FACULTY OF PHYSICAL SCIENCE
A TECHNICAL REPORT ON STUDENT INDUSTRIAL
WOR EXPERIENCE SCHEME (SIWES)
DONE AT
SILVER EAGLES COSMETICS AND CHEMICAL CO.
LTD.
ABA, ABIA STATE
DEPARTMENT OF INDUSTRIAL
MATHEMATICS AND APPLIED STATISTICS
TABLE
OF CONTENTS
Title page
Dedication
Acknowledgments Table of contents
CHAPTER ONE
1.0
Introduction to SIWES Programme
1.1 Aim and Objective of SIWES
CHAPTER TWO
2.0 Company
Profile
2.1 Aims
and Objectives of Silver Eagles
Cosmetics
CO. LTD
CHAPTER THREE
3.0 The Raw Materials Used In Soap Making
3.1 Soap Making Processes
3.2 Measuring and Gauging of Raw
Materials by Silver
Eagles Cosmetics Standard of Production
3.3 Mixing and testing of the Raw Materials
3.4 Soap Cooking/Boiling
3.5 Processing of the Soap
CHAPTER
FOUR
4.0
Application of Mathematics In Soup Making
4.1 Some of
the Relationship and Application of Mathematics
In The
Packing Unit
4.2
My Suggestion of
A Possible Solution To The Challenge of The Industry
4.3 The
Relevance of Mathematics In Soap Making
4.4 The diagram of the cooking Pot/Boiling Kettle
4.5 The diagram of the first Grinding Machine
4.6 The
diagram of the second Grinding Machine Which is also used for Molding
CHAPTER FIVE
5.0 Summary
5.1 Recommendation
5.2 Conclusion
CHAPTER ONE
1.0 INTRODUCTION
TO SIWES PROGRAMME
SIWES programme is a skill training programme that is
widely accepted nationally across the country. It is designed to expose the
undergraduates to the use of technology and how to function in their various
fields of life. It is a bridge between the major theory and the practical
aspect of skills. This scheme is a tripartite programme involving students,
university and the industry. These schemes are to be funded by federal
government of Nigeria and coordinated by the industrial training fund and
National University Commission (NUC).
1.1 AIM AND OBJECTIVE OF SIWES
SIWES is aimed at providing skills for students in
their various fields. Some of the various objectives why the program was put in
place are.
1. To
give the Nigerian student acquired skills industrially to perform in their
field of study.
2. To
enlighten, the students on how to use machinery heavy equipment available in
the universities.
3. To
give them the knowledge of what they are likely to face in their fields in
future.
4. It
enhances job transaction within the universities and its environs.
5. It
strengthens employers to participate in the educational process.
6. To
provide students with ample opportunities to apply the theoretical knowledge in
real work situation.
7. To
provide an opportunity for students in Nigeria Universities to get acquainted
with Industrial Skills and experience in their course of study.
8. To
make the transition from the university to the labour market easier and as well
enhance students contacts for later job.
9. To
prepare students for the work situation they are likely to meet after
graduation.
Silver Eagles Cosmetics And
Chemical Co. Ltd is located at
Aba, in Abia State.
It is headed by Mr. Jude O. Okike who is the director
and manager of the establishment. The company has 24 staff with two assistant managers
inclusive working as staff directors.
The size of the company would be approximately double
the size of FANS Hall. It is made up of the following units.
The production unit, called the Kitchen, in charge of
cooking the soap. The processing unit in charge of filtering, grinding and moulding
the soap to its consumable state. The store/packaging unit in charge of packing
finished/ready soap into cartons. The Director is in charge of the sells unit. I
worked in all the units of the company, especially in the production unit, processing
and packaging unit.
2.1 AIMS AND OBJECTIVES OF SILVER EAGLES
COSMETICS CO. LTD
a) To
help promote cleanliness and eradicate sickness.
b) To
minimize the rate of importation of soap.
c) To
develop and promote the economy of the country.
d) To
generate income for the owner.
e) To
create employment.
 |
| COOKING POT OR BOILING KETTLE |
 |
| FIRST GRINDING MACHINE |
 |
| SECOND GRINDING MACHINE USED FOR MOULDING |
CHAPTER THREE
3.0 THE RAW
MATERIALS USED IN SOAP MAKING
The raw materials used in soap making are:
a. Water
b. Tallow
oil or palm kernel oil
c. Caustic
Soda
d. Liquid
Colorant
e. Sodium
silicate (Liquid)
f. Fragrant
or perfume
3.1 SOAP
MAKING PROCESSES
During the period of time that I worked in the
production unit/kitchen I observed the following processes of soap making.
a. Measuring and gauging of raw materials
b. Mixing and testing of the raw materials
c. Soap cooking/boiling
d. Processing of the soap
e. packaging
3.2 MEASURING
AND GAUGING OF RAW MATERIALS
BY SILVER EAGLES COSMETICS STANDARD OF PRODUCTION
Measure out 4 drums of palm kernel oil or tallow oil
4 bags of caustic soda
21/3 drums of water
1/2
drum of sodium silicate
11/2 litres of liquid colorant
15 litres of perfume.
REPORT/COMMENT
I observed that in soap making all the raw materials,
even water is weighed and measured and this ensures that the raw materials are
added in the appropriate ratios and this further ensures the formation of the
soap.
3.3 MIXING
AND TESTING OF THE RAW MATERIALS
Pour the 21/3 drums of water
into a separate tank and add the 4 bags of caustic soda of 25kg each into the
tank and stir well with the water after stirring well we test the mixture with
a hydrometer if the calibration reading on the hydrometer balanced with the
mixture at level 1275 then our mixture is balanced but if the hydrometer
reading is above 1275 then it implies that the ratio with which we added the
two materials is not appropriate that is that the level of our water is greater
than that of the caustic soda so we add more caustic soda to balance the
mixture.
And if the hydrometer reading is below 1275 then the
quantity of our caustic soda is higher than it should be in order to balance
with the water so we add more water. After which we retest to know if the
mixture is now balanced.
REPORT/COMMENT
I learned that without the appropriate mathematical knowledge of the ratios and equations of the raw materials and its combination soap making would be a work of probability.
I learned that without the appropriate mathematical knowledge of the ratios and equations of the raw materials and its combination soap making would be a work of probability.
3.4 SOAP COOKING/BOILING
After measuring, mixing and testing the raw materials,
pour the 4 drums of palm kernel oil into the boiling kettle or cooking put
which is approximately the size of a medium GP tank of about 3,000 liters and
boil to melt well for about 20-30 minutes depending on the strength of the
burner used, this is to allow the oil to melt well, after the 20 - 30 minutes
we add the liquid colorant of about
11/2 liters then add the measured and tested
caustic soda mixture and leave to stir and mix well under the heat of the burner
for about 20-30 minutes.
After the 20-30 minutes we pour in 1/2 drum of sodium silicate and allow to mix and
boil well for additional 20 minutes. By this time the soap has begin to form
but still in liquid form. After the 20 minutes the soap is due but yet in
liquid form as it is still hot. The total cooking duration is about l hr - l hr
30 minutes.
REPORT/COMMENT
I observed that the mathematical cautions and measures
taken helps to ensured the formation of the product/soap and the quality as
well.
3.5 PROCESSING
OF THE SOAP
With a basin shaped wheel barrow we collected the
liquid soap from the boiling kettle and discharge it on a broad floor covered with
sack to cool and solidify.
After cooling we cut the solidified soap into small
portable sizes. Then this soap will be grinded severally by the grinding
machines. The first machine grinds the soap into marshes and this soap is
further grinded by the 2nd machine up to three to four times by separate
workers with the same type of machine.
The reason for further grinding is to filter the soap
from stones that might have entered into it during cooking, and to make the color
blend well from this time till moulding the soap takes the shape of a cooked Indomie noodles this shape is
given to the soap by the
help of the structure placed at the discharging opening of the grinding machine.
help of the structure placed at the discharging opening of the grinding machine.
After filtering then the final moulding, this is done
by the same filtering machine only that the structure
placed at the discharging opening is changed with another that bears the desired shape that the soap will have.
by the same filtering machine only that the structure
placed at the discharging opening is changed with another that bears the desired shape that the soap will have.
REPORT/COMMENT
From the mathematical caution and measures taken the standard and quality of the product is achieved and maintained.
From the mathematical caution and measures taken the standard and quality of the product is achieved and maintained.
CHAPTER FOUR
4.0 APPLICATION OF MATHEMATICS IN SOUP MAKING
Mathematics is been applied practically in;
a. the
regulation of the amount of raw material input to give a required amount of
product (output).
Using the production standard of Silver Eagles Cosmetics And Chemical Co. Ltd
where I did my IT as an example.
Where a pot of soap is made up of
4 drums of palm kernel oil.
21/3 drums of water
4 bags of caustic soda.
11/2 litres of sodium silicate
and
15 litres of perfume.
And after the boiling and processing this pot of soap
will yield 300 cartons of bar soap with each carton containing 30 bars of soap.
With this knowledge the soap industry is able to regulate its input and output
and this measures further ensures that the raw materials are not used in
excess.
b. Quality Control: Through the
mathematical cautions taken in that all the raw materials are measured, weighed
and added in appropriate ratio the
quality of the soap is set and maintained and can also be enhanced by
increasing the quantity of some of the raw materials used in producing a
pot/batch of soap.
4.1 SOME OF THE RELATIONSHIP AND APPLICATION
OF MATHEMATICS IN THE STORAGE/PACKAGING UNIT
During
my stay in the storage/packaging unit 1 observed some close relationship
between the arrangement of the cartons of bar soap and matrix arrangement.
(a) Starting
from the arrangement of the bars of soap in the carton where we have 30 bars of
soap in each carton having a matrix arrangement of S6x3.
30 bars of soap packed into a carton in a matrix order
of A6x5
a11 a12 a13 a14 a15
a21 a22 a23 a24 a25
A6x5 = a31 a32 a33 a34 a35
a41 a42 a43 a44 a45
a51 a52 a53 a54 a55
a61 a62 a63 a64 a65
1. One
batch of soap containing 100 cartons of bar soap in a matrix order of C5x20.
Here each row is in a rectangular shape of 4 by 5 (4
cartons along the width and 5 along the length)
20 cartons
of bar soaps in a matrix order of C5x4
C11 C12 C13 C14
C21 C22 C23 C24
C5 x 4 = C31 C32 C33 C34
C41 C42 C43 C44
C51 C52 C53 C54
24 cartons of bar soap in a matrix order of C6x4
C11 C12 C13 C14
C21 C22 C23 C24
C6 x 4 = C31 C32 C33 C34
C41 C42 C43 C44
C51 C52 C53 C54
C61 C62 C63 C64
I also observed a practical application of the subject
that we studied called “LINEAR PROGRAMMING OPTIMIZATION FUNCTION) in the
activity/management of the industry, in that the raw materials where
enough/excess to compare with the quantity of labour available thus due to the
shortage of labour and the capital to pay the workers well, there is shortage in
the amount of output required and hence “capital and labour” is the constraint
to the maximization of profit.
4.2 MY SUGGESTION OF A POSSIBLE SOLUTION TO
THE CHALLENGE OF THE INDUSTRY
To
maximize profit with the increase in output the two variables labour and
capital/raw materials should be balanced the industry should reduce the money
that it spends on raw materials and use it to employ more labour and at the
same time maintain the appropriate quantity of raw materials required.
|
Max/Min z = ∑cj xj
j
= I
¯
Objective function
j = I ¯
Linear
constraint
Where xj >
o Nonnegative constraint
Where x and y represents capital and labour
4.3 THE RELEVANCE OF MATHEMATICS IN SOAP
MAKING
In
the soap making industry, the standard of production is set and maintained
through mathematical cautions and measures thereby the company knows before
hand, the number of raw materials that will give a required amount of output
and this can help a lot in budget making and future planning.
Example: that a pot of Soap will give approximately
300 cartons of bar soap.
INPUT
A pot of
soap
a) 4
drums of palm kernel oil
b) 4 bags
of caustic soda of 25kg each
c) 21/3
drums of water
d) ½ drum
of sodium silica
e) 1½
litres of liquid colorant
f) 15
litres of perfume.
OUT PUT
300 cartons of bar soap containing 30 bars of soap
each totaling 9000 bars of soap.
CHAPTER FIVE
5.0 SUMMARY
I did my Industrial Training (IT) in Silver Eagles
Cosmetics and Chemical Co. Ltd Aba, Abia State. The company is headed by Mr.
Jude O. Okike who is the Director and general manager of the establishment. I
worked in all the units of the company, especially at the processing and
packaging unit.
I
learned that without the appropriate mathematical knowledge of the ratios and
equations of the raw materials and its combination that soap making would be a
work of probability.
I
also observed that with the help of mathematical caution and measures taken
that the standard and quality of the product is set and as well maintained.
5.1 RECOMMENDATION
I
recommend the Industrial Training for all students of higher institution in
Nigeria so that they can gain knowledge and be more exposed to their various
fields. This will help them to give their best to the community and help in
developing the educational standard and skill acquisition across the county.
5.2 CONCLUSION
I participated fully and learnt a lot that has to do
with my field of study. I also gained a lot of knowledge from the staff and the
company’s manager. I served for the period of six months from July to December,
2012.