Best practice in mechanical engineering for job creation and poverty ...
178
United ations Educational. Scien 'fic and Cultura Orgamza ion PROCEEDINGS OF UNESCO -NASENI ROUNDTABLES ON BEST PRACT!CES IN ENGINEERING FOR JOB CREATION AND POVERTY REDUCTION: 2002 AND 2003 Edited y n ony ad le we A UNESCO- NASENI PUBLICATiON
Transcript of Best practice in mechanical engineering for job creation and poverty ...
United ations Educational.
Scien 'fic and Cultura Orgamza ion
PROCEEDINGS OF UNESCO -NASENI ROUNDTABLES ON BEST PRACT!CES INENGINEERING FOR JOB CREATION AND POVERTY REDUCTION: 2002 AND 2003
Edited yn ony ad le we
A UNESCO- NASENI PUBLICATiON
Unesdoc
Note
Document partially illegible
BEST PRACTICE IN
MECHANICAL ENGINEERING
FOR lOB CREATION AND POVERTY
REDUCTION IN NIGERIA
PROCEEDINGS OF UNESCO-NASENI ROUNDTABLES ON BESTPRACTICES IN ENGINEERING FOR JOB CREATION AND POVERTYREDUCTION: 2002 AND 2003
Edited byAnthony Maduekwe
A UNESCO - NASENI PUBLICATION
Copyright © UNESCO Abuja
Published in 2004
All rights reserved
No part of this book may be reproduced by any means,or transmitted, or translated into a machine languagewithout the written permission of the publisher.
Any opinions expressed in this book reflect exclusively those of the authors and arenot necessarily those of UNESCO or any affiliated organisation.
ISBN
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PAGE
1. Practical Engineering Training for Nigeria: Case Studies in theBrewing and Oil exploration industriesDr. O. J. MBONU, Ph.D., FNSE, AIPM 15
...2. Agricultural Equipment Fabrication in Nigeria: Guidelines for
Mechanical and Agricultural Engineering GraduatesBankole OYENIYI 24
..e..3. Packaging Feasibility Studies
Engr. Adolphus OJOBO (MNSE) 34
4. Development and Transfer of Appropriate Post-Harvest Technologies inSub-Saharan AfricanEngr. Leonides HALOS-KIM 58
5. Machine ToolsEngineer Madu A. YATETENGI 84
6. Machining: The Virtue to Effective Manufactur.ing and Production ofMachines and ComponentsMr. I. M. NWAEDOZIE ~ 93
7. Annexure 155
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1.
INFORMATION ABOUT CONTRIBUTORS
Dr. Okechukwu John MBONU graduated as a Mechanical Engineer from
Manchester University, England where in 1977; he obtained a BSc degree
(with first class honours). He was later awarded the Manchester University
Noel Philip Bedson Research Scholarship which in 1982 led to the award of
a PhD degree in Mechanical Engineering.
John started his career as an engineer with Nigerian Breweries Plc in 1982.
He was appointed the Group Engineering Manager of the company in 1990.
In 1996, he was "seconded" by Nigerian Breweries Plc to Shell Petroleum
Development Company of Nigeria (SPDC) on contract to set up the Special
Intensive Training Programme (SITP). He returned to Nigerian Breweries
Plc in late January 1999 to assume-the position of Head of Personnel. He
was elevated to the Executive Board of Nigerian Breweries Plc in November
1999 as the Human Resource Director. In November, 2001, he was
appointed to his current position as Customer Service Director of Nigerian
Breweries Plc.t
2. Mr. Banko/e oYENIYI , is the Managing Director, Nova Technologies Nig
Limited, 126 Oyo Road, Ajibode Bus-Stop, Ibadan
3. Engineer Adolphus OJOBO (MNSE), is the Managing Director/CEO of CAST
PRODUCTS LIMITED, (Engineering and Manufacturing Consultants), 17,
Avielele Close, Etete GRA, Benin City. Tel: 090 - 415848, 0802-306-8236, E
mail: [email protected]
4.
4
Engineer Leonides HALOS-KIM is the Post-harvest Research Specialist at
the International Institute of Tropical Agriculture (IITA), Oyo Road, PMB 5320
Ibadan, Nigeria. E-mail: [email protected]
•....
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5. Engineer Madu A. YATETENGI, is the Chief Executive of Kemaben Industries
Nig. Ltd Kaduna. He has a wide range of experience in the private sector.which includes work with Peugeot Automobiles Nigerian Limited also in
Kaduna.
6. Mr. I. M. NWAEDOZIE is a Chief Technology Officer in the National Office fo r
Technology Acquisition and Promotion (NOTAP), Plot 168 Cotonou Crescents,
Wuse, Zone 6, Abuja. Mr Nwaedozie is a highly experienced engineer and
consults for such agencies as UNIOO and other national engineering bodies.
7. Dr. Anthony MADUEKWE, the Editor, is currently the National Professional
Officer for Science in the UNESCO Office in Abuja. Or Maduekwe was
formerly an Associate Professor of Physics at the Usmanu Oanfodiyo
University Sokoto, Nigeria.
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PREFACE I
The UN Millennium Declaration passed by the UN General Assembly in September
2000, enjoined each member state and certainly the United Nations family to re
examine on-gong and planned programmes from the perspective of this commitment
to a systematic effort to promote meaningful development and in particular to reduce
global poverty, improve health and education delivery systems, improve the status of
women by 2015.
Here in Nigeria, the Millennium development effort, focussed principally against
poverty has been gaining momentum. The challenges are enormous and from
evidence emerging from on-going research, seeming more intractable. To some
extent, the MDG campaign is still too much of a government affair. It is likely that a
government-led effort intended to allow all segments of the society to become familiar
with the MDGs and to assist in their realisation will bear fruit in terms of popular
awareness, not only of the goals but of the growing international compact being built
to pursue them.
This publication speaks to a laudable effort on the part of the UNESCO Abuja
Science Unit to engage engineers in exploration 'of ways in which the craft of
mechanical engineering can contribute to job-creation and to poverty reduction. This
nexus between science and social transformation speaks to the \l3ry intention of the
emerging Millennium Development Compact - the development of partnerships of
concern intended to contribute to formation of a just society.
It
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We wish to underscore our commitment to the continuation of these efforts that are in
fact at the heart of the Science Sectors concern - reinforced during the recent World
Summit on Sustainable Development held in Johannesburg - that the Sciences must \
be engaged in the pursuit of improved human security. The field is wide open - small
water systems, particularly in rural areas must be appropriately constructed for easy
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access and simplified maintenance, new designs for school construction are required
and traditional approaches to the construction of low cost housing (including the use
of local materials) must be evaluated and where appropriate new designs considered.
Our thanks go out to NASENI, the Nigerian Breweries Plc and others who have
partnered us in this initiative. These entities have demonstrated that it is possible to
focus on the needs of others - that being professional and businesslike does not
prevent an entity from being aware of and engaged with the business of social
change..
Hubert J. CharlesDirector, UNESCO Abuja
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PREFACE 11
.No event can be timelier than the issue of "Best practice", capacity building and skill
acquisition in Engineering. In these chapters are lectures well written and of critical
importance to defining standards of best practice. It is also important that we should
find avenues to proliferate these ideas for the upliftment of engineering. Engineering
is so germane to the development and widespread utilization of technologies
required for basic industrial and service infrastructure. The National Agency for
Science and Engineering Infrastructure (NASENI), will strive to always collab?rate
with stakeholders to define and uphold standards in all areas of engineering
infrastructure. To this end, we have a few of such "Best Practice Programme" lined
up in the near future. Some of these have to do with Foundry Technology, Electronic
Instrumentation, Design, Hydraulic System CNC machining, Material Selection.
The chapters have been well written wrth clarity and elucidation and contribute
immensely to the o~going debate to find the best practice in the engineeri~ industry.
The imperatives of globalisation stipulate that our products and services must be
standard and favourably competitive. It is axiomatic that the possession of raw
materials without best engineering practice engendered by knowledge and requisite
human resource development will not lead to the production of standard goods and
services. Time and time again, it has been shown that human resources
development is the most critical prerequisite for national development.
Setting up 'procedure for best practices is obviously a daunting task in the present
clime and yet, setting them is a must. The alternative is too grievous to contemplate.
UNESCO, led in Nigeria by Hubert Charles brings to us not only a partnership laden
with empathy but also concise understandings of what the needs are to re-engineer
the nation in our quest for 'sustainable development. The present unstable condition
of our society is a reflection of the, inadequacy of our productive forces and more
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importantly, a lack of definition of Best Practices, the latter which ultimately defines
thE~ wealth of our nation. The diversification of the economy from an enclave one
balsed on Oil to that which creates jobs, eliminates poverty and creates wealth
de:pends critically on manufacturing, hence best practices in engineering.
The book contains six well-written chapters by practitioners with sound educational
attainment and wealth of industrial experience.
The first chapter by O. J. ~bonu draws extensively from the brewing and oil refining
industry. The chapter discusses the declining standards of our graduate Engineers
which led Shell Petroleum Development Company to institute a one year Shell
Special Intensive Training programme. The appropriate need for joint programmes by
trade groups and tertiary institutions to correct this obvious skill gap is recommended.
I'he second paper by B. Oyeniyi presents the guideline or mechanical and
Elgricultural ngineering graduates on how to fabricate agricultural engineering
equipment. He identifies the major players, draws examples from his interaction with
International Institute for Tropical Agriculture (I.I.T.A), Ibadan, and finally prescribes a
typical organizational structure of a modern fabrication shop. He finally prescribes
closer collaboration between important stakeholders while stressing the urgent need
for a re-orientation of engineering curricula to reflect current market needs.
The third paper by Engineer A Ojobo is a hands-on lecture on how to conduct
standard feasibility studies..It is a highly elucidatory and pedagogic chapter which is a
"must" read for all practicing engineers. The paper deals with the issue of pre
feasibility, feasibility and viability of a project. It presents a concise layout to include
technical, marketing and financial viability of any engineering project. It finally
presents a simple Feasibility Report for a cassava processing factory. This subject
which is barely taught in tertiary institutions has been taught excellently.
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The paper "Development and transfers of appropriate post-Harvest Technologies in
sub-Saharan African" by Engineer Leonides Halos-KIM is an expository undertaking
which takes critical factors into consideration. Issues such as gender, labour,
technology transfer, appropriateness etc. are considered. He further elucidates the
components of ~ functional technology transfer programme. He makes prescription
of all factors that will assist at arriving at a holistic procedure.
The last two chapters titled: 'Machine Tools" by Engineer M. A. Yatetengi and
"Machine; the Virtue of Effective Manufacturing and Production Machine and
Components" by I. M. Nwaedozie describe the various kinds of machine tools, their
uses, the need for machine shops, management of machine shops, the importance of
machine shops, etc.
The paper by I. M. Nwaedozie contains additional useful data on the Foundry
Industry, Raw Materials Sourcing, Human Resources and Capacity Development and
Comparative Data on student enrolment in Engineering. He finally provides a typical
feasibility report of a machine shop business.
Finally, A. Maduekwe has done a good job putting them together to reflect a
continuous thought process.
Prof. O. O. Adewoye
Director -General, NASENI
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INTRODUCTION
Engineering and technology are a vital but ofte n overlooked part of our knowledge,
infrastructure, culture and heritage, and are vital assets that require development,
management and maintenance. The development and application of knowledge in
engineering and technology is a driving force of sustainable social and economic
dE!Velopment and an important factor for poverty eradication.
Human and institutional capacity-building, policy and planning issues in the
engineering sciences and technology are important priorities in the development and
application of knowledge in many developing countries and transitional economies.
International cooperation in engineering and technology is essential in many areas
and also contributes to intercultural dialogue.
Tl1e overall strategy of UNESCO in the engineering sciences and technology is to
promote human and institutional capacity-building, particularly in the developing
countries. In poverty eradication the focus will be on technology for basic needs, and
will involve close cooperation with the cross-cutting project on technology and
poverty eradication (UNESCO 32 C / 5 Draft Programme and Budget, pp. 1772003).
In view of the importance of engineering and technology to the economic
development of Nigeria, UNESCO Abuja in cooperation with the National Agency for
Science and Engineering Infrastructure (NASENI) started working in 2001 to bring
together the best in practical engineering practice from the private and public sectors
of the economy. The idea was to put together what can be considered as best
practices in engineering in the country which eventuarly can be used by educators
and unemployed engineering graduates. The aim was to create a forum where local
and international experts can make available their ideas and experiences. These
ideas when practicalised will bring about it is hoped, the imparting of practical skills to
young Nigerians who may have graduated but are not able to secure jobs and those
still in school who may find the experiences shared and documented useful in
preparing them for the world of work.
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Because engineering is a vast field, UNESCO and NASENI decided to begin with the
subject of mechanical engineering which has relevance in a society that is still largely
agrarian. At the same time, the two cooperating agencies having also realized the
importance of emerging clusters of industries in the field of production of machine
tools and spare parts for automotive and related sectors dominated presently by
artisans and small scale entrepreneurs. These clusters play some important role
today in meeting the demand for local contents of both low and high tech industries in
the country. It is clear that the future of the manufacturing sector in Nigeria will
depend on the diverse engineering skills found in these clusters and their ability to
create competitive products for both local and export markets.
This has led UNESCO and NASENI to include practical demonstrations by world
class experts in industry during the programmes as it will directly help both teachers
and students to improve their skills in a most exciting and real-life manner. The
importance of this cannot be overemphasized as innovations in engineering and
technology can only be brought about by those who have the requisite skills to
understand systems and make useful and beneficial changes to them.
The document we have produced here represents the products of the first two
meetings organised by the two agencies between 2002 andt 2003. The first meeting
was on 10 December 2002 and took place at the NASENI Complex located at Idu, in
the outskirts of the Federal Capital Territory of Abuja. The focus of the first meeting
was more on theorectical processes that make clear how to succeed in creating new
and successful engineering based companies. It also afforded the participants an
opportunity to know the view of the private sector on the state of engineering
education in the country today.
The second meeting was held in the premises of the Scientific Equipment
Development Institute (SEDI), Tagwai Dam Road, Chanchanga, Minna the capital of
Niger state on Thursday, 6th November, 2003. The focus was on a hands-on
approach in the area of machine tools usage and production. Participants had the
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•
opportunity of working with machines after being tutored by experts who conducted
the affairs for the day.
We would like to thank all those who have contributed to the success of these
meetings. They are many but we will like to recognise especially, the Honourable
Minister of Science and Technology, Professor Turner 1. Isuon who has never failed
to attend these meetings and contribute his quota, the immediate past Director
General of NASENI, Or. 1. I. Obiaga and his successor Professor A. Adewoye both
have been wonderful in their support for this programme. We also thank the Nigerian
Breweries Plc. and the Diamond Bank for their contributions for the 2002 and 2003
meetings. We also note for the records the contributions of the Director of UNESCO
Abuja, Mr Hubert Charles who also has been very active in his support for the
programme. Dr. A. Adeg oke, the Director for Planning and Research Department of
f\IASENI has been very wonderful too.
PIS for the next stage, we intend to work seriously to increase the involvement of the
key players in the private sector in these meetings. We fully recognise that they hold
the key to the development of functional skills in our tertiary institutions. This will
remove the stigma of being educated but unemployable from the graduates of
engineering schools in Nigeria. To ,-,;s end we would desire very much to sign a few
Memoranda of Understanding with the key players in the industry so as to make their
Elxpertise, skills and state-of-the-art facilities available to a wider range of Nigerians
students and teachers - who will benefit by knowing first, what the standards
operating today in the industries are and, also to acquire those skills that can make
them useful to the industries eventually as suppliers of skilled labour and innovations.
Anthony Maduekwe
National Professional Officer - Science
UNESCO Abuja
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PART - I
ENGINEERING EDUCATION FOR YOUNGENTREPRENEURS
UNESCD-NASENI ROUNDTABLE DISCUSSION ON PROMOTION OF BESTPRACTICES IN MECHANICAL ENGINEERING FOR JOB CREATION, AT THENASENI COMPLEX IDU, ABUJA, NIGERIA 10 DECEMBER 2002.
14
PRACTICAL E~GINEERINGTRAINING FOR NIGERIACase Studies in the Brewing and Oil exploration industries
Dr. O. J. MBONU, Ph.D., FNSE, AIPM
IN'TRODUCTION
Today, more than ever before, the ability of any nation (Nigeria inclusive) to
successfully realise its potential and sustain any form of national growth
depends almost entirely on its ability to build and develop high quality local
Human Resources. Increased competition in a global marketplace, adds to the
need and urgency to get the right people, wit h the right skills in the right place,
at the right time. Considering the fact that the main thrust of current global
competition is technologically driven, a well-articulated and co-ordinated
nation-wide strategy for the development and training of engine ering personnel
bE!comes a critical success factor.
We don't have to belabour the fact that successive military governments in
Nigeria grossly corrupted, mismanaged, under-funded and neglected all the
kE~y institutions and infrastructure of good governance in Nigeria. The police,
judiciary, education, health, telecommunication, agriculture, public financial
institutions, mines & power, transportation, etc were all adversely affected.
TJ'1is is more so with the development of top quality manpower in general
and engineering personnel in particular. The damage to the whole system is
so far reaching that it will take at least fifteen years of concerted efforts to
remedy the situation. The advent of democracy and the determined drive of the
present government to remedy the situation are positive steps in the right
direction.
To remedy the current sorry state of our tertiary technical institutions, we
nHcessarily have to deploy huge amounts of resources (both on the short and
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long term), before we can administer any meaningful practical training that will
bring our young engineers to world class competitive standards. I will leave the
way and means of achieving this Herculean task to other experts.
To retain their competitive advantage. some leading companies, both i n the
public and private sectors, are compelled to put their fresh graduates through
fairly ambitious and elaborate remedial training programmes. The experiences
(If two companies in Nigeria, Nigerian Breweries Pic NB Plc) and Shell
Betroleum Development ompany (SPDC) are well documented in some
previous papers.
Tile approach of both companies, though different in magnitude, has principally the,same objectives - setting up of programmes that will supplement the basic
education and practical skills of fres h graduatHs from current Nigerian tertiary
institutions.
CASE STUDIES ~
This discussion paper will briefly touch on some salient points that were critical
success factors for these two programmes including the available statistical data
that clearly illustrate the positive impact of the programmes.
In 1995, the "Technical Division of NB Plc raised a request for the recruitment of
eighteen (18) young engineering graduates (sixteen mechanical and two electrical).
As with any major graduate recruitment exercise in NB .Plc, the campaign started
with advertisements in all the national daily newspapers, which will normally run for
about four weeks.
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Re,levant statistical data for the NB Plc recruitment exercise are as follows:
Total no. of applicants > 3,000
No. short listed for the first written aptitude tests -120
No. short listed for the second written aptitude tests 36
No. invited for oral interviews 24
Finally recruited as "suitable" candidates 1-
Finally recruited as "marginal" candidates 2
As shown in the above table, at the end of the interviews, only one (1) out of the
twlenty-four (24) candidates was found suitable for employment (by NB Plc
standards) - a pass rate of less than 5%. Two other candidates were found to be
"marginally" acceptable. The recruitment exercise was therefore adjudged to have
beHn unsuccessful.
To remedy the situation, NB Plc decided to invite all the twenty-four short listed
candidates (in IV above) for a three month~ intensive remedial re -training
programme, using locally recruited Nigerir:Hl lecturers. Only thirteen of the twenty
four candidates made it to the end of the re -training programme. After another
panel interview, all the thirteen (13) of the candidates were found to be suitable
for recruitment (by NB Plc standards) - a pass rate of 100%. They were all offered
jobs and only one of them declined the offer. To date all twelve (12) engineers are
currently performing very well in NB Plc.
In 11994/1995, SPDC embarked on an aggressive recruitment exercise for a total of
250 technical staff. Disciplines covered included the Engineering (mechanical,
electrical & civil), Petroleum Engineering, Geology, Computer Science, etc. As with
the initial experience of NB Plc, the recruitment exercise failed to produce desired
results.
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Relevant statistical data for the SPOC recruitment exercise are as follows:
Total No. of applicants > 11,000
Total No. short listed fqr first written aotitude -2800No. of successful candidates invited for Qral -44Finallv recruited as "mature" candidates 17Finally recruited as "young trainee" graduates 5
The recruitment process in SPDC is very similar to that of NB Plc.
As shown in above table, at the end of the final interviews, only a total of twenty
two (22) out of the fa rty-four (44) candidate interviewed were found suitable
for employment (by SPDC standards) - a pass rate of only 50%.
More significantly the entire recruitment exerci;::;e could only deliver less than ten
(10) percent of the original requirement of 250 techn ical recruits.
After reviewing the situation SPDC decided to adopt the method used by NB Plc
this time on a much larger scale because of the numbers involved. The end result
of that exercise is the commissioning of the 511ell Special Intensive Training
Programme (SITP) - a one - year i,·1.8nsive training programme.
In 1996, the author was seconded from Nigerian Breweries Plc (NB Plc) to head
the newly created Corporate Education Department of SPDC. His mandate was to
set up and run the first few batches of SITP more or less in line with the aims and
objectives of the above re -training programme in NB Plc.
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v
Rel,evant SITP/1 (graduate programme) statistical data are as follows:
Total No. of applicants for SITP/1 > 4,500Total No. short listed for first written aotitude tests - 1 800No. of trainees recruited for SITP/1 Batch No. 1 120No. of successful trainees left at end of I 89Total No. of trainees found "recruitable" bv SPDC ! 78No. of trainees "unrecruitable" 11
As shown in the table above at the end of the final interviews of the SITP/1
graduates a total of seventy-eight (78) out of the eighty-nine (89) candidates
intl~rviewedwere found suitable for employment (by SPDC standards) - a pass
rate of over 87%.
The success of the above programmes clearly demonstrates that on the short
term, a properly organised remedial pre-recruitment training; programme can
eliminate the obvious shortcomings of graduates from our run down tertiary
institutions.
Apart from the shortcomings of our tertiary institutions, the use of remedial
programmes is also very useful due to the following contemporary developments:
• advancing and rapidly changing technology now requires frequently
updated higher levels of knowledge than ever before;
• we now operate in a global economy that is more competitive and
dynamic, thereby calling for very rapid responses in the market
place.
We therefore expect these short-term remedial programmes to remain with us
for a long time.
,From the above results, it is very obvi ous that our tertiary institutions have some
very key challenges they must have to address before their products can "land
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and run" in a typical Nigerian industrial organisation. For this to happen, these
tertiary institutions must have to redesign their engineering curricula and align
same with the requirements of the industries they strive to serve.
3. KEY CHALLENGES FOR OUR TERTIARY TECHNICAL INSTITUTIONS
For our technical tertiary institutions, the key-challenging question to be
addressed is: "How can we modify our current engineering curricula in
order to produce the correct types of graduates for the Nigerian industry?"
Unlike his/her counterpart in a developed industrial country, an Engineer in a
Nigerian industrial environment must be both a ''jack of all trade" and "master
of all" - all at the same time. This IS because there are very few good third party
external technical support bodies in the Nigeria. Industrial operators must
therefore have to "grow their own timber". By extension, adopting standard
engineering curricula from universities in developed economies will therefore not
solve our problems. This line of thought will almost certainly degenerate to the
age-old argument for and against "generalists" or "specialists" The paradox we
have to resolve IS that we need both. However, In our current state of
development, our industries currently need engineers who are more "genera lists"
than "specialists"
The major communication gaps that we must address can be Illustrated
conceptually as shown In the attached Appendices I through to III Four major
communication gaps are Identified In Appendix I Some recommended remedial
steps for addressing these gaps are shown in Appendix 11 and Appendix III
In addition to addressing the above indicated communication gaps, it is
essential for companies, particularly within the same trade group to pool
resources with tertiary technical institutions and take advantage of the resultant
synergy to set up appropriate engineering schools/curricula that will produce
20
the correct quality of graduates required for the Nigerian industty. This was how
some top rated international institutions started e.g. UMIST in UK, MIT ill USA,
etc. External bodies like NUC, COREN, ITF, SITSIE, NASENI can act as
facilit,ators for programmes.
4. CONCLUSION
A unique advantage any country or organisation has over its competitors is its well
developed, skilled, dedicated, committed and motivated human capital. In an
increasingly global and competitive economy, principally driven by technology, the
ability to articulate and execute a robust programme for the practical training and
development of engineers will remain crucial. For sustainable growth and
development, it is essential for our tertiary institutions to continuously align their
engineering curricula with the end users of their
Appendix I
CONCEPTUAL MODEL OF MAJOR COMMUNICATION GAPS
t~
CZZ -0<mm:;o:;0(j)>
=i Z
m(j)
Internal quality level specifications for "suitable"PI~engineers for Nigerian Industrial Companies
, I Gap 3
I Expected Quality Level of Fresh Graduates~Gap 1 I I Gap 4
I Actual Quality Level of fresh Engineering~r~rlll~tAC:
I I Gap 2
Internal Quality Level Specifications of fresh EngineeringGradates from Nigerian Universities.
Appendix 11
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Gap 1: Nigeria Universities not knowing what the industries actually want
Possible Key Reasons:
(1) Insufficient regular and up to date "market" research on indu~try requirement;
(2) Inadequate use of market research findings;
(3) Insufficient interaction between Nigerian universities and thE industry - sabbaticals,
personnel exchange, etc.
Gap 2: University graduates are of wrong university specified quality standards
Possible Key Reasons:
(1) Inadequate funding, management and' commitment to service quality by the universities;
(2) Inadequate internal standardisation of tasks;
(3) Poor internal organisational structures, processes and system~ within the universities;
(4) Poor quality human resources practice within the universties - conferences and
seminars, skills, remuneration, management development, etc
Appendix III
Gap 3: Dissonance between industrial expectations ar,d reality
Possible Key Reasons:
(1) "Confused" Nigerian industrial sector;
(2) Improper organisation, job fit, work load, structures, processes, systems, etc.;
(3) Poor quality human resources practice within the industries -- "coaching", "mentoring"
and supervision of fresh graduates, skills acquisition, remuneration, management
development, etc.
')')
Gap 4: When promises do not match delivery
Possible Key Reasons:
(1) Inadequate "feedback" and internal horizontal interactions between the industry and
universities;
(?)
(~I)
Policies and procedures are developed without inputs from the "end-users";
Lack of appreciation of the magnitude of the challenge by the Nigerian industries.
Dr John Mbonu's paper was presented during the UNESCO-NASENlRoundtable discussion on Promotion of Best Practices in MechanicalEngineering for Job Creation, at the NASENI Complex Idu, Abuja, Nigeria 10December 2002.
23
AGRICULTURAL EQUIPMENT FABRICATION IN NIGERIA: GUIDELINES FORMECHANICAL AND AGRICULTURAL ENGINEERING GRADUATES
Bankole OYENIYI
INTRODUCTION
The invitation of the organizers of this round -table discussion came with a caveat
that our presentation must be more practical than academic.
We were requested to relate to the par ticipants our experience in agricultural
equipment manufacture in Nigeria and hov\;' others can benefit from such
experience.
The result of this challenge is what we have presented here. This essentially is a
"How To" guide for students in the field of Agric ultural and Mechanical
Engineering other Nigerians who desire the challenge that equipment
manufacturing presents.
Being a guideline, the presentation is designed to be simple. It is a highlight of
what to expect and do before starting an equipment manufa cturing venture. It is
our hope that University and Polytechnic administrators will find the guide useful
in curriculum restructuring so that our engineering graduates will be best
prepared to meet the challenges being provided by our new orientation towar ds
agric-based market driven economy.
Finally, the presentation is descriptive rather than prescriptive. We have tried to
cover a broad spectrum of best manufacturing practices and we have used
cassava processing machines as a model. Without doubt, the sa me skills and
practices required for the production of these machines can equally be applied
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for groundnut, grain or any other agro products. What is important is that the
market will decide what machines are required and from whom they are most
likely to be sourced.
MAJOR PLAYERS IN AGRICULTURAL EQUIPMENT MANUFACTURING IN
NIGERIA.
(A) THE ARTISAN -FABRICATOR
The artisan-fabricator is largely a creation of the market. Even though he lacks formal
engineering training, he has been dominant in the burgeoning small-scale years.
The artisan-fabricator more often than not went through the apprenticeship in the
technical know-how of copying one or two machines such as the pepper grinder and
cassava grating machine. He produces these exactly the way he first learnt and sells
one or two units as the market dictates. While at this. he equally produces water
tanks, iron-gates and other durable steel goods. He is creative enough to use scraps
from his activities to turn out stoves, garden tools and the like.
The artisan-fabricator can be found in nooks, crannies and along highways in Nigeria.
He operates in mechanic villages, mammy markets and anywhere he can source for
electricity and pay little rent. There is hardly a State in Nigeria where you would not
find the artisan-fabricator even though he is established in larger numbers in the
South-West and South-East states.
PRODUCT LINE
The Artisan-Fabricator is all things to all people. He may have started out building
water tanks and steel gates. However, he is most likely to later add the ubiquitous
pepper grinder (Plate mill) to his product line.
25
The usual expansion scenario is that a customer brings an idea or, better still, a
sample/prototype of agricultural equipment, which the artisan-fabricator ingeniously
copies. The copy may not be a perfect replica but usually it works.
This symbiotic relationship between the artisan-fabricator and the consumer is wholly
market-driven and it has largely succeeded in the evolution of the made-in-Nigeria
agro-processing machines such as the cassava grater, plate mills, palm oil and
kernel processors, maize shellers and so on.
PRODUCTION EQUIPMENT
The artisan fabricator uses the following basic fabrication equipment.
(a) Welding machine
(b) Hand grinder
(c) Table Vice
(d) Manual steel saw
(e) Other small tools such as chisel, hammer, etc.
Many years ago, these basic workshop equipment were imported, but again thanks
to his ingenuity, all of the above-mentioned production equipment are now made in
Nigeria by the Artisan-Fabricators.
MARKETING
The artisan-fabricator is in tune with market forces. He has little capital and he has
learnt to produce only those machines that could be sold within a short period. He
has even learnt the essence of specialization as he sometimes produces just one ...
item, usually the plate mill, in multiples and supplies these to middlemen/marketers.
One of the largest marketers of agricultural equipment in Ibadan, Quickpenny Limited,
26
depends solely on Artisan-Fabricators for the supply of large units of Pepper Grinders
and! palm oil Digesters.
ORGANIZATION STRUCTURE
The artisan fabricator is generally a one-man concern. However, sooner than later he
tak43s in apprentices generally from his extended family and occasio~ally neighbours.
He does everything from sourcing of raw materials through fabrication to selling. He
seldom produces any machine that requires installation but when he does, the
installation is contracted out to professionals such as Diesel Mechanics and
Electricians. With increased demand, the one-man outfit expands with more
production equipment, which may include the universal Lathe. He equally builds up
his apprenticeship base and sometimes, an outfit with up to 30 apprentices can be
found in Southwest Nigeria.
FUTURE PROJECTION
The artisan-fabricator has been around for two to three decades and thanks to a
booming population and increasing demand for agro-processing equipment, he will
continue to be around for a long time. In fact, he has made Nigeria not only self
sufficient in basic processing machines, his products are now found in neighbouring
African countries. He is a contributor to the GDP, a saver of foreign exchange and an
employer of labour.
His modus operandi may be the model for the young engineering graduate seeking to
establish an agricultural equipment-manufacturing venture.
B. THE MODERN FABRICATOR
The mainstream equipment fabricating companies such as Nova Technologies (Nig)
Ltd, Ibadan, Addis Engineering, Lagos and WNTC, Ibadan were established by
proprietors solely for the business of equipment production and marketing.
27
PRODUCT LINE
The engineering background of their proprietors and heavy capital infusion into such
establishments make it necessary that they produce a wider range of agro-processing
machines with exacting standards. Some of the products found in this category are:
• Multi-grain Threshers
• Complete (semi-automated) Feed mill
• High capacity cassava processing equipment
• Oil Expellers.
• Complete Fruit Juice Processing Plant
• Rice and Palm Oil Processing Equipment etc
PRODUCTION EQUIPMENT
The mainstream fabricator is equipped with a full compliment of production equipment
such as the universal Lathe, Milling and Shaping machines, Folding/bending machine,
Guillotine machine, Spraying and Finishing equipment. Some of these machines are
acquired in multiples as the companies often produced standard spare
MARKETING
The mainstream fabricator has a Showroom and applies modern Marketing strategies
to get his Products to the consumer.
He attends trade-fairs, advertises parts such as pulleys, threaded shafts etc which are
sold to artisan-fabricators and retailers.
More often than not, a large percentage of their turnover is from the patronage of
government (all tiers), NGOs and major multinationals who SJpport community-based
agro-activities in their operating areas.
OIRGANIZATION STRUCTURE
The organization structure of the, Mainstream Fabricator may not be too different from
the classic structure of medium-scale manufacturing concerns in the developing oorld
LE!. Board of Directors, Managing/Executive Directors, Department/Division Heads and
so on.
BI9cause the mainstream Fabricator attaches much importance to after sales services
the tendency to establish a robust technical crew for production is equally matched
with that for installation and repairs. He has learnt that despite a modern production
set-up, things really do go wrong with products far away from the factory. He needs to
get these fixed and promptly too in order to maintain good customer relationship.
TYPICAL ORGANISATIONAL STRUCTURE OF A MODERN FABRICATOR
BOARD OF DIRECTORS
RESEARCH & DEVELOPMENT/INSTITUTIONAL
11 MANAGINGI' COLLABORATION11
I11
ADMINISTRATION11
PRODUCTION IMARKETING/AFTER SALES I ACCOUNTS I
II MACHINING I IFABRICATION I FINISHING/ QUALITY
CONTROL
29
C. INSTITUTIONAL FABRICATORS
Nigeria has many research institutions, Industrial Development Centres (IDCs) and
Vocational Training Centres that were established by Federal and State
governments with the sole aim of conducting research on agricultural equipment.
Specifically, IDCs were established to provide engineering support services and
spare-parts for private fabricators who otherwise would find it difficult to acquire
expensive production equipment mentioned earlier.
However, with continued shortfall in government funding and the need to stay
relevant, many of these research institutions and engineering support organs have
taken to direct commercialisation and mass production/ marketing of their findings
and services.
We will not dwell much on the structure, products and marketing strategies of these
institutional fabricators but suffice to say that they represent a veritable source of
working models of agricultural equipment, spare parts and technical know how for
the potential engineering entrepreneur.
INTERNATIONAL INSTITUTE FOR TROPICAL AGRICULTURE A
QUINTESSENCE PARTNER IN GETTING STARTED
Unlike the institutional fabricators mentioned above, the International Institute of
Tropical Agriculture (IITA) is one research institute that transfers agricultural
equipment production know low to all categories of fabricators in Nigeria. From IITA,
a graduate engineering entrepreneur has a long list of proven research-backed
models from which he can chose to establish his venture. These include:
• Cassava processing machines
• Grain processing machines
• Groundnut decorticator
• Several hand tools and farm implements. (see Appendix 1 for full list)
30
It is pertinent to note here that IITA does not produce any of their research findings
for sale. Rather, they seek for and establish relationship with collaborating individuals
Bind companies to whom these technologies are transferred at no cost. What's more,
once a fabricator is adjudged proficient, his outfit and products receive other supports
s.uch as free listing in bulletins for potential customers, participation in the Institution's
fiield days and lately free listing on its website.
TECHNOLOGY TRANSFER
We will illustrate the potential, which exists in agricultural equipment manufacture for
students of agricultural and mechanical engineering with the adoption of the IITA
Cassava Processing Machines by our company.
In 1993, Nova Technologies was seeking to expand its product line and chose not to
"reinvent the wheel". Rather, we sent our technicians to IITA for training in the
fabrication of its Cassava Grater under a grant from the Ford Foundation. Our
nominees joined others at the IITA Campus where they were taken through the
complete production process from material layout, jigs and fixtures making, cutting,
welding, assembling, finishing and test running. At the end of the training, our
technicians were given the prototype that was produced during the training to take
back to our factory for mass production.
The IITA Cassava Grater has since become a money-spinner for Nova
Technologies. It is compact and simple to operate and all th~ parts are
standardized. Over the years, the Institution had made some modifications that are
regularly communicated to us.
The various range of IITA Cassava Processing machines produced by our company
are now in use by many buyers both within and outside Nigeria. Some buyers in
Nigeria include:
31
• UNICEF
• UNDP, Lagos State
• Women in Agricultures, Kogi State
• ADP, Ondo State etc
WHERE TO GO FROM HERE?
As mentioned in the beginning, the objective of this presentation is to inform and
demonstrate to our mechanical and agriculture engineering students and
institutional policy-makers alike that the old paradigm of white-collar job seeker has
dramatically shifted.
Our institutions of higher learning need to look beyond the imparting of
traditional knowledge in engineering to now include marketable knowledge and
entrepreneurship. Graduate of mechanical agricultural engineering needs but a
moment's reflection in our research on the opportunities in the equipment fabrication
sector of our economy and the yawning gap between the available prototypes in our
research institutes and their commercialisation to know that he has no business on
the unemployment line. He also needs to keep in mind a few tested truisms listed
below:
v You don't need millions in start-up capital.
v You can share existing workshop facility to fabricate your first product.
v Cassava machines are fast-sellers. So also are pepper grinders, palm oil
machines etc.
v You don't have to "re -invent the wheel as prototypes are waiting for
commercialisation.
v If the artisan-fabricator can sell his cruelly-finished machines, you surely can
sell more with attention to finishing details.
v You don't have to be a perfect or excellent welder. Employ one or more and
get started.
32
The going may be rough at the start but don't give up. Remember that the biggest
gold mine and strains that had bee'n discovered in America was fou nd two
inches beneath the last miner who gave up.
RECOMMENDATIONS
1. There is an urgent need for the re-orientation of engineering Syllabi and
course requirement to reflect current market need in agricultural machine
production.
2. Counselling and placement of students on industrial training should emphasize
servicing with agricultural equipment manufacturers and markets. This will
open the student to a better appreciation of the potentials for self-employment
in this sector.
3. Industrial attachment practical mLSt reward the fabrication of marketable
prototypes rather than esoteric projects usually left at the department shelf
long after graduation.
4. Faculties of Mechanical and Agricultural Engineering must be encouraged to
seek close rapport with cutting-edge organizations such as Lagos Business
School, relevant NGOs such as rATE Foundation for programme on
entrepreneurship development.
5. Students must be encouraged to attend seminars and workshops on
technology transfer occasionally organized by research institutes such as JlTA,
FIIRO and ARCEDEM. It may not be out of place for such activities to be
rewarded with elective credit hours.
6. Students should be encouraged to use Internet to access information from
their counterparts world-wide that could help them translate their latent
entrepreneurial dreams into realities.
Mr Bankole Oyeniyi's paper was presented during the UNESCO-NASENIRoundtable discussion on Promotion of Best Practices in MechanicalEngineering for Job Creation, at the NASENI Complex Idu, Abuja, Nigeria 10December 2002.
33
PACKAGING FEASIBILITY STUDIES
Engr. Adolphus OJOBO (MNSE)
1. INTRODUCTION
It is usual for an entrepreneur when seeking finance, to prepare a report detailing the
technical, marketing, financial and other relevant aspect of the project. This report,
which literarily is a Business Plan, is presented to the investor or financing institution
as a means of convincing them about the financial, economic and social benefits to
be derived from their participation in the project. Some common forms of report are
the Pre-feasibility report, the Feasibility report and the Viability report.
The Pre-feasibility report is a summarised version of the feasibility report, and is
usually prepared particularly for a large-scale industrial project, in order to determine
the merit of undertaking a feasibility report, which may be lengthy, expensive, and all
embracing.
A Feasibility report is basically aimeu at ascertaining whether a project is capable of
being done such that it will yield a satisfactory return, and is expected to contain
comprehensive data and information on all relevant aspects of the project, which will
influence the decision to participate.
A Viability report examines whether a project is capable of growing beyond its
present position or level, and would therefore cover all aspects of current operations
and any envisaged expansion. A viability report is thus concerned with an existing
project unlike the feasibility and pre-feasibility reports, which focus on new projects.
Viability reports may be required when management wishes to assess whether a
particular enterprise be kept on or closed up; when a major physical expansion of
operational facilities is being planned; or the benefit of new investments or lenders.
34
In this presentation, the Feasibility Report will be the main focus.
1.1 Features of a Feasibility Report
The major features of a feasibility Report can be outlined as follows:
1) EXECUTIVE SUMMARY
Gives the essential elements of the project in brief:- Project background,
objectives, location and size, main components, costs, organisation,
financial and economic result.
2) INTRODUCTION
• Project Background
• Project Objectives
• Project Sponsors
• Study Methodology - Preliminary Survey and Data ~ollection
3) REVIEW OF THE PROJECT
• The Sector of the Project
• Government Policies
• The Project Indicators - Product price regime, International trade,
employment characteristics etc.
4) MARKET STUDIES AND DEMAND ANALYSIS
• Domestic Production and Consumption
• Imports and Exports
• Domestic Consumption Market Prices, Duties and Taxes
• Factory, Wholesale and Retail Prices
• Methods of Distribution and Marketing
• Attitude of Customers
• Demographic and Income Characteristics of Demand
35
36
• Product's Market Share, the Competitors and the Product's
Competitive Position
5) TECHNICAL ASPECT OF THE PROJECT
• General Description of the Technical Aspects of the Project and the
Products
• Main Processes
• Optimum Size and Capacity
• Basic Raw Materials
• Proposed Location (including location map, general site plan which
should include proposed works, ancillary works e.g. access road,
buildings, water works, electricity etc)
• Proposed Source of Equipment, rqaterials, labour
• Technical Alternatives
6) ORGANISATION AND MANAGEMENT
• Determination of the type and number of each class of personnel,
recommendation on relevant and minimum qualification and
experience.
• Suitable organizational structure for the project
7) ANALYSIS OF THE FINANCIAL ASPECT
• Total Project Investment - Fixed and Working Capital
• Estimates of Project Budget
• Operating Costs
• Estimates of Total Sales Revenue
• Financial evaluation - Projected Profit and Loss Statement, Cash
Flow Statement, Balance Sheet, Ratio Analysis, Sensitivity Analysis
etc."
8) ANALYSIS OF THE ECONOMIC AND SOCIAL PROFITABILITY
• Estimation and Valuation of Benefits
• Estimation of Economic and Social Profitability
2. MARKET STUDIES
Market studies and analysis is a crucial and the first step in the preparation, analysis
and appraisal of projects. It is important in the determination of the size and location
of the project. The identification of a market is a " sine qua non" of business growth
and the starting point for new project development
2.1 Market Analysis
Market analysis of a project is a systematic inquiry seeking to gain information about
the whole environment in which the project is expected to operate and to forecast the
future trends to which the project is expected to adapt. It is concern not only with
individuals or organisation who are actual or potential consumers of the product of
the project but also with the competitors and all kinds of technical, material, political,
legal and administrative constraints within which the project is expected to thrive and
grow.
The overall objective of market analysis is to measure and forecast the market in
order to determine whether the project will produce the right product at the right time
and the right place. The specific objectives of market analysis are its ability to
address the following questions:
• What is the size of the market - estimation of present and future
demand?
• What volume of output can the project in question hope to sell in the
future bearing in mind potential customers, the reactions of existing
competitors, the possible arrival or entry of new competitors, costs and
37
38
price patterns and the past and expected future trends. This enable the
determination of the market share of the project
• On what geographical or sectoral market or markets is the project to
compete?
• What is the basis of its distribution and marketing policy?
2.2 Supply Analysis
.Information on supply can be obtained from a statistical time series of
production, imports, exports and changes in stock. It is imperative that the
present sources of supply of the product in question whether foreign or
domestic must be known. If the sources are domestic it is well to inquire into
the existing production capacity, level of utilization, location, characteristics of
typical productive units, whether small scale, artisan or large scale. If the
source is foreign, information can be obtained through the trade summary
published by the Federal Office of Statistics or from the Central Bank of
Nigeria.
2.3 Demand Estimation
The demand for a product that is of interest to the analyst is the effective
demand that is backed up with purchasing power. The quantity of demand for
consumers goods will be directly related to income, prices, population whilst
the demand for intermediate and capital goods, although affected to some
extent by the level and distribution of income and relative prices, depends
largely on structural changes in the economy.
2.4 Pricing and Market Strategy
The report should state clearly the prices of the various products, competitors
and the distribution/pricing strategy to be adapted.
3. TECHNICAL FEASIBILITY
Technical appraisal of a projec t considers first whether the project is sound from a
technical and engineering point of view. The technical aspects of a project usually
considered include:
3 Location and Site
Alternative sites should be considered with due regards to the availability, proximity
and cost of:
a) Adequate land with acceptable physical characteristics
b) Raw materials
c) Markets
d) Utilities such as water, power, fuel, communication etc
e) Transport infrastructures such as roads, rail
f) Labour (skilled, semi-skilled and unskilled)
g) Provision of expansion
The selected site should be such as to maximize benefits and reduce costs.
3.2 Choice of Technology, Process and Plant
In selecting the appropriate technology and plant for a project, it should be ensured
that:
i. They are suitable for the type of raw materials available and the end
product envisaged.
ii. They are well proven
iii. They entail minimum risk of obsolescence
iv. Plant design considers possible future expansion of facilities and is
flexible enough to allow introduction of newly developed technologies
39
v. Usage of locally available factors of production - a blend of capital
intensive technology against labour intensive technology
3.3 Plant Layout
The equipment manufacturers could on demand supply this. However, when
considering plant layout, the following factors should be borne in mind:
i. The process flow and flow of materials
ii. Storage needed for raw materials and supplies, work- in-progress and
finished goods
iii. Space requirement for maintaining in-plant transport
iv. Utility services systems (compressors, boilers etc)
v. Interdepartmental communication
vi. General Administrative and Services
vii. Future expansion alternatives
3.4 Raw Materials and Auxiliary Materials
Availability of raw materials and auxiliary materials is essential for the success of any
project. Points to be considered include:
i. The effective costs of materials delivered to the plant
ii. The weight and volume of raw materials
iii. Proximity to source of raw materials
iv. Availability of raw materials in adequate quantities and at economic
prices throughout the project life
To ensure availability of raw materials and auxiliary materials for the project, the
following points should be considered:
40
i. Specification of the types and qualities of materials to be acquired
ii. Investigation of the market for raw materials and contacts with
potential suppliers
iii. Placing orders and committing contracts including negotiation of
terms
iv. Supervision of delivery of raw materials
v. Taking action in the event of inadequate performance
vi. Payments
4. Management Analysis
The success of a project depends on the management. A project must have the
requisite management, technical and labour skill. The skills of the personnel involved
have to be developed partly by formal education and in-service training. Evaluation of
the required skills should cover the following:
i. Assessment of the workstations of the project
ii. Scrutiny of the organisational structure
iii. Examination of the availability of skilled personnel
iv. Arrangement of training
v. Provision for hiring foreign experts
vi. Remuneration of the various categories of manpower
An organizational structure, depicting the various departments envisaged should be
provided. The broad categories of the manpower requirement should be defined to
cover the following:
• General Management
• Production and Technical Units:
The overall manning list for any plant is usually dependent on the technology
adopted and the number of shifts to be operated.
41
5. PROJECT COST
This is an estimate of the total cost of the project and is usually given under three
main headings; cost incurred, to be incurred and total cost
Project Item Cost Cost to be Total
Incurred Incurred Cost
• Land and Site Preparation• Buildings• Professional Fees• Physical ContinqencyTOTAL LANDS & BUILDINGS
• Plant and Machinery C & F• Custom Duty, Insurance an Port Charges• Installation and Commissioning
TOTAL PLANT AND MACHINERY
• Essential Services/Utilities• Standby Generator and Transformer• Borehole and Accessories• Physical ContingencyTOTAL UTILITIES
• Vehicles• Furniture and Fittings• Prelim inary Expenses• Working Capital• Interest During Construction• Legal and Appraisal Fees• Price Contingencies• Contingencies
TOTAL PROJECT COST
6. PROJECT FINANCING
Project financing deals with the procurement of fund, that is, the process of raising
funds to finance expenditure decisions that have already been made It is concerned
with the choice of methods of financing and sources of funds. Project financing
42
therefore presupposes knowledge of the accounts required and the dates at which
the funds will ardve.
6.1 Sources of Finance
Funds for financing capital projects are provided from two general sources; internal
and external. The internal sources include the undistributed profits, depreciation
provisions and other reserves within the enterprise itself.
The external sources may either be domestic or foreign. The domestic external
sources include the capital market and the banks.
The Domestic Sources
a) The Capital Market:
The capital market handles new issues of market securities to the public. The new
issues can be sub-divided into three main groups:
i. Public issues of new shares, debentures and other long-term
obligations of public companies, either by an offer for sale by an issuing
house, or by an issue by the company itself. For these two methods, a
full prospectus is required and advertisement is necessary in leading
papers.
ii. Rights issue to shareholders by circular. New issues of ordinary shares
for cash are offered to shareholders in proportion to their existing
holdings. This is available only where a company's shares are already
quoted and the amount required in reasonable in relation.to the existing
capital.
iii. Private placing, either directly or through an issuing house with
institutional investors, or in the case of quoted securities with members
of a stock exchange for subsequent marketing.
b) Banks
43
This can be in form of equity or loans. Raising funds in form of equity is the
cheapest source. Such funds will be used to finance fixed assets and in some
cases working capital. Interest charges, which are on the loan component, will be
highly reduced.
In arriving at a financing arrangement for a project, the debUequity ratio
acceptable to the financial institution that will provide the term loan should be
applied. Some banks prefer a 60:40 ratio while others can accommodate a 70:30
situation. Generally the lower the gearing, the better for the project and the more
comfortable the financial institutions are.
The financial plan or financing arrangement for projects is usually of the form:
• Equity (Project Sponsors)
• Long Term Loan (DFI, Commercial Banks)
• Bank Overdraft (Commercial Banks)
7. FINANCIAL ANALYSIS
7.1 Estimated Capital Expenditure
Capital Expenditure refers to expenditure on such items as plant and machinery,
tools transportation equipment, utilities, office furniture and equipment. Capital here
refers to those items that tie up capital for a long time and do not turn over into cash
fast enough but takes several years to return their cash outlay
The total capital expenditure is made up of:
• The cost of fixed assets (equipment and fixtures)
• Start-up costs - initial expenditure in starting the project before actual
operation commences.
7.2 Estimated Working Capital
This is the amount of cash necessary to cover anticipated expenditure befo re
revenues begin to accrue. This involves a study of anticipated payments for labour,
utilities, rents, supplies and other expenses following the commencement of
operation. Inventory requirements (covering initial r;i.,.; materials cost) are included in
this estimate.
7.3 Cash Budget
This is an estimate of cash receipts and payments over a given period. It helps not
only to anticipate cash needs but also enables a proper control over the management
of cash in the business.
7.4 Projected Income Statement
tThis summarizes the estimated operating expenses and the operating revenue and
shows the Net Profit or Loss as the case may be. The Net Profit is the return on
investment and a desire minimum or acceptable level indicates the profitability of the
project.
7.5 Projected Balance Sheet
The Balance Sheet summarizes the assets and liabilities of the business. The
estimated figures for cash balance for a year; accounts receivable and inventories
are together called current assets and will be derivefi from previous estimates of the
items while fixed assets refer to all items in the estimated capital expenditure (after
deducting allowances for depreciation).
Liabilities will consist of amounts due to third parties and the owners of business.
Amount due to third parties include accounts payable (i.e. the amounts the business
45
is owing on purchases). Amounts due to owners include the capital invested and the
Net Profit.
7.6 Profitability Analysis and Evaluation of Project
The profitability of a project can in simple erms be evaluated by the Break-Even
point, which in the algebraic approach is
Break - Even Point = FC
P-VC
where FC stands for Fixed Cost
P stands for unit Selling Price
VC stands for units Variable Cost
This is most applicable for a sing le product output. However, in the case of multi
product situation, great care must be exercised in the allocation of fixed costs and
indirect costs to the various products.
In general, methods of appraising a project include:
• Payback Period
• Annual Rate of Return
• Net Present Value
• Discounted Cash Flow.
The Payback Period represents the number of years it will take the business to
recover the original investment from the net cash flow. Again in simple terms:
46
Payback = Total Investment
Net Profit + Depreciation
For projects involving a relatively small capital investment and with a short payback
period, this can be established without undertaking detailed analysis beyond the pay
back calculation.
In the Annual Rate of Return evaluation, the profit on the investment is expressed
as a percentage of the capital outlay. A rate usually above the minimum interest rate
of banks is considered is considered profitable.
Details of these financial analysis and evaluation are presented in the Sample
Feasibility Report (Executive Summary) in the Appendix.
47
48
APPENDIX
SAMPLE FEASIBILITY REPORT
FOR
A CASSAVA PROCESSING FACTORY PROJECT
EXECUTIVE SUMMARY
1.0 The following feasibility report relates to the proposal by a State
government to establish a Cassava - Processing Plant. The project, to be
located in Local Government Council headquarters, will involve the
processing of cassava tubers into industrial products of chips, flour and
starch.
2.0 The installed capacity of the plant is about 60,00 to nnes of fresh tubers per
year to be processed into the following finished products:
§ Cassava chips: 12,000 tonnes per annum
§ Cassava starch: 3,000 tonnes per annum
§ Cassava flour: 3,000 tonnes per annum
§ Re-processed wastes 18,000 tonnes per annum
The capacity utilization of the plant will rise from 60% in the first year of
operation to about 100% in the third year.
3.0 A ready market in the country has been identified for the products with a
possibility of an export market particularly for the more prefe rred products of
pellets, which is to be embarked upon as soon as the production of the initial
products stabilizes.
4.0 The project is estimated to be fully effected with a total of about N335 million
in fixed capital and N15.0 millionTin working capital. hE estimated total
project cost of approximately N350 million is to be initially fir,anced wholly by
the government. However, it is expected that efforts will be made in due
course to privatise this investment by way of encouraging state indigenes to
acquire shares in the company.
5.0 llliTmncial projections on the operations of the project reveal very
satisfactory level of liquidity and stability. The sales figures will increase from
N250 million in the first year to N456.23 million in the third year while the
Profit after Tax is N23. 67 million in the first year and up to N78.04 million in
the third year.
6.0 The Return on Turn Over rises from 9.5 in the first year to 17.10 in the third
year. During the same period, Return on Equity increases from 6.76 to 22.3.
The financial analysis shows that the project will pay for itself by the fourth
year of operation.
8.0 The cash flow indicates that there will be sufficient cash balances during the
projected three years. The cash balances Increase from N73.23 million in the
first year to N311.97 million in the third year.
9.0 The implementation schedule shows that the project can be fully realized
within 9 months of date of investment decision. This entails:
§ Engineering Design of Factory Complex and other Utilities
§ Land Acquisition, Clearing and Fencing
§ Factory Complex Construction
§ Equipment Installation and Commissioning
§ Training and Start up
§ Project Management
49
-----"--
GRATINGCRUSHIN(3r-__
"
FERMENTATIONEXTRACTION
---.----SQUEEZING
CENTRIFUGING..CRUMBLINGDEF;BERING
+COOKING
DRYINGDRY~G
"---- ---
SIFTING
STAGES OF CASSAVA PROCESSING
TAILING"--"----"-..-··f·_..--··_..-··---"-- --." "---
WASHING
+PEELING
GRANULAOON
1CUITING
FERMENTATION
f
t.GRATING
1DRYING
PACKAGINGPACVAGING
"- ---.---CASSAVASEMOLINASTARCH
(GARI,FARINHADEMANDIOCA)
+
PELLETS
PACKAGING
+ +
CASSAVA
FLOUR(FOUFOU)
PACKAGING
CASSAVA
CHIPS
so
SCHEME OF FACTORY PRODUCTION
60, 000 tonnes of cassava tubers per year
10,000 tonnes of tUbers 40,000 tonnes of 10,000 tonnes of tubersfor Flour cassava for chips for starch
I I I
I Section 1: Preparation of Tubers II I
Maximum Capacity: Maximum Capacity: Maximum Capacity:48t/day 144t/day 48t/day
3t/hr x 16hrx 27 daysx10m = 9t1hr x 16h x27 x 10m = 38, 3t/hr x 16hrx 2712,960t 880t daysxlOm = 12,960t
I I I8400t of disinfected and 36,000 tonnes of sliced Starch Extraction
sliced tubers tuber
I II Section 2: IDrying of Chips Starch Concentration and
I Drying
Max Capacity: 180t/dayMax. Capacity: 60t/day I60t/day x 24 x 10 = 14400 180t/day x24 x 10m = Max. Capacity:
43,2000 60t/day
I I3,800 t of chips I 1 14,800t of chips I
60t/day x 24 x 10 =14400
II IFlour Production Chips ProductionMax. 1.5t/h Max.4t/h I 3,800 t of starch1.5t/h x 12b/day x 24 x lOm = 4t/h x 16b/day x 24days x 10m =4320t 15,360 I
Starch PackagingMax. 1.5tlh1.5t/h x 12b/day x24 x lOm =4320t
3,OOOt of Flour 12,000 t of chIps3,000 t of starch
51
10. Specific Project Statistics
Table 1: Plant Capacity and Production Programme
ITEM YEAR 1 YEAR 2 YEAR 3Capacity Utilization 60% 80% 100%Quantities Tonnes Tonnes Tonnes
Cassava Chips 7,500 9,600 12,000Cassava Starch 1,800 2,400 3,000Cassava Flour 1 800 2 400 3000Reprocessed Waste 10,000 15,000 18,000TOTAL 21,100 29,400 36,000
Table 2: Raw materials Requirement (Cassava Tubers)
ITEM YEAR 1 YEAR 2 YEAR 3Capacity Utilisation 60% 80% 100%Quantities Tonnes Tonnes Tonnes
Cassava Chips 23 000 30 000 40 000Cassava Starch 6,000 8,000 10,000Cassava Flour 6,000 8,000 10,000TOTAL 35.000 46 000 60 000
Table 3: Category Of Manpower
SIN CATEGORY GROUP OF OFFICERSIWORKERS1 01 General Manaaer2 02 Managers3 03 Head of Unit, Superintendent, Accountant, Auditor4 04 Admin. Officers, Technicians5 05 Clerical Officers Plant Operatives6 06 Workers
Table 4: Summary Of Manning List And Category
SIN DEPARTMENT 01 02 03 04 05 06 TOTAL1 General 1 - 1 1 5 2 10
Manager'sOffice
2 Commercial - 1 3 - 16 - 203 Accounts - 1 1 2 4 - 84 Production - 1 3 15 50 7 765 Admin. - 1 - 1 10 8 20
IPersonnelTOTAL 1 4 8 19 85 17 134
52
PROPOSED ORGANIZATION STRUCTURE
Internal
II AuditGeneral Manager I
ICommercial 1 Admin/Personnel 1Accounts Production
I I I IMaint. Plant Quality IAdmin I PRO IControl
Security
Extension Salesunit
Purchasing
53
PROCESS EQUIPMENT, MACHINERY AND FACILITIES
(A) PLANT AND MACHINERY
(a) Cassava Chips And Flour Production
DESCRIPTION QUANTITYCassava Reception/WashinQ 1Cassava Cuttina 1Dryinq 1GrindinQ - SievinQ 1PackaQinQ 1
(b) Starch Production
DESCRIPTION QUANTITYReception/CleaninQ 1Starch Milk Extraction 1Starch Concentration and Dryinq 1Starch PackaqinQ 1
Utilities 1
(c) By Products Processing Plant
DESCRIPTION QUANTITYGrindinq/Sievinq 1PackaqinQ 1Utilities 1
(B) FACTORY COMPLEX FACILITIES
Main Factory Complex
• Factory Complex Building;• Steam and Electricity Building;• End Products Storage Building;• Waste Products Reclamation Building;• Weigh Bridge Building;
General and Service Buildings• Administrative Building• Canteen and Clinic
Civil Works• Road Works and Drainage• Fence and Gate House• Effluerrt WastelTreatment Plant
(C) AUXILIARY FACILITIES:
• Water Supply (Borehole) and Associated Facilities• Electricity Supply to the Factory Site• Standby Generators• Weigh Bridge and Accessories• Steam Boiler and Water Treatment Plant• Effluent Waste and Treatment Facilities• Transport Equipment and other Machinery• Furniture and Fixtures
Table 5: Summary of Project Cost
COST ITEM LOCAL COST FOREIGN TOTAL COST(N '000) COST (N' 000)
(N' 000)Land and Site Development 5,000 - 5, 000Building 39,600 - 39,600Civil Works 7,500 - 7,500Plant and Machinery - 210,284 210,284
Auxiliary Equipment 22, 350 - 22,350Transport Equipment 11,000 - 11,000Furniture & Fittinqs 5,000 - 5,000Preliminary Expenses 25,200 - 25,200Sub - Total 115,650 210,284 325,934Contingency 2,891 5,257 8, 148Total Fixed Capital 118,541 215,541 334,082Working Capital 15,000 - 15,000TOTAL INVESTMENT 133,541 215, 541 349,082
350,000(approx.)
55
Table 6: Annual Production Estimate
YEAR 1 2 3Prod. Proqramme. 60% 80% 100%
Expenditure (N' 000) (N'OOO) (N'OOO)Raw Materials 121,760 165,314 229,400Salaries & Wages 16,020 17,622 19,384Maint. & Insurance 15,038 16,542 18,196Utilities 13,305 14,636 16,099Factory Cost 166, 123 214, 114 283,079
Overheads 16,612 21,411 28,308(10 % of Factory Cost)Operating Cost 182, 735 235, 525 311, 387
Depreciation 28,418 28,418 28,418
Total Production Cost 211,153 263,943 339,805
Table 7: Projected Profit And Loss Statement
YEAR 1 2 3
Prod. Programme. 60% 80% 100%
(N' 000) (N'OOO) (N'OOO)Sales Revenue 250,000 321,000 456,323
Less:Production Cost 211, 153 263,943 339,805
Gross Profit 38, 847 57, 054 116,518
Less:Amortization 5,040 5,040 5,040
Profit Before Tax 33, 807 52,014 111,478
Taxation: 30% 10, 142 15,604 33,443
Profit After Tax 23,665 36,410 78,035
56
Table 9: Cash Flow Projection
YEAR Construction 1 2 3Period
(A) INCOME (N' 000) (N'OOO) (N'OOO)
Capital 350,000 - - -Sales Revenue - 250,000 349,335 456,323
(A) 350,000 250,000 349,335 456,323
-(B) EXPENDITURE
Fixed Assets 300, 734 - - -Preliminary. 25,200 - - -
Expenses
Production Cost - 211, 153 263,943 339,805
Less: 28,418 28,418 28,418Deprec iation
-
Net 325,934 182, 735 235,525 331,387
Cash Balance (A - 24,066 49, 166 113,810 124,936
B)
Balance b/fwd - 24,066 73,232 187,042
Balance c/fwd 24,066 73,232 187,042 311,978
Engineer Adolphus Ojobo's paper was presented during the UNESCONASENI Roundtable discussion on Promotion of Best Practices inMechanical Engineering for Job Creation, at the NASENI Complex Idu, Abuja,Nigeria 10 December 2002.
57
DEVELOPMENT AND TRANSFER OF APPROPRIATE POST -HARVESTTECHNOLOGIES IN SUS-5AHARAN AFRICAN 1
Engr. Leonides Halos-Kim
INTRODUCTION
Majority of the post-production activities in Africa are done manually which is time
consuming and labour intensive. Introduction of innovations and technologies
since early 70s had limited success because the technologies often do not fit the
users' needs. This was due to the fact that the technologies were based on the
classical "piece-meal" technology development approach that satisfies the whims
of the designers, but not the end-users. Also, imported technologies introduced
through aids, grants or loans failed to consider the technical requirements for
operating the technologies. As a result subsistence agricultural production
generally prevails, and processing at the family level dominates.
Improved farming techniques introduced in recent years have raised agricultural
production markedly. This change has however underscored the inadequacy of
post-production practices 2 and infrastructure. Production increases have had little
impact on the rural farm economy because of the inability of the agricultural
development system to support post-production operations. Agro-processing 3
remains a subsistence industry with few incentives for expansion. The lack of
appropriate and low cost equipment is one of the problems encountered by small
scale processors.
I ThIS paper was first presented during the Workshop on Gender, Technology and Development: PromotIOn of
Appropriate Agro-processing Technologies in West Africa orgalllzed by the Post-harvest Technology ResearchGroup (PHTRG), Obafemi Awolowo University, Ile -Ife, NIgeria. 23-26 October 2002.2 Post-production actIvities cover operations occurring from the time the crop is mature enough for harvest andprocessing to the pomt of consumptIOn.- Off-farm post-harvest activities done to transform agricultural crops into convenient forms for sale or forconsumption consIsting of various unit operations 1I111qlle for any desired product. Examples of generaloperations are peelmg. washing, tuber cutting. soaklllg. dcfibcnng. dry1l1g. thrcshll1g. and cleaning.
58
Processing is a traditional responsibility of women who often are not in position to
make decisions about investing in improved technologies. Their inability to
acquire new equipment, and the distance to processing centres, which are usually
located in urban areas, limits the type and volume of products they can produce,
so they forgo an opportunity to earn more income.
To increase agricultural production in Africa, it is imperative that the needs of
women farmers and women agro-processors be given serious attention. Recently,
development institutions such as IITA have started to add gender-related issues
to their agendas to improve the delivery and utilization of research results.
IITA addresses constraints in post harvest systems by developing simple, low
cost, labour-saving devices and equipment that can be fabricated from locally
available materials. These innovations are intended to minimize losses, increase
labour productivity, improve product quality, and reduce drudgery, especially for
women processors. The technologies are now being introduced to farmers and
agro-processors in West Africa in partnership with national development
programmes, as well as, non-governmental organizations.
Crop post harvest System Development Concerns
The post harvest system can be divided into two stages: crop processing and
food processing. Crop processing involves harvesting and all activities done until
the crop is brought home to store or to process further. Food processing starts
when the crops are withdrawn from storage and lasts until they processed into
desired form for sale or consumption.
60
o Crop and Food Processing Patterns
Agriculture in sub-Saharan Africa is characterized by small, fragmented,
resource- poor farms, cultivated to multiple food crops. Cassava is the diets
and live hoods of many smallholders. The producing household consumes
1ID0ut 80 percent of the produce. arvesting for consumption is usually
done weekly, and processing is done throughout the year by women and
children using traditional methods, which are slow and unhygienic.
Cereals and grains legumes are also grown extensively. The producing
household consumes Seventy-five percent of the produce. Maize is mainly
grown as a cash crop, while sorghum, millet, and cowpea are grown for
family consumption. Each crop has a brief harvest period, but the
harvested crop is processed into food products in small quantities
throughout the year. The average farm family's production of cereals and
grains legumes is sufficient to feed the household for not more than 3
months. The crop are processed into indigenous forms (foods) requiring
special preparations unique for any given region.
o Labour Requirement
Because most post harvest operations use slow traditional methods, they
are time-consuming. In Nigeria, it normally takes 663 labour-hours to
harvest and process a 1-hecter field yield of 10 tonnes of cassava roots
(Jeon and Halos-Kim. 1994). Harvesting and processing require the most
labour. Women contribute 87 percent of the time required to process food
for family consumption, and they are also involved in harvest and handling
(Jeon and Halos 1991).
Labour input for harvesting, handling, drying and processing cereals and
grain legumes (217 labourer-hour/t) is provided mainly by the family
members-20 percent is contributed by the husband, 62 percent by the wife,
and about 25 percent by adult sons or daughters (Jeon and Halos-Kim
1994).
Timing of harvesting and consequent operations for cereals and grain
legumes is critical because, for safe processing and storage, the crop has
to be gathered quickly before severe deterioration and pest damage occurs.
This urgency places a heavy load on the women and children who normally
do most on the job.
o Handling Efficiency
Production increases resulting from improved growing practices are
diminished by improper handling of the nops after harvest. For cassava,
post-production losses could be as high as 45 percent, with about 14
percent during harvesting and 22 percent processing. Qualitative and
quantitative post-production losses in cereals and grain legumes had been
estimated at 30 to 50 percent. These losses result from field and
environmental conditions, varietals characteristics, untimely harvesting,
improper drying, insect damage, consumption by livestock, operators'
attitude, and lack of processing tools and equipment.
o Gender Roles in Crop and Food production
Men and women perform distinct roles in crop and food production. The
division of labour is based more on the physical difficulty of the task than
magnitude. Men are generally involved in production activities, while post
production activities, in addition to household chores, are reserved for
women. The woman's role in processing is dictated by social and cultural
norms.
Farms tend to differentiate tasks by the type of crops grown. Maize is
considered a cash crop and is controlled mostly by men from production to
marketing. Sorghum, millet, and cowpea are crops grown by women for
61
family consump,tion. In many cases, women and children provide the
labour required from crop care and management to processing.
Division of land resources among family members is common in Africa.
Land allocation distinguishes each family member's role and status in crop
and food production. The wife plays a strong decision role in her own farm.
In some cases she consults her husband on land preparation and other
production activities. The husband, on the other hand, relies on his wife's
decision on harvesting, handling, and processing.
Implications for Technology Development
The problems associated with post harvest operation can be overcome through the
introduction of appropriate tools and equi pment, system arrangement 4, and
investments in training of farmers and agro-processors.
Analysis of the post harvest system (Jeon and Halos 1991; Jeon and Halos-Kim 1994)
has indicated that losses and labour inefficiencies are mainly due to lack of
appropriate tools and equipment for processing. Processing food is a job reserved for
women, who use traditional methods and have limited access to improved production
and investment opportunities.
Arrangement of competent operations so that process and material flow is most
efficient handled with the least movement and costs, therefore avoiding losses (due
to spillage, etc.) and unnecessary delay.
Maintaining a separate farm, in addition to performing household chores and
providing post-production labour in the husband's farm, puts a heavy load on the wife,
.j Arrangement of component operatIons so that process and material flow is most efficiently handled with theleast movement and costs. therefore avoiding losses (due to sptllage. etc.) and unnecessary delay.
62
who also has to mange her meagre resources. Increasing production will demand
more and more of the women's time both for orrfarm and off-farm activities.
Providing incentives and appropriate facilities for w.>men while at the same time
providing improved production technologies for men, as has been the object of many
development projects, should balance the situation.
Because women perform the bulk of the post-production activities, small-scale crop
and food processing technologies are vitally needed to help women at least cope
with family food-processing requirements. However, the development of technologies
should focus on food products that are sufficiently available and for which competitive
markets exist so that families can both satisfy their own needs and increase their
incomes. To accomplish this, the development approach needs to incorporate the
mechanization aspect of the operation. This, however, is a short-sighted strategy if it
overlooks the other factors in the system such as the economic capability of farmers
and agro-processors and the nature of the farming system.
Strategies for Technology Development
Strategies for technology development are varied. At IITA, technology development
does not end in the workshop rather it is passed on to the then back to the designer,
and so on, until the desired result is attained. The technology designer and user
should work together until a satisfactory solution to a defined problem is found.
Experiences in the generation and introduction of post harvest technologies provide a
basis for suggesting guidelines for developing technologies that will suit users'
requirements.
Apply a participatory development process
The need for farmer-tested technologies is crucial in the African environment.
The participatory approach will improve the understanding of constraints,
63
64
opportunities, and criteria in order to ensure a greater adoption of technology by
target users. This approach requires the involvement of the target users in the
planning and development stages. It encourages the users to give full support
in the information-seeking process so that designers can fully understand users'
needs and limitations. This method has been widely recommended, but fully
integrated and truly interdisciplinary teams involving both technical and social
scientist have rarely been constituted.
Define a holistic view of the problem
Because technology is introduced with a social system, the different subsystems
that will affect and will be affected by the technology must be considered. The
technology should be suited to these environments. The strategy for technology
development should then involve the examination of the post harvest system as
a whole rather than limiting the examination to specific commodities, techniques,
processes, or technologies. This approach also overcomes gender-bias and
provides more sustainable options- the designer who has a holistic view
understands the gender division of jobs and is able to design technology to fit
them.
Consider existing technologies
Existing technologies, although mostly traditional, are potential materials for
development. Because people are used to them, modifications and improvement
can be appreciated more readily. Once people have experience with the
development process, they become eager for better technology and are more
willing to try out new ideas.
Appropriate is affordable
Some technically efficient machines may be impractical for a specific
environment. The applicability of the technology will depend on whether it can
be locally manufactured using locally available materials. To reduce operational
costs, it should be simple to operate and maintain. Costs considerations are
important to investors, and more so to fa rmers and processors who barely have
enough cash for their daily needs.
Technology development should properly focus its objectives. Analysis of the
farming system and processing operations should be done conscientiously
taking into consideration constraints and their causes, as well as doers of the
job, among other production and post-production factors.
A full farming systems approach should be considered with the groups chosen for
emphasis. Research, development, and funding institutions should also realize that
investments in yield -increasing innovations could be useless if post-production
constraints are ignored. For women farmers, bottlenecks in processing are major
constraints to higher productivity.
Any technological innovation should be enhanced with the farmers' traditional
knowledge to ensure effective technology transfer. Farmers are likely to innovate if
given the proper incentives.
Technology Attributes Desirable for African Conditions
Indeed the application potential of post harvest and agro-processing technologies
introduced under African conditions is based on whether these technologies are
simple enough to be operated and maintained, even by women. A checklist of
lliesirable characteristics of post harvest technologies that is likely to ork under
65
African conditions is summarized below and should be given increasing attention in
technology design and development.
Characteristics related to technology design
Addressing the diverse nature or African farming systems, in addition to the
taste and food preferences of the consumers require different types of
technology packages or components having the following attributes:
CHARACTERISTIC
T Simple, easy to operate and maintain
T Technology level based on existingtechnologies and indigenous knowledge
T Ability to handle different crops
T Dual, or multiple applications
T A range of capacity for different levels ofoperation
T Balanced technology mix
T Uses locally available materials forconstruction
66
RESULTING ATIRIBUTE
- Technologies are manageable, even bywomen processors
- Reduce technical problems, Le.mechanical breakdowns
- Adapts potential existing technologiesalready known to users.Relates to compatibility andtransferability of existing technologies.
- Facilitates adoption of technologies.- Allows farmer to diversify and expand
production.- Reduces investments cost- Ensures utility continuum- Addresses user's production objectives:
for consumption and / or marketing.- Matching capacities of each component
technology in the system.- Eliminates voids and clots in the
processing chain.- Eliminates importation costs
- Low investments, operation andmaintenance costs
- Encourages the participationof private sectors
• Characteristics related to technology, economics and social science
The ultimate goal of technology introduced in any development project is a
favourable impact on the economic and social well being of the target users.
User's attitudes and economic status affect decisions and investments made on
technologies. Technologies addressing these concerns are characterized as:
T
T
T
CHARACTERISTICAffordable
Equally beneficial to farmers, processorsand consumers
Gender-sensitive empowering farmersand processors in their rights
RESULTING ATIRIBUTE- Requires low investment, operation and
maintenance costs- Availability of good and nutritious foods
- Creates additional sources of incomeBetter allocation of resources
- Improves economic scale of the farmersand processors at all levelsEliminates dependency on vested groups
- Allows farmers and processors to managetheir time and operations effectively.
• Characteristics related to technology and utilization
Adoption of new products developed to expand the market potential of a crop may be
hindered by consumer preference for traditional processes and products. New high
quality products should be similar to existing preferences to ensure a high level of
acceptability. The nutritional attributes of the crops must be considered along with
providing expanded utilization alternatives for added value products. Therefore,
technobgies development should provide for:
CHARACTERISTICT Product diversification
T New products similar to existingpreferences
T Improved nutritional attribute
RESULTING ATTRIBUTE- Allows the production of more food and
non-food products- Opens market opportunities- Better chances of being accepted
- Improved the heath status particularly ofthe children
- Added-value increase marketcompetitiveness of the product
67
Features of Post harvest Technologies
In order to enhance agricultural productivity of rural farmers processors, the
development objective is to provide appropriate tools and equipment that overcome
excessive losses, high labour input, and poor product quality, which can result from
inability to process crops immediately afte r harvest. Consequently, technology should
create opportunity to increase the income and save the time of processors, which can
then be developed to other productive activities.
The technologies development featured simple design that allows operation,
maintenance and replicability. They are also adopted for multi -crop application to fit
the farming system where small farms are planted to different crops at one time.
Another advantage of IITA machines is that it is portable, has good mobility and
therefore suitable for women. Mobile equipment is easy to move around when there
is need to expand business area. They also offer opportunity to reduce the initial
investment for farms structures since they could easily be accommodated in existing
farmhouse or processing centres.
The technologies can be packaged for different levels of operation targeted towards
specific user-groups. The family-based processing package consists of manually
operated equipment designed for women and children responsible for family bod
preparations. It is recommended for a hamlet-based operation that three to five family
units can use in turn.
The technology package for women's group processing is designed to reduce the
drudgery of individual processing and to encourage women to invest collectively. It is
partly mechanized to process family food and at the same time to provide opportunity
for women to generate income. It is intended to be operated for food-exchange,
contract processing, and product marketing. The food-exchange scheme offered by
the centre relieves the women of individual household processing - the women can
come to the processing centre to exchange raw materials for processed products and
work to earn income. Technologies for small-and medium-scaled enterprises are
68
more mechanized and designed for enterprising men's and women's grOJJps,
community associations, or private individuals, primarily to generate income.
Technology Transfer
As a consequence of the particular approach adopted, improved technologies were
actually introduced at the same time with technology generation. From 1991 to 1994,
IITA with finding from the Ford Foundation pursued a model village development
project in Nigeria in an effort to hasten the technology transfer process. The strategy
was to introduce and demonstrate different packages of improved post harvest
technologies selected on the basis of needs assessment in selected villages to verify'
technology for further development and to monitor technological impact. The strategy
had a tangible impact on villagers' way of life. That is, increased processing activities
encouraged production of more crops using improved varieties, thus improving the
villagers' economic and social status.
Although the project involved research and extension officers form national research
and extension system, there was no established linkage to further the technology
transfer. The project was biased to IITA's research and development goals leaving
the partner from national research and extension system fully responsible for
dissemination, although aware of their weakness. Therefore, despite the positive
feedback from farmers and agro-processors, the rate of adoption and diffusion was
slow due to the weak extension infrastructure and lack of trained staff. Many
technologies are still on the researchers' desk,
The weak linkage between agriculture and industry can be seen quite often. Most of
the agro-metal workshops (manufacturers) are located in the urban areas while most
farmers and agro-processors are in the rural areas- do not have access to the
manufacture and do not know the kind of technologies available. His gap between
farmers and manufacturers obstructs the integrated business development interests
of both parties.
69
The SAA 5 -IITA partnership forged in '1994 attempts to bridge this gap so that
technologies reach the end-users where and when needed, and to establish a
support mechanism to sustain the demand and supply, and utility continuum of the
technologies. The project operates to provide information on agro-processing
technology opportunities and training. Activities of the project are designed at
enabling the environment including human and material resources to source, adapt
and adopt technological interventions.
The SAA-IITA Agro-processing project is a collaborative effort among organisation to
make the agro-processing technology available to agro-metal workers
(manufacturers) and rural farmers and processors. The collaboration may be viewed
as an inter-sector effort involving agricultural and industria! sectors. The major
activities of the project include research and development, agro-industrial extension
and manufacturers training.
The partners collaborate effectively with full understanding of their specific roles and
responsibilities. IITA is responsible for technology development and spearheads the
training courses on development, fabricDtion and servicing of selected agro
processing technologies. SAA staff and the collaborating partners are responsible for
the promotion of the technologies through demonstrations and by developing
partnerships/linkages with the appropriate sectors to make technologies accessible to
the end-users. They also organize and provide training on the management of the
technologies.
Local manufacturers are also important partners in the project. They are engage in
the fabrication of the agro- processing equipment and make them available locally
with the associated services needed to maintain and sustain functionality of the
5 SAA, the Sasakaw<l Afric<l Association, is a non -governmental org<lI1I/illlOn funded by Nlpp\)n Foundationbased in Tokyo, Japan.
70
equipment. Their commercial activities give farmers and aJro-processor access to
industrial products and services at each location.
The farmers and agro-processors who are the ultimate beneficiaries influence rural
agro-processing enterprise development and support the manufacturing industry
while increasing their own capacity. Their participation and feedback on utility,
adequacy, and profitability of the technologies are valuable guides for adapting the
technology to the local environment with improved efficiency. Different user groups
(individuals or private entrepreneur's women's groups, and community organizations)
are encouraged to participate in demonstrations and field-testing activities. Their
participation can stimulate their interest in investing in the technology.
Regular meetings and monitoring visits make the visible and effective project
managers. Field demonstrations and activities in the model processing centres
proved useful in creating awareness and generating interest from farmers, agro
processors, manufacturers as well as funding organizations.
Component Technology Transfer Activities
• Training
Training is provided to development and extension workers as well as end-users to
enable them manage the project and sustain the technologies. Different types of
training are conducted for various groups of beneficiaries.
One type is training on design, development management of improved agro
processing technologies. It is designed to develop skills of personnel who are
responsible for demonstrating the technologies and in training operators. They are
also expected to oversee the sustainability of the technologies in the transition from
a project-based to a processor or farmer-managed system. The training impacts
basic understanding of strategies for technology generation and transfer, design
71
features and management aspects of the technologies. The training is given an
intensive specialized course, and tllroUgh their continual participation in the project
activities.
A second type of training is on manufacturing of agro-processing equipment. It is
aimed at enabling local manufacturers to meet the demands for improved agro
processing equipment. Recently, t.he importance of after·"sales service 'and quality
control to sustain the functionality ot the processing equipment has become
necessary. Servicing of the equipment is now integrated in the training programme
for manufacturers. Consequently also, quality control task forces or maintain a high
standard of equipment being deliverec.
The training has been decentralized and conducl l3d in country to promote the local
manufacturing industry. Trlis encourages the use of locally available materials and
services reducing manufacturing costs and eliminating importation costs, thus
making the technologies more affordable to the U8f:.:r,3.
The third type of training covers operation and management of technologies. It is
intended to enable operators. far: r'I~::H·S. and agm-processors to optimize the
utilization of the technologies ana Cl d13nce the value of their investments. The
training includes actual operation of the equipment, analyses of advantages and
disadvantages of the technologlGs, and tips for successful agro-enterprise
management. Trained extension workers <=lnd the manufacturers usually conduct
this type of training. Consequently, the extension vvorkers increase their contacts
with farmers and agro-processon:., which improve their credibility. For the
manufacturers, it is part of their prociuct promotion and after-sales services.
• Field Demonstrations
Field demonstrations are conducted to promote awareness in improving the ha ndling
and processing of farm produce and expose technological options available to
potential users as well as policy makers.
72
The demonstrations provide an opportunity for extension workers and manufacturers
to get direct response form farmers and agro-processors on the suitability of the
technologies being introduced. Farmers and processors are allowed to operate the
equipment during the demonstration giving them immediate exposure to the
technology. His process stimulates interaction and generates information on design,
making and performance of the technologies which are communicated back to the
designer. This feedback mechanism facilitates technology development and
enhances the suitability and adoptability of the technology being promoted.
Involving policy makers and development agencies during demonstrations also allow
for sensitisation of rural development projects which could solicit support for funding,
adoption and implementation.
• Establishing Model Processing Centres
Parallel to the demonstration activity, model-processing centres are established to
showcase improved agro-processing technologies and their associated benefits. The
set-up of the centre is based on system jynamic in which factors affecting and
affected by the technologies are present. Unlike field demonstrations, which are done
occasionally, the processing centre operates under actual circumstances affecting
operation efficiency, management and profitability. The centre also serves as training
venue for researchers and extension workers while providing more information on
utilization potentials and constraints that are used to fine tune the technologies.
The centres are established with the active participation of farmers and agro
processors in different agro-ecological environments. The sites selected on the basis
of crops and cropping patterns, volume of production, nature of crop processing and
utilization, accessibility to marketers, availability of extension services, etc. The sites
are also selected for their potential commercial activities and market expansion. The
73
expressed willingness of the agro-processors to participate is also an important
selection criterion.
• Multilateral Information Exchanges
Technology development and technology transfer processes take time and require
multilateral information exchanges among agencie::' involved to optimise utilization of
their limited resources. One key role that the project plays is to stimulate multilateral
information exchange and cooperation that could create a consensus that develo ping
an agro-processing industry must be a joint effort of several stakeholders, each one
having a unique and complementary role to play. Collaborating institutions come
together and share their resources and benefit from it. This linkage also promotes
exchange of information and eliminates duplication of development efforts resulting in
more efficient project management.
NGO (non-governmental organizations) and other development organizations in each
country contact SAA/IITA project for information on appropriate type of equipment
available and where they could be purchased. They participate in demonstrations
and request assistance for trainim~ on operation and management of the
technologies. Some, funds for agro-processing project to assist women groups or
organizations they work with are channelled through the project. There is a mutual
trust and understanding created to sharing resources and responsible for a defined
purpose.
Impact
• Benefits from improved technologies
The packages of technologies deveJoped IITA are being tested and introduced in
village of Nigeria, Benin, and Ghana. Some of the technologies (such as a mutually
74
operated cereal grinder, a field cart, a garri 6 processing package 'and a multi- crop
thresher) are now being utilized by the ta rget user groups. Among the features of the
equipment that lead to ready adoption are adaptability to various crops, a range of
capacities, ease of operation and maintenance, and use of locally available materials.
In village operations, these technologies reduced handling and processing losses by
50 percent and increased labour efficiency by 75 percent in the first 6 months of
utilization (Jeon and Halos-Kim 1994). Technologies for maize processing reduced
labour input by 23 percent in harvesting, 70 percent in handling, and 65 percent in
processing. Women's handling and processing burden was significantly reduced.
Time savings resulted in more intensive production and post harvest activities during
the succeeding cropping season.
Impacts were also notable among women's groups using cassava -processing
package and among women and children using the family-based processing package
for cereal and grain legumes.
In the cassava-processing technology package although part of the operation is
mechanized, the control of the enterprise is still in the hands of the women. Women
hire male operators for granting and dewatering (Pressing). In the classic approach of
piecemeal technology development, men usually take over the type of technology is
difficult for women to operate.
Analysis of the cassava-processing package used by the women's group in Dogbo
Village, Benin, indicates that even at 30 percent utilization capacity, the garri
processing enterprise alone is capable of generating profits, with a benefit-cost ratio
of 1.43 (Halos-Kim, 1996).
In northern Nigeria Where technologies for hamlet-based processing were introduced
even modest innovations such as apron-type and knapsack-type for cowpea and
I, A grated. fcrmcllkd. and roasted cassava rruduct
75
maize have been quickly adopted by women farmers. Men farmers' interest In
mechanized processing is explained by their need to process their produce for
marketing and the opportunity to use the equipment for custom hiring.
• Effectiveness of strategy
The success of the project is seen not only in the number of agro- processing
equipment manufactured and sold by trained manufacturers but also in the
strengthening of linkages among the various stakeholders. The stakeholders know
their roles and responsibilities in relation to the different elements of the project
resulting in its smooth implementation.
• Capacity Building
A notable accomplishment of the project is building up the capability of the partners
and strengthening the human resource-based in each country, recognising the
comparative advantage of the local partners in dealing directly with the end -users.
Trained staff of participating national and other development programmes is now able
to organize effective field demonstrations c)lJd implement training courses in relation
to technology operation and manacernent. Several adoption decisions in each
country resulted from recommendations of trained staff. They also participate in
design and implementing monitoring surveys to assess the impact of the project.
The increasing demand for improved agro-processing equipment in different parts of
sub-Saharan Africa necessitates involvement and mobilization of the local
manufacturing :ndustries. Training of manufacturers and coordinating their activities
so that the technologies are supplied with the right quality is yet another output of the
project. The after-sales service component of the training makes the manufacturing
industry more viable and attractive, eliminating one of the constraints to adoption of
imported technologies, the availability of spare parts and services.
76
In-country training courses conducted broadened the geographic spread of the
technologies where users can now obtain equipment locally and be assured that
services for need repair and maintenance are available.
• Formation and Co-ordination of Manufacturers' Network
A vision shared by project collaborators is to develop the local training capability to
reduce project costs and empower the local stakeholders. Manufacturers are trained
to understand the design features of the equipment so that they could dO some local
adaptations. Their training also focuses on quality control and after sales services
more than skill development. The project also encourages manufacturers to take up
the costs of demonstrations as pert of their promotional activities. Operator's training
should in fact be considered as part 01 rna.nufactur~rs' care. They need to evolve their
business operations to adopt the cost of operators' training in order to maintain their
linkage with the customers.
The collaborating manufacturers in Ghana and Benin agreed to form a network. The
network will enhance their capacity on the basis of complementarities of roles in the
supply of demanded equipment while maint8ining competitiveness a driving factor in
producing high quality products and pi Hsuing business objectives.
Neighbouring West Africa countries (Togo, Guinea, Mali and Burkina Faso) solicited
assistance from project to train their manufacturers after an initial set of agro
processing equipment (grater, chipper and multi -crop thresher) were demons trated
and purchased from manufacturers in Benin and Ghana. In the last two years, the
activities in Ghana and Benin also spread to East Africa (Ethiopia, Uganda and
Mozambique). Project staff trained extension officers and their women groups in garri
processing using improved techniques, and trained local manufacturers in fabrication
and servicing of equipment to supply the anticipated demand for improved equipment.
Collaborating manufacturers in these countries reported initial sales of grater, chipper
and thresher.
77
The role of government entities is rn()r~?' explicit in providing follow~up training on
fabrication and maintenance rnar18g~::ment of the equipment. They also have
important role in advising on governrnent polici(:)s affecting the availability and
accessibility of improved technologies to the end users. The role of the private
entrepreneurs is to provide farmers and agro~processors direct access to agro··
processing equipment and benefit most through their increasing productivity and
income from sales of eq uipment.
• Monitoring the Adoption of TeGhnoiogies
A monitoring survey is being carr:!:::cl oui' to loc;.",;; the ar.}w-processing equipment
fabricated and sold by trained manufacturers allCl find out the extent to which project
intervention is affecting the ownership and management of the equipment that could
relate to who actually benefits from the process and the sustainability of the system.
Initial results from the survey indicated that some individual entrepreneurs are
already adopting the technolo~r'{ 8f1(J :' 'Iat n lana8ernenc of the technologies is mainly
in the hands of these users. The level c,lf adoption of the technologies is encouraging.
One contributing factor is the awaren8SS cmated by the activities of the project and
the linkages crested between technology-users, the manufacturers and potential
finding organizations.
On request of government and non-governmental organizations, the project extends
its activities to the other countries in East and West Africa where Sasakawa Global
2000 (SG2000) is currently operating, and where there is already existing demand for
improved agro-processing equipment. The corresponding SG2000 country projects
such as in Ethiopia, Uganda, Malawi and Guinea have recently integrated agro
processing into their programmes and collaborate closely with SAA-IITA project.
78
Limited by funding the approach being taken is to continue to strengthen the local
human resource base (development and extension staff) and the manufacturers. The
development and extension staff is sensitise on project objectives, strategies and
activities, and allow them to develop a suitable project for implementation in their
countries. Support for training on manufacturing, operation and maintenance
management is done through the cooperation of local agro-metal workshops selected
from recommendations of the collaborating development and extension programmes.
The numbers of countries importing is expected to reduce as the project responds to
request for tapping local artisans in manufacturing the equipment demanded.
However, the project emphasizes on the importance of quality control so that agro
processing equipment are delivered and utilized to their full merits.
Challenges and Opportunities
Developing technologies for African condition is complex. This process entails a
careful analysis of the socio-cultural and economic characteristics of the rural farm
families including attitudes and preference, more than the technical criteria. Any
strategy adopted should consider system development in items of modifying existing
production and post- production patterns to include possibilities of making commodity
price competitive in the market while providing enough food for the family.
An appropriate technology transfer mechanism should be put in place to ensure that
the technqlogies are delivered and fully utilized by the target beneficiaries. Fitting the
technology into farming system is as crucial as the development process. Technology
transfer can be likened to a transplanting process. Providing training to users on
technology management will equip them with the understanding and skill to transfer
and sustain the technology. A lot of investment on this area is needed.
79
Increasing the participation of the privah:l sector has been difficult. Even the fast
privatisation policies of the industrial sec.tor in many countries resulted in difficulties of
the sector, for example, in obtaining support for training, low interest loans, heavy
taxes levied in their products. The private agm-metal manufacturers face more
difficult situation. In Africa these manufacturers generally operates at a small scale,
and quite often have work force of less than ten workers many of whom do not
possess formal technical qualifications. Also because their operating fund is very
limited, they are less likely to risk in building machines to use in their promotional
activities. Sending their staff for training to improve skill and competency is also a
difficult decision as the absence of the staff could cripple their business. The project
however continues to encourage their participation through training and linking them
to potential customers.
Problems on operation, repair and maimenance re;·,i)rted by users such as proximity
of services, lack of training on proper operation and management of the equipment
are guiding the project team to re-orient its training strategy.
Report form the survey also underscores the importance of regular monitoring visits
particularly by the manufacturer to chock on the conditions of the machines and
provide necessary repair and services Th~ri: are cases where machines are being
moved form one site to anther becausf': of availability of raw materials. This makes
reconciling sales record from manufacturers with utilization record difficult. Reported
users from initial survey are only about 90%) 01" the listed buyers.
While the experiences discussed herE.-~ i-elate to development and transfer of post
harvest technologies, the adopted can be applied to any agricultural development
project.
The questions in front of us are:
KO
•
• What benefits have farmers and agro-processors gained from using improved
processing techniques?
• Are national and other development programmes ready. to take up the
challenging with less external funding? - \
A quick look at the project achievements highlights the visibility of in helping to
promote the agro-processing enterprise to provide sustainable income to farmers,
agro-processors and manufacturers. The project is able to demonstrate that a
collective efforts of different agencies could bring improve agro-processing
technologies to target beneficiaries.
Different entities working together reduce the cost of the project as it eliminates
duplication of efforts and waste of resources. It also addresses directly the specific
issues raised by the stakeholders. Ta rget beneficiaries are guided properly on
appropriate sources of information and possible linkages to relevant projects and
funding institutions.
The national programmes have direct responsibility in improving the delivery of
technological development in their domain. It should make a clear message and a
strong initiative to lead several collective efforts in pursuing projects towards the
national goal of good availability and sufficiency. This includes promotion of agro
processing enterprises which cut across different sectors. The government should
have a genuine interest and commitment to support the program and provide
incentives to allied industries, for example, through legislation on importation of
machinery or through control of market prices both for raw materials and products.
Investments into agro-processing projects are justified since improving this sector of
the production continuum has proven to sustainability, food security and poverty
alleviation.
81
Literature Cited
1. Halos-Kim, L. and T. Mado. 2001: Introducing improved agro-processingequipment in sub-Saharan Africa: The SAAlIITA Experience. Paper presentedto Workshop 2001 - Africa Food Security in a Changing Environment: SharingGood Practices and Experiences. Kampala, Uganda 5-9 June 2001.
2. Jeon, Y.W. and L. Halos 1991: Addressing R&D for cassava post harvestsystem in West Africa. Paper 915530 presented at the America Society ofAgricultural Engineering Winter Meeting, Chicago, 17-20 December.
3. Jeon, Y. W. and L. Halos -Kim. 1994: Gender implications for post-productiontechnology development. Paper 948004 presented at the 1994 AmericanSociety of Agricultural Engineering Summer Meeting, Kansas City, Missouri,19-22 June.
4. Joen, Y.W. and L. Halos-Kim. 1996: Improving post harvest technologydevelopment in Africa. In: Women, Agricultural Intensification and HouseholdFood Security. 1997. Workshop Proceedii'.gs edited by Breth, Steven A.Mexico City: Sasakawa Africa Association. pp 133-141.
5. Jeon, Y.W. and L. Halos-Kim. 1998: Characterizing he desirability of postharvest technologies for African Conditions. In: Enhancing Post harvestTechnology Generation and Dissemination in Africa. 1999. WorkshopProceedings edited by Kwarteng, Joseph. Mexico City: Sasakawa AfricaAssociation. pp 36-46.
6. Joen, Y.W. , T. Mado and L. Halo.;. Kim. 1998: A partnership in developing postharvest technology for small··scale farmers. In: Partnership for RuralDevelopment in sub-Saharan Africa. 1999. Workshop proceedings edited byAreth, Steven, A. Geneva: Centre for pplied Studies in InternationalNegotiations. pp. 31-42
Engineer Leonidis Halos-Kim's paper was presented during the UNESCONASENI Roundtable discussion on Promotion of Best Practices inMechanical Engineering for Job Creation, at the NASENI Complex Idu, Abuja,Nigeria 10 December 2002.
82
•
PART -- 11
MACI--IINING
UNESCD-NASENI ROUNDTABLE DISCUSSION ON PROMOTION OF BESTPRACTICES IN MECHANICAL ENGINEERING FOR JOB CREATION,SCIENTIFIC EQUIPMENT DEVELOPMENT INSTITUTE (SEDI), TAGWAI DAMROAD, CHANCHANGA, MINNA, NIGER STATE THURSDAY, 6 TH NOVEMBER,2003.
83
MACHINE TOOLS
Engineer Madu A. Yatetengi
INTRODUCTION
Machine Tools, stationary power-driven machines used to shape or form solid
materials, especially metals. The shaping is accomplished by removing material from
work piece or by pressing it into the desired shape (machining). Machine tools form
the basis of modern industry and are used either directly or indirectly in the
manufacture of machine and tool parts.
Machine tools may be classified under three main categories: conventional chip
making machine tools, presses, and unconventional machine tools. Conventional
chip-making tools shape the work piece by cutting away the unwanted portion in the
form of chips. Presses employ a number of different shaping processes, including
shearing, pressing or drawing (elongating). Unconventional machine tools employ
light, electrical, chemical, and sonic energy; superheated gases; and high-energy
particle beams to shape the exotic materials and alloys that have been developed to
meet the needs of modern technology.
HISTORY
Modern machine tools date from about 1775, when the English inventor John
Wilkinson constructed a horizontal boring machine for producing internal cylindrical
surfaces. About 1794, Henry Maudslay developed the first engine lathe. Later,
Joseph Whitworth speeded the wider use of Wilkinson's and Maudslay's machine
tools by developing in 1830, measuring instruments accurate to a million of an inch.
His work was of great value because precise methods of measurement were
necessary for the subsequent mass production of articles having interchangeable
parts.
84
The earliest attempts to manufacture interchangeable parts occurred almost
simultaneously in Europe and the United States. These efforts relied on the use of
so-called filing jigs, with which parts could be hand-filed to substantially identical
dimensions. The first true mass-production system was created by the American
inventor EIi Whitney, who in 1798 obtained a co ntract with the U.S. government to
produce 10,000 army muskets, all with interchangeable parts.
During the 19th century, such standard machine tools as lathes, shapers, planers,
grinders and saws and milling, drilling, and boring machines reached a fairly high
degree of precision, and their use became widespread in the industrializing nations.
During the early part of the 20th century, machine tools were enlarged and made
even more accurate. After 1920 they became more specialised in their applications.
From about 1930 to 1950 more powerful and rigid machine tools were built to utilize
effectively the greatly improved cutting materials t\ ,;~tt had become available. These
specialized machine tools made it possible to manufacture standardized products
very econo mically, using relatively unskilled labour. The machines lacked flexibility,
however, and they were not adaptable to a variety of products or to variations in
manufacturing standards. As a result, in the past three decades, engineers have
developed highly versatile and accurate machine tools that have adapted to
computer control, making possible t :- ecunomical manufacture of products of
complex design. Such tools are now vVidely used.
CONVENTIONAL MACHINE TOOLS
Among the basic machine tools are the lathe, the shaper, the planer, and the milling
machine. Auxiliary to these are drilling and boring machines, grinders, saws, and
various metal-forming machines.
85
Lathe
A lathe, the oldest and most common type of turning machine, holds and rotates
metal or wood while a cutting tool shapes the material. The tool may be moved
parallel to or across the direction of rotation to form parts that have a cylindrical or
conical shape or to cut threads. With special attachments, a lathe may also be used
to produce flat surfaces, as a milling machine does, or it may drill or bore holes in the
work piece.
Shaper
The shaper is used primarily to produce flat surfaces. The tool slides against the
stationary work piece and cuts on one stroke, returns to its starting position, and then
cuts the next stroke after a slight lateral displacement. In general, the shaper can
produce almost any surface composed or straight-line elements. It uses a single·-point
tool and is relatively slow, because it del1ends on reciprocating (altemating forward
and return) strokes. For this reason, the shaper is seldarn found on a production line.
It is, however, valuable for tool and die rooms and for jobs shops where flexibility is
essential and relative slowness is unimportant because few identical pieces are being
made.
Planer
The planer is the largest of the rf:cipnx ... ,1'19 machine tools. Unlike the shaper, which
moves a tool past a fixed work piece. The planer moves the work piece past a fixed
tool. After each reciprocating cycle, the v'vork piece is advanced laterally to expose a
new section to the tool. Like the shaper. the planer is intended to produce vertical,
horizontal, or diagonal cuts. It is also possible to mount several tools at one time in
any or all tool holders of a planer to execute multiple simultaneous cuts.
Milling Machine
In a milling machine, a work piece is fed against a circle device with a series of
cutting edges on its circumference. The work piece is held on a table that controls the
feed against the cutter. The table conventionally has possible movements:
86
longitudinal, horizontal, and vertical; in some cases it can also rotate. Milling
machines are the most versatile of all machine tools. Flat or contoured surfaces may
be machined with excellent finish and accuracy. Angles, slots, gear teeth, and recess
cuts-can be made by using various cutters.
Drilling and Boring Machines
Hole-making machine tools are used to drill a hole where none previously existed; to
alter a hole in accordance with some specification (by boring or reaming b enlarge
it .or by tapping to cut threads for a screw); or to lap or hone to create an accurate
size or a smooth finish.
Drilling machines vary in size and function, ranging from portable drills to radical
drilling machines, multi-spindle units, automatics production machines, and deep
hole-drilling machines. See Drill.
Boring is a process that enlarges holes previously drilled, usually with a rotating
single-point cutter held on a boring bar and fed against a stationary work piece.
Boring machines include jig borers and vertical and horizontal boring mills.
Grinders
Grinding is the removal of metal by rolating abrasive wheel; the action is similar to
that of a milling cutter. The wheel is composed of many small grains of abrasive,
bonded together, with each grain acting as a miniature cutting tool. The process
produces extremely smooth and accurate finishes. Because only a small amount of
material is removed at each pass of the wheel, grinding machines required fine wheel
regulation. The pressure of the wheel against the work piece can be made very slight,
so that grinding can be carried out on fragile materials that cannot be machined by
other conventional devices.
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Saws
Commonly used power-driven saws are classified into three general types, according
to the kind of motion used in the cutting action: reciprocating, circular and band
sawing machines. They generally consist of a bed or frame, a vice for clamping the
work piece, a feed mechanism, and the saw blade.
Cutting Tools and Fluids
Because cutting process involve high local stresses, fictions, and considerable heat
generation, cutting-tool material must combine strength, toughness, hardness and
wear resistance at elevated temperatures. These requirements are met in varying
degrees by such cutting-tool materials as carbon steels (steel containing 1 to 1.2
percent carbon), high-speed steels (iron alloys containing tungsten, chromium,
vanadium, and carbon), tungsten carbide, and diamonds and by such recently
developed materials as ceramic, carbide ceramic, and aluminium oxide.
In many cutting operations fluids are used to cool and lubricate. Cooling increase
tools life and helps to stabilize the size of the finished part. Lubrication reduces
friction, thus decreasing the heat generated and the power required for a given cut.
Cutting fluids include water-based solutions, chemically inactive oils, and synthetic
fluids.
PRESSES
Presses shapes work piece without cutting away material that is without making chips.
A press consists of a frame supporting a stationary bed, a ram, a power source, and
a mechanism that moves the ram in line with or at right angles to the bed. Presses
are equipped with dies (see die) and punches designed for such operations as
forming, punching, and shearing. Presses are capable of rapid production because
the operation time is that needed for only one stroke of the ram.
8X
UNCONDITIONAL MACHINE TOOLS
Unconditional machine tools include plasma-arc, laser-beam, electro -discharge,
electrochemical, ultrasonic, and electron-beam machines. These machine tools were
developed primarily to shape the ultra hard alloys used in heavy industry and in
aerospace applications and etch the ultra thin materials used in such electronic
devices as microprocessors.
Plasma Arc
Plasma-arc machining (PAM) employs a high-velocity jet of high-temperature gas
(see Plasma) to melt and displace material in its path. The materials cut by PAM are
generally those that are difficult to cut by any other means, such as stainless steels
and aluminium alloys.
Laser
Laser-beam machining (LBM) is accomplished by precisely manipulating a beam of
coherent light (see Laser) to vaporize unwanted material. LBM is particularly suited to
making accurately placed holes. The LBM process can make holes in refractory
metals and ceramics and in very thin materials without warping the work piece.
Extremely fine wires can also be welded using LBM equipment.
Electro-discharge
Electro-discharge machine (EDM), also knuwn as spark erosion, employs electrical
energy to remove metal from the work piece without touching it. A pulsating high
frequency electric current is applied between the tool point and the work piece,
causing sparks to jump the gap and vaporize small areas of the work piece. Because
no cutting forces are involved, light, delicate operations can be performed on thin
work pieces. EDM can produce shapes unobtainable by any conventional machining
process.
89
Electrochemical
Electrochemical machining (ECM) also uses electrical energy to remove material. An
electrolytic cell is created in an electrolyte medium, with the tool as the cathode and
the work piece as the anode. A high-amperage, low-voltage current is used to
dissolve the metal and to remove it from the work piece, which must be electrically
conductive. A wide variety of operations can be performed by ECM; these operations
include etching, marking, hole making, and milling.
Ultrasonic
Ultrasonic machining (USM) employs high-frequency, low-amplitude vibrations to
create holes and other cavities. A relatively soft tool is shaped as desired and
vibration against the work piece while a mixture of fine abrasive and water flows
between them. The friction of the abrasive particles gradually cuts the work piece.
Materials such as hardened steel, carbides, rubies, quartz, diamonds, and glass can
easily be machined by USM.
Electron Beam
In electron-beam machining (EBM), electrons are accelerated to a velocity nearly
three-fourths that of light. The process is performed in a vacuum chamber to reduce
the scattering of electrons by gas molecules in the atmosphere, The stream of
electrons is directed against a precisely limited area of the work piece; on impact, the
kinetic energy of the electrons is converted into thermal energy that melts and
vaporizes the materials to be removed, brming holes or cuts. EBM equipment is
commonly used by the electronics industry to aid in the etching of circuits in
microprocessors. (See Microprocessor)
NECESSITIES FOR A COMPETENT ENTREPRENEUR MACHINIST IN NIGERIA
It is very essential to have knowledge of the following:-
(1) Engineering Drawing. This permits easy communication of need.
90
(2) Properties of Engineering Materials and their applications as well as their
prices.
(3) Simple workshop tests for identifying/comparing materials.
(4) General bench fitting practice
(5) Writing, interpreting and using accounting information
(6) Marketing - advertising -correcting pricing
(7) Quality control- Proper use of measuring instruments/metrology
(8) How to use the machine(s) and adapt to need
(9) Operations procedure writing (short and straight-to the-point language)
(10) Safety
(11) Records Keeping
(12) Some examples of specific situations experienced in practise sources
of raw materials- vendors-re-circulation of materials etc.
See a typical operations procedure below:-
Op.No Operation Tools Time Sketch Cost(min) (N)
1. Clamp in vice andCut material to 120mm Hacksaw 30
2. Clamp in 3-jaw chuckface one end and centre- Facing tool 10drill . Centre drill
3. Reverse end for end Face tool 10face to 118mm and Centre-drillcentre Drill
REMARKSOPERATION SUPERVISORMATERIALQUALITY CONTROLLER OK/NOT OK SIGNATUREDATE
SETTING UP A MACHINE SHOP?
Some questions:
(a) Who needs the service?
(b) How frequently?
91
(c) From where are they getting the service now?
(d) What advantage(s) do I have over present source?
(e) What location?
(f) Which name?
(g) Sources of funds?
(h) Which machine(s), accessories, tools?
(i) Complimentary hand tools Le. hammer, hacksaw, chisel files, drills, and a few
spanners, etc.
0) What source of energy (generator, NEPA, etc)
(k) Where could machines be purchased from and will install etc?
Engineer Madu A. Yatetengi's paper was presented during the UNESCONASENI Roundtable discussion on Promotion of Best Practices inMechanical Engineering for Job Creation, Scientific Equipment DevelopmentInstitute (SEDI), Tagwai Dam Road, Chanchanga, Minna, Niger State Thursday,6th November, 2003.
92
MACHINING: THE VIRTUE TO EFFECTIVE MANUFACTURING AND•
PRODUCTION OF MACHINES AND COMPONENTS
Mr. I. M. NWAEDOZIE
Content
Part I:
Part 11:
Part Ill:
Part VI:
Part V:
Part VI:
Part VII:
Part VIII:
Part IX:
Part X:
Part XI:
Referenc:;es:
Annexure:
Introduction
Conceptual Definition of Machining
Typology of Machining Process
Considerations for the establishment of machine shop
Guidelines for setting up organization to manage the workshopFor machinery
The important of machining in manufacturing:Typical machine components produced by machining processAdvantages of machinery
Overview of Nigeria Engineering Sector
Constraints of Engineering sector in Nigeria
Observations
Conclusions
Recommendations
93
Part 1: INTRODUCTION
Machining can be defined as that solid state manufacturing process in which desired
~hapes are roduced by removal of selected area of a work piece through
mechanical means. This is distinct from deformation processes where shapes are
produced by plastic deformation in which the material is moved while its volume is
conserved. And casting process in which the material is melted and poured into a
prepared cavity where it hardens taking the shape of the cavity.
As early as 4000 B.C., the Egyptians used a rotating bowstring device to drill holes in
stone. There after there was not any significant scientific work in metal cutting until
about mid-nineteenth century when the first attempts at defining chip formation were
reported.
Machining usually is employed to produce shapes with high dimensional tolerance, good
surface finish, and often with complex geometry. Machining is a secondary processing
operation since it usually is conducted on a work piece that is produced by a primary
process such as hot rolling, forging, or casting. Something more than 80 percent of all
manufactured parts must be machined before they are completed. The variety of
machining processes and machine tools that can be utilized is very great ~ terms of
annual dollars spent machining is the most important of the manufacturing processes.
PART 11: CONCEPTUAL DEFINITIONS OF MACHINING
According to the 6th Edition of Oxford Advanced Learners dictionary, a machine is a
piece of equipment with moving parts designed to do a particular job. Such machine
include those used for operations, of milling, grinding, turning, shearing, forming,
cutting machining is making or shaping of an item wholly or in part with the aid of a
machine. There is mostly practiced as a profession under mechanical engineering.
Apart from machining, items can be shaped through operations of casting, extrusion,
94
forging, bending, pressing and stamping. Based on the definition of machine above,
machining in a wider sense can also be extended to include forging, stamping,
pressing and bending. For the purpose of this keynote address, only the earlier
mentioned machining operations like turning, grinding, milling etc. shall be borne in
mind.
For machining to be a veritable operation for manufacturing of high quality products
with the view to enhancing economic development through wealth creation and
generate employment, the issues involved would be critically examined in the key
note address
Hence, part two of the address will treat the location and the equipment of a
workshop for manufacturing. Part three will examine the availability of engineering
raw materials for manufacturing of spare parts and Gomponents. The issues of good
standard practices and specializations of machined products for competitive market
will be discussed in part four. In part five, we shall consider capacity building and
state of machining practices in Nigeria while part six will contain the
recommendations and conclusions.
PART Ill: TYPOLOGY OF MACHININ(;' PROCESSES
(1) TRADITIONAL MACHINING PROCESSES
It is important to view machining, as well as all manufacturing operations, as a
system consisting of the work piece, the tool and the machine.
The tra~itional machining includes turning, milling, drilling, and grinding. It also
includes computer applications like:
(a) TURNING
Turning is the machining operation that produces cylindrical parts. In its basic
form, it can be defined as the machining of an external surface with the work
95
piece rotating with asingle-point cutting tool, and with the cutting tool feeding
parallel to the axis of the work piece and at a distance that will remove the outer
surface of the work.
Taper turning is practically the same, except that the cutter path is at an angle to
the work axis. Similarly, in contour turning, the distance of the cutter from the work
axis is varied to produce the desired shape.
Even though a single-point tool is specified. this does not exclude multiple-tool
set-ups, which are often employed in turning. In such set-ups, each tool
operates independently as a single-point cutter.
(b) DRILLING
Drill: Drill can be defined as a rotary end cutting tool having one or more
cutting lips, and having one or more helical or straight flutes for the passage of
chips and the admission of a cutting fluid. Drill: Drill can be defined as a rotary
end cutting tool having one or more cutting lips, and having one or more
helical or straight flutes for the p8ssas -; of chips and the admission of a cutting
fluid.
General Classifications
Classification Based on Construction
1. Solid Drills: Those made of one piece of material such as high-speed
steel.
2. Tipped Solid Drills: Those having a body of one material with cutting lips
made of another material brazed or otherwise bonded in place.
3. Composite Drills: Those having cutting portions mechanically held in
Place.
96
(c) Classification Based on Methods of Holding or Driving
1. Straight Shank Drills: Those having cylindrical shanks which may be the
same or different diameter than the body of the drill; the shanks may be
made with or without driving flats, tang, grooves or threads.
2. Taper Shank Drills: Those having conical shanks suitable for direct fitting
into tapered holes in machine spindles, driving sleeves or sockets; tapered
shanks generally have a driving tang.
3. Taper Shank Square Drills: Those having tapered shanks with four flat
sides for fitting a ratchets or brace.
4. Shell Core Drills: Core drills mountable on arbours specifically designed
for the purpose; commonly used with shell reamer arbours.
5. Threaded Shank Drills: Those made with threaded shanks generally used
in close centre multiple spindle applications or portable angle drilling tools.
6. Beaded Shank Bits: Drills with flat shanks having raised beads parallel
to the axis.
MILLING
Milling is the process of cutting away material by feeding a work piece past a rotating
multiple tooth cutter. The cutting action of the many teeth around the milling cutter
provides a fast method of machining. 1. ,c machined surface may be flat, angular, or
curved. The surface may also be milled to any combination of shapes. The machine
for holding the work piece, rotating the cutter, and feeding it is known as the Milling
machine.
CLASSIFICATION OF MILLING
Peripheral Milling
In peripheral (or slab) milling, the milled surface is generated by Eeth located on the
periphery of the cutter body. The axis of cutter rotation is generally in a plane parallel
to the workpiece surface to be machined.
97
Face Milling
In face milling, the 'cutter is mounted on a spindle having an axis of rotation,perpendicular to the workpiece surface.
The milled surface r~u'ts from the action of cutting edges located on the periphery
and face of the cutter.
End Milling
The cutter in end milling generally rotates on an axis vertical to the workpiece. It can
be tilted to machine tapered surfaces. Cutting teeth are located on both the end face
of the cutter and the periphery of the cutter body.
METHODS OF MILLING
Up Milling
Up milling is also referred to as conventional milling. The direction of the cutter.rotation opposes the teed motion. For example, if the cutter rotates clockwise, the
workpiece is fed to the, right in up milling.
Down Milling
Down milling is also referred to as climb milling. The direction of cutter rotation is
same as the feed motion. For examplr\ if nl(~ cutter rotates counterclockwise, the
workpiece is fed to the right in down milling.
The chip formation in down milling is opposite to the chip formation in up milling. The
figure for down milling shows that the cutter tooth is almost parallel to the top surface
of the workpiece. The cutter tooth begins to mill the full chip thickness. Then the chip
thickness gradually decreases.
The milling machine is, one of the most versatile machine tools in existence. In
addition to straight milling of flat and irregularly shaped surfaces, it can perform gear
and thread cutting, drilling, boring and slotting operations which are normally handled
on machine tools designed specifically for these specific operations.
98
(2) NON-TRADITIONAL MACHINING PROCESSES
A number of new material-removal processes have been developed since World
War II which mostly use forms of energy other than mechanical energy. The impetus
for developing most of these processes was the search for better ways of machining
complex shapes, in hard materials. The various techniques are listed below in terms
of the major energy source. However, space permits only a brief description of a few
of these processes.
Source of Energy Name of Process
Thermal energy processes Electrical discharge machining, EDM
Laser-beam machining, LBM
Plasma-arc machining, PAM
Electrical processes Electrocherr,::;al machining, ECM
Electrochemical grinding, ECG
Chemical process Chemical machining, CHM
Mechanical process Ultrasonic machining, USM
Electrical discharge machining (EDM;:s a r!1ethod for producing holes, slots, or
other cavities in an electrically conducive material by the controlled removal of
material through melting or vaporization caused by a high-frequency spark discharge.
The work piece (the anode) and the tool (the cathode) are immersed in a dialectic
fluid with a spark gap of 0.0005 to 0.020 in. Important advantages of EDM are that it
can produce deep holes in hard material without drifting or can machine cavities of
irregular contour. The metal-removal rate is independent of the hardness of the work
piece, but it does depend on thermal properties such as heat capacity and
conductivity, melting point, and latent heat of melting and vaporization. Electrode
wear is a problem which requires selection of the proper electrode material for the
work piece material. Because high temperatures are attained in the spark, the metal
99
is melted and then rapidly quenched by a mass effect when it resolidifies. This recast
laye r may be deleterious to fatigue properties.
Electrochemical machining (ECM) is the controlled removal of metal by anodic
dissolution in an electrolytic cell in which the work piece is the anode and the tool is
the cathode. It is similar to a reverse electroplating process. The electrolyte is
pumped through the cutting gap while direct current is passed through the cell at low
voltage to dissolve the metal from the work piece. The rate of removal of material is
proportional to the amount of current passing between the tool and the work piece
and is independent of the harness of the work piece. ECM is a cold process which
results in no thermal damage to the work piece. It results in a smooth burr-free
surface. However, it is not suited for producing sharp oorners or cavities with flat
bottoms. Electrochemical grinding (ECG) is a combination of ECM and abrasive
grinding in which most of the metal is removed by electrolytic action. It is used with
hard carbides or difficult-to-grind alloys where wheel wear or surface damage must
be minimized.
Chemical machining 3 (CHM) involves metal removal by controlled chemical attack
with chemical reagents. The essentiai <;tep:: involve cleaning the surface, masking
those areas which are not lo be dissolved. attacking with chemicals, and cleaning.
Chemical milling refers to chemical machining of large areas, such as aircraft
structural parts. Chemical blanking is used for cutting or stamping parts from very thin
sheet.
In ultrasonic machining (USM) the tool is excited at around 20,000 cycles/sec with a
magnetostrictive transducer, while slurry of fine abrasive particles is introduced
between the tool and the work piece. Each cycle of vibration removes minute pieces
of the work piece by fracture or erosion. USM mostly is used for machining brittle
hard materials such as semiconductors, ceramics, or glass.
100
PART IV: CONSIDERATIONS FOR THE ESTABLISHMENT OF MACHINE SHOPS
(1) LOCATION
For small or large·-scale manufacture of machined products, the workshop, as much
as possible should be located based on market surveyor feasibility report. (Annex 8)
The location should be closer to the source of raw material and market of the finished
products. It will be a futile effort, for example to locate a machine workshop for
manufacture of bicycle spare parts in a large riverine swampy area full of ponds
swamps, creeks engine boats and fishermen since no bicycle can be popularly used
there. A location of workshop for machining boat and engine boat parts would be
economically noble.
2 EQUIPMENT
The equipments and tools in the workshop for machining should be selected based
on the expected specifications of the finished market surveyor feasibility study must
have also justified the selection of these products. The equipments and machinery in
the workshop will consist of the following:
(i) Primary Equipment - Lathe, grinding, drilling, polishing, milling, puffing
machine, etc
(ii) Supporting equipment eg sofjy and testing equipments, tools, welding,
stationing, pressing, forging and heat treatment equipments, etc.
(iii) Utility equipments eg generators. water pumps, air conditioners etc.
(iv) Furniture and fixtures.
In this workshop eleven out of the twelve items identified are primary equipments for
machining. In another shop for manufacture of spanners whose manufacturing
process briefly includes the following:
101
1. Cutting the steel bars into specific lengths
2. Milling the spanner ends and printing
3. Heat treatment
4. Buffing and polishing the hammer
5. Electroplating
6. Testing and packaging
There will be only one primary machinery equipment i.e. belt grinder. There will be
money supporting equipments to the machine shop operation in the workshop for the
manufacture spanner. These equipments include
1. Power press
2. Drop forging Hammer
3. Breaching machine
4. Belt grinder
5. Shot blasting machine
6. Tempering machine to make the metal hard by heating and rolling
7. Equipments of Hardening Furnace
3 SPECIFICATIONS OF EQUIPMENT AND THE ISSUES OF STANDARDS INMACHINING
The primary equipments and some supporting equipments including tools and dies
should be selected based on the specifications of the anticipated finished products.
Testing equipments should be of high pre~ision types.
For example a workshop for manufacture of tumbler locks which particular pad locks
marketed in different shapes a nd sizes must be equipped with the
1. Lathe 6 kinloskar
2. Lathe 6' Bed with motor
3. Planner 6' with all electricals
4. 41/2" with motor and starter
5. Drilling machine
6. Bench Grinder
102
7. Hand Grinder
8. Hand Drill
9. Shaping machine
10. Trimming machine
11. Polithing machine
12. Tools and texting equipments
4 ISSUES OF STANDARD PRACTICES AND SPECIFICATIONS IN MACHINING
Many Nigerian firms pay scant attention to issue of industrial standard. This is also
applicable to machining industries. The issue of standards and specifications is going
to be an important consideration if these firms are going to excel as manufacturers
and exporters of manufactured prcxkcts especially to the western industrialized
country markets. Industrial standards 3ft~ an inte~,; component of public innovation
policies (Ergas, 1987). These policies on standard provide two main benefits. The
first comprises of what may be termed as direct benefits. These are discussed, albeit
briefly below. The immediate impact of standardization is to reduce transaction costs
by providing clearly specified interface requirements for machined products. It can
then lower the barriers. In the marKr.'! entry and speed up competition and hence
demand for new technologies and n.::hirI8d products. Further, it fulfills the quality
certification, function, which is especially important to industrial components of
machined products. Nigerian Government should prepare new innovation policies on
standards and specifications of machined products.
In terms of indirect benefits, the preparation of new standards on machined products
and the ongoing review of the existing ones provides an important forum for
exchange of technical information within the machining industry and within the users
and suppliers of machined products.
103
Ergas (1987) argued that innovation policies on standardization and their
enforcements can also function as a means of placing ongoing pressure on firms to
upgrade their products, while providing them with technical information to do so.
It has to be emphasized that under the Techni cal Barriers to Trade (TBT) Agreement
which was part of the WTO Treaty signed in 1994, all signatory governments are
obliged to give preference to international standards in their activities. This is also
applicable to machining industry in Nigeria .. The motivation for this agreement is the
long-term goal of free trade across the world. If trading partners on machined
products adhered to identical or equivalent standards, then the costly problems of
satisfying the arbitrary technical requirements peculiar to nations or regions would be
substantially reduced if not eliminated ..
For a credible presence with Nigeriar", machined products in international markets,
certification under 150 9000 (international organi.."l;on for standardization 9000) has
become increasingly important. 150 9000 (first published in 1987 and revised in
1994) is primarily concerned with quality management. The definition of quality in 150
9000 refers to all those features of a product or service required by a customer.
5 ENGINEERING RAW MAT ERIAL.S FOR '(lIACHINING
The most popular body of items in form of raw materials for machining are obtained
by casting, extrusion, stamping, pressing to obtain the required shape with proper
tolerance for machining. The body ot such items can be made from wooden, metallic
and plastic materials. In case of metallic items serving as raw materials for
machining, the body can be made from any of the following:
Mild steal, gray iron forged steel, cast ferrous iron, aluminium, alloys, etc. Items that
can be machined include stamped and extruded sections. Also machined are
sections obtained by casting. Objects to be machined can have different shapes.
The major problem in Nigeria is the scarcity of local engineering materials like the
aforementioned mild steel, forged cast, irons, alloys etc. The need for Federal
104
Government to address the issue of mass production engineering materials locally to
facilitate the metallurgical production of items that can be machined is long over due.
6 TARGET INDUSTRIES
It is important to note that it is better to locate machine shops around industrial
estates or clusters e.g. Lagos-,Aba-Onitsha, Kaduna-KANO cluster. This why most of
the machine shops are located around Lagos and Nnewi in Anambra state (see
annex).
PART V: GUIDELINES FOR SETTING UP ORGANIZATION TO MANAGE THE
WORKSHOP FOR MACHINERY
Once an entrepreneur has decided to set up a machining workshop for the
manufacture of some products based on the techno-economic survey report
prepared by a consultant (see Annex - 3), he has to commission the evaluation of
the report to his bank to look at the following factors: -
1. Amount of capital readily available
2. Raw material availability and trend
3. Location of the workshop
4. Technical feasibility of the equipments and process technology
5. Market conditions
6. Total capital investment estimated and source of money raising at that
level of capital
7. Profit margin against cost of production with cash flow statement
With the evaluation report, he has to take a decision of implementation or not There
should be no delay in taking decision in order not to lose opportunity. The next
decision to take is on the type of organization to be set up to manage the machining
105
workshop. A suitable organization to be considered is discussed below. Every type of
organization has its merits and demerits. The organizations are:
(a) Sole ownership or proprietor
In this organization, as the name implies, a single person is the owner of the
machining workshop. He invests his capital, employs his labour and purchases
his equipments and the materials.
He is fully responsible for the growth or decline of the workshop for machining.
He has the power of all decision making in his hand. The only set-back of this
organization is that the owner is taking a heavy risk all by himself.
(b) Partnership organization (Private Limited)
This organization is to be established by the relevant law of Nigeria which
shows a relationship of two persons who have agreed to share the risks and
profits of the machining workshop established by the two partners or any of
them acting for the two partners. This type of organization has got lesser
individual risk than the one discussed in paragraph 2.3a above. Governments,
State or Federal can, through appropriate agency like NASENI form
partnership in such organizations to manage the machining workshop for
manufacture of quality products for export.
( c ) Cooperative Society
This is a voluntary organization of persons with unrestricted membership and
collectively owned funds, united on democratic basis, to establish a workshop
for machining under a joint management for the purpose of improving their
economy. Government can also promote this kind of organization through
appropriate agency like NASENI. All the three types of organizations
mentioned above have to get government approvals to establish the
workshop. However, there are several ir.formed workshops around the
country, especially in rural areas without official registration with government
106
such workshops should be encouraged to form clusters to be able to run
viable and profitable business.
MACHINE TOOL
Machine tools are power-driven machines which are designed to cut or form metal
(work pieces) within predetermined tolerances and finishes and to a specified size
and shape. There are two categories of machine tools, namely metal cutting (or metal
removal) and metal forming.
Metal cutting machine tools include among others machines for boring, drilling, gear
cutting and finishing, surface grinding, filling, lapping and honing. It is not known
when the first machine tool was made, but objects that appear to have been
machined in a lathe have been dated by archaeologists to early 1500 B.C.
Sculptured friezes show that the bow drill and a whole range of hand tools were in
use hundreds of years before Christian era.
The eighteenth century saw great advances in many engineering fields and
considerable advances in machine tools. In the decade preceding 1712, Thomas
Newcomen brought his steam engine to satisfactory working state. The duplication of
the engine, however, was done only with great difficulty and much of the work had to
be done by hand. The same limitation applied to spinning and weaving machines.
The constant search for improved methods of making wheels, shafts, and other
cylindrical items led to the development of lathe. Although the early lathes were used
entirely for turning cylindrical items, they gradually became more versatile and many
other tasks were assigned to them.
~enry Maudsley, an Englishman, is credited with making the first crew-cutting
engine lathe in about 1797.
107
In this presentation, economic utilization of these machines in the production of
industrial machine and machine components is referred to as ' ,our subject of
disclJssion
LIST OF SOME MACHINES AND THEIR SPECIFICATIONS
MACHINE TOOLS
Universal Centre Lathes
Turret Lathes for Bar Stock and ChuckworkSemi-automatic lathes
Boring and turning mill
Multi-spindle lathe
Radial drilling machines
Precious-type boring machine
Horizontal-boring mact)i nes
Jig boring machine
Gang drilling machines
Horizontal knee - type milling machines
Vertical milling machines
Tool room milling machines
Double - column plana - milling machine
Horizontal Planning machine
Vertical Planning - slotting machine
Thread and Splinted shaft
milling machine
108
SPECIFICATION
Swing over sec. 350- 600 mm
Length of turning 750 - 250 mm
Capacity of spindle 32 - 63 mm
Swing 120 320 mm
Length of turning 120 mm
Swing 32- 40 mm
Length of turning 120 mm
Drilling 40 - 60 mm
Drilling stroke 260 mm
Boring diameter 75-130 mm
Clamping surface of table 1000 x
1600 mm
Drilling diameter 200 mm
Clamping width 230 315 mm
Clamping length 1200 - 1600 mm
Clamping width 2530315 mm
Clamping length 1200 - 1600 mm
Clamping surface 200 x 600 mm
Clamping surface of table 800 x 2500mmClamping surface of table 1000 x 2500mmStroke 315 mm
Max. 250/500 mm
Max. Milling length 1250 mm
Pantographic milling machine
Centre type grinding machine
Centreless grinding machine
Internal grinding machine
Vertical surface grinding machines
Grinding machine for guide-ways
Homing machine
Spur gear planning machines
Spur gear and worm
Milling machines
Gear grinding machine
Thread rolling machine
Eccentric press
Press brake
Bending rolls
Hydrauic sheet metal bending machine
Double - spindle centre drilling machine
Circular Power Saws
Shears for cutting sections
Power shears for metal plates
Oxygen cutting machine for sheet metalpartingLathe tool grinding machines
Universal tool room grinding machines
Circular saw blade - sharpening machines
Threading jaw grinding machines
Hob grinding machines
Electric tool grinder
Clamp'ing surface 200 x 315 mm
Sing 250 mm
Distance between centres 600 - 1000mmGrinding diameter max 60 mm
Swing 400 mm
Clamping surface of table 600 x 300mmMax. clamping surface 1000 x 3000mmDiameter 25 - 5000 mm. Length
Module of teeth - 16
Module of teeth - 7
Max. gear 710 mm
Max. Gear 250 mm
Module-6
M16 -40
25 -160 tons
125 tons
Max. sheet metal thickness 8 mm
Width 2000 mm
Max. sheet metal thickness
Max. of stock 350 mm
Max. thickness of plate 10 mm
109
PART VI: THE IMPORTANCE OF MACHINING IN MANUFACTURING
In recent times, machining services has grown to become so essential and invaluable,
to the technological and industrial development of any nation that seeks economic
relevance. This has seen the emergence of many small, medium to large machine
shops in most industrial and commercial cities providing employment to many
: craftsmen, technicians and engineers. Machine shops are workshops that utilize
machines to cut, form, or shape metals and other substances. It is difficult to
specifically define machine shops, as the services they offer and types of materials
with which they work can vary so widely. Primary capabilities of machine shops
include boring, broaching, computer numerical control (CNC) machining, debarring,
electrical discharge machining (EDM), gear manufacturing, grinding, honing,
precision cutting, swaging, tool and die manufacturing, trepanning and gun drilling,
and turning and screw machining.
Some machine shops offer secondary operations such as heat-treating and stress
relieving, welding, lapping and polishing, anodizing, anti-corrosion treatment
electroplating, ard paint and powder coating. Machine shop services are so
diversified that it has offers a substantial of degree of employment generation in the
informal sector.
In most cases, machine shops are not designed to handle large-scale production
projects, Instead; machine shops are ideal service providers to support R& D projects,
repairs, modifications, prototypes and small quantity production. They are able to
follow the process from blueprint designing, to prototype fabrication and testing.
Although &>me machine shops may be used for limited runs of a product, very few
are capable of large-scale production runs. In such cases, once a working prototype
is designed and has been tested, manufacturing or fabricating services provider
should be contacted b complete the run. Machine shops also offer services like
component assembly, CAD! CAM Support, Design Assistance, Inspection! Quality
Control, and Prototyping, and certification testing (for international organizations such
as ISO, UL, VDE, etc.).
110
Turning and screw machine services provide custom machined components
fabricated to the specifications required by a design engineer. Turning and screw
machine services perform a diverse range of services including cutting, facing,
tapering, boring, grinding, threading, drilling, knurling, and necking. These processes
are completed using CNC automatic lathes, Swiss screw machines, bar loaders,
chucklers, or manual lathes. Part piece volumes may vary depending on the size of
the component and the capabilities of the turning and screw machine services
provider. Some shops also provide secondary processing such as cleaning,
debarring, cross drilling, milling, grinding, surface coating and heat treatment. Many
turning or screw machining services houses offer engineering / design assistance.
Turning machines are lathes that are used to mass-produce parts efficiently and
inexpensively. Turning is performed on a machine called a lathe (fig. 1a) in which the
tool is stationary and the part is rotated (fig. 1b). This style of machining can be
precisely controlled, allowing for very tight tolerances, even at a high rate of speed.
Screw machines are a classification within the turning family of machinery. They are
automated lathes, which can turn at a very high rate of speed that are used to
produce a high volume of parts at a low cost. Screw machines have one or more
turning spindles upon which the work pieces are placed. The screw machine
automatically turns/faces the part, parts it off, and advances the rod for the next part.
Automation is provided by bar feeders, robots, and pallet delivery systems.
In turning and screw machine services, rotating work piece comes into contact with
cutting or lathing bars, which cut, strip, or plane away unwanted portions of the part
stock. Facing is a term that is used to describe the removal of the unwanted material
from the flat end of a cylindrical part. Facing can be performed on fresh stock, or it
may be used on previously machined or fashioned parts, such as castings or
moldings, to refine them and prepare their surfaces for further finishing.
111
Knurling is another operation that may be performed by turning and screw machine
services providers. Unlike screw machines, which are used to plane generally
smooth parts, the knurling process fabricates components that are textured.
Turning and screw machine services may be used to design or finish parts that have
been fabricated from a wide range of materials. Some of the more commonly
machined materials include carbon steel and carbon steel alloys, aluminium, brass,
bronze, copper, plastics, stainless and other types of steel, nickel and cobalt alloys,
titanium alloys, exotic and precious metals, and wood.
The annual cost of operating machine tools in the United States (labour and overhead)
exceeds $40 billion. Thus, there is a demonstrated need for understanding the cost
elements in machining. In addition, the problem of determining the cutting speed to give
minimum cost is a classic problem in cost optimization using Kelvin's law. If we consider
for the moment only the costs involved in actual cutting, the machining time (and thus the
cost of machining labour for one piece) will decrease with increasing speed or feed.
However, tool wear will increase with speed and feed, and thus, there will be increased
costs for tools and tool changing. There will be an optimum speed, which balances these
opposing factors and results in minimum cost per piece.
I5pecifically, machining provides assortments of equipment and components arts
needed in the industries. It serves as innovation and creativity unit in the manufacturing
establishment.
Machining unit constitutes a strategic unit in the entire workshop complex. This is
because of the unique products produced and the relevance to the sustenance of
industrial production.
It creates jobs and guarantees employment in the informal sector and provides a life wire
to the SMEs and the roles of SMEs in any economy not be over emphasized.
112
It leads to economic empowerment of the proprietors or the entrepreneurs.
It leads to skill development, innovations and creativity in the society.
TYPICAL MACHINE COMPONENTS PRODUCED BY MACHINING
Flanged shafts - Automobiles, Generators
Crank shafts - "
Cam shafts -
Bearing housings - grinding machines
Jigs milling, threading, tapping machines
Press tools - presses
Blow molds - plastic blow machines
Injection molds - plastic Injection machines
Fixtures - miscellaneous equipment
Pulleys -
Gears etc.
ADVANTAGES OF MACHINING OVER OTHER MANUFACTURING PROCESSES
Most machining has very low setup cost compared to forming, molding, and casting
processes. However, machining is much more expensive for high volumes. Machining is
necessary where tight tolerances on dimensions and finishes are required.
PART VII: OVERVIEW OF NIGERIA ENGINEERING SECTOR
Engineering Sector produces a wide variety of products ranging from castings and
forging to fabricate metal products and components for mechanical and electri cal
equipment. Similarly, parts and components produced in this sector are used in the
113
manufacture, assembly of capital and consumer goods including automobiles and
other types of machines. The products of the sector are covered in the International
Standards Industrial classification (ISIC) Category: 3200 - 5000. The substance
ISIC Code37003800
3900410042005000
Industrial GroupBasic Metal IndustriesManufacture of Fabricated Metal Products,
Machinery and EquipmentOther Manufacturing industriesElectricity, gas and waterWater works and supplyConstruction
The sector employs the techniques and technologies of metal fabrication such as
cutting, bending, pressing, forming, casting, drillings, machining, etc for the
production of rudimentary capital goods (machinery and equipment), tools, spare
parts and components for the provision of repairs and maintenance services. The
sector provides linkages to other sectors of the economy - backward to the basic
metal production (Iron and Steel) and forward to the automotive, transportation,
construction, agriculture and defence industries. Generally, specialisation and sub
contracting provides meaningful growth to the engineering industries. Unfortunately,
this linkage pattern has not developed well in Nigeria, rather, the sector suffers from
a high level of import dependence and is dominated by assembly - type operations
based on imported completely knocked down (CKD) and semi-knocked down (SKD)
parts. Table I shows the importation value of machinery and equipment from 1990
1996. This indicates the level of foreign dependence in the provision of machinery
and equipment for the manufacturing industries. For how long shall we continue to
rely on importation of engineering goods to sustain our industries?
114
TABLE 1: Importation value of capital goods in Nigeria (1990 -1996)
Year Importation Value (N'OOO)
1990 14,048,680,576,000
1991 39,815,628,764,000
1992 82,181,830,721,000
1993 85,029,992,533,000
1994 39,926,283,509,000
1995 84,318,379,768,000
1996 143,438,655,000
Total 345,464,234,526
Source: FOS: Nigeria Trade Summary (1990-1996)
CHART:
Importation 1990 - 1996
90
80
70
60c£ 50toCJ
40CJCJ 30~
20
10
0
lIB Importation Value (N'OOO) I
19901991 1992 1993199419951996
Year
Between 1990 and 1996, Nigeria spent about three hundred and forty five trillion
Naira on importation of capital goods, mostly machinery and equipment to till in the
equipment supply gap existed in the manufacturing sector. These equipment and
machinery ranges from iron and steel, shot, grit, powders, sponge, Ferro-
115
manganese, Ferro-silicon, pig iron, high carbon steel ingots, stainless steel ingots,
alloy steel ingots, bricks, lumps, slabs, billets, coils, bars, rods, forged, sections,
angles, shapes, not rolled, sheet piling, plates, sheets, tinned plates, hoop strip
railway trucks, rails, steel wire (insulated) steel seamless tUbes and pipes, high
pressure conduct steel, fittings, iron castings, rough, forgings silver, semi -rods,
platinum materials and component copper bars, wire, sheets, foil, tubes, Nickel
Aluminium products, zinc and lead products, Tin foils and its products, non ferrous
base metals; doors, window,. Frame and structures, Aluminium containers and
compressed gas cylinders, Nails, fencing wire, machetes, agric tools. Machines and
hand saws and saw blades. wrenches and spanners, metal carbide scissors/blades,
knives and cutlery, galvanized buckets, springs, hooks, motor vehicle combust piston
engines, AC motors, generators, rotary commuter, power generating set, Agric
equipment, tractors and mechanical parts, sewing machines, air conditioners
compressors, pneumatic elevators/conveyors, weighing machinery etc. These are
the engineering inputs that sustain the manufacturing in Nigeria. The indigenous
machinery and equipment manufacturing establishments in Nigeria lacks the capacity
and capability to produce standard spare parts hence, the solution to the problem lies
in the importation of these capital goods .The negative impact on the economy has
been widely acknowledged. Basic industrial units such as foundries, forged shops,
heat treatment plants, machinery shops, fabricati9n shops and metal furnishing
plants constitute the base for the manufacture of these products. Dominant players
in the sector are (a) Metal Fabrication Industries: These are industries that employ
techniques which basically tansforms steel and allied profiles into various products
for both household and industrial uses. It is one of the engineering industry sub
groups so vital for the sustenance of the manufacturing sector. In its simplest form,
the production process involves cutting to size joining and looking these sizes
together by holding to obtain the required shapes, heat treatment, stamping,
pressing, extrusion/cladding and machining. It employs the raw materials from
primary metallurgical industries such as semi-finished ferrous and non-ferrous
products which are transformed into engineering components and parts for the
capital goods industries. It also provides the essential linkage between primary metal
116
production and built up machinery and equipment. The sub -group, has the greatest
number of forms in the engineering sector. It accounts for about 43 per cent of the
total forms in the sector. However, its proportion of gross output and value added
one only about 18 and 20 per cent respectively. The village blac k smith, panel
beaters, Iron binders, tinkers and welders are good examples of metal fabricators in
the informal sector that provide engineering services and generating significant
employment.
(b) Foundry and Forged Shops
Foundry and forge shops plays comple mentary roles in metal fabrication in the
production of a wide range of metallic components and spare parts for the assembly
of consumable engineering products, machinery, plants and capital goods. The
basic difference between the two sub-groups lies in the type of products and the
production process while the foundry and forge shop operations require the
application of direct heat on the input material during processing the metal fabrication
operation does not necessarily require heat in the production process. There are
more Foundry shops in Nigeria than there are forge shops although both are in
relatively short supply.
Foundry is essentially, a process for the production of ferrous and non-ferrous
equipment of varying regular and irregular shapes and configurations through melting
of metals into liquid of fluid state and then pouring the hot molten metal into patterned
moulds. The molten metal then acquires the shape in the mould on cooling in a
process known as casting. The particular casting proces s adopted for a foundry
shop varies according to the type of metal to be cast, the geometry of the product, its
metallurgical properties and the finishing characteristics. There are fire main casting
processes, sand, die centrifugal, continuous and investment casting. The one
commonly used in Nigeria are sand and centrifugal casting.
The Delta Steel Company Liplited (DSC) presently employs continuous casting for
the production of billets while Ajaokuta Steel Company Limited (ASCL) uses
117
centrifugal casting in its plant. Auto -components Nigeria Limited at Otta in Ogun
State employs gravity and pressure die-casting machines for the production of engine
mounting and other products for the auto-industry. About 90 per cent of the
foundries produce both ferrous and non-ferrous castings. Commonly, cast metals in
the nonferrous group are copper, aluminium and the alloys.
Forging process is employed in the production of metallic parts by heating metallic
work-pieces until they are red-hot when an external force is applied to give them the
required shapes. The two basic methods generally in use are harmer and press
system. The choice of process technology is determined by the type and shape of
object to be produced, size of work piece, material in use and mechanical properties
to be achieved. The use of hammer system is however, the common practice in
Nigeria forge shops. Other forging process technologies are flat die (smith) forging,
drop forging and upset forging.
Presently, there are about seven major forge shops in Nigeria, these are captive to
the large parastatals such as the Nigerian Railway Corporation (NRC), Nigerian Ports
Authority (NPA) and Ajaokuta Steel Company Limited (ASCL) and facilities produce
only limited shapes. The drop, press and upset te chniques are those that are
generally used in the country. The drop forging techniques constitutes about 70 per
cent, followed by press forging with 20 per cent and upset technique 10 per cent.
she characteristics of selected foundries are given below, ee table 2. These
foundries are capable of producing components and spare parts. There are other
private steel and foundry shops. Private participation dominates the activities in the
engineering sector, though there are a handful of government parastatals in he
engineering sector mostly in the foundries and forge; they are installed a "Captive
Plant" and in playing a vital role in meeting the challenges of the spare parts supply.
118
Installed Capacity T/a Capacity Utilization T/aName of Company Ferrous Non Ferrous Non Ferrous
FerrousNigerian Foundry Limited 1408 · 1225 (87%) .Roadside Engineering and 14.40 8.40 14.40 (100%) 7.2 (85.7%)FoundryContinental Foundry 24.0 130.0 24.0 (100%) 130 (100%)Nigerian Ports Plc. · 2.5 · 1.29 (51.6)Nigerian Railway 2537 1500 1015 (40%) 603 (68.3)CorportionModern Foundry Limited · 740 · 505 (68.3)Suchit Aluminium Company · 5 · 5 (110%)Adeyera Limited Company 11 2 6 (54.5%) .Western Nigeria Technical 50 · 47 (80%) -CompanyAdekunle Foundry 12 · 12 (100%) -Delta Steel Company 1200 · 826 (45.7%) -Defence Industry 30 23 43.7 15 (32.67%)Corporation (45.77%)Nigerian Sugar Company 70 18.75 56 (80%) 15 (80%)
Source: National Council on Industrial Development Field Survey, 1991
Demand from the large industry. Nigerians have developed enough capability in
the sector; about 90 per cent of the engineering firms in Nigeria is manned by the
local engineers. The contribution of the sector to the gross domestic products is
not impressive in the past three decades.
The capacity utilization in the sector also varied accordingly. 37.51 to 61.47 with
1989 recorded the highest industrial production and utilization in Nigeria, see table 2c
in average of 20.25 was recorded between 1987 to 1997.
119
2c: Percentage Capacity Utilization 1987 - 1995
Sector: Year
Engineering 87 88 89 90 91 92 93 94 95
(a) Basic metals, 23.2 25.8 27.6 34.9 809. 25.5 25.4 23.5 22.41Iron 5 0 9 2 78 2 5 8Steel andFabricated
Metals(b) Motor Vehicle 37.1 35.4 33.7 24.1 7.03 24.0 25.8 16.4 23.62
and 6 6 8 6 3 7 3MiscellaneousAssembly
Source: Manufacturers Association of Nigeria
Percentage Capacity Utilization 1987 - 1995
1995199319911989
A-----------i""..._---------!
.J----------I:"._-----------!
s:: 100o;;
.~ 80-;;~ 60~.~ 40c.~ 20
o1987
Year
I!I Basic metals, Iron Steel and Fabricll Motor Vehide and misecellaneous Assembly
"
The local sourcing of raw materials was taken as a deliberate policy of mos~·
companies during the 80's and 90's. This may be explained by gove rnment policy on
local sourcing of raw materials and the trade incentives associated with it. Table 3
indicates that Nigeria Engineering Sector recorded the highest percentage of local
120
sourcing of raw materials in 1995 with an average of 49.55 percent whereas 19~jO
recorded the least with 24.74 per cent.
Table 3: Local Sourcing of Raw Materialssector Local Sourcing of Raw Materials
,---Engineering 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1S-')'r-'-Basic Metals, Iron 33.45 31.00 36.75 25,59 31.88 43.03 43.27 35.00 55.74 37.30 56.0Band Steel andFabricated MetalMotor Vehicles 33.45 38.71 40.66 23.88 37.50 41,10 30.00 43,35 37.16 26.19
Average 34.45 34.86 38.71 24.74 34.69 40.23 42.19 22.4 49.53 37.23 4i1'g-Source: Manufacturers Association of Nigeria "Economic Review"
60
50
~40Cl)
ClBc 30~:. 20
10
o
Local Soucing of Raw Materials 11 Basic Me1aIs, 1100
cm SEe! cmFabricated Metal
• Local Sa.xi'YJ r:iMaterials
1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997
Year
The Index 'of manufacturing of the sector according to Central Bank of Nigeria ;;
Federal Office of Statistics, indicate a comfortable level of 55.34 per cent in 1986 ::' ::,
is the year Structural Adjustment Programme was introduced in Nigeria. The SU~' ".
started declining, ranging between 45.73 in 1994 to 23.7 per cent in 1992. The yt-I
1995 witness a remarkable decline in the performance of the sector with an aV~~(d:.;;
of 18.23 per cent. This was the pick period of military dicta torship in Nigeria, S·, -3
table 4.
Table 4: Index of Manufacturing Production: Base Year 1985 =100
Sector: YearLight/Heavy 85 86 87 88 89 90 91 92 93 94 95 96EngineeringRoofing Sheet 100 84.5 54.7 50.6 1490 79.6 57.9 41.20 39.3 30.8 37.8Vehicle 100 46.8 27.0 4.4 15.7 24.1 171 18.3 18.9 17.4 11.7Assemblyadio &T.V 100 1548 45.8 14.7 12.5 1221 11.8 11.6 10.1 89 5.2Average 100 42.5 2323 59.07 3864 28.92 23.70 22.77 45.72 18.23
Source: Central Bank of Nlgena and Federal Office of Statistical (Annual Report and Trade Summary)
o Radio&TV
o VehicleAssembly
o
•
. • Roofingsheet
,.,.' .. l<
~ ~ ••il t(, L 0 "',' ~f
: <.
~; ','
ll.'
~ C") L() I"- (J) ~
~
YEAR
2300
2200
21000/0
2000
19001800 ..f'IU'F~~"""'......-I~urf!lUlflILJIII'"
The Manufacturing Investment in 1988 indicates that an average of 50.8 million Naira
was expended on capacity expansion while 18.15 was invested in the replacement of
worn out parts and equipment during manufacturing at an efficiency level of 89,95
Percentage; See table 5.
.122
Table 5: Manufacturing Investment and Employment
Sector: Light & Heavy Investment (N' Million)Engineering: Capacity Replacement Efficiency Others
ExpansionElectrical and ElecTonics 80 20 76.81 -Basic Metal, Iron and Steel and 69.9 20.05 29.30 29.11Fabricated Metal ProductsMotor Vehicles and 2.5 14.41 13.84 14.00Miscellaneous AssemblyAveraqe 50.8 18.15 39.93 21.56
Source: Man, Economic Review, 1988
PART IX: CONSTRAINTS OF ENGINEERING SUB -SECTOR IN NIGERIA
Among the factors identified as inhibiting the development and performance of the
sub-sector are:
(i) lack of primary inputs such as cast products, iron ingots &billets and flat
sheets
(ii) the general preference for imported parts and components to locally
produced ones.
(iii) tariff regimes that have tended to favour imported finished products
over local ones.
(iv) inability to exploit locally available raw materials
(v) inadequate and inefficient infrastructural base
(vi) lack of standardisation of equipment and machinery. In most cases,
some of these machines are no longer produced and become
technological obsolescence. Consequently, replacement of the various
worn-out parts and components became increasingly difficult.
Furthermore, owing to the diverse nature of the origin of these various
types of equipment and machinery, the local spare parts manufacturers
find mass production extremely difficult, not only as a result of lack of
appropriate input materials but more importantly to limitations of
economics of scale. Among the longer term solutions would be the
l23
standardisation of equipment and machinery and in effect, the
standardisation of various parts and components.
PART X: OBSERVATIONS
(1) fftm;hine tools industry is extremely very heterogeneous and as such
considerable segmentation exists rather within the industry.
(2) Machining has helped many Nigerian Engineering graduates to take to self
employment. Quietly, they have continue d to service and sustain our
manufacturing sector without being noticed. They fabricate the moulds used in
producing most of the articles seen in our markets which carry inscriptions
such as "made in Germany", "made in Japan" and so on. They design and
construct millers, boilers, ovens, furnaces and other machines used by some
of our manufacturing companies. All these help to increase our national
productivity.
(3) In national terms, the contribution of machine tools industry is very small and it
account~ for between -3 per cent of manufacturing employment in the
advanced industrial countries. However, the industry's complex interrelation
with others makes it strategic and without this vital sector, the production of
modern industrial capital goods would be difficult to imagine.
4) Producers of machine tools are also small. For instance, 80 per cent of
employees in the UK machine tools form are under 500. In the United States,
there were 1,392 establishments in 1,290 firms; only eight establishments had
more than 1,000 employees. All of these accounted for less than 20 per cent
of total employment. In Nigeria, there are about 150 public owned
establishments for machinery and equipment manufacturing with more than
2,000 employees. The usual inefficiency in the public institutions in Nigeria has
not allowed these shops to achieve the desired results and make significant
impact on the industrial manufacturing.
(5) In spite of its smallness in terms of overall national contribution and
employment, the industry is at the heart of the engineering industry and most
124
modern processing units could not be established without it. "All innovations
whether they involve the introduction of a new product or provide a cheaper
way of producing an existing product requires that the capitals sector shall
produce a new product (machine) according to certain specifications,
(Resenberg, 1976)"
(6) The machinist in this part of the country seems to lack the basic vocational
skill to understand what the market requires.
(7) Most government rmchining shops are captive units and in most cases not
given adequate funding, lack of equipment replacement and poor
remuneration of the employees.
(8) There is great dearth of standard raw materials for machining.
(9) Lack of adequate and efficient engineering aboratories in most Nigerian
technical institutions.
(10) The innovative and inventive conscientiousness/attitudes are not inherent in
most young Nigerian engineers and technicians.
PART XI: CONCLUSION
The availability of machine shops within the industrial zones in Nigeria has helped to
encourage and sustain the spirit of dynamism and entrepreneurship in some hard
working Nigerian Engineers, Technicians and small scale industrialists. Without such
machine shops, independent private entrepreneurship development in the productive
sector would be completely hindered.
Machining process provided opportunity for indigenous engineers and technicians to
get acquainted with the incoming and transient technologies of machine tools
development and other heavy engineering techniques which hitherto they were not
so familiar with.
1. Machining industry has therefore provided the much needed technological
base and engineering infrastructure for industrial development in the formal
and informal sector.
125
2.
3.
4.
5.
6.
7.
126
The steel and allied industries including Oshogbo Machine Tools Company
limited should be resuscitated so as to provide the necessary material backup
requirement in the downstream engineering sub-sector.
There are well known capacity building developments in the machining sub
sector of the engineering sector. The apprenticeship training systems in many
private workshops have continued to afford many Nigerians who could not
attend formal technical college opportunities to acquire skills on machine
operations.
The industrial, science and technology policies of successive administrations
in Nigeria has always emphasized the need for rapid technological
development of the country but lacks t necessary political will to fund
technology development programmes adequately.
Various schemes and technology projects have been established in Nigeria
but for the fact that they are mostly public owned, they have failed to achieve
the desired results. Many engineering projects has failed or are in a state of
coma in Nigeria eg Ajaokuta Steel Industry, Nigerian Machine Company
Oshogbo Aluminium Smelter Industry, Sugar Factories, Paper Mills, Rolling
Mills, etc. It is surprising to notice that private industrial projects have
continued to survive despite the prevailing economic environments (the case
of Nnewi, Onitsha, Aba industrial development prove the case that
government are not good industrial managers)
The present administration has often reiterated the need for a private sector
led and technology driven society and it is therefore set to creating enabling
environment and privatising and commercialising most government owned
industries.
Many secondary and tertiary institutions of higher learning lack basic
equipment for technical training. Basic industrial engineering processes such a
machining should be included in tile educational curriculum for technical
institutions (universities and polytechnics inclusive).
..
Though the share of developing countries like Nigeria in 1SO 9000 certifiGation has
shown increases, there is considerable concentration of it within the East Asian countries
(the traditional Asian Tigers, plus China, Malaysia, Indonesia, Thailand ald the
Philippines) (Mani, S. 2001). There is need therefore for developing countries, especially
those of the sub-Saharan Africa including Nigeria to develop or review policies on
standardization of all products and services under 1SO, 9000 certificatior, machined
products should not be an exception. In case of Nigeria, implementation of these policies
should be vehemently enforced and monitored by such Government agencies like
Standard Organisation of Nigeria (SON) for mechanical and electrical/electronic products
etc. while NAFDAC should be concerned with food and drug administration of standards.
Human Resource Development and Capacity Building
Capacity building is the most important measure to stimulate domestic manufacture
of machined parts for industrial development in Nigeria. The importan:;e of availability
of steady stream of trained personnel in the country cannot be overemp hasized. All
successful countries including the recent stories from South Eastern Asian counties
had a policy of developing high quality trained personnel in Science and Engineering
in large numbers (Lall, 1998). Most developing countries including Nigeria treat
policies on human resource development separately from public innovation and
manufacturing activities like machining. Unless there is a critical mass of technically
trained personnel, no amount of fiscal incentives can spur innovative activities in
machining industries. There are two separate but related statistics which capture this
state of affairs:
127
a. Density of Tertiary Students in Selected Countries Including Nigeria.
Table 1: Density of Tertiary Students (per 10,000 inhabitants)
Brazil China Korea Malaysia Singapore India Tanzania Uganda Zambia Nigeria
1980 1,158 166 1,698 419 963 515 22 45 128 229
1985 I\lo 328 3,568 595 1,474 582 22 69 181 352
Data
1990 1,082 331 3,568 595 1,474 582 22 69 212 no
data
1991 1,077 313 4,071 753 1,956 no 28 126 no no
data data data
1992 1,042 313 4,375 856 2,080 no 29 124 no no
data data data
1993 1,067 377 4,420 886 2,273 no 33 135 no 410
data data
1994 1,092 437 4,637 973 2,328 538 36 150 238 no
data
1995 no 461 4,950 1,048 2,527 610 43 160 no no
data data data
1996 1,424 473 5,605 no 2,730 638 48 179 no no
data data data
1997 no 488 6,106 no no no 57 no no no
data data data data data data data
Source: Human Capacity Development Centre (2000)
b. The Density Of Research Scientists And Engineers (RSEs) (Table 2). In
fact as can be seen in table below, there is very strong positive correlation
between RSEs and research intensity according to UNESCO (1999). The
zero-order correlation coefficient between the two works out to +0.88.
Moreover, the number of students enrolled at the tertiary level in science and
engineering subject does not work out more than 15 to 20% in most
developing countries like Nigeria.
128
1able 2: Densitv of Research Scientists and Research lntensit" (per 1 million
labour force)
Year Researchers per Rese arch Intensity
Country 1 million labour force (R~.D/GNP*100)
USA 1993 3676 2.63
UK 1996 2448 1.95
Germany 1995 2831 2.41
Korea 1996 2193 2.82
Singapore 1995 2318 1.13
Malaysia 1996 93 0.24
India 1994 149 0.73
China 1996 454 0.66
Brazil 1995 168 0.84
South Africa 1993 1031 0.70
Nigeria 1987 15 0.09
Uganda 1997 21 -__ .. _ a
Source: UNESCO (1999}
c. A third point, which is usually forgotten, is that it is not mendy the supply of
technically trained personnel that matter. There has to be a ma tch between
the requirements of industries especially the machining indus ries and the kind
of training in the technical institutions. Failure to recognize this can result in
loosing the important market.
As far as machining industries are concerned, the trainees should be at ached to
machine shops in large companies using industrial training fund. Such ~ rogrammes can
be promoted by NASENI and National Directorate of Employment for thn development of
machining industries.
129
The paper has highlighted the importance of development of machining industry in
view of its contributions to the final surface qualities of products desired by
customers. Furthermore, there is no production process where one kind or the other
operation of machining is not included. Development of quality standards in line with
1SO 9000 is therefore needed. Efforts are to be made by agencies of government
dealing with small and medium enterprises to promote clustering of informal
machines shops in the country especially within the rural areas. Government should
introduce a programme of central purchase of raw materials for such clusters and
also assist in locating a market for the products.
PART XI: RECOMMENDATIONS
(i) Young engineers and technicians should be empowered technically by eas y
access to relevant machinery, funds and tax rebates as this will have a
positive multiplier effect on the development of SMEs and cottage industries.
(ii) NASENI should encourage training of young Nigerian graduate engineers and
technicians in the area of engineering process such as machining. This will
make them self-employed, create jobs for others and alleviate poverty in the
Nigeria.
(iii) International agencies, non-governmental organizations including National
Government should provide enabling socio-economic environment under
which private led enterprises would thrive.
(iv) Critical infrastructure facilities such as electricity power supplies should be
provided by the government or by the community to ensure steady operation
of the machining operation and allied processes in manufacturing.
(v) If we must build a virile technology base, if we must acquire the capacity for
wealth creation and value added. If we must cut away through technology
130
chasm then, we must acquire the basic technological facilities (machining etc)
which constitute the springboard necessary for us to leap-frog into the new
technological revolution and get into the centre of global industrial power
structure.
BIBLIOGRAPHY
(1) Boothroyd G. & Knight W. - Fundamentals of Machining and Machine
Tools
(2) Kalpakjian S. - Introduction to Manufacturing Processes
(3) Roy A. Linderberg - Processes and Materials of Manufacture
(4) Nweke F.O. - The Role of refurbished Machinery in Nigeria's Industrial
Development
(5) Simi, (1982) "834 Reserved Small and Cottage Industries", Eight Revised
and enlarged edition, by Simi Board of Consultants and Engineers, Dehli-7,
India.
(6) Lall, S.(1998) "Putting knowledge to work for Development in Background
!Report for World Development Report 998 PSDBE, World Bank and
Queen Elizabeth House, Oxford, Processed.
(7) Banji Oyelaran-Oyeyinka et al (1997) - Ailing Public Enterprises:
Technological Project Failures and Prospects for Industrial Renewal in
Nigeria
(8) V.S. Korsakov (1979) - Fundamentals of Manufacturing Engineering
(9) United Nations Industrial Development Organisation Monographs No. 4:
Appropriate Industrial Technology for Agricultural Machinery and
Implements.
131
ANNEX I
TYPICAL FORMAT OF FEASIBILITY REPORT FOR ESTABLISHMENT OF
MACHINES SHOP
Feasibility Report on the manufacture of............... At.. .
1. Introduction
1. A brief summary about the product and manufacturing techniques
in shell and viable capacity of the plant.
2. Brief summary of properties and uses of the product.
3. ISI specifications and req uirements of the product.
4. Market survey.
5. Process of manufacture - In simplest understandable may along with
flow sheet diagram.
6. Cost estimation.
NON - RECURRING EXPENDITURE
(a) Land and Building Area(Along with, area specified)
(i) Land N
(ii) Factory N
(iii) Administrative Building N
(iv) Stores/other Building N
Sub-Total (a) N
(b) Plant and Machinery
1. Cost of all machinery /equipment
(with details of capacity each) N
2. Cost of spares N
3. Installation charges N
4. Office furniture N
5. Consultation /Pre-Commissioning
Expenses N
132
Sub-Total (b) N
Total Fixed Capita (non-recurring) (a+b) N
RECURRING EXPENDITURE (PER MONTH)
(c ) Raw Materials
(Quantity with rate)
1.
2.
3.
etc
N
Consumable Stores
1.
2.
3.
Sub - Total (c) N
(d)-1 Personnel Salary & Wages
Management Cadre
(i) Manager No at p.m N
(ii) Supervisor No at.. p.m N
(iii) Sales Incharge No at.. p.m N
(iv) Store Incharge No at. p.m N
Sub- Total (d) -1 N
(d)-2 Non Management Cadre
(i) Skilled Labour No at.. p.m N
(ii) Semi-Skilled Labour No at.. p.m N
(iii) Helpers No at.. p.m N
(iv) Typist-Clerk No at.. p.m N
(v) Others No at.. p.m N
Sub-Total d -2 N
Total SalarylWages(d -1 +d-2) N
133
Give provision for P.F, ESI, & TA etc
Total (d)-3
(e) Utilities Cost
1. Electric Cost
2. Fuel
3. Water
4. Postage
5. Stationery
6. Transportation
7. Miscellaneous Expenses
N
N
134
PROFITABILITY ANALYSIS
Cost of Production (Monthly)
1. Working Capital N
2. Depreciation on Machinery at 10% p.a N
3. Depreciation on Building at 5% p.a N
4. Interest on total Capital Investment
At 15% p.a N
Total N
Receipt (Monthly)
Receipts through selling of produced item N
Receipt through sales of by-products, if any N
Total Receipts N
Less cost of production N
Profit Month before tax N
% of profit on Total Capital
Invest= ProfiUyear x 100
Total Capital Investment
BREAK EVEN ANALYSIS
Break Even point - Fixed Cost x 100
(Fixed Cost + ProfiUyear)
Fixed Cost
1. Depreciation on Machinery at 10% p.a N
2. Depreciation on Building at 5% p.a N
3. Interest of Total Capital Investment at 15% p.a N
4. 40% of Wages N
5. 40% of Utilities N
Fixed Capital N
B.E.P = FC x 100
Fc x ProfitlYear
Date: Signature
Prop.lPartner/Director
135
ANNEX 11
SOME PUBLIC MACHINERY & EQUIPMENT MANUFACTURERS IN NIGERIA
Type of Machinery Name and Address of ManufacturersEquipment
1. Palm Oil Extracting Plant African Regional Centre for Engineering Designand Manufacture (ARCEDEM),KM 9, Iwo Road, U.1. Post Office,Ibadan,Oyo.
Department of Mechanic Engineering PTI, MainCampus, PTI. P.M.B. 20, Effurun,Delta State.
Department of Agricultural Engineering,University of IbadanO.A.U. CampuslIe-lfe,Oyo State.
IMT Campus Ili,Independence LayoutP.M.B. 136, Enugu,Enugu State.
Nigerian Institute of Oil Palm Research (NIFOR)NIFOR Main Station,P.M.B. 1030, Benin City,Edo State.
Project Development Institute (PRODA),3, Independence Layout, P.O. Box 609, EnuguEnugu State.
Rural Agro-Industrial Development Scheme(RAIDS),11 University Crescent,Ibadan,Oyo State.
136
2.~-----:---=-:---..,----:-----=----------------......,
Gari F--rocessing Plant African Regional Centre for Engineering Designand Manufacture (ARCEDEM)Km 9, Iwo, U.1. Post Office,Ibadan, Oyo.
Federal Institute of Industrial Research, Oshodi(FIIRO)Cappa Bus Stop, PM.B. 21023, Ikeja,Lagos State.
Project Dev. Institute (PRODA),3, Independence Layout, Enugu,PO. Box 600,Enugu State.
Rural Agro-Industrial Development Scheme(RAIDS),11, University Layout, Crescent, IbadanOyO State.
3. Rice F--;'Jcessing Plant African Regional Centre for Engineering Designand Manufacture (ARCEDEM).KM 9, Iwo Road, U.1. Post Office,Ibadan, Oyo.
I---~---t------=------+-~~~'::""<"""-'---------------l
4. Grain 8i1 Extracting African Regional Centre for Engineering DesignPlant and Manufacture (ARCEDEM).
KM 9, Iwo Road, U.1. Post Office,Ibadan,Oyo.
School of Metallurgy, The Federal Polytechnic,Ayangba RoadP.M.B. 1037, Idah,Kogi State.
I.A.R. & T, Ibadan, Moor Plantation,Pfvl.B. 5029, Ibadan,Oyo State.
5, Grain Dryer African Regional Centre for Engineering Designand Manufacture (ARCEDEM).KM 9, Iwo Road, U.1. Post Office,Ibadan, Oyo.
School of Metallurgy, The Federal Polytechnic,Ayangba RoadP.M.B. 1037, Idah,KOQi State.
137
I.AR. & 1, Ibadan, Moor Plantation,P.M.B. 5029, Ibadan,Oyo State.
6. Grain Silo African Regional Centre for Engineering Designand Manufacture (ARCEDEM).KM 9, Iwo Road, U.1. Post Office,Ibadan, Oyo.
Department of Agric Engineering, University ofAgriculture,P.M.B. 2373, Makurdi,Benue State.
7. Multipurpose Crop Dryer African Regional Centre for Engineering Designand Manufacture (ARCEDEM).KM 9, Iwo Road, U.1. Post Office,Ibadan,Oyo.
8. Multipurpose Crop Agric. Mech. Research Programme & DepartmentThrasher of Agriculture Engineering, AB.U., Ahmadu Bello
University Campus,P.M.B. 1044, ABUKaduna State.
Manual Sheller Institute for Agriculture ResearchABU, Zaria.
9. Maize Sheller Agric. Mech. Research Programme & Departmentof Agriculture Engineering, AB.U., Ahmadu BelloUniversity Campus,P.M.B. 1044, ABUKaduna State.
Agric. Mech. Section, College of Agriculture,ABU Ahmadu Bello University Campus.P.M.B. 1044, ABUKaduna State
Enugu State University of TechnologyIndependent LayoutP.M.B. 01660, Enugu,Enugu State.
Centre for Industrial Studies(CIS), FederalUniversity of Technology Samek Road,P.M.B. 1526, Owerri,Imo State.
138
Department of Agric. Engineering,University of Ilorin,Kwari State.
Department of Agric Engineering, University ofAgriculture,P.M.B. 2373, Makurdi,Benue State.
Department of Agric. Engineering, KadunaPolytechnic, Polytechnic Campus,P.M.B. 2373, Kaduna.Kaduna.
Department of Agric. Engineering, University ofNigeria Nsukka,Enugu.
Department of Mechanical Eng. Ibadan SouthCampus, The Polytechnic,P.M.B. 22, U.1. Post, Ibadan,Oyo State.
Industrial Centre (IMT) Ltd.,IMT Campus III Independent Layout,P.M.B. 1136, Enugu,Enugu State.
I.A.R. & T, Ibadan, Moor Plantation,P.M.B. 5029, Ibadan,Ova State.
10. Sunflower Agric. Mech. Research Programme & Departmentof Agriculture Engineering, Ahmadu BelloUniversity Campus,P.M.B. 1044, Zaria.Kaduna State.
11. Correction Solar Dryer Agric. Mech. Research Programme & Departmentof Agriculture Engineering, Ahmadu BelloUniversity Campus,P.M.B. 1044, Zaria.Kaduna State.
12. Natural Convention Agric. Mech. Research Programme & DepartmentSolar Dryer of Agriculture Engineering, Ahmadu Bello
University Campus,P.M.B. 1044 Zaria Kaduna State.
139
13. Ground Nut Thresher Agric. Mech. Research Programme & Departmentof Agriculture Engineering, Ahmadu BelloUniversity Campus,P.M.B. 1044, Zaria.Kaduna State.
Department of Engineering, Federal Polytechnic,Polytechnic CampusP.O. Box 231 BauchiBauchi State.
Institute for Agriculture Research,ABU, ZariaKaduna.
14. Groundnut Roaster Food Science and Tech. Dept. University ofMaiduguri Campus, Maiduguri,Bornu State.
15. Cassava Anambra State Polytechnic, Oko, OrumbaL.G.A. P. O. Box 21, OkoAnambra State
University of Ilorin,1I0rin Kwara State.
Centre for Industrial Studies (CIS), FederalUniversity of Tech. Samek Road,P.M.B. 1526, OwerriImo State.
Dept. of Technical Engineering, The PolytechnicIbadan South CampusP.M.B. 22 U.I., Post Office IbadanOyo State.
Dept. of Agric. Engineering of Nigeria,NsukkaEnugu State
Industrial Centre (IMT) Ltd.IMT Campus IIIIndependent LayoutP, M, B, 1136, EnuguEnuqu State, --Project Dev, Institute (PRODA)3, Independent Layout,P, 0, Box 609, Anambra State
140
---16. Cassava Mash Anambra State Polytechnic, Oko Onumbra
LGA, P.M.B. 21, Oko,Anambra State
Dept. of Agric Eng. University of AgricultureP.M.B. 237, Markurdi,Benue State
Project Dev. Institute (PRODA),3, Independent Layout,P.O. Box 609, Enugu,Enugu State --
17. Food Palletizer Anambra State Polytechnic, Oko, OrumberLGA, P.M.B. 21, OkoAnambra State.
18. Baking Oven Enugu State University of TechnologyIndependent Layout,P.M.B. 01660, EnuguEnugu State.
Project Dev. Institute (PRODA)3, Independent Layout, P. 0.609, EnuguEnugu State.
19. Industrial oven and Chemical Engineering DepartmentBurner University of Lagos,
Akoka,LagosLaQos State.
20. Distillation Equipment Chemical Engineering DepartmentUniversity of Lagos,Akoka, LagosLagos State.
21. Gari Fryer Enugu State University of TechnologyIndependent Layout,P.M.B. 01660, EnuguEnugu State
Department of Mechanical Eng. The Polytechnic,Ibadan South Campus,P.M.B. 22, U.1. Post, Ibadan, Oyo State.
The Polytechnic, Nekede Village, Nekede,
-- Owerri, Imo State. - ._~
22. Cassava Press Enugu State University of TechnologyIndependent LayoutP.M.B. 01660, EnuguEnugu State
- -~ -
14l
Industrial Centre (IMT) Ltd. IMT Campus Ill,Independent Layout,P.M.B. 1136, Enugu,Enugu State.
Project Dev. Institute (PRODA),3, Independent Layout, P.O. Box 609, Enugu,Enugu State.
Rivers State University of Science & Technology.P.M.B. 5080, Port Harcourt,River State.
23. Cassava Peeler Project Dev. Institute (PRODA)3, Independent Layout. P.M.B. 609, EnuguEnugu State.
Dept. of Agric. Engineering of Nigeria,NsukkaEnuqu State
24. Cassava Pulverizer The Polytechnic, Nekede VillageOwerriImo State
25. Cassava Starch Rural Agro-Industrial Dev. Scheme (RAIDS),Processing Plant 11, University Crescent Campus,
P.M.B. 1058, Zaria,Kaduna.
26. Melon Separator Department of Agric Eng. Federal Polytechnic,Polytechnic Campus,P. M.B. 55, Bida,Niqer State.
27. Melon Seed Cleaner Dept. of Agric Eng. Kaduna Polytechnic,Polytechnic Campus, P.M.B. 2021, KadunaKaduna State.
28. Palm Kernel Cracker Enugu State University of TechnologyIndependent LayoutP.M.B. 01660, Enugu,Enugu State.
Department of Mech. Engineering PTI MainCampusP.M.B. 20, EffurunDelta State.Industrial Institute of Oil Palm Research (NIFOR),NIFOR Main Station,P.M.B. 1080, EnuguEnuau Sate.
142
fI
29. Palm Fruit Digester Project Development Institute (PRODA)3, Independence Layout P.O. Box 609, Enugu,Enugu State
The Polytechnic, Nekede Village, Nekede, Owerri,Imo State
30. Palm Fruit Stripper Project Development Institute (PRODA)3, Independence Layout P.O. Box 609, Enugu,Enugu State
The Polytechnic, Nekede Village, Nekede, Owerri,Imo State
31. Palm Oil Press Project Development Institute (PRODA)3, Independence Layout P.O. Box 609, Enugu,Enugu State
The Polytechnic, Nekede Village, Nekede, Owerri,Imo State
32. Palm Wine Bottling Federal Institute of Industrial Research, OshodiPlant (FIIRO), Cappa Bus Stop,
P.M.B. 21023, IkejaLagos State
Nigerian Institute of Oil Palm Research (NIFOR)NIFOR Main Station,P.M13. 1030, Benin City,Edo State.
33. Palm Kernel Crusher Centre for Industrial Studies (CIS),Federal University of Technology Samek Road,P.M.B. 1526, Owerri,Imo State.
34. Palm Kernel Oil Nigerian Institute of Oil Palm Research (NIFOR)Extractor NIFOR Main Station,
P.M.B. 1030, Benin City,Edo State.
Rural Agro-Industrial Development Scheme(RAIDS)11, University Crescent, Ibadan,Oyo State
35. Palm Kernel Department of Agricultural Engineering, O.A.UDecorticator Campus, lIe-lfe OyO State
36. Palm Fruit Boiler Project Development Institute (PRODA)3, Independence Layout P.O. Box 609, Enugu,Enuqu State
143
37. Hammer Mill Enugu State University of TechnologyIndependent LayoutP.M.B. 01660, Enugu,Enugu State.
Department of Agric., University of Agriculture,PM.B. 2373, Makurdi, Benue State
Dept. of Mechanical Eng. University of Nigeria,Nsukka,Enugu State
I.A.R. & T, Main Plantation,P.M.B. 5029, Ibadan,Oyo State
Project Dev. Institute (PRODJ\)3, Independent Layout, P O. 609, EnuguEnugu State.
The Federal Polytechnic,Ayangba Road,P.M.B. 1037, IdahBenue State.
38. Milling Machine Department of Agric. Eng. Federal Polytechnic,Polytechnic Campus,P.M.B. 55, Bida,Niger State
39. Gritting Flour Milling Plant Department of Food Science and Technologyand Components Nigeria Nsukka, Enugu State.
40. Cowpea Thresher Agric Mech. Section, College of Agric. Universityof Campus ABU,P.M.B.1058Kaduna State
Dept. of Agric. Eng. OAU Campus,lIe-lfe,Dyo State.
41. Multi Crop Thresher Dept. of Agric. Eng. Federal Polytechnic,Polytechnic Campus,P.M.B. 55, BidaNiger State
42. Fruit Juice Extractor Centre for Industrial Studies (CIS), FederalUniversity of Tech. Samet Road, P.M.B. 1526,Dwerri, Imo State
144
•
FederClIM.B '15~(j
!.__._._ .__.. ,~.J
IpU':'>. PTI.
echnoloqy
alll:'~"
-- - -._-------- --.----
Fedmal.M B. 1526.
-.
(RAIDS),yo State
AG,
------- ---III
IIII
,G I
SI't'! (IfiIOfln-~'--~State.
~ ~
43. Fruit Slice Centre for Industrial Studies (CIS),University of Tech. Samet Road, fJOwerri, !mo State ,______0 __
44. Fruit Juice Processing Rural Agro-Industrial Dev. SectanPlant 11, University Crescent, Ibadan, 0
FIIRO, Cappa Bus Stop Oshodi La45. Palm Fruit Stripper Rural Agro-Industrial Dev. Scheme
11, University Crescent Campus,P.M.B. 1058, Zaria,Kaduna.
~--'--
46. Rice Huller Centre for IndLStrial Studies (CIS),University of Tech. Samet Road, POwerri, Imo State
The Federal Polytechnic,Ayangba Road,P.M.B. 1037, IdahBenue State.
47. Sterilizer Chemical Engineering Dept. UNILAkoka, LagosLa~os State.
48. Solar Dryer Department of Agric. Engineering,Federal Polytechnic, Polytechn;c CP. O. Box 231, Bauchi,Bauchi State
Dept. of ~Jlech. Eng. PTI, Main CanEffurun,Delta State. -_.-
49. Solar Cooker Sokoto Energy Research Centre,Usmanu Danfodiyo,University of Campus,P.M.B. 2346, Sokoto,Sokoto State.
Chemical Engineer in9 Dept. UNIL/'Akoka,LagosLa~os State. -- _..,
50. Dryer Dept. of Agric. Eng Unilorin UniverCampus P.M.B. 1515, lIorin, Kwara
Department of Food Science and TNigeria Nsukka, Enugu State.
Dept. of Agric Eng. O.A.U. CampuslIe-lfe, Ova State.
Industrial Centre (I.M.T.) Ltd., IMT Campus Ill,Independent Layout, Enugu, Enugu State.
Project Dev. Institute (PRODA)3, Independent Layout, P. O. 609, EnuguEnuQu State.
51. Forage Chopper Dept. of Agric. Eng. Federal Polytechnic,Polytechnic Campus,P.M.B. 55, BidaNiqer State
52. Locus Bean Decorticator Dept. of Agric. Eng. Unilorin University of 1I0rinCampus P.M.B. 1515, 1I0rin,Kwara State.
53. Grinding Machine Dept. of Agric. Eng., University of Agriculture,P.M.B. 2373 Makurdi, Benue State
54. Soya Beans Thresher Dept. of Agric. Eng., University of Agriculture,P.M.B. 2373 Makurdi, Benue State
55. Soya Beans Sheller Dept. of Agric. Eng., University of Agriculture,P.M.B. 2373 Mak urdi, Benue State
56. Crop Moisture meter Dept. of Eng. University of Nigeria Nsukka, EnuguState.
I.A.R. & T., Moor Plantation,P.M.B. 5029, Ibadan, OyO State.
57. Orange Squeezer Mechanical Eng. Programme, Abubakar TafawaBalewa University Campus,P.M.B. 248, BauchiBauchi State
58. Bitter Leaf processing Oept. of Agric, Eng., University of Nigeria,Machine Nsukka Enugu,
EnuQu State59. Bread Fruit Processing Oept, of Agric. University of Nigeria Nsukka
Machine EnuQu State.60. Sorghum Malting Plant Oept of Food Science & Tech. University of
Nigeria NsukkaEnuqu State.
61. Industrial Fans Oept. of Food Science & Tech. University ofNigeria Nsukka,EnuQu State
62. Mechanical Vibrator Oept. of Mech. Eng. University of AgricultureMakurdi,Benue State.
63. Fruit Juice Filler Press Oept. of Mech. Eng. University of NigeriaNsukkaEnuQu State.
146
64. Yam Four Mill Dept. of Agric. Engineering O. A. U. Campus,lIe-lfe, Oyo State
65. Hand Maize Shellers Dept, of Mech., Eng. University of Ibadan
f--Ibadan Oyo State
66. Biodigester Dept. of Agric. Engineering University of IbadanIbadan Ova State
67. Fermentor Chemical Engineering University ofIbadan,Ibadan, Oyo State
Dept. of Agric Engineering University ofIbadan
1--Ibadan, Oyo State.
68. Maize Mill Federal Inst. of Ind. Research Oshodi(FIIRO),Cappa Bus Stop,
~.
P.M.B 21023, Ikeia, Laqos State.69. Distillation Equipment Federal Inst. of Ind. Research Oshodi (FIIRO)
Cappa Bus Stop,P.M.B. 21023, Ikeja, LaQos State.
70. Benniseed Oil Extractor Federal Inst. of Ind. Research Oshodi, (FIIRO).Plant Cappa Bus Stop.
1-.-PM.B. 21023, Ikeia, LaQos State
71. Sorghum Oil Extracting Federal Inst. of Ind. Research, Oshodi (FIIRO),Plant. Cappa Bus Stop,
PM.B. 21023. Ikeia. LaQos State72. Soyi Ogi Processing Federallnst. of Ind. Research Oshodi (FIIRO),
P~a1t Cappa Bus Stop,i P.IVl B. 21023, Ikeia, Laqos State.
73. Yeast Production Plant Federal Inst. of Ind. Research Oshodi (FIIRO),Cappa Bus Stop,P. M. B, 21023, Ikeia, Laqos State.
74. Fish Dryer Federal Inst. of Ind. Research Oshodi (FIIRO),Cappa Bus Stop,P. M. B, 21023, Ikeja, LaQos State.
75. Meat Smoking Kiln Food Science & Tech. Dept. UNIMAID,University of Maiduguri Campus,Maiduguri,Bornu State.
76. Groundnut Roaster Food Science & Tech, Dept. UNIMAID,University of Maiduguri CampusMaiduguri,Bornu State
77. Coconut Thresher Mechanical Eng. Programme, Abubakar TafawaBalewa University Campus.P. M. B. 248, BauchiBauchi State
147
78. Groundnut Oil Extractor Mechanical Eng. Programme, Abubakar TafawaBalsa University CampusP.M.248, Bauchi,Bauchi State
79. Brown Sugar Processing National Cereals Research Inst. NCR.I premises,P.M.B. 8, Badge, Bida,NiQer State.
80. Soap making Plant Nigeria Inst. of Oil Palm Research (NIFOR),NIFOR Main StationP.M.B. 1030, Benin City,Edo State.
81. Egg Incubator The Polytechnic, Nekede village, Nekede, "Owerri,Imo State
82. Production of Ceramic Project Dev. Inst. (PRODA),Water Filler Elements 3, Independence Layout,and Plastic P.O. Box 609, Enugu
EnuQu State.83. Electricity (NEPA) Lamp, The Centre for Adaptation of Technology
with Automatic Voltage (CAT) 16, Iqweze St,Regulated Sources P.M.B. 5099, Awka,
Anambra State.84. Printed Circuit Boards The Centre for Adaptation of Technology
(PCB) Production (CAT) 16, Iqweze St,P.M.B. 5099, Awka,Anambra State.
85. Solar Water Distillation The Centre for Adaptation of TechnologyPlant (CAT) 16, Iqweze St,
P.M.B. 5099, Awka,Anambra State.
86. Laundry Soap Kit Federal Institute of Industrial Research,Oshodi (FIIRO)Off Cappa Bus-stopP.M.B. 21023, IkejaLagos State.
148
'Annex 11/
Some FoundrylMachine Shops in Nigeria
S/No. Products Name and Address of Local Foundries Shops1. FERROUS AND NON- ADEBOWALE ENGINEERING SERVICES LTD.
FERROUS PRODUCTS Found & METAL Fabrication Div. ::>.0. Box 743.Otta.
2. AJAOKUTA STEEL COY. LTD. P.M.B. 100Ajaokuta. Kogi State
3. ASSOCIATED TECHNOLOGY Ar~D
ENGINEERING LTD. Plot 5/9, Kosebinusi St.OREGUN industrial Estate, 9 Welfare Bus-StopOREGUN.
4. CENTRAL WORKSHOP, Federa; Ministry ofWorks & Housing Ijora-Lagos Phone 01-837788
5. CONTINENTAL FOUNDRY LIMITED, 8, BurdlandStreet, Akiode, off Agege Isheri Road Ikeja-Lagos.
6. MUHAYAK CO. NIG LTD. 116 Oko -Ogun Street,P.O. Box 55, Owo, Ondo State Phone, 051 -41707.NIGERIA FOUNDRY LIMITED, 1 Adeyemi BeroCrescent, lIupeju Industrial, Estate, G.P.O. Box3574, Lagos, Tel. 963266/7,964202.
8. NIGERIA PORT AUTHORITY, 61:28 MarinaP.M.B. 12588, Lagos. Phone, 600620-12.
9. SYSTEMAX FOUNDRIES AND ENGINEERINGWORKDS LIMITED. 7, Adeyemo Close, Oshodi 9,(Off International Airport Road) P. O. Box 2262,Oshodi, Lagos. Phone 963148
10. COKSEE ENGINEERING WORKS LIMITED, AmjeBus-stop Km 34 Agege Otta Expressway, P.O. Box8826, Marina - Lagos, Telex 201'17 (TDS 423)
11. STAR PRECISION FOUNDRIES LTD , EnuguOffice, 2A Colliery Avenue, P. O. Box 1772, G.R.A.Enugu.
Lagos Office, 28 Ademola Street, S, W. Ikoyi.P.0.Box5422,LagosPhone, 01-684346
Factory, Factory Road(Opp. Pac. Breweries)Oko Orumba L.G.AP. O. Box 693AguakaPhone, 946- 911366.
149
12.------,---------------r-- .-- --
LEOS ENGINEERING NORKSFactory, 38 Fedeyi Street,Olowora, IsheriOff Isheri RoadLagos.
Office; 45-51, Kujore StreetOjotaP.O. Box 1266Laqos
13.
14.
15.
BLESON FOUNDRY & ENGINE:ERING WORKSLTD,6, Sanyaolu Street,Via, Owookade Olowora,Isheri-Ikeja,
Postal AddressP. O. Box 23 Unilag Post OfficeAkoka, YabaLagos.POA TECHNICAL WORKS L1M TED2A Babatunde Oduse CrescentOlowora Via IsheriP.O. Box 4626Marina - LagosPhone: 847309PREVISION FOUNDRY INDUS fRYP.O Box 30~IO
Apapa,Lagos.
16.
Workshop Address:5, Orile Isaka StreetOpp. Shelter (Abestors)Sango Ota, Ogun State.FOUNDRY & METALLURGICAL RESEARCH &DEVELOPMENT UNIT,Federal Institute of Industrial Research,Oshodi (FIIRO)Off Cappa Bus-stopP.M.B. 21023,Ikeja - LagosPhone 522760_ •.••._. L,. ...L..:-...:..;_:..:...=.-~"_'__"_'__ __'
150
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17. OGUNDIPE FOUNDRY NIG. ENT.18, Agbe Road,Off Santos Avenue,Abule - EgbaLagos.
B. LIGHT ALLOY JIMEX INDUSTRIESPRODUCTS Head Office, Umuanuka Village, Otolo
P.M.B. 5005, Nnewi, Anambra SateTelex: Jimex NnewiPhone: 046-460928
Branch: 21, Seinde- Callistro Crescent, OshodiOff Oshodi - Apapa Express way, Lagos.
C. PATTERN MAKERS LEOS ENGINEERING WORKSFactory:38, Fadeyi Street,Olowora,lsheriOff Isheri RoadLagos.
Office: 45-51, Kujore StreetOjotaP.O. Box 1266Lagos.
D. FOUNDRY AGRO MASTERS NIG. LTD.28 Church Street,2nd Floor IdumotaLagos.Phone 660277, 664723
E. FOREIGN SUPPLIERS CAPITAL REFRACTORIES LIMITEDOF FOUNDRY Station Road, Clowne, Derbyshire, U.K.EQUIPMENT
GEMCO ENGINEERING B.V.Science Parck Endhoven 50535692 SONThe NetherlandsTel: 31 .40 643643Fax: 31.40.643640Telex: 59388 Gemco nl.
FOUNDRY &TECHNICAL L1ASON LIMITED6-11 Riley Street, WillemhallWest Midlands, WV 131 RHTel: 0902 630222Fax: 0902 636593.
151
INDUCTHOTHERM EUROPE LTD.The Furlong, Berry Hill,Droitwich WR9 9AH, U.KTel: 0905 795100Fax: 0905 795138Telex: 339813
COOPERHEAT (UK) LIMITEDFylde Road Trading Estate,Southport, PR9 9YF, U.K.,Tel: 0704213311Fax: 070425800 ,i
Tel: 67417 CHSPRT G. I~_--L ....L--~~__~~~~ ~ J
152
ANNEX IV:
SOME INDUSTRIES AND THEIR FOUNDRY PRODUCTS REQUIREMENT
INDUSTRY TYPE OF CASTINGS REQUIREDCEMENT INDUSTRIES Step Liners, Manhole coves and frame, Collier
IGrate plate, impellers, Joint-PiE:ces (Clinkerconveyor and pot packet) machine spares, MediaBalls, etc.
TEXTILE INDUSTRY Pulley, Gears Reed frames,Spinning mules, Spindle rails,
ISpinning drive cylinders,
I Sewing parts, tricot beans, etc.MANUFACTURERS OF Electric iron base, dish washer housing, FoodCUSTOMER mixer housings, lawn mover housing RefrigeratorDURABLES and freezer evaporators, stove and gas cooker
parts ceiling & table fan part etc.AUTOMOTIVE Crank shafts, Gears Pinions,INDUSTRY Rollers, slides, steering
Knuckles, Disk-brake clippersRocker arms, Brake drums Carburettor bodies,Connecting rods, Pistons, Fuel Pumps Intakemanifolds, Master cylinder body, Master cylinderpistons, Transmission housings, Valve rocketarms, Water pump bodies, Cylilder heads,Flywheel housings, Axle housings, Crank-cases,Spring brackets, Engine Block, Cylinder Head, etc.
METAL tJRESS Bolsters, Punch plates, rings, press plates, RamINDUSTRY body, etc.TOOL INDUSTRY Housing for power drills,
Butting machines Power shears,Hydro press form blocks,Hydro stretch from dies, JigsAnd fixtures, Machine & table vices, etc.
SHIP BUILDING Pumps, Housing Gears ValveBodies, Propellers, CylindersEngine blocks, Blower housing water jackets,Pistons pulleys, shavers, gener ator housing etc.
FURNITURE Door locks, Base for ChairsINDUSTRY (Rotating)BUILDING & ROAD Manhole covers, Grate, Pipe
I CONSTRUCTION Fitting, Valves Street lamp housings, DoorI INDUSTRY hangers, etc.
ARCH ITECTURAL Ornamental hardware,DESIGNERS Architectural fittinqs etc.
153
MINING, QUARRYING, These castings require alloying resulting in highAND CEMENT chromium and nickel chrome iron casting ballMANUFACTURING Milling Liners, Rool Crusher Sleeves, Dredge
pump liners, Grinding balls, Conveyor castings, etcCERAMIC AND Wearing parts for clay mixer, extrusion press diesREFRACTORY and impellers, ceramic press arm stone polishingINDUSTRY spiral, Dies for tiles and bricks etc.TEXTILE MACHINERY Small machine beds, machine tool parts, Small millAND MACHINE TOOLS rolls, Metal forming, dies, etc.AGRICULTURAL Parts for mower ploughs and equipment, CornEQUIPMENT &AGRO- Mills parts & platters, oil expeller parts, WaterALLIED Pumps, hand pumps (Bore Well & for Oils) agric.
Diesel engine parts, etc)RAILWAY EQUIPMENT Brake shoes, Grating and Stroker part, etc.ELECTRICAL Motor frames and heads, Refrigerator compressorEQUIPMENT parts, part for power lines, cast resistor grids,
Electric meter base, Change-Over switch bodies,Gear switch bodies, Glands (ducting) etc.
GENERAL Dead weights weighing machine part, mooringanchors, conveyor parts plumber blocks, BearingLaboratory stands for schools, etc.
Mr. I. M. Nwaedozie's paper was presented during the UNESCO-NASENIRoundtable discussion on Promotion of Best Practices in MechanicalEngineering for Job Creation, Scientific Equipment Development Institute(SEDI), Tagwai Dam Road, Chanchanga, Minna, Niger State Thursday, 6th
November, 2003.
154
•
ANNEXURE
155
SUMMARY REPORT OF THE ONE DAY TABLE DISCUSSION ON BESTPRACTICES IN MECHANICAL AND AGRICULTURAL ENGINEERING FOR JOBCREATION ORGANISED BY UNESCO IN COLLABORATION WITH NASENI ON10TH DECEMBER 2002.
1. The One-day Round Table discussion on the promotion 0 f "Best Practices in
Mechanical and Agricultural Engineering for Job Creation!} organised by
the United Nations Education Scientific and Cultural Organisation (UNESCO)
in collaboration with National Agency for Science and Engineering
Infrastructure (NASENI) took place on the 10th December 2002, at the
Conference Room of NASENI Headquarters, Idu Industrial Area, Abuja.
2. The Conference was declared open by the Honourable Minister of science and
Technology Prof. Turner 1. Isoun and it attracted a total of 49 participants from
Universities, Polytechnics, Federal IlIlinistries, Research Institutes,
Development Centres private sectors, UNESCO and NASENI. The list of
participants is attached as Annex 1.
3. The Opening Ceremony was chaired by Prof. TT lsoun and a good will
message delivered by UNESCO. The Honourable Minister for State for
Science and Technology Mr .. P.. fallen, ably represented by Dr. Sunday
Wuyep, co-chaired the technical Session with Directorate/Representative,
UNESCO, Mr. Hubert Charles. Or. Wuye p gave closing remarks.
4. A lead paper was delivered by Dr. O.J. Mbonu, Director Customer Services,
Nigerian Breweries Plc; while three other papers were presented as follows:
Practical Engineering Training for Nigeria:- Dr. O.J. Mbonu, Case Studies in
the Brewing and Oil Nigeria Breweries Plc. Breweries Exploration Industry
(Lead Paper).
156
•
(i) Packing of Feasibility Studies, Engr. A. Ojobo, Er gfneering and
Manufacturing Consultant.
(ii) Diffusion of Appropriate Technology in Food Proces~ Ing, Dr. (Mrs)
Halos-Kim IITA, Ibadan.
(iii) Fabrication Techni~; 'es, Engr. B. Oyeniyi, Nova Technolcgies.
MAJOR OBSERVATIONS
5. The papers were exhaustively discussed. Some major observations made by the
participants are as follows:
(i) The education quality of Mechanical and Agricultural engineering
graduates from institutions in the country is very low.
(ii) Fresh graduates are deficient in basic engineering skills and practices and
key the ability to correctly, read and interpret engineering drawing and
designs.
(iii) Most graduates do not possess the entrepreneur capability to start
engineerir.;} cntmp;·,s,:::.... c.cn:::oquently they tend to be seel<ers rather than
creators of jobs.
(iv) Most graduates are not sufficiently professionally equipped to be absorbed
by production industries or factories without retraining.
(v) tn spite of abundantly opportunities in the country, most graduates are no;
able to generate employment within their immediate environment: rather
they migrate to cities for white collar jobs.
(vi) liBere need to introduce polic ies that will provide for hands-on
practical experience for both lecturers and undergraduates in OUr
institutions
(Vii) Most graduates are not equipped to package bankable feasibility studie~~
that will enable them establish viable enterprises.
15'
158
(viii) There is virtually no relationship eXistihg between generators of new
technologies and engineering undergraduates; and
(ix) There are serious g.aps that exist between industrial requirement for fresh
engineering graduates and academic specifications for these'graduates,
RECOMMENDATIONS:
The following recommendations were made at the end of the, Round Table'
Discussion:-
(i) There is need to conduct this kind of disoussions. to cover other areas of
engineering endeavours from time to time;
(ii) There is urgent need to review and develop a curriculum to take account of
the deficiencies identified in this meeting to enable the nation's tertiary
institutions to produce engineering graduates who are practically oriented
who can either immediately fit into existing industries or are able to
establish viable enterprises of their own.
(iii) Noting that Nigeria is currently loosing between USD 3-4 billion annually as
a result of shortage of adequately skilled technicians and craftsmen, it is
recommended that, as early.as the beginning of next year, a si milar Round
Table Discussion should be organised to identify the problems in his area
and recommend remedial actions.
(iv) The meeting was highly impressed with the cooperation between NASENI
and UNESCO and applauded the assistance which UNESCO gave to
NASENI and recommended a future stronger mutual fruitful relationship.
(v) Agriculture has a critical role to play in the overall development of the
country, and consequently for job creation. Mechanical and agricultural
engineering curricula must be made to be more practically oriented in order
to meet this need,
(vi) Nigeria needs to face most serious the challenge of producing world class
engineering graduates in terms of the academic programmes, practical
training oriented and provision of adequate facilities.
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(vii) There is a need for a more effective programme of dispersion of
technological innovations and machineries produced in the nation's
Research and Technological Organisations ( RTO's)
(viii) There is a need to initiate a national programme for effective engineering
extension services to the pUblic.
(ix) There is a need to improve on the quality control of fabrication products
and after sales serv.ice by local producers.
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UNESCO-NASENI ROUND TABLE DISCUSSION ON THE PROMOTION OF BEST PRACTICES IN MECHANICAL
AND AGRICULTURAL ENGINEERING FOR JOB CREATION 10TH DECEMBER, 2002.
PARTICIPANTS REGISTRATION
08037876059 I
IliA, Ibadan I 234-2-2417676NSPRlllorin
Fed. University of Tech.Minna
Fed. University of Tech.Minna
NASENI
NEDDEC NASENI Nnewi 1046-463539
!d~m"7i"i:- - -- - -
ResearchSpecialist
Ag. Director
Sub-DeanS.E.E.T.
Dean S.E.E.T
Deputy Director
Centre ManagerNEDDEC NNewi
1. I Usman Ali!uL. I ~Iomon Nshem.1. A Maduekwe4. Gbashah E.M5~ G.Akpeluo. IO.J. Mbonu7. IDr. A.O. Ohakwe
B. IUr. Frank Obi
~. Mr. Aniebone Victor
10. Udechukwu Fred N.
11. N.A. Ezeife
12. Abdulmalik 0.1.
13. Prof. EO.Akinbode
14. I Engr. B.A.Alabadan
15. N.t.Okoye16. L.S. Halos-Kim
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17. Engr. AE Ojobo MD Cast Provs Ltd Benin. 08023068236 [email protected]
18. Bankole Oyeniyi MD Nova Technologies Ibadan 08023450655 [email protected]
19. Mrs Emenose G.A CEO (Audit) NASENI20. Alh. K.O.A Olatunji DD (APXP) NASENI21. Anum Isaac Scientific Officer FMST22. Engr. Ken Ibe S.C.E. HEDI- Kano23. Mr. S.B.A CAO (Tsw) NASENI
Abdulraheem24. Mrs. W.O.Muss CEA(NC) NASENI25. I.M.Obibuzor DD.(P) NASENI, Abuja. 5235161,269826. V.M. Ibigbam AD (TAA) Fi\':ST 08042147048 [email protected]. Ndudim E. SNR. NASENI
IAccountancy -28. Obiaqa AU. Student FUr Minna i 09-4131058 [email protected]
,29. A.K. Hassan HOD MF HEDI- Kano I 064667589J8033114225
30. Engr. N.M. Junaid Dean Sch. Of Fed. Poly Nasarawa 09-3142037 [email protected]. 047-66707
31. Ifeanyi Enedu Student FUT Minna 01-4131058 [email protected]. Habibu Mejie Ag. Director HEDI HEDI Kano 08033113112
Kano33. Engr.M.N. Mahmood Director SEDI- Minna 066-224907
34. Mr. J.B. Habu ACSO NASENIHQS 09-5212475 [email protected]. Prof. E.I.E. Ofodile Reqistrar COREN, Abuja 413889136. Chikas Ohadoma Journalist THISDAY 08033031436 [email protected]
37. S.B.Suliaman P/Ub NASENI38. H.J. Charles Director UNESCO 09-5237088 Hj [email protected]. L. Fabusuyi Head Protocol NASENI40. Dr. 1.1. Nnadi Director/CE SEDI- Minna
! (l I
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41. Ekaro C.C. Chief Admin. NASENIOfficer
43. E.M.Onwubuya Head of Admin. SEDI- Enugu 042-459495,455040
44. Engr. O.A. Kayode Deputy Director Fed. Min. of Ind. Garki 2340259Abuja Fax 2341319
0803348994545. Dr. S.N Wuyep SA- FMSr FMST 5235204 wuyepsn@hotmail
.com46. Prof. C.O. Adegoke Dean Engineering FUr Akure I Coadegoke2002@
I yahoo.co.uk47. Okonkwo Chizoba M . Journalist Abuja Today 3141483, IChizoba2001@
3211604 Yahoo.com48. Adora Okonkwo Journalist Dal"iy Independent Abuja 5237665 adoraok@yahoo.
08033209522 corn49. Hassan Idris Journalist Daily Trust, Abuja I 5235787 hassanitc@yahoo.
I corn
162
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WELCOME ADDRESS PRESENTED BY THE DIRECTOR GENERAL/CHIEFEXECUTIVE OF NASENI, PROF. 0.0. ADEWOYE AT THE 2 NO NASENI-UNESCONBTE ROUND TABLE DISCUSSION ON TRAINING WORKSHOP ON MACHININGFOR SELECTED TERTIARY IN GRADUATES AND LECTURERS, AT SEDI,MINNA, ON NOVEMBER 6TH, 2003.
Hon Ministers, (HMST, HME, HMI, HM Labour)
Director/Representative of UNESCO Office, Abuja,
Directors and Chief Executives
Distinguished Ladies and Gentle men
It my pleasure and privilege to welcome you to the nd Training Workshop for
graduates & Lecturers of tertiary Institutions involved with engineering and
Technology education in Nigeria. Training workshop aims at promoting the best
practices in Engineering and Technology.
I want to recall that the first Round Table Discussion on best Practices was held in
NASENI Headquarters, Idu, Abuja, on 10th December 2002.
The Discussion at that meeting focused on "Best Practices in Mechanical
Engineering for Job Creation". This guided the selection of the lead that shared their
experiences with Participants. At thal meeting, the lead paper treated, Practical
Engineering Training for Nigeria: case studies in the brewing and oil exploration
Industries. Three other Presents shared Experiences in:
• Packing of feasibility studies.
• Diffusion of appropriate Technology in food processions; a nd
• Fabrication Technologies
The experiences highlighted in the aforementioned papers and the exhaustive
discussion that followed brought to the fore the magnitude of the confronting the
young engineers, the educational Institutions offering mechanical eng ineering outfits
and the employers of labour. The meeting thereafter made a number of
163
recommendations including the need to conduct similar discussions to cover other
areas of engineering endeavours from time to time. That explains the organizations
of this 2nd round Table Discussion on Machining for selected Polytechnic graduates
and Lecturers.
This workshop will provide opportunity for graduates and lecturers to share
experiences. on selected topics on the current best practices in machining as it
constitutes an important and critical aspect of effective manufacturing and production
of machine and parts for sustainable job creation.
It is to be noted that the main round table discussion is to develop materials which
will enhance the skill and knowledge of fresh graduates of tertiary institutions to
prepare them for ready employment by industries and for self-employment. The
report of the workshop would be made availabh:-;for curriculum development for
tertiary technical institutions in Nigeria.
You will please permit me to acknowledge the fruitful and immense support that
UNESCO had given to this project and to other projects of the Ministry of Science
and Technology in general and to NASENI in particular. We salute UNESCO through
its able Director Mr. Hubert Charles. 0 National Board for Technical Education
(NBTE) that considers this project very important, relevant and timely for the
empowerment of the Polytechnics. We express our sincere appreciation and look to
many years of mutually beneficial collaboration to the benefits of our fatherland and
Glory of God.
I wish to thank the Honourable Ministers of Education, Industries and Labour,
Stakeholders in this enterprise, we are immensely grateful for your show of solidarity.
I cannot overlook the un-wavering support provided by the Director/Chief Executive
of Scientific Equipment development Institute, Minna (SEDI-M). Although he is a
member of the NASENI family, I should like to recognise his visibility at this workshop.
164
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I also welcome Engineer I. M. Nwaedozie from NOTAP, a sister Parastatal of the
FMST who will give the keynote address.
I cannot sufficiently thank my Honourable Minister for his understanding, prompt
response, and fatherly guide and for his patience. The fruits of this exercise and other
noble bold initiatives he had taken would bear testimony to vision and hard-work.
I welcome you all to this worship and I thank you for your attention.
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1.
GOODWILL MESSAGE BY THE HONOURABLE MINISTER FOR SCIENCE ANDTECHNOLOG~ PROFESSOR TURNER ~ ISOUN AT THE ROUNDTABLEDISCUSSION ON BEST PRACTICES IN ENGINEERING FOR JOB CREATION:MACHINING, NOVEMBER 6TH
, 2003, AT MINNA NIGER STATE
It is my pleasure to welcome you all this morning to thi"s unique Round
Table Discussion on Promotion of Best Engineering Practices for Job
Creation. Since independence various steps have been taken· to move
Nigeria from the status of a developing nation to one that is industrialized.
These steps have included policy and economic measures as well as
development plans. The debate about how this can be done is ceaseless
and on-going. This led to the recommendation for the adoption of a
national policy for the development of a viable science and engineering
infrastructure base. This recommendation came from a 150-member
Committee made up of engineers, sck:l lusts, economists, bankers and
other professionals, drawn from Federal Ministries, State Governments, the
organised private sectors, various institutions of higher learning and
Research Institutes.
2. The need to have an institutional arrangement for the development of such
a viable science and engineering infrastructure base thus became more
compelling to move the i\ligerian economy forward. The federal
Government promulgated Decree 33 of 1992 to establish the national
Agency for Science Engineering Infrastructure (NASENI). Essentially,
NASENI was created to provide basic engineering infrastructure that will
invigorate technology-based nationai wealth and well-being through home
initiated and home-sustained industrialization processes achievable
through local machine design and machine building capabilities, resulting
in the general provision of capital goods and equipment that would
enhance the proliferation of viable small and medium enterprises.
3. In pursuance of this objective the Agency has embarked on a number of
programmes and projects. This Round Table Discussion, the second of its
type in the series, is yet one of the measures adopted by the Agency to
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4.
5.
6.
boost the manpower capability of the nation in a short term and create job
for our teeming youth. I must commend the Agency's effort in this direction
as well as in its effort to overcome the unique challenge it faces in the
execution of its mandate on the provision of Science and Engineering in
the country. It is now common knowledge that the world is a global village
driven by a knowledge based economy. In spite of our abundant natural
resources we must do everything to place ourselves in a vantage position
within the global economic tide. It is therefore, necessary to quickly evolve
and continuously maintain a large pool of well-trained human resources to
manage and drive our economy to be competitive in the global village.
More so, now that emphasis is placed on competitive advantage as against
the old tradition comparative advantage. I once more commend the
organizers and urge them to explore more avenues and deploy more
methods of training our graduates so as to give them the competitive edge.
I also wish to cease this opportunity to thank UNESCO for considering if
worthwhile to partner with us, not only on this project but in so many other
fronts. I hope your investment in this direction would yield great dividend.
My appreciation also goes to NBTE, NUC and all other stakeholders
including the participants for taking advantage of this unique opportunity to
expand our knOWledge ba~e. I also urge and solicit your continuous
support and joint collaboration with my ministry in our quest to provide a
better future for our youth.
In conclusion, I wish you fruitful discussion as you brainstorm on one of the
important arrears in machine and component production Le. machining. I
pray that at the end of the day we shall reach mutual accord on best
practices applicable for job creation and self-sustenance.
Thank you and God bless.
167
COMMUNIQUE NASENI·UNESCO ROUND TABLE DISCUSSION ON TRAININGWORKSHOP ON MACHINING FOR SELECTED POLYTECHNIC GRADUATESAND LECTURERS, NOVEMBER 6TH, 2004.
1.
2.
3.
4.
5.
6.
7.
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The one-day Round Table Discussion on the Training Workshop on
Machining for selected Polytechnic Graduates and Lecturers organised by
the National Agency for Science and Engineering Infrastructure (NASENI)
in collaboration with the United Nations Educational, Scientific and Cultural
Organisation (UNESCO) took place on the 6h November, 2003 at the
Scientific Equipment Development Institute (SEDI) Minna, Niger State.
The conference was declared opened by the Honourable Minister of
Science and Technology Prof. 0.0. Adewoye and it attracted a total No. of
78 participants from Polytechnics, Universities, Federal Ministries,
Research Institutes, Development Centres, Private Sectors, UNESCO,
NASENI and the National Board for Tech'1ical Education (NBTE).
The Opening Ceremony was chaired by the D-G, NASENI and goodwill
messages were delivered by The Honourable Minister of Science and
Technology represented by the D-G NASENI and Director/Representative
of UNESCO Mr. Hubert Charles, respectively.
Engr. M.N. Mahmood Director/Chief Executive of SEDI Minna delivered the
welcome Address on behalf of O-G, NASENI.
The Keynote Address was presented by Engr. I .M. Nwaedozie of
(NOTAP), while the technical paper titled "Machining" was presented by
Engr. Madu A. Yatetengi of Kemaben Industries Nigerian Limited, Kaduna.
The tour of exhibition of machines/products displayed by the private
sectors and workshop demonstration was headed by Engr. Madu A.
Yatetengi. He explained the uses of the different types of machines in the
workshop to the participants.
Mr. S.B.A. Abdul-Raheem on behalf of NASENI expressed the Agency's
sincere appreciation to UNESCO for collaborating with NASENI, the HMST.
NBTE. Engr. I.M. Nwaedozie- the keynote presenter, Engr. Madu A.
Yatetengi for presenting the technical paper and all other stake holders
•
•
(iv)
(v)
'I'
(vi)
(vii)
(viii)
(ix)
(x)
(xi)
(xii)
c
including the participants that attended th8 ~kshop and solicited their
continuous support and joint collaboration with the Agency in its future
activities.
MAJOR OBSERVATIONS
The papers were exhaustively discussed. Some major observations made by the
participants are as follows:
(i) There is a general believe that almost all graduates depend on the
government to secure jobs, unfortunately the jobs are scarce.
(ii) Government investment are under utilized
(iii) The people's conception, generally of inferiority of local products,
discourages potential investor am retard progress.
There is general shortage of engineering materials in the country.
Producers of local materials are negligence of design for product
attractiveness and finishing principles to encourage patronage.
Scarcity and high cost of hand/machine bols discourages graduates or
otherwise to establish machine shop enterprises.
Graduates of tertiary institution across the country are not competent
enough to establish machine enterprises.
Lack of infrastructure e.g. roads, Power supply; machine etc. militates
against the growth of machining shops in the country.
Absence of relevant government policies to encourage individuals to set up
machining enterprises.
There is general absence of relevant public statements.
fiieneral lack of information of the need f consumers of engineering
products.
Machining has helped many Nigerian Engineering graduates to take self
employment.
169
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(xiii) Most government Machining shops are handicapped e.9 no adequ.:lh;
funding, lack of equipment Replacement and poor Remuneration of the
employees.
(xiv) Lack of sufficient and efficient engineering laboratories in most Nigerian
tertiary institutions.
RECOMMENDATIONS
(i) Institutions should start adopting the unconventional machining process to
update graduates.
(ii) Graduates should be re-oriented by those concerned to change focus and
establish enterprises rather than depending solely on government jobs.
(iii) Government agencies like NASENI should improve capacity utilization in
order to raise employment opportunities.
(iv) Training of engineering students in tertiary institutions should dwell more
on practical aspects to improve graduates skills and competence in
Engineering practices.
(v) Federal and State Government and their agencies should formulate
supportive for establishment of machining enterprises.
(vi) GovernmenUagencies etc should develop relevant infrastructure to aid e.g.
accessibility and delivery of Engineering products and services.
(vii) Engineering agencies and enterprises should improve design and finishing
of products to encourage patronage.
(viii) Marking strategies and trademarks of products by producers should be
improved.
(ix) Interaction between consumers and producers of products should be
formalised
(x) Research into the identification of raw materials should be undertaken on
behalf of enterprises.
•
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(xi)
(xii)
(xiii)
(xiv)
(xv)
(xvi)
(xvii)
(xviii)
(xix)
(xx)
Research into the identification of raw materials for engireering products
should be encouraged. A central equipment and materia's research and
testing to be established.
NASENI should emphasize training of young Nigerian graduates Engineers
and technicians. This will make them self-employed and create jobs for
others and alleviate poverty among Nigerians
Agencies to be encouraged to organize training workshops
Engineering drawing to be encouraged at the School level
Nigerian Society of Engineers should work more closely with schools.
Young people that leave schools should be part of the Association.
Government should increase funding of education and Resources provided
must be used efficiently and transparently.
Technical/Engineering education should be encouraged.
The engineeri ng and technical graduates should be encouraged by way of
remuneration in the government sector this will in no smal! way boosts the
moral of the graduates.
Further training activities should be follow-up by UNESCO/NASENI
collaboration.
]7 j
NASENI - UNESCO ROUND TABLE DISCUSSION ON TRAINING WORKSHOP ON MACHINING FOR SELECTEDPOLYTECHNIC GRADUATES AND LECTURERS NOVEMBER 6 TH, 2003.
PARTICIPANTS .REGISTRATION
1. I Igwe ,Agwu Dean of University of Agric. I (044) 531355Gabriel Engineering Makurdi
2. A.S. Adegoke Director NASENI, Idu, Abuja (09) 521247415 [email protected]. Usman Aliro FSTC Abuja (080)44110694 [email protected]. Olunlade, B.A. Ag Dir. EMDI, Akure (034)244929 [email protected]
[email protected]. I Suleiman Moh'm IProgramme I MBTE-Kaduna I (080)44127629 I smJ'[email protected]
Yusuf Officer(mech)
6. 1Uno Uno Reporter FUT Minna7. I Ibrahim Y. H.OD. Manufac. I HEDI Kino I (080)35875851
Tokarawa &Tech. Service.8. Nwaedozie I.M. NOTAPAbuja (080)235037429. H.J Charles Director UNESCO Abuia 523809410. G. Akpelu Librarian UNESCO Abuja 523708811. M. Udoh D.Mech. UNESCO Abuja 523708812. Hussani H. HOD Tech. TBIC TBIC Minna (066)220403
Umbugala Minna13. I MA Masin Assistant Chief ISEDI Minna ·~(66)
Technology 224907,(080)36011081
14. I Engr. Ahmed A. IDir. Sch. Of Engr. IFed. Poly. I(063)60452,Lugard Technology P.M.B.1012 Kaura 60315
Namoda ZamfaraState.
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16. Ndagi Abdulmalik Centre Manager TBIC Minna (066)222816220403
17. Wakindi Ambrose Centre Manager TBIC B/Kebbi (068)32147018. J.G.Ocheje Admin. CO.ord. SEDIMx (066)22465719. Engr. Umaru Sani- Rector Fed. Poly Bida (066)461609 [email protected]
AnQo20. Alfred Paul E.O.(Acct) TBIC Minna (066)22040321. Jumai Audu Scientific TBIC Minna (080)23858418 [email protected]. Zachariah Tukura HOD TBIC Minna (066)220403
Commerc)23. Afolayan J.A. Hod(Engr.) SEDIMx [email protected]. Dr.O.N. HOD, Mech.Engr Fed.Univ. of Te ch. (083)233434 [email protected]
Oguoma FUTO PMB15260werri25. S.B.A. Abdul- Deputy Director NASENI HQ. Abuja (080)44182776
Raheem26. Babalola O.M. PAlDG NASENI NASENI HQ. Abuja (080)3473011427. Ladipo Fabusuyi Head of Protocol NASENI HQ. Abuja
NASENI28. Kazeem M.A State Co- Fed. Min. of Industry (080)33506322
ordinator Minna29. Opaluwa J. Industrial Officer
Minna Fed. Min. of Industry (080)33506322Minna
30. Ebhota S. Williams Mech. NEDDEC Nnewi (080(34005094 Willymoon2001 @yahoo.comEngr.Grade 11
31. Engr. N.O. HOD Mech. Engr. Kaduna Poly (062)411380 [email protected]
32. M.A Dawaki Design& SEDI MinnaPlanning Officer
33. Solomon Jonathan P.A SEDI Minna34. Fidelis Yunusa Tech. Assistant. SEDI Minna35. Yahaya N. Dirsu Snr. Tech SEDI Minna
Assistant _.
173
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36. Bawa J. Paiko Snr. Tech. SEDI f\1lnnaAssistant
37. Amos Bature JUQu Assistant Clerk SEDI Minna38 Eromi Samuel B. Student FU1. Minna39. Alhassan N.E. Snr. Tech .1 1 SEDI Minna
Usman40. Omazo E. Asuo Snr Store Keeper SEDI Minna41. Albert G. Muakpo Snr. Tech. SEDI Minna
AssistantMaintenance
42. Nasiru A.G Salilu Assistant Tech SEDI MinnaOfficer
43. Taunid Abdullahi Tech/ SEDI MinnaAssistant.
44. Aisheru Ndayako Snr. Tech. SEDI MinnaAssistant.
45. Usman 1. Salilu Tech Assistant SEDI Minna46. Ayodeji OQunsiwa Tech Assistant SEDI Minna47. Awwal Ibrahim Snr. Tech SEDI Minna
Assistant48. Adamu Isreli K. Tech. Assistant SEDI Minna49. G.O. Jimoh Principal Trade Fed. Ministry of
TTC Labour50. Baba Ndagi Office Assistant SEDI Minna51. Eji Ochoche Snr. Tech. SEDI Minna i
Assistant52. Sunday Ohiye Snr. Tech. SEDI Minna
Assistant53. Isaa A.O. Snr Tech. SEDI Minna
Assistant54. Mohin Abubaka Messenger SEDI Minna55. Mohammed Ndace E.O (Acct) SEDI Minna
174
.".
56. Maria S.T.A. SEDI MinnaUgbah
57. Hadiza Umaru TechnolOQY SEDI Minna58. Fagi Usman Typist SEDI Minna59. Raman A. S.T.A. SEDI Minna
Abubakar60. Tukur Usman PlTech SEDI Minna61. Yunusa Musa Marson SEDI Minna62. Musa Alfa W/shop Attendant SEDI Minna (062)22182563. Abubakar B. Nana S.T.A SEDI Minna64. Abubakar E.O.(Acct) SEDI Minna
Abdul.rham, 135. Ayedoqbon Dayo Craft-Man SEDI Minna
66. Aliyu Siyi W/A SEDI Minna67. Ali B. Mohd Store Asst. SEDI Minna68. Oparaku G.A Principal SEDI Minna
Technologist69. Nimdom Zitta Marketing Officer SEDI Minna70. M.A. Nassarawa Principal Tech. SEDI Mx (066)224472
Quality Control71. Tiyon Ebbu S.T.A SEDI Minna72. Danladi Mathew S.T.A SEDI Minna73. Abdullahi Mayali Assistant Quality SEDI Minna
Control Officer74. Engr. M.N. Director/Chief SEDI Minna (066)224907,
Mahmmod Executive (080)370221675. Abubakar Kabir P.E.O Tech. Min. of Science &
Muh'd Tech Edu. HQSokoto
76. M.A Shaba HOD (P&T.S) SEDI Minna (066)22490777. A.A Ibekwe PPO NASENI Abuja 523964978. S.B. Sulaiman PPO NASENI Abuia 523964979. . Prof. 0.0 Adewoyi DG/CE NASENI NASENI Abuja 5212474 [email protected]. Melarin L Chief Typist NASENI Abuia 5239649
175
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--- ~' 81. Mrs Ekaro C.C. Chief Admin NASENI AbuJa- 5239649,Officer 5212475
82.. Mrs G.I Adams Deputy Director NASENI Abuja 5239649, [email protected], 5212475
83. •Engr D.A Daw8!<i OAF NASENI Ablljrt 521247584. Mr. N.P.Pawa ACSO(E) NASENI Abuja 521247585. Mrs N. Onyechi CSO (E) NASENI Abuja 521247586. Mrs W.O. Muse CSO(F&A) NASENI Abuia 5239649
176
