MPEN 239 -WORKSHOP PRACTICE

2025/2026

PRESENTED BY:
NAME : AGWATA CHRISTOPHER ONDIEKI
REG. NO : MPE/078/24
SUBMITTED TO : ENG. K. TALAM
DATE :4TH AUGUST, 2026
AFTER COMPLETION OF 12 WEEKS OF WORKSHOP PRACTICE AT THE
UNIVERSITY OF ELDORET

FROM : 18TH MAY, 2026

TO : 31ST JULY, 2026

THIS REPORT IS SUBMITTED AS A PARTIAL FULFILLMENT OF THE

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REQIREMENT FOR THE AWARD OF THE DEGREE IN MECHANICAL AND

PROUCTION ENGINEERING.

University of Eldoret is ISO 9001:2015 Certified

DEDICATION
I dedicate this report to my lecturers, friends, and family for their continuous support,
encouragement, and guidance throughout my workshop practice.

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DECLARATION BY STUDENT
I hereby declare that this report is my original work and has not been submitted to any other
institution for academic credit or award. The report is based on the Engineering Workshop
Practice undertaken by me, and all sources of information used have been duly
acknowledged.

Student Name: CHRISTOPHER ONDIEKI

Registration Number: MPE/078/24

Signature: _____________________________

Date: _________________________________

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ACKNOWLEDGEMENT
First, I would like to express my sincere gratitude to the Department of Mechanical and
Production Engineering for organizing the workshop practice program, which enabled us to
gain practical skills and hands-on experience in various engineering fields. The training
greatly enhanced my understanding of workshop operations and the application of theoretical
knowledge learned in class.
I would like to sincerely thank Eng. Talam for his guidance and support during the Sheet
Metal and Benchwork sections. His dedication and technical knowledge greatly contributed
to my learning experience.
Special appreciation also goes to Koech and Eng. Ogolla for guiding us through the Machine
Shop practice and for their valuable support during the Carpentry section. Their patience and
professional guidance enabled us to acquire important practical engineering skills.
I am also grateful to Eng. Ogolla and Kiprotich for their guidance during the Automotive
workshop sessions, where we gained practical exposure to automotive systems and
maintenance procedures.
My sincere appreciation goes to Mwaniki for the guidance and support offered during the
Electrical workshop practice, which helped us understand basic electrical principles and
applications.
In addition, I would like to thank Robinson and Eng. Ogolla for their guidance during the
Welding section, where we acquired essential welding techniques and safety practices.
Finally, I extend my heartfelt appreciation to all instructors, technicians, and fellow students
who contributed towards making the workshop practice successful and beneficial throughout
the training period.

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ABSTRACT
This report presents the activities and skills acquired during the Engineering Workshop
Practice undertaken as part of the Mechanical and Production Engineering training. The
workshop practice provided hands-on experience in various sections, including safety and
orientation, sheet metal work, machine shop operations, bench work, automotive
engineering, electrical engineering, welding and fabrication, and fitting processes.
The training enabled the application of theoretical knowledge in practical situations through
the use of engineering tools, machines, and equipment. Various tasks such as fabrication of
sheet metal components, machining operations, bench fitting, vehicle maintenance
procedures, and electrical installations were carried out under the guidance of workshop
instructors.
The workshop practice enhanced technical skills, safety awareness, teamwork, problem-
solving abilities, and understanding of engineering manufacturing processes. The experience
gained forms a strong foundation for future engineering studies and professional practice.

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EXECUTIVE SUMMARY
Workshop practice is an important part of the engineering curriculum and is designed to
provide students with practical skills and hands-on experience in various engineering fields.
The training enables students to apply the theoretical knowledge acquired in class to real
workshop operations and industrial activities.
The workshop practice aimed at achieving the following objectives:
• To bridge the gap between theoretical classroom learning and practical engineering
applications.
• To introduce students to different workshop sections and expose them to real
engineering tools, machines, equipment, and safety procedures.
• To equip students with practical skills and technical knowledge in various engineering
operations including Sheet Metal, Machine Shop, Benchwork, Automotive, Electrical,
Carpentry, and Welding.
• To develop teamwork, discipline, problem-solving abilities, and professionalism required
in the engineering field.

During the workshop practice, students attended different sections where various practical
activities were carried out under the guidance of qualified instructors and technicians.
Standard workshop procedures and safety measures were observed throughout the training
period.
The Sheet Metal section involved marking out, cutting, bending, folding, and joining sheet
metal materials. In the Machine Shop section, students were introduced to machining
operations such as turning, drilling, shaping, and grinding using different machine tools.
The Benchwork section focused on fitting operations, measuring, filing, cutting, and
assembling metal parts using hand tools. In the Automotive section, students learned basic
vehicle systems, maintenance procedures, and servicing techniques.
The Electrical workshop introduced students to electrical components, wiring systems, circuit
connections, and safety precautions when handling electrical equipment. The Carpentry
section involved woodworking processes, measuring, cutting, and joining timber materials
using different carpentry tools.
In the Welding section, students acquired practical welding skills, safety practices, and
knowledge of different welding techniques used in fabrication and repair works.
Overall, the workshop practice provided valuable practical exposure and enhanced the
students’ understanding of engineering operations, preparing them for future industrial and
professional experiences.
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Table of Contents
DEDICATION ................................................................................................................................ 2
DECLARATION BY STUDENT .................................................................................................. 3
ACKNOWLEDGEMENT .............................................................................................................. 4
ABSTRACT .................................................................................................................................... 5
EXECUTIVE SUMMARY............................................................................................................. 6
WEEK ONE .................................................................................................................................. 10
[Link] TO ENGINEERING WORKSHOP SAFETY ........................................... 10
1.1General workshop safety regulations ................................................................................... 10
[Link] TO WORKSHOP SECTIONS AND TOOLS ............................................ 11
2.1 Introduction to machine shop .............................................................................................. 11
2.2 Introduction to benchwork tools ......................................................................................... 12
2.3 Introduction to welding technology .................................................................................... 13
WEEK TWO ................................................................................................................................. 15
3. INTRODUCTION TO SHEET METAL .................................................................................. 15
3.1 Fabrication of a 90-Degree Elbow ...................................................................................... 15
3.2 Fabrication of an Irregular Elbow ....................................................................................... 16
3.3 Fabrication of a Twin Elbow .............................................................................................. 17
3.4 FABRICATION OF A POULTRY FEEDER .................................................................... 18
WEEK THREE ............................................................................................................................. 21
4. BENCHWORK PRACTICE..................................................................................................... 21
4.1 Exercise 1: Fabrication of Grinder Key .............................................................................. 21
4.2 Exercise 2: Fabrication of a Double Ended Spanner .......................................................... 24
WEEK FOUR ............................................................................................................................... 28
5. LATHE OPERATION PRACTICE......................................................................................... 28
5.1 Exercise 1: Stepped Shaft Fabrication ................................................................................ 28
5.2 Exercise 2: Machining of a Threaded Stud ......................................................................... 31
WEEK FIVE ................................................................................................................................. 35
ANCE Program – Sustainable Feeder Prototype for Hens ........................................................... 35
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6.1 Materials and Tools ............................................................................................................. 35

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6.2 Principle of Operation ......................................................................................................... 35

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 6.3 Design ................................................................................................................................. 36
6.4 Mechanical Analysis ........................................................................................................... 36
6.5 Testing and Challenges ....................................................................................................... 36
6.6 Conclusion .......................................................................................................................... 37
WEEK SIX .................................................................................................................................... 38
Pump System Evaluation .............................................................................................................. 38
7.1 Theory of Operation ............................................................................................................ 38
7.2 Challenges Encountered ...................................................................................................... 41
WEEK SEVEN ............................................................................................................................. 42
Automotive Engineering: Engine Dismantling and Gear Systems ............................................... 42
8.1 Introduction ......................................................................................................................... 42
8.2 Engine Components and Their Functions ........................................................................... 43
8.3 Gear Systems....................................................................................................................... 45
WEEK EIGHT .............................................................................................................................. 47
Electrical Installation and Motor Systems .................................................................................... 47
Practical Activities ........................................................................................................................ 48
9.1 Installation of a Single Switch, Socket, and Bulb ............................................................... 48
9.2 Connection of a Double Switch .......................................................................................... 48
9.3 Study of Electric Motors ..................................................................................................... 48
WEEK NINE................................................................................................................................. 51
Bungalow Setting Out and Plumbing Practical............................................................................. 51
10.1 Bungalow Setting Out ....................................................................................................... 51
10.2 Plumbing Practical ............................................................................................................ 52
WEEK TEN .................................................................................................................................. 55
Welding Practical and Fabrication Processes ............................................................................... 55
Types of Welding Practised .......................................................................................................... 55
11.1 Arc Welding ...................................................................................................................... 55
11.2 Gas Welding ...................................................................................................................... 55
11.3 Spot Welding..................................................................................................................... 55
FIELD TRIPS ............................................................................................................................... 58
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COMPREHENSIVE FIELD TRIP REPORT: SIRIKWA QUARRY LTD ................................. 58

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1.0 INTRODUCTION .............................................................................................................. 58

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 2.0 COMPANY PROFILE ....................................................................................................... 58
3.0 PRODUCTION AND MANUFACTURING PROCESSES .............................................. 59
4.0 MACHINES AND EQUIPMENT OBSERVED ................................................................ 60
5.0 MAINTENANCE PRACTICES OBSERVED ................................................................... 60
6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT .................................................. 60
7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED .................................. 61
8.0 NEW TECHNOLOGIES OBSERVED .............................................................................. 62
9.0 CHALLENGES IDENTIFIED ........................................................................................... 62
10.0 CONCLUSION ................................................................................................................. 62
COMPREHENSIVE FIELD TRIP REPORT: KENYA COOPERATIVE CREAMERIES
(KCC) ELDORET ........................................................................................................................ 63
1.0 INTRODUCTION .............................................................................................................. 63
2.0 COMPANY PROFILE ....................................................................................................... 63
3.0 PRODUCTION AND MANUFACTURING PROCESSES .............................................. 64
4.0 MACHINES AND EQUIPMENT OBSERVED ................................................................ 65
5.0 MAINTENANCE PRACTICES OBSERVED ................................................................... 66
6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT .................................................. 66
7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED .................................. 67
8.0 NEW TECHNOLOGIES AND PRACTICES OBSERVED .............................................. 68
9.0 CHALLENGES IDENTIFIED ........................................................................................... 68
10.0 CONCLUSION ................................................................................................................. 68
COMPREHENSIVE FIELD TRIP REPORT: SIRET TEA ESTATE ......................................... 69
1.0 INTRODUCTION .............................................................................................................. 69
2.0 COMPANY PROFILE ....................................................................................................... 69
3.0 PRODUCTION AND MANUFACTURING PROCESSES .............................................. 70
4.0 MACHINES AND EQUIPMENT OBSERVED ................................................................ 71
5.0 MAINTENANCE PRACTICES OBSERVED ................................................................... 72
6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT .................................................. 72
7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED .................................. 73
8.0 NEW TECHNOLOGIES AND PRACTICES OBSERVED .............................................. 73
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9.0 CHALLENGES IDENTIFIED ........................................................................................... 74

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10.0 CONCLUSION ................................................................................................................. 74

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 WEEK ONE

[Link] TO ENGINEERING WORKSHOP SAFETY

Engineering safety refers to the collective protocols, psychological awareness, and physical
barriers designed to eliminate risks, hazards, and accidents within an engineering
environment. In a mechanical and production workshop, safety is not merely an option but a
foundational discipline. The primary objective is to cultivate a "zero-accident" environment.
Every engineering process, whether machining, fabrication, or casting, presents inherent
risks. Engineering safety teaches a student or technician to anticipate these dangers, conduct
quick risk assessments before starting any operation, and understand that human life and
equipment longevity depend entirely on strict safety compliance.

1.1General workshop safety regulations

Workshop regulations represent the mandatory operational frameworks established to govern
human behavior and machine operations within a mechanical engineering facility. Their
primary purpose is to control hazards at the source, minimize risk, and enforce a strict culture
of safety among students, technicians, and visitors.
Compliance with these regulations is compulsory at all times:
• Authorized Access and Supervision: The workshop floor is a restricted engineering zone.
No personnel or student is permitted to enter the active shop floor, handle tools, or
energize any machinery without the explicit permission and direct supervision of a
qualified workshop instructor or technician.
• Industrial Dress Code Standards: Proper industrial attire must be maintained before
crossing the workshop threshold. Loose clothing, unbuttoned dustcoats, unzipped
overalls, neckties, rings, bracelets, and open-toed shoes are strictly prohibited. Long hair
must be securely tied back or contained in a cap to eliminate the risk of severe injury
from entanglement in rotating machine spindles (such as lathes, milling machines, or
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pillar drills).
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• Adherence to Safety Signage: Workshop users must recognize, understand, and strictly
obey the four standard classes of industrial safety signs displayed on the walls:

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 I. Prohibition Signs (Red/White): Indicating absolute restrictions or actions
that must not be taken (e.g., "No Smoking", "Do Not Enter").
II. Warning Signs (Yellow/Black): Alerting personnel to potential
environmental hazards (e.g., "High Voltage", "Crush Hazard", "Hot
Surface").
III. Mandatory Action Signs (Blue/White): Specifying protective measures
that must be actively taken before proceeding (e.g., "Eye Protection Must
Be Worn", "Wear Safety Boots").
IV. Safe Condition Signs (Green/White): Indicating the location of emergency
routes, emergency exits, eyewash stations, and first aid kits.
• Material Handling and Housekeeping Regulations: Heavy raw materials, metal sheets,
and long bars must be transported using proper ergonomic lifting techniques (lifting with
the legs, keeping the back straight) or mechanical assists. Materials must be stored in
designated racks and must never block designated walkways, fire extinguishers, or
emergency exits.
• Mandatory Reporting Protocol: Any variance from normal, safe workshop operations
must be reported immediately to the workshop supervisor. This includes minor personal
injuries (such as small cuts or abrasions), near-miss incidents, malfunctioning machinery,
frayed electrical cables, ungrounded equipment, or active fluid leaks (oil, grease, and
coolant).

[Link] TO WORKSHOP SECTIONS AND TOOLS

During the week, we were taken through different workshop sections where we were
introduced to various tools and equipment used in engineering practice.

2.1 Introduction to machine shop

During the first week of the Engineering Workshop Practice, we visited the machine shop
where we were introduced to various machines, tools, and equipment used in machining
operations. The instructor explained the importance of the machine shop in engineering and
manufacturing industries, where different metal components are shaped, cut, drilled, and
finished to the required dimensions and accuracy.
We were first taken through the general layout of the machine shop and the safety
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precautions observed while operating machines. Students were advised to avoid loose
clothing, properly secure workpieces before machining, and maintain concentration while
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operating machines to prevent accidents. The importance of cleanliness and proper
maintenance of machines was also emphasized.
Several machines found in the machine shop were introduced and their functions explained.
One of the major machines introduced was the lathe machine, which is used for turning
operations such as reducing the diameter of cylindrical workpieces, facing, threading, and
drilling. The instructor demonstrated the main parts of the lathe machine, including the
chuck, carriage, tailstock, tool post, and bed.
We were also introduced to the drilling machine, which is mainly used for producing holes in
metal workpieces. Different types of drill bits and their applications were explained. The
instructor demonstrated how workpieces are clamped firmly before drilling to ensure
accuracy and safety.
Another machine introduced was the milling machine, which is used for cutting and shaping
materials using a rotating cutter. The instructor explained that milling operations are
commonly used to produce flat surfaces, slots, and grooves on metal components.
The grinding machine was also introduced, and its purpose in smoothening and finishing
metal surfaces was explained. Students were advised to wear protective goggles during
grinding operations to protect their eyes from flying particles and sparks.
In addition to machines, we were introduced to measuring instruments commonly used in the
machine shop. These included vernier calipers, micrometers, steel rules, and try squares. The
instructor explained the importance of accurate measurements in engineering work to ensure
components fit correctly and meet the required specifications.
The session in the machine shop helped us understand the functions of different machines
and tools used in engineering manufacturing processes. It also gave us basic knowledge of
machine shop safety and proper handling of equipment before starting practical machining
operations

2.2 Introduction to benchwork tools

During the first week of the Engineering Workshop Practice, we were introduced to the
benchwork section where various hand tools and fitting equipment used in engineering
operations were demonstrated. The instructor explained that benchwork involves the use of
hand tools to cut, shape, mark, hold, and finish metal workpieces accurately. Benchwork is
important because it forms the foundation of many engineering fabrication and fitting
processes.
At the beginning of the session, safety precautions observed in the benchwork section were
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explained. We were advised to handle tools carefully, maintain cleanliness at the workbench,
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and always wear protective clothing such as overalls and safety boots. Proper storage of tools
after use was also emphasized to prevent accidents and tool damage.

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Several benchwork tools were introduced and their functions explained. One of the tools
demonstrated was the bench vice, which is used for firmly holding workpieces during
operations such as filing, cutting, and chipping. The instructor showed how workpieces are
clamped securely to avoid movement during work.
We were also introduced to the hacksaw, which is used for cutting metal bars, pipes, and
plates. Different types of hacksaw blades were discussed, and we were shown the correct
method of mounting the blade and applying pressure while cutting.
Different types of files were also introduced, including flat files, round files, and half-round
files. The instructor explained that files are used for smoothening surfaces, shaping
workpieces, and removing excess material after cutting. Proper filing techniques such as
maintaining even pressure and using both hands while filing were demonstrated.
Other tools introduced included hammers, chisels, steel rules, scribers, punches, and try
squares. Hammers and chisels are used in chipping operations to remove unwanted material,
while scribers and punches are used for marking lines and points on metal surfaces before
machining. The try square was introduced as a tool used for checking right angles and
ensuring accuracy in marking and fitting operations.
The instructor also explained the importance of measuring and marking out in benchwork
operations. Accurate measurements help ensure that components are produced according to
the required dimensions and specifications.
The benchwork session gave us practical knowledge of common hand tools used in
engineering workshops and their applications. It also helped us understand the importance of
precision, safety, and proper tool handling in engineering practice.

2.3 Introduction to welding technology

During the first week of the Engineering Workshop Practice, we visited the welding
workshop where we were introduced to various welding tools, equipment, and safety
practices used in welding operations. The instructor explained that welding is a fabrication
process used to join metal parts permanently through the application of heat and, in some
cases, pressure and filler materials.
The session began with an introduction to safety precautions observed in the welding
workshop. We were informed that welding operations involve hazards such as electric shock,
intense heat, sparks, harmful fumes, and ultraviolet radiation. Therefore, students were
advised to always wear protective clothing and safety equipment while carrying out welding
activities.
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Various protective equipment used in welding was introduced, including welding helmets,
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gloves, aprons, safety boots, and protective goggles. The instructor emphasized the

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importance of using welding helmets to protect the eyes and face from harmful radiation and
sparks produced during welding.
We were also introduced to different welding machines and accessories used in the
workshop. The instructor explained the basic parts and functions of an electric arc welding
machine, including the electrode holder, welding cables, earth clamp, and power source. The
process of creating an electric arc between the electrode and the workpiece to generate heat
for joining metals was briefly explained.
Different types of welding electrodes were shown and their applications discussed. The
instructor explained that electrodes are selected depending on the type of metal being welded
and the required strength of the joint. We were also shown how electrodes are properly
connected and handled during welding operations.
In addition, we were introduced to tools used for supporting welding activities, such as
chipping hammers and wire brushes. Chipping hammers are used for removing slag formed
after welding, while wire brushes are used for cleaning welded surfaces.
The instructor also demonstrated proper workshop arrangement and handling of gas cylinders
and electrical connections to prevent accidents. Students were advised never to touch live
electrical parts and to ensure proper ventilation in the workshop to reduce exposure to
harmful fumes.
The welding workshop session provided us with basic knowledge of welding equipment,
tools, and safety procedures. It also helped us understand the importance of proper protective
measures and correct handling of welding machines before engaging in practical welding
activities.

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 WEEK TWO

3. INTRODUCTION TO SHEET METAL

During the second week of the Engineering Workshop Practice, we were introduced to sheet
metal work and various fabrication processes carried out in the sheet metal workshop. The
instructor explained that sheet metal work involves cutting, bending, folding, and joining thin
metal sheets to produce different engineering components and products used in industries
such as ventilation, construction, and automobile manufacturing.
Safety precautions observed in the sheet metal workshop were first explained. We were
advised to wear protective clothing such as overalls, gloves, and safety boots to prevent
injuries caused by sharp edges of metal sheets and workshop tools. Proper handling and
storage of tools and materials were also emphasized.

3.1 Fabrication of a 90-Degree Elbow

During the second week of the Engineering Workshop Practice, we carried out the fabrication
of a 90-degree elbow using manila paper. The activity was aimed at helping students
understand pattern development techniques used in sheet metal work before working with
actual metal sheets.
The instructor first explained the purpose and application of a 90-degree elbow in
engineering. It was explained that elbows are commonly used in ducting and piping systems
to change the direction of airflow or fluid flow.
The fabrication process began with the drawing and development of the elbow pattern on
manila paper. Measurements and dimensions were first calculated and then transferred
carefully onto the manila paper using drawing instruments. Accuracy during marking out was
highly emphasized to ensure that the final elbow would fit properly after assembly.
After completing the marking out process, the developed pattern was carefully cut out using
scissors. The instructor demonstrated the correct cutting procedure to avoid damaging the
edges of the pattern and to maintain the required dimensions.
The cut sections were then folded and shaped gradually to form the curved structure of the
90-degree elbow. Care was taken to align the edges properly before joining the sections
together. The parts were then assembled to form a complete elbow with a 90-degree bend.
Through this activity, we learned the importance of accurate pattern development, careful
measurement, and proper alignment in fabrication work. The exercise also helped us
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understand the practical steps followed in the manufacture of sheet metal duct fittings.
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 Figure 1:Fabricated 90 degrees Elbow

3.2 Fabrication of an Irregular Elbow

We also carried out the fabrication of an irregular elbow using manila paper. The instructor
explained that an irregular elbow differs from a normal elbow because it involves unequal
diameters or varying shapes, making its pattern development more complicated.
The activity began with drawing the required dimensions and developing the irregular pattern
on manila paper. The instructor guided us on how to divide and transfer measurements
correctly to achieve the desired shape of the elbow.
After marking out, the pattern was carefully cut out using scissors. Extra care was taken
during cutting and shaping to ensure that the irregular sections matched correctly during
assembly.
The different sections were then folded and joined together carefully to produce the final
irregular elbow. During the exercise, we learned that irregular fittings require a high level of
concentration, precision, and patience because slight errors in measurement can affect the
final outcome.
The activity improved our understanding of geometrical development and pattern formation
used in engineering fabrication processes.

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 Figure 2:Fabricated Irregular Elbow

3.3 Fabrication of a Twin Elbow

Another activity carried out during the week was the fabrication of a twin elbow using manila
paper. The instructor explained that a twin elbow consists of two connected elbow sections
used to direct airflow or fluid flow in different directions.
The fabrication process started with the development of the patterns on manila paper
according to the provided dimensions. Measurements were carefully marked out and checked
before cutting to minimize errors.
The patterns were then cut out neatly using scissors. The cut sections were folded and shaped
gradually to achieve the required elbow curves and angles. Proper alignment of the sections
during assembly was emphasized to ensure symmetry and neatness of the final product.
After shaping and assembling the sections, the complete twin elbow was formed successfully.
The exercise helped us understand the practical procedures involved in pattern development
and fabrication of complex duct fittings.
The activity also enhanced our skills in measuring, marking out, cutting, folding, and
assembling fabricated components using development techniques.

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Figure 3:Fabricated Twin Elbow

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3.4 FABRICATION OF A POULTRY FEEDER
Introduction
The fabrication of a poultry feeder involved the design and construction of an improvised
feeding system for hens using locally available materials. The project aimed to develop a
cost-effective and sustainable feeder that minimizes feed wastage, reduces labor
requirements, and ensures a continuous supply of feed to poultry. The activity enabled
students to apply engineering principles such as design, measurement, fabrication, assembly,
and testing.
Objectives
✓ To design and fabricate a sustainable poultry feeder.
✓ To reduce feed wastage during feeding.
✓ To apply engineering design and fabrication skills.
✓ To utilize locally available and recyclable materials.
✓ To improve understanding of mechanical systems and their operation.

Materials and Tools Used

Materials
• Plastic bucket or container
• PVC pipes and fittings
• Wooden planks
• Wire mesh
• Bolts and nuts
• Adhesive
• Feed tray
• Tools
• Hacksaw
• Measuring tape
• Hand drill
• Screwdrivers
• Hammer
• Pliers
• Marker pen
• File
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Procedure
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The fabrication process began with designing the feeder and determining the dimensions of
each component. Measurements were taken and marked on the materials using a measuring
tape and marker.
The feed reservoir was constructed from a plastic container, while PVC pipes were used to
create channels through which the feed could flow into the feeding tray. The materials were
cut to the required sizes using a hacksaw and assembled using bolts, nuts, and adhesive.
A supporting frame was fabricated to ensure stability and maintain the feeder in an upright
position. All joints were tightened and reinforced to increase durability. Finally, the feeder
was inspected and prepared for testing.
Principle of Operation
The poultry feeder operates on the principle of gravity. Feed stored in the reservoir flows
downward through the outlet channel into the feeding tray as the hens consume the available
feed. The feeder automatically replenishes the tray without requiring constant human
intervention.
The design minimizes feed losses by controlling the amount of feed released and protecting it
from contamination.
Testing and Evaluation
The feeder was tested by filling the reservoir with poultry feed and observing its
performance. The following aspects were evaluated:
✓ Uniformity of feed distribution.
✓ Stability of the structure.
✓ Ease of operation.
✓ Feed wastage.
✓ Durability of the feeder.
✓ The prototype successfully supplied feed to the hens while reducing wastage and labor.

Challenges Encountered
• Difficulty in achieving uniform feed flow.
• Blockage at the outlet opening.
• Weak joints during assembly.
• Limited availability of materials.
• Maintaining structural stability.

Safety Precautions
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✓ Wear protective clothing during fabrication.

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✓ Handle cutting tools carefully.

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 ✓ Secure all components properly.
✓ Keep the workplace clean and organized.
✓ Follow workshop safety rules.

Conclusion
The fabrication of the poultry feeder was successful and demonstrated the importance of
engineering in solving agricultural problems. The feeder provided a sustainable and
economical method of feeding poultry while reducing feed wastage and labor costs. The
project improved practical skills in design, fabrication, assembly, testing, and problem-
solving.

Figure 4:Fabricated Poultry Feeder

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University of Eldoret is ISO 9001:2015 Certified

 WEEK THREE

4. BENCHWORK PRACTICE
Bench work is one of the fundamental operations in mechanical and production engineering.
It involves the use of hand tools and simple workshop equipment to shape, cut, mark, fit, and
finish metal workpieces accurately. Bench work serves as the foundation for many
engineering manufacturing processes because it develops the practical skills required for
precision work and component assembly.
During the bench work practice, students were introduced to various hand tools and
measuring instruments commonly used in engineering workshops. These included files,
hacksaws, chisels, hammers, scribers, steel rules, try squares, centre punches, and bench
vices. Emphasis was placed on the correct selection, handling, maintenance, and safe use of
these tools to achieve accurate and quality workmanship.
The bench work training involved several operations such as measuring and marking out,
cutting, filing, chipping, drilling, and fitting. These activities enabled students to understand
the importance of dimensional accuracy, surface finish, and adherence to engineering
drawings. The practical exercises also enhanced hand-eye coordination, patience, precision,
and problem-solving skills.
Furthermore, safety precautions and workshop discipline were emphasized throughout the
training. Students were required to wear appropriate personal protective equipment (PPE),
maintain clean workstations, and follow standard operating procedures while carrying out
bench work activities.
Overall, the bench work practice provided valuable hands-on experience and laid a strong
foundation for advanced manufacturing, machining, fitting, and fabrication processes
encountered in mechanical and production engineering.

4.1 Exercise 1: Fabrication of Grinder Key

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Objective

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To fabricate a grinder key from a mild steel plate using bench work tools and operations
while following the given engineering drawing and specified dimensions.
Materials Used

• Mild steel plate

Tools and Equipment Used

▪ Steel rule
▪ Scriber
▪ Centre punch
▪ Hacksaw
▪ Flat file
▪ Half-round file
▪ Round file
▪ Drilling machine
▪ Twist drill bits
▪ Vernier caliper

Procedure

I. A mild steel plate of suitable size was selected and cleaned to remove dirt
and rust.
II. The dimensions of the grinder key were obtained from the engineering
drawing.
III. The profile of the grinder key was marked out on the metal plate using a
steel rule, scriber, and try square.
IV. The centres of all holes were accurately located and marked using a
centre punch and hammer.
V. The workpiece was firmly clamped on a bench vice.
VI. Excess material around the profile was cut using a hacksaw, leaving a
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small allowance for filing.

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VII. The external profile was shaped to the required dimensions using flat and
half-round files.

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 VIII. Sharp corners were filed to the specified radii according to the drawing.
IX. Holes were drilled using appropriate drill bits on a drilling machine.
X. The drilled holes were checked for accuracy and finished using round files
where necessary.
XI. Final finishing was carried out using files and emery paper to obtain a
smooth surface finish.
XII. The completed grinder key was inspected and compared with the drawing
to ensure dimensional accuracy.

Observations

A. Accurate marking out was essential for achieving the correct

dimensions.
B. Centre punching prevented the drill bit from wandering during drilling.
C. Filing required patience and precision to achieve the required profile
and surface finish.
D. Frequent measurement during fabrication helped minimize dimensional
errors.

Challenges Encountered

a. Maintaining dimensional accuracy during cutting and filing.

b. Achieving smooth curved sections and radii.
c. Preventing over-filing of critical dimensions.
d. Ensuring proper alignment of drilled holes.

Safety Precautions

✓ Safety boots and workshop overalls were worn at all times.

✓ The workpiece was securely clamped before cutting, filing, or drilling.
✓
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Care was taken when handling sharp tools and metal edges.
✓ Safety rules for operating drilling machines were strictly observed.
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✓ The work area was kept clean and organized throughout the exercise.

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Conclusion

The fabrication of the grinder key provided practical experience in bench work operations
such as marking out, centre punching, hacksaw cutting, filing, drilling, and finishing. The
exercise improved accuracy, tool-handling skills, and understanding of engineering drawings,
which are essential skills in Mechanical and Production Engineering.

Figure 5:Fabricated Grinder Key

4.2 Exercise 2: Fabrication of a Double Ended Spanner

ABSTRACT
This report presents the fabrication process of a double-ended spanner carried out during
bench work practice in the mechanical engineering workshop. The exercise involved
interpreting an engineering drawing and producing a functional tool using standard bench
work operations. The main processes included marking out, cutting, filing, shaping, drilling,
and finishing. The objective was to develop precision skills in manual metal working while
adhering to workshop safety standards. The final product was evaluated based on
dimensional accuracy, surface finish, and conformity to the given drawing.
INTRODUCTION
Bench work practice forms a fundamental component of mechanical and production
engineering training. It involves the use of hand tools and basic workshop machines to
fabricate components with high accuracy. The double-ended spanner is a common hand tool
used for tightening and loosening nuts and bolts of different sizes.
In this exercise, a double-ended spanner was fabricated from mild steel stock material. The
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work required careful interpretation of engineering drawings and precise execution of

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manufacturing processes to achieve the required geometry and finish.

AIM OF THE PRACTICAL

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The main aim of this exercise was to fabricate a double-ended spanner from a mild steel flat
bar according to the provided engineering drawing using bench work operations.
OBJECTIVES
The specific objectives of the exercise were to:
1. Interpret engineering drawings and transfer dimensions accurately onto a workpiece.
2. Develop competence in marking out using standard measuring tools.
3. Apply bench work operations such as sawing, filing, drilling, and finishing.
4. Enhance accuracy and surface finishing skills.
5. Observe and apply workshop safety precautions.

TOOLS AND EQUIPMENT USED

• Steel rule
• Scriber
• Try square
• Divider
• Centre punch and hammer
• Bench vice
• Hacksaw
• Flat file and round file
• Vernier caliper
• Sandpaper

MATERIALS USED
Mild steel flat bar (selected according to required dimensions in the drawing)
PROCEDURE
Marking Out
The mild steel bar was first cleaned to remove rust and oil. Measurements were taken from
the engineering drawing and transferred onto the workpiece using a steel rule and scriber.
The outline of the spanner, including the circular ends and central profile, was marked
accurately. A divider was used to mark circular arcs, and centre points were punched using a
centre punch to improve visibility and guide subsequent operations.
Cutting Operation
The workpiece was firmly clamped in a bench vice. Excess material was removed using a
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hacksaw, ensuring cutting was done slightly outside the marked lines to allow for finishing.
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Care was taken to maintain accuracy and avoid bending or distortion of the material.

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Filing and Shaping
Rough edges were removed using a flat file to approach the required dimensions. A round
file was used to shape internal curved sections of the spanner jaws. Continuous measurement
and checking against the drawing were carried out to ensure dimensional accuracy. Filing
was progressively refined to achieve smooth surfaces and correct geometry.
Finishing Operations
Final shaping was carried out using fine files and sandpaper to improve surface finish. Sharp
edges were chamfered to enhance safety and appearance. The workpiece was cleaned and
inspected for compliance with the drawing specifications.
SAFETY PRECAUTIONS
✓ Personal protective equipment (PPE) such as overalls and safety goggles was worn
throughout the exercise.
✓ The workpiece was securely clamped before any operation.
✓ Files were used with proper handles to prevent injury.
✓ Hacksawing was done carefully to avoid blade breakage.
✓ Metal chips were removed using a brush, not bare hands.

RESULTS AND DISCUSSION

A double-ended spanner was successfully fabricated according to the given engineering
drawing. The final product demonstrated acceptable dimensional accuracy, smooth surface
finish, and proper symmetry. Minor deviations were controlled during the filing process
through continuous measurement and correction.
The exercise reinforced the importance of precision, patience, and proper tool handling in
achieving engineering accuracy.
CHALLENGES ENCOUNTERED
I. Maintaining accurate curvature during internal filing.
II. Time consumption during finishing operations.
III. Minor errors during initial marking out requiring correction during filing.

CONCLUSION
The fabrication of the double-ended spanner was successfully completed using standard
bench work techniques. The exercise enhanced practical skills in marking out, cutting, filing,
and finishing, while reinforcing the importance of accuracy in engineering fabrication
processes. The objectives of the practical were fully achieved.
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 Figure 6:Fabricated Double Ended Spanner

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 WEEK FOUR

5. LATHE OPERATION PRACTICE

5.1 Exercise 1: Stepped Shaft Fabrication
INTRODUCTION AND OBJECTIVES
The purpose of this workshop practical was to develop hands-on proficiency in machine shop
operations using the center lathe. The exercise involved transforming a raw mild steel round
bar into a complex, multi-featured stepped shaft.
Learning Objectives:
1. To master the sequence of operations required for turning multi-diameter profiles
(stepped turning).
2. To perform precise external thread cutting to standard pitches.
3. To successfully execute form-turning through grooving and surface texturing via knurling.
4. To adhere strictly to machine shop safety protocols.

EQUIPMENT, TOOLS, AND MATERIALS

Workpiece Material: Mild Steel (Low Carbon Steel) round bar stock. Purpose: Raw
material for machining.
Machine Tool: Conventional Center Lathe / NC-assisted Lathe. Purpose: Primary machining
platform.
Cutting Tools: HSS/Carbide Right-Hand Turning Tool, Grooving Tool, 60° Threading Tool.
Purpose: Metal removal and profiling.
Forming Tool: Medium Diamond-Pattern Knurling Tool. Purpose: Surface texturing of the
handle/base.
Measuring Tools: Vernier Caliper (0.02 mm precision), Pitch Gauge. Purpose: Quality
control and dimensional accuracy.
Auxiliary Tools: Center Drill, Chuck Key, Tool Post Spanner. Purpose: Workpiece setup
and centering.
SAFETY PRECAUTIONS
✓ Adherence to workshop regulations is critical to prevent personal injury and machine
damage. Based on the workshop mandate, the following rules were strictly observed:
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✓ Personal Protective Equipment (PPE): Safety goggles and workshop coats must be worn
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at all times. Never wear gloves when operating rotating spindles or machine switches to
prevent entanglement hazards.

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 ✓ Workpiece Security: Ensure the raw stock is firmly clamped in the 3-jaw chuck and that
the chuck key is removed immediately after tightening.
✓ Parameter Controls: Do not alter established NC system parameters or feed rates
without the explicit confirmation of the workshop instructor.
✓ Housekeeping: Keep the lathe bed free of loose tools and clear long, stringy swarf using
a rake. never with bare hands.

PROCESS SEQUENCE / METHODOLOGY

The fabrication process followed a logical sequence from the largest diameter features to the
finest detailed elements to maintain structural rigidity during heavy cuts.
Step 1: Workpiece Setup and Facing
The raw round bar was clamped securely in the 3-jaw self-centering chuck, minimizing
overhang to avoid deflection.
The lathe spindle speed was set according to mild steel cutting parameters. The right-hand
turning tool was used to face the end surface, creating a flat, true datum line perpendicular to
the axis of rotation.
Step 2: Center Drilling
A center drill was mounted into the tailstock chuck.
The lathe was turned on, and the tailstock quill was slowly advanced to create a pilot center
hole on the faced end to support later operations or ensure axial alignment.
Step 3: Progressive Parallel Turning (Stepped Profile)
Rough Turning: Heavy passes were made to reduce the entire length of the stock to the
maximum required outer diameter of the base.
Step Turning: Moving from right to left, the tool was advanced longitudinally to turn down
the progressive steps. The workpiece was systematically sectioned into three distinct
diameters:
The large base section (destined for knurling).
The intermediate shoulder.
The smallest diameter section at the front end (prepared to the exact major diameter required
for thread cutting).
Step 4: Grooving (Neck Undercut)
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The turning tool was replaced with a parting/grooving tool aligned perfectly square to the
workpiece axis.
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A deep, radial plunge cut was executed near the bottom base of the shaft, creating a smooth
clearance groove (undercut) between the two lower distinct sections.
Step 5: Knurling
A diamond-pattern knurling tool was set up in the tool post and aligned precisely with the
center axis of the workpiece.
The spindle speed was reduced significantly to a low-speed, high-torque setting.
Under heavy lubrication (coolant application), the knurling wheels were pressed firmly
against the two wider diameter sections near the base. The tool was fed slowly across the
faces to deform the metal plastically, producing a clean, cross-hatched grip texture.
Step 6: External Thread Cutting
The lathe gear train was configured to match the desired standard metric pitch using the
quick-change gearbox.
A 60° single-point threading tool was clocked perfectly perpendicular to the workpiece using
a center gauge.
Over successive, shallow incremental passes synchronized by the threading dial, the external
threads were cut onto the smallest step profile until a full, clean thread profile was achieved.
Step 7: Parting-off and Finishing
The components were deburred using a fine file to remove sharp edges.
A parting tool was used to cut the finished stepped shaft from the remaining raw stock bar to
its final total length specification.
QUALITY CONTROL AND INSPECTION
An evaluation of the finished component featured in the figure below indicates the following
structural outcomes:
Visual Quality: The diamond knurling shown in figure below displays excellent geometric
consistency without double-tracking, providing an effective high-friction surface.
Threading Integrity: The external thread profiles on the top section are well-defined, clean,
and free of tearing, indicating correct spindle synchronization and depth-of-cut increments.
Dimensional Accuracy: The transitions between the distinct shoulders and the central
grooved neck are sharp and perpendicular, aligning well with general engineering tolerances
for manual lathe production.
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CONCLUSION
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The practical session was successfully concluded with the fabrication of the stepped shaft
according to standard workshop procedures. The exercise provided valuable practical insight

University of Eldoret is ISO 9001:2015 Certified

into the behavioral properties of mild steel under different machining operations (cutting vs.
forming) and reinforced the importance of strategic operational planning in multi-stepped
machining.

Figure 7: Stepped Shaft with External Thread

5.2 Exercise 2: Machining of a Threaded Stud

Introduction
A threaded stud is a cylindrical mechanical fastener having external threads and is widely
used in machine assembly, fastening applications, and mechanical joints. The manufacture of
a threaded stud involves several lathe operations, including facing, turning, step turning, and
thread cutting. This practical exercise was carried out in the machine shop to develop skills in
the operation of a centre lathe and the production of threaded components according to
specified dimensions.
Objectives
The objectives of this practical were:
✓ To understand the operation of a centre lathe machine.
✓ To perform basic lathe operations such as facing, turning, and thread cutting.
✓ To develop precision measurement and machining skills.
✓ To produce a threaded stud according to the required specifications.
✓ To observe workshop safety regulations during machining operations.
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Tools, Equipment and Materials Used

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Tools and Equipment

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 • Centre lathe machine
• Three-jaw chuck
• Turning tool
• Facing tool
• Thread-cutting tool
• Centre drill
• Vernier caliper
• Steel rule
• Thread pitch gauge

Material
Mild steel round bar
Procedure
Preparation of the Workpiece
A mild steel round bar of suitable diameter and length was selected. The material was
cleaned and inspected to ensure it was free from defects before machining.
Mounting the Workpiece
The workpiece was securely mounted in a three-jaw self-centering chuck. Proper alignment
was checked to ensure smooth and concentric rotation during machining.
Facing Operation
The free end of the workpiece was faced using a facing tool to obtain a flat surface
perpendicular to the axis of rotation. This provided an accurate reference surface for
subsequent machining operations.
Plain Turning
The workpiece diameter was reduced using a turning tool until the required dimensions were
achieved. Roughing cuts were followed by finishing cuts to improve dimensional accuracy
and surface finish.
Step Turning
Selected sections of the workpiece were machined to different diameters to produce the
stepped profile required for the threaded stud. Measurements were taken regularly using a
vernier caliper.
Thread Cutting
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The thread-cutting tool was set at the correct centre height and aligned properly. The lathe
gearbox was adjusted to obtain the required thread pitch. Successive cuts were made until the

University of Eldoret is ISO 9001:2015 Certified

required thread depth and profile were achieved. The threads were checked using a thread
gauge and matching nut.
Finishing
After thread cutting, burrs and sharp edges were removed. Fine finishing cuts were made to
improve surface quality, and the workpiece was cleaned before final inspection.
Safety Precautions
✓ Safety goggles and workshop overalls were worn throughout the exercise.
✓ The workpiece was firmly secured before starting the machine.
✓ The chuck key was removed immediately after tightening the chuck.
✓ Measurements were not taken while the machine was running.
✓ Loose clothing and jewellery were avoided.
✓ Metal chips were removed using a brush.

Results
A threaded stud was successfully machined from a mild steel round bar. The finished
component had a uniform thread profile, accurate dimensions, and a satisfactory surface
finish. The stud conformed closely to the specified design requirements.
Challenges Encountered
1. Maintaining dimensional accuracy during turning operations.
2. Achieving the correct thread depth without overcutting.
3. Preventing vibration during thread cutting.
4. Ensuring accurate alignment of the cutting tool.

Conclusion
The machining of the threaded stud was successfully completed using a centre lathe. The
exercise provided practical experience in facing, turning, step turning, and thread-cutting
operations. It enhanced understanding of machining principles, precision measurement, and
safe machine operation. The practical objectives were achieved, and a functional threaded
stud was produced according to the required specifications.
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 Figure 8: Threaded Stud

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 WEEK FIVE

ANCE Program – Sustainable Feeder Prototype for Hens

6.1 Materials and Tools
The following materials and tools were used in the construction of the improvised sustainable
feeder prototype:
Materials
• Plastic container or bucket
• PVC pipes and fittings
• Metal wire
• Wooden supports
• Fasteners (nuts and bolts)
• Adhesive
• Feed tray
• Tools
• Measuring tape
• Hacksaw
• Hand drill
• Screwdrivers
• Hammer
• Pliers
• Marker pen

6.2 Principle of Operation

The sustainable feeder prototype was designed to provide a continuous and controlled supply
of feed to hens while minimizing feed wastage. Feed is stored in a reservoir and flows
gradually through gravity into the feeding tray as the hens consume it. The feeder is elevated
above the ground to prevent contamination by dirt and moisture.
The design ensures that the feeding tray is replenished automatically without frequent human
intervention. By regulating the amount of feed released, the feeder reduces wastage and
improves feeding efficiency.
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6.3 Design
The feeder prototype was designed using locally available and recyclable materials to reduce
production costs and promote sustainability. Measurements were taken to ensure that the
structure could hold sufficient feed while remaining stable.
The feeder consisted of three major sections:
Feed reservoir: Stores the poultry feed.
Delivery channel: Guides the feed from the reservoir to the tray.
Feeding tray: Provides access for the hens to consume the feed.
The structure was designed to withstand environmental conditions and allow easy cleaning
and maintenance.

6.4 Mechanical Analysis

The feeder operates mainly through the principle of gravity. The weight of the feed creates a
downward force that moves the feed from the storage chamber to the tray. Proper support and
fastening were necessary to maintain structural stability.
The mechanical considerations included:
✓ Load distribution on the supporting frame.
✓ Stability of the feeder during operation.
✓ Resistance to wear and corrosion.
✓ Adequate feed flow without blockage.
✓ Strength of joints and fasteners.
✓ The design was analyzed to ensure that the feeder could support the weight of the feed
and withstand continuous use in a poultry environment.

6.5 Testing and Challenges

The prototype was tested by filling the reservoir with poultry feed and observing the flow
into the feeding tray. Several tests were conducted to evaluate efficiency, durability, and feed
distribution.
Challenges encountered
• Irregular feed flow due to blockage.
• Difficulty in joining some components.
• Material limitations.
•
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Ensuring stability of the feeder.

• Preventing feed wastage.
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• Solutions implemented

University of Eldoret is ISO 9001:2015 Certified

 • Adjusting the outlet size.
• Reinforcing weak joints.
• Improving the support structure.
• Modifying the feeding tray design.

6.6 Conclusion
The construction of the sustainable feeder prototype provided practical knowledge on design,
fabrication, and testing of engineering systems. The project demonstrated how locally
available materials can be used to develop cost-effective solutions for poultry farming.
The feeder successfully supplied feed to hens while reducing wastage and minimizing human
labor. Through this exercise, students gained skills in problem-solving, teamwork,
measurement, fabrication, and mechanical analysis.

Figure 9:Sustainable Feeder

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University of Eldoret is ISO 9001:2015 Certified

 WEEK SIX

Pump System Evaluation

Introduction
During the sixth week of workshop practice, we carried out the evaluation of a pump system.
The purpose of the practical was to understand the operation, components, and performance
of different types of pumps used in domestic, agricultural, and industrial applications. The
exercise involved inspecting the pump system, identifying its components, and evaluating its
efficiency under different operating conditions.
Objectives
✓ To study the working principles of a pump system.
✓ To identify the major components of a pump.
✓ To evaluate the performance and efficiency of the system.
✓ To understand the applications of pumps in engineering.
✓ To develop practical skills in operating and maintaining pump systems.

Materials and Equipment Used

• Centrifugal pump
• Electric motor
• Water reservoir
• Suction pipe
• Delivery pipe
• Pressure gauge
• Flow meter
• Valves
• Measuring instruments
• Wrenches and spanners

7.1 Theory of Operation

A pump is a mechanical device used to transfer fluids from one point to another by
converting mechanical energy into hydraulic energy. In a centrifugal pump, the electric
motor rotates an impeller, which creates centrifugal force that moves water from the inlet to
the outlet.
The pump draws water through the suction pipe and discharges it through the delivery pipe at
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a higher pressure. The efficiency of the system depends on factors such as flow rate,
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pressure, power consumption, and pump speed.

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Procedure
✓ The pump system components were identified and inspected.
✓ The suction and delivery pipes were connected properly.
✓ The pump was primed before starting.
✓ The electric motor was switched on to drive the pump.
✓ The pressure and flow rate were measured.
✓ Data was recorded for analysis.
✓ The performance and efficiency of the pump system were evaluated.

Observations
✓ Water flowed continuously from the reservoir to the outlet.
✓ The pressure increased as the pump speed increased.
✓ Minor losses occurred due to pipe friction.
✓ The pump operated efficiently under normal conditions.
✓ Proper priming was necessary for smooth operation.

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Applications of Pump Systems
✓ Irrigation systems.
✓ Domestic water supply.
✓ Industrial processes.
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✓ Sewage treatment.
✓
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Fire-fighting systems.
✓ Water distribution networks.

University of Eldoret is ISO 9001:2015 Certified

7.2 Challenges Encountered
• Air leakage in the suction pipe.
• Difficulty in priming the pump.
• Pressure fluctuations.
• Friction losses in pipes.

Safety Precautions
✓ Ensure all pipe connections are secure.
✓ Avoid operating the pump without water.
✓ Wear protective equipment.
✓ Switch off the power supply before maintenance.
✓ Keep electrical components dry.

Conclusion
The pump system evaluation practical enhanced our understanding of the working principles
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and performance of pumps. We learned how to operate, inspect, and evaluate pump systems
while appreciating their importance in domestic, agricultural, and industrial applications. The
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exercise also improved our practical skills in system analysis and maintenance.

University of Eldoret is ISO 9001:2015 Certified

 WEEK SEVEN

Automotive Engineering: Engine Dismantling and Gear Systems

8.1 Introduction
During the seventh week of workshop practice, we carried out automotive engineering
practicals involving engine dismantling, inspection, identification of engine components, and
the study of gear systems. The practical sessions aimed at enhancing our understanding of the
construction, operation, and maintenance of internal combustion engines and transmission
systems used in automobiles.
Objectives
✓ To dismantle and assemble an engine safely.
✓ To identify the major components of an internal combustion engine.
✓ To understand the functions of various engine parts.
✓ To study different types of gear systems and their applications.
✓ To develop practical skills in automotive maintenance.

Materials and Tools Used

• Spanners and socket set
• Screwdrivers
• Pliers
• Torque wrench
• Engine stand
• Lubricating oil
• Cleaning materials
• Vernier caliper
• Hammer

Procedure
The practical session began by disconnecting and dismantling the engine components
systematically. Various tools were used to remove the cylinder head, pistons, connecting
rods, crankshaft, valves, and other parts.
After dismantling, each component was cleaned and inspected for wear, cracks, and damage.
Measurements were taken where necessary, and the functions of each component were
discussed. We also studied the operation of different gear systems used in automobiles.
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 Figure 10:Internal View of The Engine

8.2 Engine Components and Their Functions

Cylinder Block
The cylinder block forms the main structure of the engine and houses the cylinders, pistons,
and crankshaft.
Pistons
Pistons move up and down inside the cylinders and convert the energy produced during
combustion into mechanical motion.
Connecting Rod
The connecting rod links the piston to the crankshaft and transmits force.
Crankshaft
The crankshaft converts the reciprocating motion of the piston into rotary motion.
Cylinder Head
The cylinder head encloses the combustion chamber and contains the valves and spark plugs.
Valves
Valves control the intake of air-fuel mixture and the exhaust of combustion gases.
Camshaft
The camshaft operates the valves at the correct timing.
Spark Plug
The spark plug ignites the air-fuel mixture in petrol engines.
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 Figure 11: Overhead Cylinder Head Assembliy and Cylinder Head Gasket

Figure 12: Cylinder Block Bores,Piston, and Deck Flatness

Figure 13: Front Timing Cover Housing with Chain Guides and Camshaft
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 Figure 14:Front View of The Engine

8.3 Gear Systems

We studied different types of gears used in automotive transmission systems, including:
✓ Spur gears
✓ Helical gears
✓ Bevel gears
✓ Worm gears
✓ Rack and pinion gears

Functions of Gear Systems

✓ Transmit power between shafts.
✓ Change speed and torque.
✓ Change the direction of motion.
✓ Improve mechanical efficiency.

Observations
✓ Engine components must be dismantled in the correct sequence.
✓ Proper lubrication reduces wear and friction.
✓ Gears operate by meshing their teeth together.
✓ Regular inspection improves engine performance and reliability.

Safety Precautions
✓ Wear protective clothing and safety boots.
✓ Use the correct tools for each operation.
✓ Handle heavy engine components carefully.
✓
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Keep the working area clean.

✓ Follow workshop safety procedures.
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Conclusion

University of Eldoret is ISO 9001:2015 Certified

The seventh-week practical provided valuable knowledge on engine construction, operation,
and maintenance. Through engine dismantling and the study of gear systems, we gained
practical skills in identifying engine components and understanding their functions in
automotive engineering.

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 WEEK EIGHT

Electrical Installation and Motor Systems

Introduction
During the eighth week of workshop practice, we studied basic electrical installation and
motor systems. The practical sessions involved the installation of a single switch, socket
outlet, and bulb holder, connection of a double switch, and the study of electric motors. The
exercise aimed at equipping students with practical skills in electrical wiring, circuit
connections, and the operation of electric motors.
Objectives
✓ To understand the principles of electrical installation.
✓ To install and connect a switch, socket outlet, and bulb holder.
✓ To learn the wiring of a double switch circuit.
✓ To study the operation and applications of electric motors.
✓ To observe electrical safety procedures during installation.

Materials and Tools Used

Materials
Single switch
• Double switch
• Socket outlet
• Bulb holder and bulb
• Electrical cables
• Junction box
• Insulation tape
• Screws and connectors
• Tools
• Screwdrivers
• Combination pliers
• Wire stripper
• Voltage tester
• Measuring tape
• Hammer
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• Multimeter
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Practical Activities
9.1 Installation of a Single Switch, Socket, and Bulb
The practical involved connecting a single switch to control a bulb while installing a socket
outlet for power supply. Wires were connected according to the circuit diagram, ensuring that
the live wire passed through the switch before reaching the bulb.
After completing the connections, the circuit was tested to verify proper operation.

Figure 15:Simple Home Wiring

9.2 Connection of a Double Switch

A double switch circuit was connected to control two bulbs independently from the same
location. The live wire was connected to the common terminal, while the output terminals
were connected to the individual bulbs.
The system was tested to ensure that each switch controlled its respective bulb correctly.

Figure 16:Double Switch Domestic Wiring

9.3 Study of Electric Motors

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We studied the construction and operation of electric motors, including their major
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components such as the stator, rotor, shaft, bearings, and windings. The principles of
electromagnetic induction and energy conversion were discussed.

University of Eldoret is ISO 9001:2015 Certified

Working Principle of Electric Motors
Electric motors operate on the principle of electromagnetic induction. When electric current
flows through the windings, a magnetic field is produced. The interaction between the
magnetic fields creates a force that causes the rotor to rotate, converting electrical energy into
mechanical energy.

Figure 17:Single-Phase Electric Motor

Applications of Electric Motors

✓ Water pumps
✓ Fans and blowers
✓ Washing machines
✓ Industrial machinery
✓ Compressors
✓ Conveyors

Observations
✓ Proper wiring is necessary for efficient circuit operation.
✓ Incorrect connections may cause short circuits.
✓ Electric motors convert electrical energy into mechanical energy.
✓ Double switches can control multiple devices independently.

Safety Precautions
✓ Switch off the power supply before wiring.
✓ Use insulated tools.
✓ Avoid touching exposed wires.
✓ Test all connections before use.
✓ Wear protective equipment.
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Conclusion
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University of Eldoret is ISO 9001:2015 Certified

The eighth-week practical enhanced our understanding of electrical installations and motor
systems. We gained practical experience in wiring switches, sockets, and bulbs, as well as
studying the operation of electric motors. The exercise improved our technical skills and
emphasized the importance of safety in electrical engineering work.

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 WEEK NINE

Bungalow Setting Out and Plumbing Practical

Introduction
During the ninth week of workshop practice, we carried out practical exercises on bungalow
setting out using the 3:4:5 method and the surveying method. We also performed plumbing
practicals involving the installation and connection of PVC pipes and fittings. The practical
sessions aimed to equip students with skills in construction layout, measurement, surveying
techniques, and plumbing installation.
Objectives
✓ To understand the principles of bungalow setting out.
✓ To apply the 3:4:5 method in setting out right angles.
✓ To use surveying instruments in building layout.
✓ To gain practical skills in plumbing installation.
✓ To understand the importance of accuracy in construction work.

10.1 Bungalow Setting Out

Setting out is the process of transferring the dimensions and layout of a building plan from
paper to the actual construction site. It ensures that the building is constructed according to
the approved design and specifications.
The 3:4:5 method was used to establish right angles during the setting out process.
Measurements of three metres and four metres were taken on perpendicular lines, and the
diagonal distance was adjusted to five metres to obtain an accurate ninety-degree angle.
The surveying method involved the use of measuring tapes, ranging rods, pegs, spirit levels,
and string lines to establish the building boundaries and dimensions accurately. Control
points were identified, and the building corners were marked according to the plan.

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Figure 18:Setting Out of a Bungalow

University of Eldoret is ISO 9001:2015 Certified

 Figure 19:Surveying in Progress

Tools and Equipment Used

• Measuring tape
• Pegs
• Hammer
• Ranging rods
• Spirit level
• String lines
• PVC pipes
• Pipe cutter
• Hacksaw
• PVC adhesive

10.2 Plumbing Practical

The plumbing practical involved cutting, joining, and assembling PVC pipes and fittings for
water supply and drainage systems. The pipes were measured and cut to the required lengths,
after which the edges were smoothed using a file. Adhesive was then applied to the joints
before connecting the pipes and fittings. The completed system was tested to ensure that
there were no leakages.
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 Figure 20:Engineering Drawing Layout

Figure 21: Completed PPR & PVC Water Distribution Network Assembly

Observations
Accurate measurements are essential in building construction and plumbing installation. The
3:4:5 method provides a simple and reliable way of creating right angles, while surveying
instruments improve precision. Proper pipe connections help to prevent water leakage and
ensure efficient water flow.
Safety Precautions
Protective clothing and safety boots were worn throughout the practical session. Tools were
handled carefully, and the work area was kept clean and free from obstacles. Adhesives were
used in well-ventilated areas, and all workshop safety rules were observed.
Conclusion
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The ninth-week practical provided valuable skills in bungalow setting out and plumbing
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installation. We learned how to transfer building dimensions to the construction site using
both the 3:4:5 and surveying methods and gained practical experience in plumbing

University of Eldoret is ISO 9001:2015 Certified

operations. The exercise emphasized the importance of accuracy, teamwork, and safety in
engineering and construction work.

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 WEEK TEN

Welding Practical and Fabrication Processes

Introduction
During the tenth week of workshop practice, we carried out welding and fabrication
practicals. The main objective of the exercise was to understand different welding
techniques, identify welding equipment, and fabricate a metal workpiece. We practised
various welding methods and learned how to prepare metal surfaces, join metals, and inspect
welded joints.
Objectives
✓ To understand the principles of welding.
✓ To identify different welding tools and equipment.
✓ To practise various welding techniques.
✓ To fabricate a metal workpiece.
✓ To observe safety precautions during welding operations.

Types of Welding Practised

11.1 Arc Welding
Arc welding uses an electric arc generated between an electrode and the workpiece to
produce heat for joining metals. The process is widely used in construction and
manufacturing industries because of its efficiency and strength.

11.2 Gas Welding

Gas welding uses a flame produced by the combustion of oxygen and acetylene gases to melt
and join metals. It is commonly used for repairing thin metal sheets and pipes.

11.3 Spot Welding

Spot welding joins metal sheets by applying pressure and heat at specific points. It is
commonly used in automobile body construction.
Materials and Equipment Used
• Welding machine
• Welding electrodes
• Welding helmet
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• Chipping hammer
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• Wire brush

University of Eldoret is ISO 9001:2015 Certified

 • Angle grinder
• Steel plates
• Measuring tape
• Protective gloves
• Safety boots

Procedure
✓ The metal surfaces were cleaned to remove rust and dirt.
✓ The dimensions of the workpiece were measured and marked.
✓ The metal pieces were cut to the required sizes.
✓ The welding machine was set according to the required current.
✓ The metal pieces were aligned and clamped together.
✓ Welding was carried out using different welding techniques.
✓ The slag was removed using a chipping hammer.
✓ The weld was inspected for defects and strength.

Observations
✓ Proper electrode selection improves weld quality.
✓ Excessive current causes burn-through.
✓ Uniform welding speed produces stronger joints.
✓ Surface preparation is essential for good welds.

Safety Precautions
✓ Wear welding helmets and gloves.
✓ Ensure proper ventilation.
✓ Avoid direct exposure to the welding arc.
✓ Keep flammable materials away from the working area.
✓ Use insulated tools and equipment.

Conclusion
The tenth-week practical enhanced our understanding of welding processes and fabrication
techniques. We gained practical skills in arc welding, gas welding, and spot welding while
appreciating the importance of safety and precision in metal fabrication.
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Figure 22: Fabricated welded workpiece produced during the welding practical session.

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 FIELD TRIPS

COMPREHENSIVE FIELD TRIP REPORT: SIRIKWA QUARRY LTD

1.0 INTRODUCTION
Purpose and Objectives of the Visit
The field trip to Sirikwa Quarry Ltd was organized to expose students to real industrial
operations and enable them to relate classroom theories to practical engineering applications.
The visit aimed at helping students understand quarry operations, production processes,
maintenance practices, safety measures, and the role of mechanical engineering in industrial
production.
The objectives of the visit were:
✓ To study the quarrying and stone-processing operations.
✓ To observe the various machines and equipment used in the quarry.
✓ To understand maintenance practices in industrial plants.
✓ To study safety and environmental conservation measures.
✓ To relate workshop and classroom knowledge to practical engineering applications.
✓ To understand the organizational structure of an industrial company.

Brief Description of the Company

Sirikwa Quarry Ltd is a construction-material processing company involved in the extraction,
crushing, grading, and supply of stones and aggregates used in construction projects such as
roads, bridges, houses, and dams. The company uses modern machinery and equipment to
process rocks into different sizes required in the construction industry.

2.0 COMPANY PROFILE

History and Background
Sirikwa Quarry Ltd was established to provide quality construction materials to meet the
increasing demand in the construction sector. The company has expanded its operations over
the years by acquiring modern machinery and employing qualified personnel to improve
efficiency and productivity.
Products Manufactured
The company produces various products, including:
• Ballast.
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• Building stones.
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• Aggregates.

University of Eldoret is ISO 9001:2015 Certified

 • Hardcore.
• Murram.
• Gravel.

Organizational Structure
The company operates under the following departments:
➢ Managing Director.
➢ Production Manager.
➢ Mechanical Engineering Department.
➢ Maintenance Department.
➢ Safety Department.
➢ Human Resource Department.
➢ Finance Department.
➢ Machine Operators and Technicians.

3.0 PRODUCTION AND MANUFACTURING PROCESSES

Raw Materials Used
The main raw materials used in the quarry are natural rocks extracted from the quarry site.
Production Flow and Process Sequence
The production process begins with the extraction of rocks from the quarry using excavators
and blasting techniques. The rocks are transported to the crushing plant, where they are
crushed into smaller sizes. The crushed materials are then screened and graded according to
size before being stored and transported to customers.
Production Process Flow Diagram
Rock Extraction → Transportation → Primary Crushing → Secondary Crushing →
Screening → Grading → Storage → Distribution
Description of the Production Process
Rock Extraction: Large rocks are extracted from the quarry site.
Transportation: Dump trucks transport the rocks to the crushing plant.
Crushing: Jaw crushers break down large rocks into smaller pieces.
Screening: Vibrating screens separate the crushed materials into different sizes.
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Storage: The final products are stored in designated areas.

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Distribution: The products are transported to customers.

University of Eldoret is ISO 9001:2015 Certified

4.0 MACHINES AND EQUIPMENT OBSERVED
Jaw Crusher
The jaw crusher reduces large rocks into smaller particles using compressive force. It consists
of a fixed jaw and a movable jaw that crushes the rocks.
Conveyor Belts
Conveyor belts transport crushed stones from one processing stage to another. They reduce
manual labor and increase efficiency.
Excavators
Excavators are used to dig and load rocks onto dump trucks. They operate using hydraulic
systems.
Wheel Loaders
Wheel loaders transport aggregates within the quarry and load them onto trucks.
Dump Trucks
Dump trucks transport raw materials and finished products from one location to another.
Vibrating Screens
These machines separate crushed stones according to their sizes.

5.0 MAINTENANCE PRACTICES OBSERVED

The company employs preventive maintenance to ensure smooth operation of machines. The
following maintenance activities were observed:
✓ Lubrication of moving parts.
✓ Inspection of conveyor belts.
✓ Tightening of bolts and nuts.
✓ Replacement of worn-out components.
✓ Machine cleaning.
✓ Repair of damaged parts.
✓ Regular servicing of engines and hydraulic systems.
✓ Preventive maintenance helps reduce machine breakdown and increase productivity.

6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT

✓ Personal Protective Equipment (PPE)
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✓ Workers at the quarry used the following protective equipment:

✓
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Safety helmets.
✓ Reflective jackets.

University of Eldoret is ISO 9001:2015 Certified

 ✓ Safety boots.
✓ Gloves.
✓ Ear protectors.
✓ Dust masks.
✓ Safety goggles.

Safety Procedures and Policies

✓ Workers undergo safety training.
✓ Warning signs are placed in dangerous areas.
✓ Machines are inspected regularly.
✓ Unauthorized persons are prohibited from entering hazardous areas.
✓ Emergency response procedures are available.

Waste Management and Environmental Conservation

The company has implemented environmental conservation measures, including:
✓ Spraying water to reduce dust.
✓ Proper disposal of waste materials.
✓ Noise-control measures.
✓ Tree planting programs.
✓ Land rehabilitation after quarrying.

7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED

Engineering Materials and Material Science
Different rock properties such as hardness, strength, and durability were studied to determine
their suitability for construction.
Solid Mechanics
Forces and stresses involved in crushing operations were observed. The strength of machine
components was also studied.
Manufacturing Processes
The crushing and screening operations demonstrated industrial manufacturing processes.
Engineering Drawing
The arrangement of machines and plant layout reflected engineering drawing concepts.
Thermodynamics
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Heat generation in engines and machine systems was observed.

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Fluid Mechanics

University of Eldoret is ISO 9001:2015 Certified

Hydraulic systems used in excavators and loaders demonstrated fluid mechanics principles.
Machine Tools and Machining Operations
The maintenance workshop contained lathes, drills, grinders, and welding equipment used for
machine repair.

8.0 NEW TECHNOLOGIES OBSERVED

The following technologies were observed during the visit:
✓ Automated conveyor systems.
✓ Hydraulic excavators.
✓ Modern crushing plants.
✓ Dust-suppression systems.
✓ Advanced maintenance techniques.

9.0 CHALLENGES IDENTIFIED

✓ Operational Challenges
✓ High fuel consumption.
✓ Dust pollution.
✓ Noise pollution.
✓ Frequent wear and tear of equipment.
✓ High maintenance costs.
✓ Recommendations
✓ Improve dust-control systems.
✓ Adopt energy-efficient machines.
✓ Increase preventive maintenance.
✓ Enhance environmental conservation measures.

10.0 CONCLUSION
The field trip to Sirikwa Quarry Ltd provided practical exposure to quarry operations,
machinery, production processes, maintenance practices, and safety procedures. The visit
enabled students to relate theoretical knowledge learned in class to real industrial
applications. It enhanced our understanding of engineering materials, manufacturing
processes, thermodynamics, fluid mechanics, and machine operations. The experience was
valuable in preparing us for future careers in mechanical engineering.
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COMPREHENSIVE FIELD TRIP REPORT: KENYA COOPERATIVE
CREAMERIES (KCC) ELDORET
1.0 INTRODUCTION
Purpose and Objectives of the Visit
The field trip to Kenya Cooperative Creameries (KCC) Eldoret was organized to expose
students to dairy-processing operations and industrial engineering applications. The visit
aimed to bridge the gap between theoretical knowledge acquired in class and practical
applications in the dairy industry.
The objectives of the visit were:
✓ To understand the milk-processing and manufacturing processes.
✓ To observe the machines and equipment used in dairy processing.
✓ To study industrial maintenance practices.
✓ To understand safety procedures and environmental conservation measures.
✓ To relate engineering concepts learned in class to practical applications.
✓ To understand the organizational structure of a manufacturing company.

Brief Description of the Company

Kenya Cooperative Creameries (KCC) is one of the leading dairy-processing companies in
Kenya. The company specializes in collecting, processing, packaging, and distributing milk
and other dairy products to local and international markets. KCC receives raw milk from
farmers and converts it into finished products such as fresh milk, yogurt, butter, cream, and
powdered milk.

2.0 COMPANY PROFILE

History and Background
Kenya Cooperative Creameries was established in 1925 as a cooperative society to support
dairy farmers in Kenya. Over the years, the company has expanded its production capacity
and adopted modern technology to improve product quality and efficiency. KCC has
processing plants in different parts of the country, including Eldoret.
Products Manufactured
The company produces various dairy products, including:
• Fresh milk.
• Yogurt.
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• Butter.
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• Cheese.

University of Eldoret is ISO 9001:2015 Certified

 • Cream.
• Powdered milk.
• Ghee.

Organizational Structure
The company is divided into different departments, namely:
➢ Managing Director.
➢ Production Department.
➢ Maintenance Department.
➢ Quality Control Department.
➢ Human Resource Department.
➢ Finance Department.
➢ Engineering Department.
➢ Safety and Environmental Department.

3.0 PRODUCTION AND MANUFACTURING PROCESSES

Raw Materials Used
The major raw materials used in milk processing include:
✓ Raw milk.
✓ Water.
✓ Sugar.
✓ Preservatives.
✓ Packaging materials.
✓ Cleaning chemicals.

Production Flow and Process Sequence

The milk-processing sequence is as follows:
Milk Reception → Quality Testing → Filtration → Pasteurization → Homogenization →
Packaging → Storage → Distribution
Milk Reception
Milk is collected from farmers and transported to the processing plant using insulated
tankers.
Quality Testing
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The milk undergoes quality tests to determine its freshness, acidity, density, and bacterial
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content.

University of Eldoret is ISO 9001:2015 Certified

Filtration
Impurities are removed from the milk through filtration.
Pasteurization
The milk is heated to destroy harmful microorganisms and improve shelf life.
Homogenization
Milk fat particles are broken down to produce a uniform mixture.
Packaging
The processed milk is packaged into containers and packets of different sizes.
Storage and Distribution
The packaged milk is stored in refrigerated rooms before distribution to markets.

4.0 MACHINES AND EQUIPMENT OBSERVED

Pasteurizers
Pasteurizers heat milk to high temperatures and then cool it rapidly to eliminate harmful
bacteria.
Operating Principle
Heat is transferred from steam or hot water to milk through heat exchangers.
Homogenizers
Homogenizers reduce the size of fat particles in milk.
Operating Principle
Milk is forced through small openings at high pressure to create a uniform mixture.
Pumps
Pumps transport milk through pipelines from one stage of processing to another.
Operating Principle
Mechanical energy is converted into hydraulic energy to move milk.
Refrigeration Systems
These systems maintain low temperatures for milk preservation.
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Operating Principle
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The refrigeration cycle involves compression, condensation, expansion, and evaporation.

University of Eldoret is ISO 9001:2015 Certified

Storage Tanks
Storage tanks are used for storing raw and processed milk.
Operating Principle
The tanks maintain proper temperature and hygiene conditions.
Packaging Machines
Packaging machines fill, seal, and label milk packets automatically.
Operating Principle
The machines use automated systems controlled by electric motors and sensors.

5.0 MAINTENANCE PRACTICES OBSERVED

The following maintenance activities were observed during the visit:
✓ Regular lubrication of moving parts.
✓ Cleaning and sterilization of equipment.
✓ Inspection of pumps and pipelines.
✓ Replacement of worn-out components.
✓ Preventive maintenance schedules.
✓ Calibration of instruments and sensors.
✓ Repair and servicing of machines.
✓ Preventive maintenance helps to reduce machine breakdowns and increase efficiency.

6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT

Personal Protective Equipment (PPE) Used
Workers used the following protective equipment:
✓ Safety boots.
✓ Gloves.
✓ Hairnets.
✓ Laboratory coats.
✓ Face masks.
✓ Safety goggles.
✓ Reflective jackets.

Safety Procedures and Policies

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✓ Workers undergo safety training.

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✓ Safety signs are installed throughout the factory.

✓ Emergency exits are clearly marked.

University of Eldoret is ISO 9001:2015 Certified

 ✓ Fire extinguishers are available.
✓ Machines are inspected regularly.
✓ Strict hygiene standards are maintained.

Waste Management and Environmental Conservation Measures

The company has implemented the following environmental measures:
✓ Wastewater treatment systems.
✓ Recycling of packaging materials.
✓ Proper disposal of waste products.
✓ Energy-conservation programs.
✓ Water-conservation measures.
✓ Regular environmental monitoring.

7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED

Engineering Materials and Material Science
The processing equipment is made of stainless steel because of its corrosion resistance,
strength, and hygienic properties.
Solid Mechanics
Mechanical forces acting on shafts, gears, bearings, and pumps were observed during
machine operation.
Manufacturing Processes
Milk processing involves filtration, pasteurization, homogenization, packaging, and storage.
Engineering Drawing
The arrangement of pipelines, storage tanks, and machine layouts demonstrated engineering
drawing principles.
Thermodynamics
Heat transfer principles were applied during pasteurization and refrigeration processes.
Fluid Mechanics
The flow of milk through pipes and pumps demonstrated the principles of fluid mechanics.
Machine Tools and Machining Operations
The maintenance workshop contained lathes, drilling machines, welding machines, grinders,
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and cutting tools used for repairs and fabrication.

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8.0 NEW TECHNOLOGIES AND PRACTICES OBSERVED
The following technologies were observed during the visit:
✓ Automated packaging systems.
✓ Computer-controlled pasteurizers.
✓ Modern refrigeration systems.
✓ Automated quality-control equipment.
✓ Energy-efficient electric motors.
✓ Digital monitoring systems.

9.0 CHALLENGES IDENTIFIED

✓ Operational Challenges
✓ High electricity consumption.
✓ Machine wear and tear.
✓ High maintenance costs.
✓ Waste disposal challenges.
✓ Equipment breakdowns.
✓ Recommendations
✓ Introduce renewable energy sources.
✓ Improve preventive maintenance practices.
✓ Increase automation.
✓ Enhance waste-recycling systems.
✓ Adopt energy-efficient technologies.

10.0 CONCLUSION
The field trip to Kenya Cooperative Creameries (KCC) Eldoret provided practical knowledge
on dairy processing, machine operation, maintenance practices, safety procedures, and
environmental conservation. The visit enabled students to relate theoretical concepts from
engineering materials, thermodynamics, fluid mechanics, solid mechanics, manufacturing
processes, and machine operations to practical industrial applications.
The field trip enhanced our understanding of mechanical engineering and provided valuable
experience that will be useful in our future careers as engineers.
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COMPREHENSIVE FIELD TRIP REPORT: SIRET TEA ESTATE
1.0 INTRODUCTION
Purpose and Objectives of the Visit
The field trip to Siret Tea Estate was organized to expose students to industrial tea processing
operations and to bridge the gap between classroom theory and practical engineering
applications. The visit enabled students to observe the various stages involved in tea
processing, machine operation, maintenance practices, safety procedures, and environmental
conservation measures employed in the tea industry.
The objectives of the visit were:
✓ To understand the tea production and manufacturing process.
✓ To observe the machines and equipment used in tea processing.
✓ To study maintenance practices in industrial plants.
✓ To understand safety procedures and environmental management systems.
✓ To relate theoretical concepts learned in class to practical applications in the tea
industry.
✓ To understand the organizational structure of a manufacturing company.

Brief Description of the Company

Siret Tea Estate is one of the tea-processing companies in Kenya that specializes in the
production and processing of tea products for local and international markets. The company
receives fresh tea leaves from tea plantations and processes them into finished products
through various stages such as withering, rolling, fermentation, drying, sorting, and
packaging.

2.0 COMPANY PROFILE

History and Background
Siret Tea Estate was established to support tea farmers and increase tea production in the
region. Over the years, the company has expanded its production capacity by investing in
modern processing equipment and skilled personnel to improve efficiency and product
quality.
Products Manufactured
The company produces various tea products, including:
➢ Black tea.
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➢ Green tea.
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➢ Processed tea leaves.

➢ Packaged tea products for export and local markets.

University of Eldoret is ISO 9001:2015 Certified

 ➢ Organizational Structure
➢ The company is divided into several departments:
➢ General Manager.
➢ Production Department.
➢ Mechanical Engineering Department.
➢ Maintenance Department.
➢ Quality Control Department.
➢ Human Resource Department.
➢ Finance Department.
➢ Safety and Environmental Department.

3.0 PRODUCTION AND MANUFACTURING PROCESSES

Raw Materials Used
The primary raw material used in tea production is fresh tea leaves harvested from tea
plantations.
Other materials include:
✓ Water.
✓ Packaging materials.
✓ Fuel and lubricants.
✓ Electricity.

Production Flow and Process Sequence

The tea-processing sequence follows the following stages:
Harvesting → Withering → Rolling → Fermentation → Drying → Sorting → Packaging →
Storage
Harvesting
Fresh tea leaves are harvested manually or mechanically from tea plantations and transported
to the factory.
Withering
The leaves are spread on withering troughs to reduce moisture content and prepare them for
rolling.
Rolling
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The leaves are rolled using mechanical rollers to break the leaf cells and release enzymes
necessary for fermentation.
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Fermentation

University of Eldoret is ISO 9001:2015 Certified

The rolled leaves undergo fermentation under controlled temperature and humidity
conditions.
Drying
The fermented leaves are dried using hot air to reduce moisture content and improve shelf
life.
Sorting and Grading
The dried tea is sorted into different grades according to particle size and quality.
Packaging
The final product is packaged and prepared for storage and distribution.

4.0 MACHINES AND EQUIPMENT OBSERVED

Withering Troughs
These machines remove excess moisture from fresh tea leaves by circulating air through the
leaves.
Operating Principle
Air is forced through the leaves to reduce moisture content before further processing.
Tea Rollers
Tea rollers crush and twist the tea leaves to release enzymes.
Operating Principle
The machine applies compressive and shear forces to the tea leaves.
Fermentation Units
These units provide controlled environmental conditions necessary for fermentation.
Operating Principle
Temperature and humidity are regulated to achieve the required chemical reactions.
Tea Dryers
Dryers remove moisture from fermented tea leaves using heated air.
Operating Principle
Heat transfer occurs through convection, reducing the moisture content of the leaves.
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Conveyor Belts
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Conveyor belts transport tea from one processing stage to another.

University of Eldoret is ISO 9001:2015 Certified

Operating Principle
Electric motors drive the belts to transport materials continuously.
Packaging Machines
Packaging machines weigh and package tea into bags and containers.
Operating Principle
Automated systems measure, fill, seal, and label packages.

5.0 MAINTENANCE PRACTICES OBSERVED

The following maintenance activities were observed:
✓ Regular lubrication of moving parts.
✓ Cleaning of machines after production.
✓ Inspection of conveyor belts and bearings.
✓ Replacement of worn-out components.
✓ Preventive maintenance schedules.
✓ Alignment and calibration of machines.
✓ Repair of damaged parts.
✓ Preventive maintenance helps reduce machine breakdowns and improve productivity.

6.0 SAFETY AND ENVIRONMENTAL MANAGEMENT

Personal Protective Equipment (PPE) Used
Workers used the following protective equipment:
✓ Safety helmets.
✓ Safety boots.
✓ Reflective jackets.
✓ Gloves.
✓ Ear protectors.
✓ Dust masks.
✓ Safety goggles.

Safety Procedures and Policies

✓ Workers undergo regular safety training.
✓ Warning signs are placed in hazardous areas.
✓ Emergency exits are clearly marked.
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✓ Machines are inspected regularly.

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✓ Fire extinguishers are installed at strategic locations.

✓ Workers follow standard operating procedures.

University of Eldoret is ISO 9001:2015 Certified

Waste Management and Environmental Conservation Measures
The company has adopted several environmental conservation measures, including:
✓ Recycling tea waste.
✓ Proper disposal of solid waste.
✓ Wastewater treatment.
✓ Tree planting programs.
✓ Energy conservation measures.
✓ Air pollution control systems.

7.0 MECHANICAL ENGINEERING APPLICATIONS OBSERVED

Engineering Materials and Material Science
Different materials such as stainless steel, rubber belts, and aluminum components were used
in machine construction because of their strength and corrosion resistance.
Solid Mechanics
The forces acting on rollers, shafts, gears, and bearings were observed during machine
operation.
Manufacturing Processes
The tea-processing stages demonstrated various manufacturing techniques such as rolling,
drying, grading, and packaging.
Engineering Drawing
Plant layouts and machine designs reflected concepts learned in engineering drawing.
Thermodynamics
Heat transfer principles were applied in drying and heating systems.
Fluid Mechanics
Airflow systems in the withering and drying units demonstrated fluid mechanics concepts.
Machine Tools and Machining Operations
Machine maintenance workshops contained lathes, drilling machines, welding equipment,
and grinders used for repair and fabrication.

8.0 NEW TECHNOLOGIES AND PRACTICES OBSERVED

The following technologies were observed:
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✓ Automated conveyor systems.

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✓ Computer-controlled dryers.

University of Eldoret is ISO 9001:2015 Certified

 ✓ Modern packaging machines.
✓ Energy-efficient motors.
✓ Automated quality-control systems.

9.0 CHALLENGES IDENTIFIED

✓ Operational Challenges
✓ High energy consumption.
✓ Machine wear and tear.
✓ Maintenance costs.
✓ Waste management challenges.
✓ Production downtime.

Recommendations
✓ Introduce renewable energy sources.
✓ Increase preventive maintenance.
✓ Improve waste-recycling systems.
✓ Adopt energy-efficient technologies.

10.0 CONCLUSION
The field trip to Siret Tea Estate provided practical knowledge on tea processing, machine
operation, maintenance practices, safety procedures, and environmental conservation. The
visit enabled students to relate theoretical concepts from engineering materials,
thermodynamics, fluid mechanics, manufacturing processes, and machine operations to real
industrial applications. The experience enhanced our understanding of industrial systems and
prepared us for future careers in mechanical engineering.

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 75
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University of Eldoret is ISO 9001:2015 Certified