GUMA VALLEY WATER COMPANY

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INDUSTRIAL ATTACHMENT REPORT [OCTOBER-DECEMBER]

DEPARTMENT OF MECHANICAL AND MAINTENANCE ENGINEERING

FACULTY OF ENGINEERING

FOURAH BAY COLLEGE

UNIVERSITY OF SIERRA LEONE

REPORT ON INDUSTRIAL ATTACHMENT

AT THE GUMA VALLEY WATER COMPANY (G.V.W.C)

OCTOBER – DECEMBER

WRITTEN AND SUBMITTED BY:JOHN YAVANA

FINAL HONOURS II (YEAR 5)ID: 22081

FACULTY SUPERVISOR: DR. KELLEH GBAWURU-MANSARAY

FIELD SUPERVISORS: MR. A. S. K. THOMAS(PRODUCTION ENGINEER – G.V.W.C)

MR. D.H.C. YOUNGE(SENIOR MECHANICAL SUPERINTENDENT – G.V.W.C)

MR. BRIMA MANSARAY(SENIOR FOREMAN - GARAGE - G.V.W.C)

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TABLE OF CONTENTS

CERTIFICATION……………………………………………………………………………………………………………………………….3

ABSTRACT……………………………………………………………………………………………………………………………………….4

ACKNOWLEDGEMENT…………………………………………………………………………………………………………………….5

CHAPTER ONE…………………………………………………………………………………………………………………………………6

1.1 INTRODUCTION (BACKGROUND INFORMATION)………………………………………………………..6

1.2 DEPARTMENTAL STRUCTURE OF THE ENGINEERING/PRODUCTION DEPARTMENT…….8

CHAPTER TWO: (ATTACHMENT ACTIVITIES)……………………………………………………………………………………9

2.1 INTRODUCTION TO THE GARAGE…………………………………………………………………………………9

2.2 WORK AT GUMA VALLEY WATER COMPANY……………………………………………………………….9

2.3 DAILY TASKS…………………………………………………………………………………………………………….9-24

2.4 GUMA VALLEY WATER TREATMENT PLANT – CONTRACT – C2……………………………………24

CHAPTER THREE…………………………………………………………………………………………………………………………….27

3.1 FINDINGS…………………………………………………………………………………………………………………..27

3.2 RECOMMENDATIONS………………………………………………………………………………………………..27

3.3 CONCLUSION……………………………………………………………………………………………………………..27

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CERTIFICATION

I certify that this work was undertaken by John Yavana of the Department of Mechanical Engineering, Faculty of Engineering, Fourah Bay College, University of Sierra Leone, Mount Aureol, Freetown, under my supervision.

MR. A.S.K THOMAS MR. D.H.C YOUNGE(Production Engineer) (Senior Mechanical superintendent)

Sign: ……………………………………… Sign: …………………………………………………

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ABSTRACT

On a wet but yet cool Monday morning, precisely, the 4th day of October 2010; I started my internship program at the Guma Valley Water Company located at Pademba Road Works Yard. The program lasted for exactly three months (October – December 2010).

Throughout the length of this 3 months period, I was fortunate to be a part and parcel of restorative, preventive, and routine maintenance done on vehicles, pumps and turbine. On several occasions I made myself available to other sections/departments – engineering-related of course - even though I was specifically assigned to the garage. As a result, I was able to gain vast knowledge and information with respect to operation, design and troubleshooting of these machineries.

This document entails a detailed account of all the knowledge and experience I gained for the duration of my internship with the company.

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ACKNOWLEDGEMENT

First and foremost, I want to thank God for his abounding grace and mercy to see me through this internship successfully.

A tedious task like this would not have been successfully accomplished without the tremendous input of the most revered Engineer, and Head of Department – Mechanical - Faculty of Engineering, Fourah Bay College USL; Ing. Sahr T. Nyalloma. He went through hurdles to ensure my placement at the Guma Valley Water Company.A very special one also to my Faculty Supervisor, Dr. Kelleh Gbawuru-Mansaray; you are very well appreciated Sir.

I am greatly indebted to Mr. A.S.K Thomas (Production Engineer), Mr. D.H.C Younge (Senior Mechanical Superintendent) and Mr. Brima Mansaray (Senior Foreman) for their extraordinary technical support.

My sincere thanks and appreciation also goes to the entire staff of the Guma Valley Water Company particularly those of the Engineering Section at the Pademba Road Works Yard and the Water Treatment Works at Mile – 13 for the knowledge that they have impacted in me throughout my time as an intern student, for letting me realize what it looks like working in an engineering firm.

Special thanks to my Mum, Dad and Elder Sister, for their guidance, words of encouragement, and moral support in all areas of my life. They have put so much in me, may the God of Heaven continue to bless and protect them.

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CHAPTER ONE (1)

1.1 INTRODUCTION (BACKGROUND INFORMATION)

The Guma Valley Water Company (GVWC) was meant to supply water to the city of Freetown, Sierra Leone. The earth dam was constructed in 1962, with a treatment facility of 16,000 gallons per day, located at Guma Village at Mile-13 in the outskirts of Freetown. This is where the water goes through several phases of purification including filtration, chlorination and alum treatment before it leaves the treatment works for distribution to substations at strategic locations throughout the city.

As of now, large parts of the distribution system get no, or very poor supply of water, as the main network of distribution which was laid out many years ago when the population was minimal is the same one being used, with a few alterations to meet present day needs. Billing system is non-effective. The Institutional Strengthening Program (ISP) estimated that Non Revenue Water (NRW) is in the range of 69-83%. Distribution to the city is done in shifts; morning, afternoon and night.

However, projects are in the process of being implemented to help improve the system.During the process of purification and distribution, quite a few machinery are used which are crucial to the smooth running of operations. For instance, in distribution, several massive water pumps are used to pump water to substations and tanks, particularly to those which are located at higher ground. Wherever distribution cannot be done by gravity, pumps are used. As such, maintenance is regularly done on them including greasing, checking for bearings, and other parts susceptible to wear.

The facility at Mile-13 produces its own electricity and has got a 30 – inch (30”) Turgo Impulse turbine which needs to be in prime form at all times. If anything goes wrong with it, operations will be brought to a standstill. However, there is a standby generator plant in the event of an emergency.

Another very important mechanical related aspect of operations is the company’s fleet of vehicles of various types:

BOWSERS: these are bulk road vehicles for distribution of water to areas where there is a breakdown and work is being done, and to companies and individuals who have requested delivery.

MERCEDES BENZ (ACTROS) – ACX 762 MERCEDES BENZ (AXOR) – ACC 119 MERCEDES – ACY 761 INTERNATIONAL – AFB 354

“MAN DIESEL” – LEYLAND VEHICLE – AAI 590: with an over-head crane attached, it does heavy work in lifting and transporting big pipes, chlorine cylinders etc.

TOYOTA HILUX VECHICLES: they transport staffs and lightweight materials around the city.The following TOYOTA HILUX vehicles were obtained from The DFID/WORLD BANK SUPPORT TO GUMA PROJECT NO: TF 091108:AEG – 054AEG – 055 (Rapid Response Team)AEG – 052 (Rapid Response Team)AEG – 056AEG – 051With the exception of ADG 685

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These vehicles are all subject to bad roads and constant use and have to be regularly checked. The company has its own garage and mechanics that take care of problems which may arise from the day-to-day running of all vehicles.

I was mainly attached to the Works Yard at Pademba Road, Freetown. This is where the company’s garage is and a lot of repairs done there are mostly vehicle related. Sometimes, other machineries are taken there for special attention such as pumps, compressors, generators and small parts from other workstations.

During my stay, I made two visits to the Water Treatment works at Mile-13, one of which was a familiarization tour, and the other was to inspect and observe some reported faults on the 30” Turgo Impulse turbine (Gilkes Turbine).

The figure overleaf shows the organizational chart of The Engineering/Production Department of Guma Valley Water Company.

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1.2 DEPARTMENTAL STRUCTURE OF THE ENGINEERING/PRODUCTION DEPARTMENT DELINEATING THE SCOPE OF GVWC’s

PRODUCTION/ENGINEERING FUNCTION AND SHOWING BOTH ITS CORPORATE AND AREA LEVEL STRUCTURES

Figure 1

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G.V.W.C Board

General Manager

Chief Engineer (production Department)

Distribution Engineer (Distribution Branch)

Area Engineer (Operatio

ns & Maintena

nce - western

Freetown)

Supervisor (New service

Connections

section)

Supervisor

(Distribution

Maint. Section)

Suoervisor

(Operations

section)

Area Engineer (Operatio

ns & Maintena

nce - Central

Freetown)

Supervisor (New Service Connect

ions Section)

Supervisor

(Distribution

Maint. Section)

Supervisor

(Opreations

Section)

Area Engineer (Operatio

ns & Maintena

nce - Eastern

Freetown)

Supervisor (New Service Connect

ions Section)

Supervisor

(Distribution

Maint. Section)

Supervisor

(Operations

Section)

Production Engineer (Production and Transmission Branch)Water

Production

Manager (Water

Treatment Works)

Manager (Worksho

p)Supervis

or (Garage

)

Supervisor

(Equipment

Repairs Worksh

op)

Supervisor

(Meter Repair

Section)

Manager (Central

Leaks Detection

and Repairs

Unit)

CHAPTER TWO (2)

ATTACHMENT ACTIVITIES

2.1 INTRODUCTION TO THE GARAGE

As stated earlier in the abstract, most of my time at GVWC was spent at the garage. Work starts at 7:00am up to 5:00pm on Mondays to Thursdays and ends at 4:30 on Fridays.Day one was a familiarization tour. On the 4th of 0ctober 2010, I reported to the Production Engineer, Mr. A.S.K Thomas, who had once being introduced to me at the GVWC’s Head Quarters (Guma Building, Lamina Sankoh Street, Freetown) prior to my first day at the company. This introduction was done by Mr. Moore-Sourie (Distributor Engineer) who was the then acting Chief Engineer. The Chief Engineer, Mr. Awoonor-Williams, was on leave. I was introduced to Mr. Brima Mansaray (Senior Foreman), and Mr. Bob Bockarie (Senior Mechanic – Plants). I also met with other staffs at the stores department, commercial department, and those at the security post. I was also privileged to meet with the company’s Medical Doctor (Dr. Harding) and the other nurses present.

2.2 WORK AT GUMA VALLEY WATER COMPANY

Work at the garage is not routine. Problems are attended to as they arose and the time required to perform a job depends upon the availability of spare parts. From observation, most jobs were delayed due to late supply of spare parts from the stores/spare parts department.

2.3 DAILY TASKS

I. 4 TH OCTOBER 2010

Since it was my first day, I was assigned to some small, but very meticulous tasks:

a. Using a punch and a hammer, and applying some basic paper tracing techniques, I made three holes – one at the top-centre, and the other two at the two extreme ends of the registration plate (“number plate”) to be attached to one of the browsers that were bought from the Embassy of The United States, Sierra Leone (AFB 354)

b. I also shaped out an Insurance sticker into a smooth circular card pasted it at the top right corner of the windscreen of the same vehicle.

II. 5 TH OCTOBER 2010

a) VALVE GRINDING: Valve grinding being part of the decarbonization process of an engine was seldom done during my stay. In fact, this was the only valve grinding work I participated in. Upon removal of the cylinder head, it was thoroughly washed with kerosene and the valve

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clips removed with the clip removers. The cylinder head valves were also removed and head with water and later dried with compressed air. The valve is first smeared with the grinding paste (Abro Grinding Paste – coarse), with precautions that paste does not fall into cylinder head. The valve is then inserted into its holder and the protruding stem clamped into a pistol drill. As the valve is rotated in the by the drill, it is tightly held against its seat in the usual manner. This process is repeated using the fine grade paste. This was done for all the valves. The valve clips were refitted and head ready to be belted to engine stock.

b) Replacement of spark plugs to AEG 054 (Toyota Hilux).

III. 7 TH OCTOBER 2010

Designed and assist in the welding of a metal housing for a gasoline engine water pump of Net Weight (NW = 29kg) to be installed and used by Bowser – ACX 762; to help boost its pumping capacity.

Pump Specifications

QGZ80 30 [QGZ Series]

Engine Type 168FB

Max. Output 10N.M/ 2500(r/min)

Diameter of Inlet port 80mm

Diameter of Outlet port 80mm

Max. Flow Rate 64m3/h

Max. Lift 25m

Rated Suction 5m

Self-absorb time ≤ 160 sec

IV. 8 TH OCTOBER 2010

a) We completed the installation of Gasoline Engine Water Pump to ACX 762.

b) I also observed and gave a helping hand to the auto-electrician during the replacement of the rear “park” light of AEG 055 (Toyota Hilux).

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Figure 2

Figures (2) & (3), showing the newly installed Gasoline Engine Water Pump on ACX 762

Figure 3

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V. 11 TH OCTOBER 2010

a) GENERAL SERVICING TO TOYOTA HILUX AEG 054 AND AEG 051: Servicing is done regularly and is a form of preventive maintenance. It includes removing and replacing the oil and fuel filters, draining the oil from the oil sump and refilling with fresh oil. The Air Cleaner is also cleansed by blowing out with air from an air compressor. The vehicle is then taken out for a test run to detect any abnormality still present. This practice was carried out on the remaining vehicles, once after 3-4 weeks.

Figure 4 (photo of Air Cleaner mounted on Air Horn)

The automobile fuel system mixes air and fuel to produce a combustible mixture. A great deal of air passes through the carburetor and engine – as much as 1000,000 cubic feet [2831.7m3] of air every 1,000 car miles [1609.3km]. This is a lot of air, and it probably contains a lot of floating dust and grit. They grit and dust could cause serious damage if they enter the engine. Therefore, an Air Cleaner is mounted on the air horn, air entrance of the carburetor, to keep out the dirt as shown above.

All air entering the engine through the carburetor must first pass through the air cleaner. The upper part of the air cleaner contains a ring of filter material (fine mesh metal threads or ribbons, special paper, cellulose fiber, or polyurethane). The air must pass through this ring. The material provides a fine maze that traps most of the dust particles.

b) Designed and filed to fit-shape some makeshift washers to be used on the filter by-pass valves connected to the oil pump of AFB 354 (INTERNATIONAL).

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Figure 5 (Filing process with the washer firmly held in position by an engineer's Vice)

VI. 15 TH OCTOBER 2010

I paid my first visit to the Water Treatment works at Mile-13. Below are some of the photos I took.

Figure 6 & 7 (Façade of Treatment Works Building)

Figure 7

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Figure 8

Figure 9

Figure 10

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Figure 11 (Filtration Operations Room)

A lot of operations at the treatment works involve the use of hydraulics; for instance, cleaning the filter beds includes a process called Back Washing, which involves compressed air being blown into the sand bed to churn up all the dirt clogging the bed before washing it away. As such, compressors are an integral part of the system and always have to be in proper working order.

Figure 12 (Photo of Filtration Desk)

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Figure 13 (Filter Beds)

Figure 14 & 15 showing the Hydro Laboratory

Figure 15

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VII. 18 TH OCTOBER 2010 a) ADJUSTMENT OF BREAK LINERS: Break liners are made up of tough and heat resistant

materials which over time due to friction, wears out. The break shoe assembly incorporates a metal tang which makes contact with the rotor when the linings are worn out. This produces a high squealing sound when the brakes are applied which is meant to alert the driver his pads need changing. Ignoring this sound results in the wearing away of the tang it self and the backing or rivets will contact the rotor when the brake is applied, causing damage which will require reaching or replacement of drums. When the linings are worn out, in the case of the break shoe, it may be relined. For break pads, they can be replaced.

In many vehicles, the break wheels use the drum break system. In order to change the worn out break shoe, the wheel, followed by the drum must be extracted.

Figure 16 (Photographs showing various stages of extraction of the wheel)

When the drum has been removed, a lot of grayish dust was stuck to it. This is the lining material which has worn away with time. After careful arrangement of springs, clips, pins etc. the break shoes were removed; noting where everything should go when it would be reinstalled.

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SOME TECHNICAL LESSONS LEARNT DURING THIS BREAK LINER ADJUSTMENT ACTIVITY:

During the process of extraction, and installation of the wheel and drum; the method employed in screwing-up and unscrewing screws, bolts and nuts was of working on two opposite sides (Screws, Bolts or Nuts) at a time instead of applying random selection. This ensures proper alignment during installation, and also avoids the possibility binding during extraction or installation.

If the wheel pulls to one side, when the brakes are applied, this means that the lining thicknesses are different. It is important to change all pads and shoes at the same time.

The wheel binds: this could mean that the shoes have not been fixed properly. It could also indicate a problem relating to the flow of brake fluid. If there is a blockage in the tubing when the brake is applied, the brake fluid may flow to the brakes, but may have trouble returning thereby holding the wheel locked in position.

The breaks do not hold upon applying them: this could happen if there is a leak somewhere along the path of travel of the brake fluid. When the breaks are applied, the remaining fluid may not be enough to reach the brakes. The pistons cannot operate without the fluid, and the brakes won’t hold. Checking the brake fluid level is the first step in such a situation.

Sometimes the brake fluid may leak unto the lining. This will produce a sound as the pads vibrate when the lining grabs and releases the rotor’s surface. The leak must be repaired and the pads replaced.

Figure 17 (photo showing break shoe and rotating disc)

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VIII. 20 TH OCTOBER 2010

Replacement of ball joints, and repairs to the suspension system of AEG 055: Modern suspension systems of springs, torsion bars and dampers moving at 1000-1200 times a minute, help to cushion occupants against the irregularities in the road surface and make driving conditions acceptable.

Figure 18 (Photo showing an Independent System of dampers and the upper arm on the front wheel housing)

IX. 26 TH OCTOBER 2010

REPAIRS ON THE EXHAUSTER OF ACC 119: Heavy duty engines like the bulk road bowzers and the Leyland “Man Diesel” etc. incorporate an exhauster to assist in the dissipation of exhaust gases. The exhauster is assembled in the exhaust line of the engine usually after the exhaust manifolds. It is driven by the camshaft. This device operates just like an air compressor. The piston of the exhauster sucks the exhaust gases on one end, and compresses them through the other end.

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The repairs included changing of the compression rings. The exhauster was unbolted and the piston removed. The piston rings were removed and replaced with new ones. The piston was re-fitted and the unit bolted again.

X. 27 TH OCTOBER 2010

a. We went to inspect vehicle AEG 052 which encountered a breakdown at Congo Cross. The vehicle was later towed and brought to Pademba Road (Works Yard).

b. Adjusted clutch sleeves of ADG 761c. Top up transmission oil to ADG 761d. Took mileage of AEG 052 (Mileage = 54915 miles)

XI. 5 TH NOVEMBER 2010 a. I was visited and supervised by the Faculty Supervisor, Dr. Kelleh Gbawuru-Mansaray.b. I assisted in the welding and assembly operation of the broken rear bumper of ADG 682.

XII. 8 TH OCTOBER 2010

REPLACEMENT OF WORN OUT PRESSURE PLATE: The pressure plate is incorporated in the gearbox housing. This is also a part of an automobile transmission system which carries the power from the engine to the wheels. It includes the gearbox which provides the means of selecting the appropriate speed to turn a corner, or climb a hill and the clutch to disengage the gears. A motorist driving through the outskirts of a large city and making a journey of 50 miles might have to change gear more than 500 times

First, the car was parked above the garage pit such as the engine hoist could be properly and safely positioned. Next, the battery was disconnected to prevent being electrocuted or the car from accidentally starting. It also creates more with. Using spanners (Plug type, Ring and Flat), bolts and

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Figure 19 (Photos of Exhauster)

hinges the cross-member and shafts were removed so as to get full access to get full access to the gearbox. A Pilot Shaft was used to obtain proper alignment and symmetry of the pilot shaft.

Upon the pressure plate, the surrounding bolts were loosened and the worn out plate removed.

(Photo showing vehicle already parked over the garage pit)

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Figure 20 (Removing the cross-member and shaft in an effort to reach the gearbox housing)

Figure 21 (Photos of Gearbox Housing)

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Figure 22 (Extracting Pressure Plate)

Figure 23 (Photo of Shaft & Coupling)

XIII. 11 TH NOVEMBER 2010

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GREASING: This operation was carried done on one of the heavy duty bowsers. The grease was applied to its propeller shaft using a greasing gun. The barrel of the gun is filled with grease.

Its back cover is secured in pressure and the plunger released. This keeps the grease in pressure in the barrel. The nozzle of the gun is inserted into the nipples at various points of the vehicle.

When the gun handle is depressed, the grease is injected the required places at high pressure. This process is repeated until the old grease is squeezed out at the other end.

NB: Most of these activities were repeated on a daily basis; this report only highlights major activities, from the list of repeated activities.

XIV. 17 TH NOVEMBER 2010

I MADE MY SECOND VISIT TO THE WATER TREATMENT WORKS AT MILE-13.

The purpose of this visit was to inspect and observe a reported fault on the Gilkes Turbine. It was reported that some creaking sounds were heard during its operation and it was later detected that some of the ball bearings around the rotating/driving shaft were broken.

Below is a maintenance program that was designed for the turbine.

2.4 GUMA VALLEY WATER TREATMENT PLANT - CONTRACT – C2

GILKES TURBINE MAINTENANCE PROGRAMME

It is advisable that several trained personnel are familiar with the turbine plant. They should:

Know the starting and stopping procedures Be familiar with the noise under different loads Be aware of any abnormal smells, e.g. burning oil or rubber Familiarize themselves with the various running temperatures of bearings and oils

DAILY TASKS

WHILE THE PLANT IS OPERATING:

Listen for abnormal noise Smell for burning oil or rubber Check bearing and oil temperatures Look for signs of oil leaks Feel for abnormal vibrations Check control panel reading

WEEKLY TASKS

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I. WITH THE PLANT STOPPED Grease bearings Check oil level of the gearbox Examine the drive belt of the governor

II. WITH THE PLANT OPERATING Check oil level of the governor

REPORT IMMEDIATELY OF ANY ABNORMALITES!!!

Figure 24

Figure 25

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Figure 26

Figure 27 (Figs. 24-27 show photos of the Gilkes Turbine)

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CHAPTER THREE (3)

3.1 FINDINGS

As per observations on the general or day-to-day activities of the engineering section of the Company (the garage in particular), the following:

1) Delay in payments of workers’ salaries and insufficient motivation greatly affects the performance of the unit’s work force leading to loss of productivity.

2) Safety is too often neglected (lack of protective working gears, insufficient fire extinguishers etc.).

3) There is an insufficient access to original spare parts.4) Insufficient administrative work at the garage such as record keeping, reception, stores etc.5) There is a technological back draw.6) Untidiness of workshop.7) There is a tendency of the company to undertake their major repairs out of the company

and given to outside contractors.

3.2 RECOMMENDATIONS

In view of what has been observed on the field, it is clearly shown that there is a need for the establishment of a well designed workshop with sound organization and good working procedures and conditions.

I therefore recommend the following measures to be taken:

1) The availability of genuine spare parts is very important, therefore the need for a well organized parts department.

2) Collaboration with the manufacturers is recommended in order to stay abreast with technology (diagnosis software, documentation etc.).

3) Appropriate tools and equipment must be acquired.4) Safety and good working procedures must be put in application.5) Control systems in the workshop must be implemented.6) Staff development should be given paramount importance by providing study-leave to staff

and also conducting more efficient in-service courses for the workers.7) New motivating measures should be put in place to recognize outstanding workers and

assist the weaker ones to grow.

3.3 CONCLUSIONS

My three months stay at the Guma Valley Water Company was a worthy experience. It has not only exposes me to industrial settings but has helped me in putting into reality the theories I learnt in class. It has been a good learning experience, not only in learning the mechanical aspect of the job, but in observing the relationship between Senior, Intermediate, and Junior levels of workers. I was able to observe from a neutral position, the different points of view of the various levels and hence appreciate the absolute necessity of mutual respect, communication and sharing of ideas.

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I was also able to develop high esteem for authority, sense of responsibility and safety.

Finally, the experience has given me the confidence to enter any industrial establishment upon completing my Degree Course; getting in mind that with the right amount of knowledge, the willingness to continue learning and the correct attitude with respect to work and the people involved, work will go on smoothly.

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