Kirinyaga university
School of Engineering and Built Environment
Attachment Undertaken at Weru Tea Factory--Tharaka Nithi County from
4th May–22nd June 2018
Morris Mutuma
Gitonga
EE051/S/2951/16
ATTACHMENT REPORT SUBMITTED TO THE DEPARTMENT OF
MECHANICAL ENGINEERING (AUTOMOTIVE) IN PARTIAL FULFILLMENT OF
THE REQUIREMENT FOR THE AWARD OF A DIPLOMA IN MECHANICAL
ENGINEERING AUTOMOTIVE OPTION.
JUNE 2018.
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DECLARATION
I declare that this industrial attachment report is my original work that I learned and observed
during the attachment at Weru Tea Factory, and that this report has never been presented to any
learning institution before. It is a copyright work which should not be published edited or
reproduced by any interested members without my whereabouts.
SIGN …………………….
DATE …………………….
Morris Mutuma Gitonga.
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ACKNOWLEDGEMENTS
At this point in time I would like to appreciate all personalities that have made my life easier and
therefore enhanced success in my attachment programme. First, I congratulate Kirinyaga
University for giving beforehand the technical skills required in the job market. More
specifically I congratulate my lecturers for impacting knowledge that has helped me have very
relevant skills as required by the job market.
I would also like to offer my gratitude’s to the management of Weru Tea Factory. The factory
unit manager, field service coordinator, production manager, production assistant manager, and
the departmental officers for offering me this opportunity of having my training in their
institution, learning more and getting more from them.
I would also like to congratulate my host supervisors and all the employees at the factory for my
smooth day to day working together. I also appreciate the effort of my parents and other
individuals of interest for their physical, financial, moral and physiological support.
Above all, am pleased and grateful beyond words for God almighty for He was the driver all
through.
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Executive Summary
As a diploma student pursuing mechanical engineering, I was required to undergo through a field
attachment programme. The programme should assist me to apply the theoretical skills learnt in
class in real life situation as well as the validity of the school curriculum against what the job
market requires. This document outlines the details of the institution where I was attached, its
history, its management system, its contact information and all that pertain the company that I
was attached.
The attachment period is usually a maximum of eight weeks, during which the student is
expected to acquire additional practical experience to supplement their course of study in the
university. They are also exposed to the real world of work and its challenges which will prepare
them towards their future careers.
Some of the important objectives of the attachment were; to enable me grow interest in the
occupation I undertake, expose me to work learned at the school, give an opportunity to apply
knowledge in real work situation to make transition from school to the world of work smooth
and satisfy the University that it produced the best student.
This report is the outcome of the eight weeks practical training I had at Weru Tea Factory. It
was a supervised programme since a lecturer from the University was supposed to visit me
during this period of the programme to ascertain its success and the amount of seriousness I
attached to it.
This report explains in deeper details, content and information which were not captured in the
log book. It also evaluates the work done in the whole attachment period with conclusions and
recommendations that are necessary to better the attachment programme in future.
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Table of Contents
DECLARATION.............................................................................................................................2
ACKNOWLEDGEMENTS.............................................................................................................3
Executive Summary.........................................................................................................................4
INTRODUCTION...........................................................................................................................6
ORGANOGRAM.........................................................................................................................6
Organization Background............................................................................................................7
WEEK ONE.....................................................................................................................................8
New skills learnt...........................................................................................................................9
WEEK TWO....................................................................................................................................9
News Kills Learnt........................................................................................................................9
WEEK THREE..............................................................................................................................10
New skills learnt.........................................................................................................................10
WEEK FOUR................................................................................................................................10
New skills learnt.........................................................................................................................11
WEEK FIVE..................................................................................................................................11
New skills learnt.........................................................................................................................11
WEEK SIX....................................................................................................................................11
New skills learnt.........................................................................................................................12
WEEK SEVEN..............................................................................................................................12
New skills learnt.........................................................................................................................12
WEEK EIGHT...............................................................................................................................13
Lesson learnt..............................................................................................................................13
CHAPTER THREE.......................................................................................................................13
EVALUATION OF THE ATTACHMENT PERIOD....................................................................13
Learning experience acquired-knowledge and skills.................................................................13
Challenges faced........................................................................................................................14
Recommendation.......................................................................................................................15
Chapter Four: Conclusion..............................................................................................................17
APPENDICES...............................................................................................................................17
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INTRODUCTION
ORGANOGRAM
FACTORY UNIT MANAGER
Accountant Production Manager
Field
Service
Assistant Production Assistant
Driver Accounta
nt
Logistics
Accountant
Mechanics
Personnel
Casual Workers
Plumber
Consultants
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Organization Background
Weru Tea Factory is located in Muthambi Division, Tharaka Nithi county. It is about 1.5
kilometers from Marima town, off the Embu - Meru highway approximately 190 kilometers from
Nairobi KTDA headquarters and 12kms from Chuka town, on the Eastern slopes of Mt Kenya at
an altitude of 1500m above sea level. The tea factory falls within KTDA administrative Region
IV.
Weru tea Factory was constructed in May 2000 although tea was first grown in the area in
1972 with most of the farms established in the 1990's. The need for the construction of the
factory arose due to acute congestion of green tea leaf at Kinoro Tea Factory, the long
distances covered by the leaf carriers leading to high costs and the potential for further
production.
The Factory was commissioned in 2002 to manufacture black CTC teas. At the time of
commissioning, the annual installed processing capacity for the factory was 10 million Kg's
green leaf per year with two lines, but currently the Factory has been expanded to three lines
with a processing capacity of 20 Million Kg's of green leaf per year. The Factory stands on a
total of 24.7 acres of land
Weru catchment area has approximately 8,903 registered growers with approximately 4,048.15
Acres under tea. The catchment has a potential for higher production per unit area and thus a
future increase in green leaf production. The factory operates through 61 coded leaf collection
centers and the catchment is divided into six electoral areas namely; Magumoni, Chuka,
Muthambi, Mwimbi South, Mwimbi North, and Mwimbi Central all of which are represented by
a Director elected by the farmers.
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WEEK ONE
On my arrival, I was warmly welcomed by the FACTORY unit manager who then introduced
me to the firm managers During my attachment programme, I was assigned to work at the
various enterprises of the firm. Such as withering machines, automotive, mechanical production,
boiler, casuals and vehicle loaders and off loaders and the logistic workers
The week started with orientation and a general briefing on how the factory works. This included
its management, functions and objectives.
I was first assigned the mechanical department and production section where my main task was
carrying out management practices for the vehicle and machine. The activities involved included
repairing vehicles and machine, cleaning the vehicles and machine.
New skills learnt
The new skills learnt from the factory during the first week we had little to learn since many
activities were getting assigned the duties and having time to socialize with people during that
week.
WEEK TWO
The second week involved a series of activities.
This week, my mandate area was motor winding and rewinding motors are used in motor vehicle
and machinery work. They are more than five hundred motors used to drive lift. fans, belts
conveyers also move vehicle systems however we are rewinding four motors and fixed them to
the systems.
Also replacing the broken conveyors and fabricating the foot bridge that was broken
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The major work was replacing the leaf spring and break pad from the lorry.
News Kills Learnt
This was good experience since I was released to work with minimum supervision
The more you work the more you get experience and work
WEEK THREE
This week started with study on use of lithe machine of which it is used to make bolts and nuts
for locking. also sharpening rollers that are used on grinding green tea leaves. Moreover, the
vehicle was serviced and painted for inspection. This include painting. Checking signals lamp
and head lamps and side mirrors.
I got also involved in battery terminal build up and replacement. it was a new experience to me
and I appreciate for making work easier.
New skills learnt
-battery are expensive hence need maximum maintenance.
-always be careful while using machine since they can cause arm or bring disability to you.
WEEK FOUR
The week started by servicing the vehicle almost five leaf carrying lorry. Any vehicle need o
be serviced after five thousand kilometers hence this open the week. This activity involves
changing the oil filter, cleaning air filter, releasing the oil from the engine and toping more oil.
The second day was marked by replacing shoe brake in the vehicle and also servicing the vehicle
which was a good experience and it took the whole day.
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Also, that week I was involved in changing the vehicle wheels ant tire and changing machine
bearing in the conveyor belts this was good experience
I was Also involved in welding and fabrication in the dryer section of green leaf section since the
boiler and the conveyor plays major role in the industry.
New skills learnt
-the need of multitasking since many times someone is involved in different management
-I got involved in welding which since look hard but as time goes on I was able to get it easy
-also, team work since many at time we need to lift things manually
WEEK FIVE
This week started with vehicle wheels mending and replacing. this activity involved us a whole
day in the workshop
The second day also got us in changing leaf spring in the vehicle and the centre bolt for three
vehicles. This also needed combination of effort for one to achieve the goal
Also welding the fuel tank linkage, replacing the wheels and shock absorber and servicing the
vehicle
On Friday was a public holiday hence the company gave us a break.
New skills learnt
- Repairing machines or systems using the needed tools and appropriate
- Determining the kind of tools and equipment needed to do a job.
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WEEK SIX
This week started by replacing the battery cables and battery terminal to increase efficiency and
long lasting of the battery
Also replacing the brake pad in the vehicle from the rear wheel. It was also followed by
replacing the double filament bulb and rear signal bulb and the halogen bulb the next day was
followed by replacing the vehicle wheels also servicing the vehicle. this include changing oil
filters air filter and fuel filter in the vehicle
New skills learnt
Watching gauges, dials, or other indicators to make sure vehicle is working properly.
Conducting tests and inspections of products, services, or processes to evaluate quality or
performance and efficiency.
Using logic and reasoning to identify the strengths and weaknesses of alternative solutions,
conclusions or approaches to problems.
Performing routine maintenance on equipment and determining when and what kind of
maintenance is needed. This is especially in vehicle harness
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WEEK SEVEN
The week started by replacing the leaf spring from which was hectic since it need a lot of energy
to lift it and fix it in the axle also welding the broken hook lift that is u to lift the green leaf to the
troughs the second day started by cleaning the vehicle in order to prepare it for spraying also
sparing the vehicle in the latter hours. The third day was followed by the same procedure of
washing and sparing the vehicle as recommended by the factory. there was also recommended to
replace the leaf spring since there are vehicles carry green leaf and in uneven load hence
breaking the leaf spring
New skills learnt
- It was hard for me to spray paint, but I learnt a lot in spray paint since it came to be my best
choice
-the need of multitasking since many times someone is involved in different management
WEEK EIGHT
This was a rainy season hence many vehicles needed to be checked regularly. This was marked
by cleaning the vehicles daily and also carrying inspection daily, however there were minor
incident for surveillance like replacing the vehicle bulbs and replacing the spring to the vehicle.
Lesson learnt
- One must utilize time well and manage duties well for easy accomplishment of the
activities
- Using logic and reasoning to identify the strengths and weaknesses of alternative
solutions, conclusions or approaches to problems
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CHAPTER THREE
EVALUATION OF THE ATTACHMENT PERIOD
Learning experience acquired-knowledge and skills
Professionally, I had the opportunity to practically feel some of the academic work I had
acquired from school. Working at weru tea factory has given me a feel of the working
environment. I have learnt good management skills during the period e.g. I learnt good time
management. During the period, we were expected at work by 8:00 AM and leave after 5:00
PM. Throughout the period, I was able to keep time. (Good time management). I know can
communicate effectively with diverse groups of people and participate in team work.
Personally, my confidence level has improved greatly. My interactions with various friends
were made, gained first-hand experience on how to manage a workshop and my observation
skill was greatly enhanced since in mechanical wok need only observation.
Working under stress conditions can also not be overlooked. It also gave me some more integrity
especially punctuality, being submissive to and taking the views of superiors, more tolerant,
respectful and hardworking.
I also acquired knowledge and practical skills necessary to up-scale agricultural productivity,
supply chain management and improve marketing of agricultural products on both large
scale and small-scale farms.
Challenges faced
Although I learnt all these skills, there were some challenges I faced;
1. Finances - my expenditure exceeded the little I had saved during my school days and that
which my parents gave me. This did not offer a very conducive environment during my
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attachment period. I would spend time looking for money rather than research on a
management aspect hence lessen my optimization.
As a remedy I would suppose that the institution liaises with the students sponsor for provision
of capital just enough for upkeep. This would ensure that the students are comfortable and that
they can actualize their skills in agribusiness field.
2. Time frame - The time stipulated for the attachment period is roughly two months.
Given that two months count from day one during when there is orientation and stuff
that does not really account to the objectives of the attachment activity, two months is a
limited period of time. Again, like mechanical itself is a broad course which has various
sub classes of its own and feasibly speaking it’s not possible to acquire and gain
experience
on all the aspects of this course within this short period of time.
As a remedy, I would suppose that the attachment time be increased, or students go for
attachment in phases like in first year, second year and third year.
3. Inadequate knowledge – in some enterprises, there was inadequate knowledge that could
help you learn more. This is simply because some who were heading were illiterate and
in others the workers were not ready to train someone since they thought one would take
over their job.
4. Not enough direction-sometimes the assignments given were completely unclear and
didn’t want to be a bother to the supervisor by asking frequent questions. However, I
came to learn that any employer would rather answer questions rather than have to clean
up the results of a mistake that could have been avoided.
5. Climate – the climate of the company location was also sometimes not friendly.
Temperatures were sometimes extremely too low since it was during the cold month. This
was also a challenge.
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Recommendation
There should be a laid down procedure for monitoring workers (attaches) as well as some
motivational packages for those who establish them self well.
The attachment is very beneficial to students as it assists them to blend academic work with that
of the industry therefore much importance must be given to attachment by students.
I would also recommend that the department start helping students in getting the areas of
attachment. Currently, students face a big challenge in getting good institutions to go for
attachment due to competition by students from other universities. This leads to students getting
a place when it is too late and thus don’t have enough time to learn. At other times, students get
places where there is no enough information to learn. This makes the attachment to be
ineffective.
Since the experience for these few weeks was enormous I recommend that the periods for the
attachment should be increased.
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Chapter Four: Conclusion
The compulsory industrial attachment of the university gives students the opportunity to apply
knowledge in real work, exposing students to work methods not taught at the university and
provide access to products and equipment not available at the university as well as assessing
students interest in the occupation they plan to undertake, the programme should therefore be
maintained and the period extended. I can now demonstrate the importance of mechanical in the
national economy with particular importance to its contribution to development among rural
communities in Kenya.
APPENDICES
Log Book
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