1 UNIVERSITY OF MORATUWA Faculty of Engineering Non-GPA Module 3992: Industrial Training TRAINING REPORT D Samson Industries (Pvt) Ltd, Main Plant PO Box 46, Samson rajapaksa mawatha, Bataduwa,Galle From 19.10.2015 to 01.04.2016 SAMPATH E.B.J. - 120571T Department of Mechanical Engineering
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UNIVERSITY OF MORATUWA
Faculty of Engineering
Non-GPA Module 3992: Industrial Training
TRAINING REPORT
D Samson Industries (Pvt) Ltd, Main Plant
PO Box 46, Samson rajapaksa mawatha, Bataduwa,Galle
From 19.10.2015 to 01.04.2016
SAMPATH E.B.J. - 120571T
Department of Mechanical Engineering
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PREFACE
The report I have prepared concerns the experience and knowledge gained from my
training program at D Samson Industries (Pvt) Ltd, Main plant. During my training period. I
had to be at the company engineering sections and maintenance sections.
This report consists of three chapters.
Them chapter one to give an introduction about D Samson Industries (Pvt) Ltd. The chapter
two to explain my training experience and to explain things I learned. Annex one explain my
project works done during the training period and the chapter three is the conclusion.
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ACKNOWLEDGEMENT
First of all I would like to express my sincere gratitude to Mr.S.W.D.Wijithananda,
Manager – Maintenance Engineering for handling my training placement at D Samson
Industries (Pvt) Ltd and training supervisor who did a great part in our training period.. Then
I would like to thank to NAITA for coordinating our training process properly. Further, I
should thank all the engineers, supervisors, workers, and training students who helped me in
different ways to achieve goals in my training period. Finally, I must again thank all the
people mentioned above, as well as all other people who were connected in making my
training period in D Samson Industries (Pvt) Ltd a successful and a pleasant experience.
Mr. S.W.D. Wijithananda
Chief Engineer/Engineering Manager DSI/SCOM
Mr. N.S.Porawagamage
Production Engineer(Consultant)
Mr. M. Sandaruwan
Engineer (electrical) DSI/SCOM
Mr. Nimal Chandrasiri
Mechanical Superintendent (senior)
Mr. Lesly Amarathunga
Forman
Mr. Jagath Nishantha
Tool Room Assistant
All the Technical staff of Workshop DSI/SCOM Electrical & Mechanical departments
Every person who helped me to success fully finish this training period
E.B.J.Sampath
Department of Mechanical Enginnering
University of Moratuwa
20-04-2016
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TABLE OF CONTENT
CHAPTER ONE
1.1 Introduction to training establishment
1.1.1 History of DSI
1.1.2 Vision
1.1.3 Mission
1.1.4 The Samson group
1.1.5 About D Samson Industries (pvt) Ltd.
1.1.6 Hierarchy of DSI
1.1.7 SWOT analysis(DSI)
1.2 Samson Compounds (pvt) Ltd. (SCOM)
1.2.1 Vision
1.2.2 Mission
1.2.3 Hierarchy of SCOM
1.2.4 SWOT analysis(SCOM)
1.3 Samson compounds – EVA plant
1.3.1 About EVA plant
CHAPTER TWO
2. Training experience
2.1 Technical
2.1.1 Maintenance section
2.1.2 Mechanical section
2.1.3 Automobile section
2.1.4 Electrical section
2.1.5 Tool room
2.1.6 Cutter die section
2.2 Workshop experience
2.2.1 Lathe machine
2.2.2 Bending machine
2.2.3 Shaper machine
2.2.4 Electrical arc welding experience
2.2.5 Oxy fuel welding
2.2.6 Gas welding
2.3 Machineries used in DSI
2.3.1 Bam bury machine
2.3.2 Mill machine
2.3.3 Calendar machine
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2.3.4 Kneader machine
2.3.4.1 Rack and pinion system
2.3.4.2 Pneumatic control system
2.3.4.3 Main drive system
2.3.4.4 Rotor system
2.3.5 Injection moulding machine
2.3.6 Hydraulic press machine
2.3.7 Boiler
2.3.7.1 Boiler capacity
2.3.7.2 Steam distribution
2.3.7.3 Steam traps
2.3.7.3.1 Thermodynamic (disc type) steam trap
2.3.7.3.2 Float ball steam trap
2.3.7.4 Main parts of the boiler
2.3.7.4.1 Stop valve
2.3.7.4.2 Safety valve
2.3.7.4.3 Blow down valve
2.3.7.4.4 Head(man) hole
2.3.7.4.5 Hand(mud) hole
2.3.7.4.6 Burner unit
2.3.7.4.7 Photocell
2.3.7.4.8 Water level control and alarms
2.3.7.5 Boiler safety
2.3.7.6 Backfire safety
2.3.7.7 Boiler maintenance
2.3.8 Generator
2.3.8.1 Conditions for starting and stopping of the generator
2.3.8.2 Generator maintenance
2.3.9 Chilled water plant
2.3.9.1 About chilled water plant
2.3.9.2 Main parts and their functions
2.3.9.3 Maintenance
ANNEX 1(Projects)
1. Robot arm design for horizontal injection moulding machine.
2. Automated rotating table design for laser cutting machine.
CHAPTER THREE
3. Summary and conclusion
3.1 Summary
3.2 conclusion
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1. INTRODUCTION TO THE TRAINING ESTABLISHMENT
1.1.1 History of DSI
DSI is known as the number one footwear company in Sri Lanka. The founder of Mr. D.
Samson Rajapaksa put his immense effort to build up the DSI to such position. Beginning
from 1962 company has obtained number of achievement.
1.1.2 Vision
To be the leading contributor to socio-economic development of Sri Lanka.
1.1.3 Mission
To invest in manufacturing and services, meeting highest international standards to our global
customers in conventional & niche markets.
1.1.4 The Samson Group
• D. Samson Industries Ltd.
• D. Samson & Sons Ltd.
• Samson (exporters) Ltd.
• Samson Trading Company Ltd.
• Samson Rubber Industries (Pvt) Ltd.
• Samson Manufactures Ltd.
• Samson Rubber Products (Pvt) Ltd.
• Samson International Ltd.
• Samson Engineers Ltd.
• Samson Reclaim Rubbers Ltd.
• Samson Apparel Makers (Pvt) Ltd.
• Samson Compounds (Pvt) Ltd.
• Samson Sports wears (Pvt) Ltd.
• Samson Brush Manufactures (Pvt) Ltd.
• Vechenson (Pvt) Ltd.
• D. D. P. Packaging (Pvt) Ltd.
• Kelani Valley Canaries Ltd.
• D. S. R. Exporters (Pvt) Ltd.
Figure 1.1
CHAPTER ONE
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1.1.5 About D. Samson Industries Ltd
D. Samson Industries (pvt) limited which was my second training place, is the first Shoe
Manufacturing Plant in Sri Lanka who has been certified for ISO 9001:2000. It was
established in the year 1962 is a leading manufacturer and exporter of footwear and The
Company produces more than 60,000 pairs of footwear per day and has the workforce of
1,500 employees. As a result of high quality standards that it has been maintaining since its
inception, DSI enjoys a good reputation amongst the clientele.
1.1.6 Hierarchy of DSI
Figure 1.2 Different levels of DSI
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The abbreviations used in Figure 1.2
• G.M - General Manager
• D.G.M - Deputy General Manager
• D.P.M - Data Processing Manager
• A.E - Accounts Executive
• Q.M - Quality Manager
• P.M - Personal Manager
• E.M - Export Manager
• M.E - Mechanical Engineer
• Q.A.E - Quality Assurance Executive
• S.E - Supplies Executive
• ST.E - Stores Executive
• S.K - Store Keeper
• T.C - Technical Clerk
• M.S - Mechanical Superintendent
• ASST.E.E - Assistant Electrical Engineer
• C.S - Civil Superintendent
• A.R.C - Assistant Rubber Chemist
• P.E - Production Executive
• D.E - Distribution Executive
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1.1.7 SWOT analysis (DSI)
Strengths
• DSI is a family group.
• Over 50 years of experience as the pioneer in local footwear manufacturing market.
• Massive workforce of over 2000 employees.
• High recognition and reputation for the brand name.
• 250 showrooms network.
Weaknesses
• Home grown company, hence less exposure.
• Lagging behind in application of standard techniques for maintenance, quality control,
process planning and testing.
• Not dynamic because of the less competition in the market.
• Lacks interest in product development.
Opportunities
• Growing potential market for exporting footwear.
• Technical knowledge and expertise of the universities can be harnessed for betterment
of the company.
• The demand for a diabetes shoe since the diabetes population of Sri Lanka is nearly 4
million.
Threats
• Has not identified a strong local competitor. Therefore there is possibility of an
unexpected arise.
• Modern designs being imitated by the minor scale local footwear producers.
• Importing low priced footwear from countries like China and Thailand.
• High overheads due to increasing tariffs of the national power supply.
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1.2 SAMSON COMPOUNDS (PVT) LTD.
SCOM factory was established in 1996 for supplying high quality rubber compounds. Now
there are about 243 employees in SCOM. Major purpose of the SCOM factory is to provide
high quality rubber and EVA compounds and rubber sheets using natural, synthetic rubber,
chemicals and other materials to sister companies and Other companies. Mixing capacity of
the SCOM is 10 MT Rubber compounds and 3.5 MT of EVA daily. The company has two
separate mixing plants for Natural rubber and EVA with sophisticated equipment’s and one
of the best plants in Sri Lanka.
Today Samson compounds (Pvt.) Ltd. is mixing compounds either by customer provide
recipe or designed by qualified & well-experienced R&D team of SCOM with the help of
well-equipped laboratory, where the chemicals shall provide by customer or by the SCOM.
Samson Compounds Pvt. Ltd has been awarded ISO 9001, 2001 & 2008 because of the high
quality rubber compounds. All of DSI factories use 5S concept in their factories & it helps to
be awarded those certificates to the company.
1.2.1. Vision
To be in the forefront as a recognized custom compounder in Sri Lanka.
1.2.2. Mission
To be the manufacturer of rubber compounds and products for industrial needs while
optimizing returns to stakeholders.
Samson Compounds or SCOM is also located in Bataduwa, Galle. Main product of the
SCOM is compound rubber. SCOM has large range of production as shown below
Heat expanded rubber compound sheets
Heat expanded rubber compound V-Straps
Customized compound rubber products
Rubber compounding for clients
Injection molded PVC soles and V-Straps
Rubber gumboots
SCOM consist of following sections.
Research and Development Section.
Raw material stores
Laboratory
Mixing Section
Sheeting section
Forming section
Injection molding – V- Strap section
Injection molding – sole section
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Sheet yard
Recycling section
Work Shop
Transport section
Administrative office
IT section
Human Resources section
1.2.3. Hierarchy of SCOM
Figure 1.3 Different levels of SCOM
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1.2.4 SWOT analysis (SCOM)
Strengths
• Over 30 years of experience in rubber compounding.
• Colour compounding facility.
• Well experienced technical staff.
• Well-equipped laboratory facilities.
• Huge volume machine capacity.
• Volume purchaser and bulk discount.
Weaknesses
• Lack of marketing strength.
• High inventory holding period.
• High down time production.
• Limited number of finished products.
Opportunities
• Accessibility to export market due to free trade agreements.
• Growing trend for compounding and rubber products in Middle East regions and
European region of the world.
• Massive demand for EVA sheets in local market.
• Growing trend for PVC related products in the local market.
• Technical knowledge and expertise of the universities can be harnessed for betterment
of the company
Threats
• Has not identified a strong local competitor of footwear component manufacturing.
Therefore there is a possibility of unexpected rise.
• Higher dependency on inter companies.
• Low cost footwear components imported from countries like China and Thailand.
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1.3 SAMSON COMPOUNDS – EVA PLANT
1.3.1 About EVA plant
EVA plant is located in about 2km away from the DSI main plant. Eva plant consist of two
main sections EVA forming section and Eva sole section. Both these section’s production is
based on EVA or Ethylene-vinyl acetate. Products of the EVA plant is given below
Eva formed sheets
Sandal soles (Eva formed )
Eva sheet based customized products (kick boards, writing pads etc.)
Eva plant consist of following sections
Administrative office
Mixing section
Sheeting section
Forming section
Sheet yard
Cutting & splitting section
Cold pressing section
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2. TRAINING EXPERIENCES
2.1 TECHNICAL
2.1.1 Maintenance Section
There were two mechanical maintenance workshops, automobile and civil workshop in the
DSI premises. As well as the DSI premises can be divided two sections. Those are
• Footwear Production.
• Rubber Production.
All the mechanical maintenance works of Footwear Production are done by a one
maintenance section and other maintenance work of Rubber Production are done by other
maintenance section, all the civil maintenance works done by this civil maintenance section
and the automobile maintenance works done by this automobile maintenance section. In
addition to that there was few sub sections related to this mechanical maintenance section.
2.1.2 Mechanical Section
There were lot of machines in the DSI premises; those were serviced according to a schedule
for the continued good condition of them. As well as all of mechanical breakdowns are
repaired by this section. In addition to that emergency breakdowns of EVA plant are repaired
by this section.
2.1.3 Automobile Section
All the services of delivery vehicles and all the breakdown repairs of fork lift trucks and other
vehicles were done by this section. As well as lot of automobile services of all those vehicles
in the DSI premises were done by according to a calendar.
2.1.4 Electrical Section
All the electrical parts of the machines are serviced by this section and break down also
repaired by this section. When a machine was repaired according to the service calendar of
the maintenance section, both of electrical and mechanical services were done by both
electrical section and mechanical section together.
2.1.5 Tool Room
This is the place that all the tools were stored in the workshop. All the tools required for the
factory are supplied by this section. Normally there is a procedure to take tool from this
section. There should be entering in the “Tool Book” details about tools such as tool, section,
date & time etc. And also the tools required for the work shop (Maintain Section) are
supplied by this section.
CHAPTER TWO
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2.1.6 Cutter Die Section
The cutters which are used for cutter dies of shoes and slippers were created in the cutter die
section. All the cutters created in this section for shoes and slippers.
2.2 WORKSHOP EXPERIENCE
There are 2 workshops in DSI main plant having,
• 7 Lathe machines.
• 2 Universal drilling machines.
• A shaper machine.
• A hydraulic hacksaw machine.
• A surface grinding machine.
• An engraving machine.
• A bending machine.
Also having a vehicle maintenance section, civil maintenance section to do their maintaining
activities and they starts at 7.00 am and ends at 5.00 pm. Sometimes they have to work in
night shift as required. I had a chance to engage with the jobs carried out these machines and
had a hands on practice on that.
Figure 2.1 Different cutters in cutter die section
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2.2.1. Lathe machine
Work Experience
Making a diameter gauge for the lab Facing, straight turning, Knurling.