and helping
each other

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3.4 Leadership Skills

I have seen how each worker is controlled and organized to perform its day to day activities.
Among all other managements I have seen that human resource management is the most
important one.
I have actually observed the method of controlling the working time and amount of work done
by each worker so that the work proceeds according to the work plan. Leadership is a skill to
guide, control and monitor peoples. For effective leadership I understood that personal values
like confidence, effective communication and devotion are very important.
There are good qualities that one leader must have in order to work successfully and must be an
example for other workers and allowing the growth and profit of the company to go high and
creating good working condition for workers.
This skill helps me to know and develop qualities of a good leader which will be one of my
duties in the future.
The good qualities of leader I observed during internship has to be;
o Beginning every work with plan
o Finishing works just in time
o Initiative to work
o Willingness to serve others
o Ability & desire to keep learning
o Willingness to make change
o Willingness to take responsibilities
o Ability to handle stress
o Ability to solve problems
o Having self-discipline
o Good self-image
o Give encouragement
3.6 Understanding about work ethics

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I have been guided and obeyed by the rule and regulation of the company. Some of the work
ethics include;
Punctuality: - means keeping the companies work beginning and ending time and to

complete a given task within the given period.

Office disciplines: - in work place you don’t have to disturb the working atmosphere.
For example, abstain from opening loud voice, loud music, songs and things which disturb others
workers working mood.
Reliability: - The worker should be qualified for the part he is supposed to be
performing. He/she must have appropriate skill and knowledge for the task assigned.
Honesty: - Regarding this value each worker regardless of its status should abstain from
bad behaviors such as cheating, bias, corruption etc.
Finally in Akaki Basic Metal Industry I Have Good Time, and Also I developed

my thinking Also My Knowledge.

Chapter Four

Conclusion and Recommendation

4.1. Conclusion
This internship program has a great roll in giving very interesting practical
knowledge which forces us to have enough confidence in our work. It also make as
problem solvers and solution developers. This internship also can be seen as what an
employed engineer do in the company. increasing social network and sharing idea
with those students is also its nice feature. Specially acquiring work ethics,
management system, leading project, helping each other are an unquestionable uses
that we got from it.
We are so lucky to participate in this qualified internship program because I gained a
lot of knowledge and experiences which I haven’t got when we were in campus and
we have developed what we learnt before by relating theoretical knowledge with the

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 practical knowledge. And we gained additional skills which are not in formal
education but they are skills to be learnt.
Also we got the correct position for this program at ABMI because this company has
many machines workshop. This increases the chance to get more knowledge and it
makes me know about machines which we may not get at other places & and also has
high capacity to manufacture different products and the one which has big share on
our countries development and technological transformation. Therefore, this company
is ocean of knowledge for everyone & especially for the department of Manufacturing
Engineering.
4.2 Recommendation

The company has different problems on foundry shop, machine shop, forging shop, heat

treatment, store for finished products and raw materials and etc… which is identified by

the employers and students for internship (practice).finished products and raw materials

are exposed to rain sun and dust, they loss their properties and strength. Therefore, to
make the company more profitable and increase the capacity these problems has to be
solved.
Create a worker motivation by increasing their month salary and other additional benefit.
I recommend that to repair the machine that are not working/functioning like; centrifugal
die casting machine, sand drying machine, piston die casting machine, etc.
I recommend improving safety issue especially for furnace workers.

I recommend that modern welding machine is required.

4.3 Challanges in our project

When we have done this Tumbling machine design analysis, we have face some problems

 Lack of Laibrary:- by maintanance case.

 Lack of Internate accesse.
 Shortage of paper writing
 Collapce of the work time and project work.

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  The manager has busy, for our project presentation; by conference case.

From abuve Problems we are using some methods;-like

 By using soft copy,for example:- CD, DVD.

 By using hard copy , for example:-our hand out of gear, chain, coupling and so on.
 By using pucket mony.
 By using our extra time , for example:- to night, to Saturday and to Sunday.
 By using another library, for example:-
---public library in akaki.
--Addis Ababa Engineering and Technology (5- killo ) university .

References
[1.]. https://www.steelorbis.com/steelcompanies/company/akakibasicmetalsindustry/markets/
[2.]. Online www.akakibasicmetalindustry.com
[3.]. Online www.wikipidia.com

, Foundry technology text book.

, Material science text book.

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