ABSTRACT

The project design concentrated on the

development of a manufacturing
facility system that would enhance
efficient production of pole mounting
clamps. The design ensured pole band
desired specifications will be met
within industrial safety limits.
Project Designer: Eng. Eugene
DESIGN PROPOSAL OF Mutabingwa Busigazi
Project Advisor: Eng. Peter Mwanga
THE MANUFACTURING
FACILITY FOR POLE BAND
CLAMP PRODUCTION
Date of Submission: 26, June, 2020
TABLE OF CONTENTS

Acknowledgement……………………………………………………….2

Glossary
A. Scope……………………………………………………………….3
B. Cross References…………………………………………………...3
C. Applicable Codes and Standards…………………………………..3

Introduction………………………………………………………………..6

Project Design Tools

A. Product Design Specification……………………………………….8
B. Design Specification…………………………………………………18

Conclusions and Recommendations………………………………………..29

References…………………………………………………………………..30

Appendices………………………………………………………………….32

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 ACKNOWLEDGEMENT
First and foremost, praises and thanks to the God, the Almighty, for His showers of
blessings throughout my design work to complete this project proposal successfully.
I would like to express my deepest appreciation to all those who provided me the
possibility to complete this project design proposal. A special gratitude I give to my project
advisor, (Engineer Peter Mwanga), whose contribution in stimulating suggestions and
encouragement, helped me to coordinate my design especially in writing this project proposal.
Furthermore I would also like to acknowledge with much appreciation the crucial role of
the staff of Mr. Kennedy O. Haroun who gave the permission to use all the required equipment
and the necessary materials to complete this task. A special thanks goes to my teammates (Mr.
Msafiri Mohammed Mfikirwa and Mr Pascal Mremi) who helped me to assemble the parts and
gave suggestions about the task.
I am extremely grateful for my parents for their love, prayers, caring and sacrifices for
educating and preparing me for my future. I am very much thankful to my wife and my daughter
for their love, understanding, prayers and continuing support to complete this design work. My
special thanks goes to my close friend and brother Engineer Laurent Kadeghe for his keen
interest shown to complete this thesis successfully.

Last but not least, many thanks to the Operation Engineer at TANESCO Ubungo
Municipal, (Engineer Nickson Shedrack Babu) who invested his full effort in guiding my ideas
and intellect towards achieving the prime goal of this design. I have to appreciate the guidance
given by others (my colleagues, friends, classmates, staff, family) especially when I was
presenting my objectives about this design that has improved my confidence of what am I
supposed to achieve, still many thanks to their comments and advices.

GLOSSARY
A. SCOPE

This project specifies the minimum technical requirement for design, engineering,
manufacturing, inspection, testing and performance of a pole band as an accessory of a
pole line hardware for overhead power lines to be used in the medium and low voltage
[MV/LV] systems of TANESCO.

B. CROSS REFERENCE

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 The material standard specification shall be read in conjunction with TANESCO General
Specification {latest revision} for General Requirement for all Equipment/Materials as an
integral part of this project.

The standards in this project design shall be read in conjunction with TANESCO
purchase order requirement.

C. APPLICABLE CODES AND STANDARDS

The latest revision of the following codes and standards shall be applicable for the
equipment/materials covered in this design project. In case of any deviation the
vendor/manufacturer [for imported parts i.e. bolts, nuts, washers, raw materials] may
propose equipment/materials conforming to alternate codes/standards. However, the
provisions of TANESCO standards shall supersede the provisions of these alternate
standards in case of any difference.

TABLE 01 a) : List of Applicable Standards

Standard Number Title
Specification for General Requirements for Rolled Steel
ASTM A6 Plates, Shapes, Sheet Piling, and Bars for Structural
Use.
ASTM A36M Standard Specification for Carbon Structural Steel.
Standard Specification for Zinc {Hot-Dip Galvanized}
ASTM A123
Coatings of Iron and Steel Products.
Standard Specification for Zinc Coating {Hot-Dip} on
ASTM A153
Iron and Steel Hardware.
Standard Specification Method for Locating the
ASTM A239 Thinnest Spot in a Zinc {Galvanized} Coating on Iron
or Steel Articles by Pierce Test {Copper Sulfate Dip}
Standard Specification for Carbon Steel Bolts and
ASTM A307
Studs, 60000 PSI Tensile Strength.
Standard Specification for Quenched and Tempered
ASTM A354 Alloy Steel Bolts, Studs and other Externally Threaded
Fasteners.
Standard Test Methods and Definitions for Mechanical
ASTM A370
Testing of Steel Products.
Standard Practice for Safeguarding against warpage and
ASTM A384 Distortion during Hot-Dip Galvanizing of Steel
Assemblies.
Standard Practice for providing High Quality Zinc
ASTM A385
Coatings {Hot-Dip}
Standard Specification for Carbon and Alloy Steel Nuts
ASTM A563M
[metric].
ASTM E376 Standard practice for Measuring Coating Thickness by
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 Magnetic Field or Eddy Currents [Electromagnetic]
Testing Methods.
ASTM F436M Standard Specification for Hardened Steel Washers.
Specification for Carbon Alloy Steel Externally
ASTM F568
Threaded Metric Fasteners.
Standard Test Materials for Determining Mechanical
ASTM F606 Properties of Externally and Internally Threaded
Fasteners, Washers and Rivets.
Standard Specification for High Strength Structural
Bolts, Steel and Alloy Steel, Heat Treated, 120ksi
ASTM F3125M
[830MPa] and 150ksi [1040MPa] Minimum Tensile
Strength Metric Dimensions.
AISC Manual of Steel Construction, 14 Editions.
ANSI B1.13M Metric Screw Threads.
ANSI B18.2.4.6 Metric Heavy Hex Nuts.
ANSI B18.22.1 Plain Washers.
Galvanized Steel Bolts and Nuts for Overhead Line
ANSI C135.1
Construction.
BS 3692 ISO Metric Precision Hexagon Bolts, Screws and Nuts.
IEC 61284 Overhead Lines - Requirements and Test for Fittings.
ISO 630 Standard for Structural Steels.
ISO R657 Recommendations for Hot Rolled Steel Sections.
ISO 1459 Metallic Coatings - Protection
Metallic Coatings – Hot-Dip Galvanized Coatings on
ISO 1460 Ferrous Materials – Gravimetric Determination of the
Mass per Unit Area.
Metallic Coatings – Hot-Dip Galvanized Coatings on
ISO 1461
Fabricated Ferrous Products – Requirements.
Hexagon Nuts for Structural Bolting, Style 1, Hot-Dip
ISO 7413 Galvanized [Oversize Tapped] - Products Grades A &
B – Property Classes 5,6 and 8
Hexagon Nuts for Structural Bolting, Style 2, Hot-Dip
ISO 7417 Galvanized [Oversize Tapped] – Product Grade A –
Property Class 9.
SASO/SSA 107 Tensile Testing of Steel.

Table 01 b): Summary of Bolt Sizes

Type of Structure Pole Height (m) Machine Bolt
Installations Length (mm)
M16 M20
INT & MAP 10 140
LV Single Circuit HAP, TER, TAP- 10
OFF (2 WAYS)
INT, LAP, MAP, 12, 13 235 &
MV Single Circuit
HAP SEC, & TER 255

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 14, 15
COMPOSITE 12, 13
STRUCTURE 14, 15
INT, LAP, MAP, 14, 15 255 &
MV Double Circuit HAP, SEC, & 300
TER
LV Single Circuit INT & MAP 10 275
HAP, TER, TAP- 10
Self-Support
OFF (2 WAYS)
INT, LAP, MAP, 12, 13 335 &
HEP, SEC, & 370
MV Single Circuit
TER 14, 15
Self-Support
COMPOSITE 12, 13
STRUCTURE 14, 15

Abbreviations
INT – intermediate pole
MAP – medium angle pole
HAP – heavy angled pole
TER – terminal pole
LAP – low/light angled pole
SEC – section pole
TAP – OFF (2 WAYS) – tapped/ branched pole

INTRODUCTION

Pole band is a pole line hardware that consists of two or more pieces of steel bands, its
widely used on steel, wood or concrete poles to make sure that its always fastened ideally
in supporting pole line connections. It is also named pole fastener, pole fastening clamp,
pole band clamps, pole bracket. They are used more on poles to make sure they’re always
fastened ideally in support of pole line connections. Pole band is classified broadly basing
on two categories common for transmission and distribution lines;

Classification of Pole Bands

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 I. According to structure;
 Single-offset pole band; there is an outstanding square part in the middle
of one-piece pole band [it’s known for its exceptional square part]. On the
other piece of single-offset pole band, there’s no hole in the half round
band. This outstanding part is designed for bolts to through. This bolt will
connect the guy clamp or other pole line hardware, whereas in most cases
you can use it for guying, mounting secondary racks, dead-ending etc.
 Double-offset pole band; this can support two lines, because, on each half
round band, there’s an outstanding square part in the middle.

II. According to application;

 Utility pole bands; these bands are designed for utility poles.
 Cable pole brackets; are used ideally in connecting APGW and ADSS
cables. This type of a pole band has an extended leg on piece of the band.
Holes on the extended legs will connect the U clevis and ZH clevis.
 Telephone pole bands; this type is used for telephone pole and the
installation and transmission of cables.
 Link style pole band; this type of a pole band offers an ideal product for
dead-ending and guying to steels, concretes or wood poles without the
necessity for bolt holes within poles. These bands accommodate pole
diameter of different types. Half and full link style pole bands are ideally
available for addition to assemblies to adjust pole diameter ranges of
bands.
The common raw material for pole bands is flat carbon steel not slitting steel. The material
is soft and highly malleable, the carbon steel strength is up to 560N/mm2. With strict selection of
raw material there will be no broken or cracks on the pole band, after doing stamping on the flat
steel. For different pole diameter and voltage there will be different sizes for pole band clamp
[ranging in between 190mm to 323mm].
We’ll manufacture a pole band with very simple structure in which there will be three
pieces of steel bands in one set. Bolts will fasten the three pieces through the hole on each end
leg, this way the pole band clamp will not drop-off from the pole.

Components of a Pole Band

a) Steel bands; steel bands of a pole band are assembled together to tighten the pole.
b) Fasteners (bolts); they’re used to fasten bands together in order to have poles well
fastened. Pole fasteners will be made depending on the customer design and
needs.

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c) Holes; the holes at the edge of the pole bands are mainly for bolts to fasten them
together. These holes when brought together with help to create closure that
fastens the pole for all connections.
d) Clips; these clips help to clip pole bands to these poles.
e) Cotter Key; this component is made from stainless steel. Link style bonds mostly
have this cotter key with them.

How to Install a Pole Band?

i. Assemble all fastening tools and equipment’s. These may include hook,
wrenches, pliers, spanners etc.
ii. Now asses your pole band. Ensure it has all necessary parts and components
such as bands and fasteners. More importantly, they should meet your desired
application requirements.
iii. Assemble everything you want to secure on the pole, and then bring the pole
band together one by one.
iv. As you bring the bands together use the bolts and nuts to fasten them.
v. You can do this by having bolts put into each end leg of the band, then you
can fasten it. This is important to make sure nothing falls of from the pole,
especially the pole band clamp.
vi. Make sure the pole band is installed to wrap the pole tightly, keeping it
fastened.
vii. At times, once you install the pole band you can go ahead installing other
accessories.
In a nutshell installing the pole band is simple and straightforward.
Conclusion of the subject matter
As you can see pole band is a simple yet very important pole line hardware, you can
use it to secure virtually anything on poles. However we’ll be supplying our
customers with suitable pole bands in terms of their desired specifications, where
we’ll design ad manufacture high quality pole bands.

PROJECT DESIGN TOOLS

The design project used the following approach on carrying out its primary success
desired;
a) Product Design Specification. (The what of the design)
b) Design Specification. (The how of the design)

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1. Product Design Specification (PDS)
This part of the document is on our early part of the design during the problem
definition activity, as it’ll detail all the requirements to be met in order the
product and the whole process to be successful. Thus down here I’ll lay all the
groundwork for all engineering design activities and ensures that all relevant
factors are accounted for and all stakeholders are heard from

i. Performance
o A stationary device
o It’ll be bearing electrical loadings
o It should have accurate precision
o The stay tension strength of no below than 70kN.

Table 01 c): Product performance criteria

Performance Criteria Value

Unit manufacturing cost Tshs.5,000/= maximum

Time to disassemble during
180 seconds maximum
maintenance
160% extra of the unit mfg.
Selling price per unit
cost
Hook wrenches, pliers,
Tool of assembly spanners, and etc. of the same
kind
Tensile strength 1065MPa, maximum
Flexural strength 1810MPa, maximum
Yield strength 250N/mm2 minimum
Forging Forged at 12600C -9820C
Maximum Load 70kN

Corrosion Hot-dip galvanized

Unit weight of the product From 2.5Kg to 3kg maximum

ii. Environment
o All aspects of the product’s likely environment from normal
use, manufacturing process, storage, transportation, and
display, the following are the key parameters in consideration
which will hold actively throughout the production;
- Exposure to hazards during the manufacturing processes of
pole band clamp
- Work health and safety practices

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 - Work health and safety attitudes, perceptions and skills.

iii. Service life

o The pole band should have the service functioning life of at
least 20years

iv. Maintenance
The maintenance systems have all the same-end objective mission-
ready machinery and equipment at minimum cost. This end objective
can be touched using different ways. For understanding the most used
maintenance system are;

Figure1: Maintenance Systems

But in practice of this design I ought the maintenance systems to be

applied alone or in different combination as;

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 Figure2: Possible combination of Maintenance Systems

On choosing the maintenance system in which time, which

maintenance combination might prove efficient, I beseech the
maintenance system to have complete understanding of the principles
of maintenance management;

Figure3: The Principle of Maintenance System

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 Clear understanding of these may lead to the attainment of the deign
main goals below on the maintenance part of both the facility and
product;
- Reducing/eliminating if possible all accidental falls
- Reduction in maintenance costs
- Cutting out the stop times
- Decreasing number of workers engaged in these activities,
etc.

v. Packing and Shipment.

o In addition to shipping and packaging requirements that will be
provided by TANESCO also this will be fulfilled;
Items consisting of two parts such as bolts, nuts and washers shall be
delivered, as far as possible, fully assembled and packed as one set.

vi. Size
o The products manufactured will range in three different size
ranges which are as;
- Minimum sized clamps (150mm to 190mm)
- Medium sized clamps (190mm to 245mm)
- Maximum sized clamps (245mm to 323mm)

vii. Human Factors

The industry should make sure that any necessary adjustments will be
made so as to be in dynamic with the outside market. Customer
surveys to be done in different approaches as;
 Customer satisfaction surveys
 Customer satisfaction score
 Net promoter score
 Customer effort score
 Social media monitoring
 Things gone wrong

viii. Aesthetics and finish

Workmanship and surface finish should be of highest grade and the
best modern practice. The process may involve galvanization, zinc
plating, and painting.

ix. Material
All materials shall be of high grade free from imperfection and defects,
of recent manufacture and unused, and of the classification and grades
designated, conforming to the to the requirements of the latest issue of
the appropriate specification cited herein.

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 x. Standards, Specifications and legal aspects
The pole band clamp shall be of manufacturer’s standard design
and shall meet or exceed performance requirements as required by
TANESCO guiding specifications.
Manufacturer’s drawings as required by TANESCO, shall show
the details of the pole band clamp, together with pertinent dimensions.
Any variations in these dimensions due to manufacturing tolerances
shall be indicated.

xi. Guarantee.
The factory shall guarantee the materials against all defects arising
out of faulty design, sub-standard materials or poor workmanship for a
period of five (5) years. From the date of delivery.
The factory shall guarantee that the materials that will be delivered
in TANESCO warehouses are uniform and consistent with the
approved samples. TANESCO will reserve the right to blacklist the
manufacturer should they proven guilty of supplying sub-standard
materials and not uniform or consistent with the approved samples.
If no exceptions to these specifications are taken and no list of
deviations is submitted, it shall be deemed that, in every aspect, all
items shall conform to this design. TANESCO interpretation of this
specification shall be accepted.

xii. Submittals
In addition to documentations that might be specified by TANESCO,
the manufacturer will submit the following;
 Detailed working/fabrication drawings shall be supplied with
the proposal. The drawing shall include but not limited to the
following;
1) The complete dimensions and locations of bolt holes.
2) Details of connections, bends and cuts
3) Details of identification marks or numbers.
4) Type tests and routine test reports will be submitted
periodically if needed for evaluation.
 Submittals will involve the following awards of contracts;
a. Samples together with actual CAD drawings, routine
test reports, and materials certificate of compliance with
applicable standards will be submitted for
inspection/evaluation prior to issuance of approval for

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 mass production. The following attributes shall be
checked;
 Dimensional verification
 Engraved markings (TANESCO Item code,
manufacturer logo or initials, product number)
 Uniformity of the product/samples
 Finishing
b. Manufacturing schedule, progress report and test
schedules
c. Test reports including but not limited to the following;
 Certified mill test reports for all materials
 Certified welding reports, if it’ll be applicable
 Test reports on coating thickness, nuts & bolts
and reports on dimensional checks
 Report of all material testing, when required,
including photos, diagrams, etc.

xiii. Processes
All steel bands as parts of a pole band clamp will be ho-dipped after all
sawing; shearing, drilling, punching, filling, bending and machining
are completed.
The manufacturing hot-dip galvanizing should follow ISO1461: 2009
and applied by the process to provide the thickness of not less than
610gm of Zn per square meter of surface on steel bars, sections and
fittings. All surfaces should be smooth, clean, of uniform thickness
free from defects.
The preparation for galvanizing and the galvanizing itself will not
adversely affect the mechanical properties of the coated material. And
the lifetime of this accessory will be to an estimate of at least 20 years.

xiv. Quality and Reliability

To ensure quality of the products the following should be strictly
adhered;
 The name or type of fabricated steel shapes shall be as
specified in the technical data schedule of this design.
 All fabricated steel shapes shall be strictly in conformity with
the dimensions, arrangements, sizes, weights, and thickness
indicated on the drawings or stipulated in the specifications.
 Unless otherwise specified the steel material shall comply with
the applicable requirements of ASTM A36 or equivalent with
the minimum yield strength of minimum 250N/mm2.

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 All fabricated steel shapes shall be hot-dipped in accordance
with ISO 1461:2009 with the average coating thickness of
0.086mm (equivalent to 610g/m2).
 Bolts, nuts and washers shall be furnished, as components of
the fabricated materials, shall comply with the requirements in
Clause 2.2 of this design specification.
 Shearing and cutting shall be performed carefully and all
portions of the work shall be finished neatly.
 All forming and bending during fabrication shall be done by
method that will prevent embrittlement or loss of strength in
the material being worked.
 Holes shall be cut, drilled or punched at right angles to the
surface and shall not be made or enlarged by burning. Holes
shall be clean cut without torn or ragged edges, and burns
resulting from the drilling or reaming operations shall be
removed.
 All fabricated materials shall conform to the tolerances
specified in the AISC Manual and ASTM A6 or equivalent. In
particular, the tolerances are as follows;
 +/- 2mm for center-to-center distance between holes.
 +/- 0.5mm for diameter of pre-drilled holes.
 The type of machine bolts shall be as specified in technical
data schedule of this specification. The required standard
lengths of the machine bolts are given in table 01 b).
 The bolts, nuts and washers shall be of vendor’s standard
design and shall meet the basic dimensional and
performance requirements of this design in all aspects.
 Bolts, nuts shall be made from hot-rolled carbon steel
which has been produced by open hearth, basic oxygen or
electric furnace process and which is of grade and quality
suitable to meet requirements of this design.
 Machine bolts should be of high strength Grade 8.8 and
shall comply with the applicable requirements of ASTM
F3125M or equivalent.
 Nuts shall comply with the applicable requirements of
ASTM A563M or equivalent.
 Bolts, nut and washer hall be hot-dip galvanized in
accordance with the requirements of ISO 1461:2009 with
minimum average coating thickness of 0.053mm equivalent
to 381g/m2.
 Galvanized bolts, nuts shall be free from burrs, seams, laps,
and irregular surfaces that affect serviceability.

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  The top of the bolt head or nut shall be flat and the edges
shall be chamfered or rounded. The thread end of the bolts
should also be chamfered or rounded.
 All machine bolt heads and nuts shall be regular hexagonal
and shall be in accordance with ANSI B18.2.4.6M or
equivalent.
 The thread and threaded hole of the nut shall match the
thread of the bolt. The external threaded portion of all bolts
shall, after galvanizing, be in such condition that nuts
tapped will fit the galvanized bolt so that the nut can run
the entire length of the thread without the use of the tools.
 Washers shall be in accordance with ANSI B18.22.1,
ASTM F436M or equivalent.
 Unless otherwise specified each machine bolt shall be
furnished with one (1) nut, two (2) flat washers and one (1)
spring washer assembled thereon.
 All galvanized steel bolts shall be marked with property
class symbol and the manufacturer’s identification symbol.
For machine bolts markings shall be located at the top of
the head and may be raised or recessed. When raised,
markings shall not project less than 0.1mm for 12mm and
smaller bolts, and 0.2mm for 16mm and larger bolts above
the surface of the head.

xv. Testing and Inspection.

In addition to the requirements that might be specified by TANESCO,
the following shall be fulfilled;
The supplier (for the imported parts)/ manufacturer (DERM) shall
make adequate routine tests and inspections to determine the
conformity of materials furnished under this design specification.
a) Inspection/Routine Tests Requirements.
 Inspection/routine tests shall be in accordance with the
applicable standards in this design.
 Visual inspection shall include checks for satisfactory
workmanships, materials, and freedom from surface
defects and for compliance with the purchase order and
the general design specifications.
 TANESCO designated representative shall have free
have free access at any time while work is being carried
on, to all areas of manufacturer’s plant, which concern
the work.
 Inspection/routine tests may be carried in all stages of
production and shipping.

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  TANESCO or its designated representative will reserve
the right to conduct acceptance testing at the
manufacturer’s plant or take random samples after
delivery to test the products at TANESCO approved 3rd
party laboratory to verify compliance with specification
in this design.
b) Type Testing Requirements.
All materials covered in this design shall be type tested at
TANESCO approved laboratory or at manufacturer’ test
facility witnessed by TANESCO designated representatives, in
accordance with the requirements of the latest standards
specified in this design provided the manufacturer’s test facility
is certified and/or the tests are supervised by representatives of
TANESCO approved laboratories.

Following the completion of all tests, two certified copies

of the test reports, including the mill test certificate, approved
fabrication drawings, and material standard compliance
certificate demonstrating that the materials used conforms in
the standard specified in this design, shall be submitted to
TANESCO for review and approval. The following type test
shall be carried out:-
 Fabricated steel shapes should be type tested in
accordance with the following standards;
- Steel materials suitable for fabrication of steel
shapes shall conform in the applicable requirements
of ASTM A36.
- Hot-dipped galvanizing tests in accordance with
ASTM or ISO or equivalent standards referenced in
this design shall be carried out for all galvanized
materials, including the threads of the bolts.
- Design, shapes and dimensional verification as per
applicable drawings in this design.
- Fasteners (nuts, bolts and washers) included s part
of the assembly shall be tested as per applicable
standard.
- Unless otherwise specified in this design, tolerances
shall conform in the requirement of ASTM A6 or
equivalent industry standards.
 Bolts, nuts and washers should be type tested in
accordance with the following standards;
- Machine bolts shall conform in the requirement of
ASTM F3125M.

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 - Hexagonal nuts and machine bolt heads shall
conform in the requirements of ANSI B18.2.4.6 or
equivalent.
- Washers shall conform to the requirements of
ASTM F436M or equivalent.

xvi. Technical Data Schedule.

Table 02: Pole Band Clamp – 2.1 fabricated steel shapes.

NO: Description TANESCO Manufacturer’s
Specified Proposed
Values Values
2.1.1 Name/description of Flat carbon steel
fabricated material
2.1.2 TANESCO Drawings
NO;
Manufacturer’s
Drawings NO;
Shape of steel metal Simple semi-
circle
2.1.3 Standard A36, 1020 Steel
designation/Grade of
steel
Minimum Yield 250
Stress of steel
material, N/mm2.
Dimensions (mm) Constant
thickness of
6mm, width
range from 50
(for light duty
clamps) – 64 (for
heavy duty
clamps),
Strength Rating (kN)
Galvanize Coating 610
Weight, g/m2
2.1.5 Grade of Component Grade B, PB
Machine Bolt and 307B
Cotter Pins.
Components 381
Machine Bolts
Galvanize Coating
Weight, g/m2

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 Table 03: Pole Band Clamp – 2.2 Bolts, Nuts and Washers
No: Description TANESCO Manufacturer’s
Specified Proposed
Values Values
2.2.1 Type of bolt Heavy Hex
Bolts
TANESCO Drawings
No;
Manufacturer’s
Drawings No;
2.2.1 Diameter (mm)
2.2.1 Length (mm) Conform to
Threaded Length, (mm) ANSI
Coarse of thread B18.2.4.6
2.2.2 Grade/strength rating
2.2.3 Galvanize Coating 381
Weight, g/m2
2.2.4 Number of Nuts 1/bolt
2.2.4 Number of washers 2 flat washer, 1
spring washer /
bolt.
Manufacturing standard
Specification
Markings TANESCO
2.2.5 Quantity Required

Additional Specifications of the product on

1) Additional Technical information or Features specified by
TANESCO
2) Additional Supplementary Data or Features Proposed by
Bidder/Vendor/Supplier.
3) Other particulars to be filled-up by the
Bidder/Vendor/Supplier.
4) List of Deviations and Clauses to which exception is taken by
the Bidder/ Vendor/ Supplier.

2. Design Specification
With this being the secondary part of our design It’ll concern with the “how
will our product requirements be achieved?” through the following
engineering design process;

i. Definition of the problem

a) Identification and establishment of the need

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 Need: Industry development for the manufacturing of pole
bands as a pole line accessory to secure pole line connections
for concrete poles.
b) Development of a problem statement
Problem stamen: A manufacturing facility capable for pole
band production.
c) Establishment of a design criteria for success
The concept for the manufacturing design facility should
reflect the following dimension for its efficient production.

Figure4; General definition for any manufacturing systems

The Physical elements being;
a. Machines for processing;
 Hot forging plant/hearth
 Shearing machine
 Punching machine
 Drilling machine
 Galvanizing plant
b. Tooling
c. Material Handling Equipment
d. People

Measurable parameters being;

a. Production rate

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 b. Work in process/progress inventory (WIP)
c. Percentage of defects.
d. Percentage on time delivery
e. Daily/weekly/monthly/yearly production volume
f. Total cost.
g. Safety and health issues.

ii. Collection of Patent information

Governing factors on selection of a manufacturing facility system are
as;
 Cost
The key objective of any facility is to maximize profits while
offering quality to customers. Therefore, one of the strategies
that I am going to use in achievement of this objective is
ensuring that the processes being undertaken are as cost
effective as possible, through cost cutting techniques such as
outsourcing or creating partnerships with other companies in
production of some parts. Whereas the processes cost would
mean to comprise of expenditures incurred in purchase of the
equipment, labor and raw materials, and capital costs.
 Quality
Operational manager will have the role to ensure that goods
and services that are offered to clients are of optimum quality
(Mukherjee, 2006). Apart from reducing costs to maximize
benefits, I’ll also select manufacturing process design based on
the quality of the outcome desired. Even though it can be
argued that quality control processes ensure that any quality
issues can be resolved before products are being delivered to
customers, but it’s more productive if the original
manufacturing process is flawless. If the industry fails to
produce according to the manufacturing process ought in this
design it may decline to cater the needs of the clients
regardless of how cost effective it’ll be (David Bamford,
2010).

 Flexibility
This refers to the easiness at which a manufacturing process
can change certain aspects or qualities of products. These
range from the shape, materials used to manufacture the
product or the finish (Creese, 2013). The dynamism that
characterized the present day business environment also means
that organizational operational should as flexible as possible

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 so as to maintain their relevance (Merschmann & Thonemann,
2011). Lack of flexibility in manufacturing process may make
it difficult for the company to satisfy the ever-changing needs
in the market. It may also make quite expensive to replace the
existent processes with newer ones (Chou at el, 2010), with
reference to Moore’s law this capabilities of many products in
the world market often change at least once in two years. As
technological advancements increase this pace is bound to
increase (Mollick, 2006). This need of flexibility in the
manufacturing design will also help the company to stay ahead
of their competition on their industries of operation.

 Environmental Sustainability
Apart from the three aforementioned factors that would affect
selection of the manufacturing process design, there are
numerous other factors that I’ve put into consideration in
completing this ambiguous task. One of these is potential
impact that the process may have on the environment (Vezzoli
& Manzini, 2008). With the current focus of the international
business community on the environmental sustainability I
ought to select the process that will have the least adverse
effects on the environment for the company (Geels, 2011).

 Quantity of products
The quantity of products that the company will be producing
for clients will also determine the choice of appropriate
manufacturing process. In a situation if the company were to
produce ingle product to fit specification for clients, a one-off
approach may be appropriate (Jones & Robinson, 2012). On
the other hand, since the company will be dealing with
manufacturing of product in large quantities the mass
production approach is preferable.

 External Regulations
Standard and regulations, usually et by different governing
bodies also affect the selection of manufacturing approach
some of the aspects that are focused include environmental
input and specifications quality standard that ought to be
delivered to customers (Jones & Robinson, 2012).
Regardless of how cost-effective and flexible a manufacturing
process can be, the company will have the obligation of
adhering to the set standards to avoid getting into legal issues
(Bamford & Forrester, 2010).

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iii. Generation of multiple solutions
There are 6 available types of manufacturing systems that can be
applied here in my design case;

1) Job Shop;
Here varieties of products are manufactured in small lot sizes
to a specific customer order. Here in order to perform variety
of manufacturing process general-purpose equipment is
required, and workers must have relatively high skill levels to
carry out different range of manufacturing activities. Each
different part will be requiring its own sequence of operations
and can be routed through the various departments in the
proper order, layout made for this purpose is called
“functional/process layout”.

Figure5: Functional or Process Layout.

Existing examples of this manufacturing system is found in
foundries, machine shops, press working shops, plastic
industries,

Table 04: Assessment of Process Layout

Advantages of Process Disadvantages of Process
Layout Layout
Can handle a variety of In-process costs inventory can
processing requirements. be high.
Not particularly vulnerable to Equipment utilization rates
equipment failures. are low.
Equipment used is less costly. Complexities often reduce the
span of supervision.
Possible to use individual Material handling is slow and
incentive plans. inefficient.

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2) Flow shop;
Under this type our facility may be designed in a way that
special purpose equipment’s will be used to produce product
or family rather than general-purpose equipment’s. The
workstations will be arranged in line according to the
processing sequence needed called “product oriented layout”.
Here I’ll need laborers with lower skill level to operate these
production sequences to a mass production.

Figure6: Product Layout

Existing examples of industries, which use this kind of
production facility, is, Automated assembly line, Television
manufacturing factory.

Table 05: Assessment of Product Layout

Advantages of product layout Disadvantages of Product
Layout
High utilization of labor and Creates dull, repetitive jobs
equipment.
Low unit cost Poorly skilled labor may not
maintain equipment or quality
of output.
High rate of output. Fairly inflexible to changes in
volume.

3) Project Shop;
In this type, a product must remain in a fixed position or
location because of its weight and size. The machines,
materials and people in fabrication are brought to site. The
layout here is named as “fixed position layout”.

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 Fihure7: Fixed position layout
Existing factories with this type of facility are as locomotive
manufacturing, large aircraft assembly, and shipbuilding.

Table 06: Assessment of Fixed Position Layout

Advantages Disadvantages
Permit a plant to elevate the Highly skilled workers are
skill of its operators. required.
Allows the change in Complicated jigs and fixtures
production design. may be required.
Less total production cost Machines, tools, workers take
with greater flexibility. more time to reach the fixed
position

4) Continuous Process;
The design of our facility under this section will allow
products to flow (flow production) under the ease of material
handling device, when manufacturing complex single parts. It
usually has the leanest and simplest manufacturing system to
control since it has less work in progress (WIP), operating
under “continuous process layout”.

Figure8: continuous process layout

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 Existing examples are found in oil refineries, chemical plants,
and food processing plants.

5) Linked Cell Manufacturing System;

This is a manufacturing facility in which it’s the hybrid system
obtained through linking of both advantages for job shops
(flexibility in producing a wide variety of products) and flow
shops (efficient flow and high production rate).

Figure9: Cellular Process Layout

This system has some degree of automatic control for loading

and unloading of raw materials, work pieces, changing of
tools, transferring of work pieces, and tools between
workstations. It operates under “cellular layout”.

Advantages of CMS
 Set-up time is reduced
 Lot sizes are reduced
 WIP and finished goods inventories are reduced
 Tool requirements are reduced
 Product quality is improved

6) Flexible Manufacturing System;

This type of a facility, which integrates all major elements of a
manufacturing system into a highly automated system. The
flexibility of a flexible manufacturing system is such that it
can handle a variety of parts configuration and produce them
in any order. The basic elements of FMS are; a) workstations
b). Automation in material handling, storage system, retrievals
system c). Control systems.

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 Because of major capital investment machine utilization is
essential thus make proper scheduling and process planning to
be crucial where both of these are complex in nature?

Figure10: Flexible manufacturing system

This system is capable of different operations in different

order and on different machines.
Assessment of FMS
 Reduced WIP
 Labor and inventories are reduced
 Reduced factory space
 Increased machine utilization
 Greater responsiveness to change

iv. Analyzing to select the successful designs

The factors that have been highlighted above are relevant to all
companies that deal with the manufacture of products to their
customers. Whereas it’s impossible to optimize all of the above-
mentioned aspects of the manufacturing processes, I ought to make a
comprehensive evaluation on the type of manufacturing process to be
selected so to ensure we deliver quality to our customers and also
meet company goals and objectives. Therefore, the selected type of
manufacturing process is;
- Product Layout, 1st Design Selection
- Continuous Process Layout, 2nd Design Selection
- Cellular Manufacturing System, 3rd Design selection
Even though we might face a few challenges and controversies in our
product manufacturing processes, but through this competitive
evaluation we’ll confidently manage to maintain our strong position in
the pole line hardware accessory industry. This will be the partly
attribute to the effective selection of manufacturing processes.
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v. The Decision Process
Table 07: Weighting Evaluation Matrix
Rating Factor ®: Excellent 9-10, Very Good 7-8, Good 5-6, Fair 3-4,
Unsatisfactory 0-2.
First Second Third
Manufacturing Facility Design Design Design
System Selection Selection Selection
(D01) (D02) (D03)
Wei Rati
Rati Desi Rati Desi Desi
Succes ght ng
Parameter ng gn ng gn gn
s Fact Fact
s Fact Scor Fact Scor Scor
Criteria or or
or ® e or ® e e
(%) (R)
Produc Unit
tion 20 products/ 6 120 8 160 9 180
Rate man-hour
Work
in
Process 20 Tshs 4 20 6 120 7 140
Invento
ry
% Of Defects/m
20 8 160 4 80 2 40
defects illion
Units
delivered
% On
on time/
time
10 total 7 70 8 80 9 90
deliver
number of
y
units
shipped
Produc
tion
Volum
10 Tsh/ unit3 7 70 8 80 9 90
e
varianc
e
Total
20 Tshs 10 200 3 60 1 20
Cost
100 TOTAL 640 580 560

First design will be selected since it amounted more weight than other
designs.

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vi. Testing and implementation of the decision
The following are the manufacturing procedures that our product
layout system will accommodate within the facility;

Hot forging Plant

Carbon steel raw materals

Shearing Machine
The hot forged carbon steel will be formed to any desired shape here Forming Machines if neccesary

Bending Machine
the sheared parts will be bent within the required radius

Punching and Stamping Machine

the outstanding square part shapes of the product will be formed during this process

Drilling Machine

Galvanizing Plant and Painting if neccesary. all surface finish procedures will be numbered here

Testing and Inspection of the product

Assembly of the producs parts materials

Quality Controll

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CONCLUSION AND RECOMMENDATIONS
These were the primary elements (triggers) and secondary elements, which assisted in the
preparation of this comprehensive design.
The specification is and will be to subject of amendment and alteration with the passage of time
(or more intensive design which will be based much on realities of production rather than this
pre-text which relied wholly upon literature) and is, therefore evolutionary. Since standards are a
subject of ongoing review, the designer may amend the information contained in this document
any time. It’s possible that conflicts may exist between standard documents, in this event; the
most recent standard shall prevail.
Upon completion of this design, the evolved specification will provide the basic material for
handbooks, sales and technical literature, and becomes the specification of the product itself
(rather than the specification for this design). In the event; that any user of this document
considers any of its provisions is uncertain, ambiguous, or otherwise in need of interpretation,
the user should request the designer to clarify the provision.
This document has been developed using information available from other fields and other
sources and its suitable for most situations encountered in this kind of production. Particular
conditions and projects may require special or different practices, thus remain the responsibility
of the individuals involved to ensure that a safe system of work is employed and that statutory
requirements are met. All design work works, and the associated supply of equipment’s and
materials, must be undertaken in accordance with the consideration of relevant legislative and
regulatory requirements, latest revision of TANESCO Standards.
Where the procedural requirements of this document conflicts with contestable project
procedures, the contestable project procedures shall take precedent for the whole project or part
thereof which is classified as contestable. Any external contacts with TANESCO for contestable
project works will be made via the TANESCO officer responsible for facilitating the contestable
project. All other technical aspects of this document, which are not procedural in nature, shall
apply to contestable work projects.
The standard has a summary of contents labeled in “GLOSSARY”. The inclusion or omission of
items in this summary doesn’t signify any specific importance or criticality to the items to the
items described. It is meant to simply provide the reader with quick a assessment of some of the
major issues addressed by the designer. To fully appreciate the content and requirements of the
design it must be read in its entirety.

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REFRENCES
Aaron Stacheweiz Ph.D., PMP; Chris Kluse., Phillip Rufe CMfgE., Product Design and
Development- Chapter 20.
A.Ghosh and A.K Mallik (East-West Press); Manufacturing Science.
Bob Freedman, IH, Certified Lead Auditor (ISO 9001, TS16949, ISO14001)., Quality Standards-
Chapter 48
Buhholz, Marberg, Johnen, Kleingarn, Zink statt Rost, Beratung Feuerverzinken, Dusseldolf,
1989
Bureau for Workers’ Activities (ACTRAV), ILO. Your Health and Safety at Work: A modular
training Package (Geneva).
Burgess ,J.H; Design for Humans; The Human Factor in Engineering, Protocelli Books,
Princenton N.J; 1986. A good text written for the use by engineers.
Chris T., Chris Thomas Associados Madrid, Maintenance – a Business Centre Approach, http://
espania.com/cta/
Design Principles for Precision Mechanisms, H. Soemers, 2010.

Dhilon D.S., Engineering Maintenance, a modern approach, CRC Press, 2002.

Dreyfuss, H.: The Measure of Man: Human Factor in Design, Whitney Library of Design,
NewYork, 1967. This is a loose-leaf book of 30 anthropometric and biomechanical charts
suitable for mounting; two are life-size, showing a 50th-percentile man and woman.
A classic.
Dym, C. L., Little, P., Engineering Design: A Project-Based Introduction, John
Wiley, New York, 1999.
Ertas, A., Jones, J.C., The Engineering Design Process, John Wiley and Sons, New York, 1996.
Exact Constraint Design: Machine Design Using Kinematic Principles, D. Blanding, 1999.

Flurscheim, C. H., “Objectives and techniques of industrial design in engineering”, Industrial

Design in
Engineering a Marriage of Techniques, (ed.), The Design Council London, UK, 1983

G. Pahl and W. Beitz, Engineering Design, A Systematic Approach, Second

Edition, London: Springer-Verlag, 1996.
Hyman, B., Fundamental of Engineering Design, Prentice Hall, New Jersey, 1998.
Jones, J.V.: Engineering Design: Reliability, Maintainability and Testability, TAB Professional
And Reference books, Blue Ridge Summit, Pa., 1988. This book considers engineering
Design from the view of military procurement, relying strongly on military specifications

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and handbooks.
Lumsdaine, E., Lumsdaine, M., Shelnutt, J. W., Creative Problem Solving and
Engineering Design, McGraw-Hill, Inc., New York, 1999.
Moggridge, B.: Designing Interactions, http://www.designinginteractions.com/. An online
book for designing human interfaces for the 21st century.
M.P Groover (John Wiley)., Fundamental of Modern Manufacturing Materials.
Nam P. Suh, The Principles of Design, Oxford University Press, 1990
Norman, D.: The Psychology of Everyday Things, Basic Books, New York, 1988. Guidance
for designing good interfaces for humans; light reading.
Precision Machine Design, A. Slocum, 1992.

Ungureanu N., Fiabilitate si diagnoza, Risoprint, Cluj Napoca, 2003.

Sanders, M. S., McCormick, E. J., Human Factors in Engineering and Design,
McGraw-Hill, Inc., New York, 1993.
System Safety Program Requirements, MIL-STD 882D. U.S. Government Printing Office,
Washington, D.C. http://safetycenter.navy.mil/instructions/osh/milstd882d.pdf. The hazard
assessment is from this standard
The Elements of Mechanical Design, J. Skakoon, 2008.

Tilly, A. R.: The Measure of Man and Woman, Whitney Library of Design, New York, 1993.
An updated version of the preceding classic rewritten by one of Dreyfuss’s associates.
V.K Jain (CRC Press); Micro manufacturing Processed.

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APPENDICES
For complete flow of information to ensure efficient communication with the design the
following are being attached;
 Parts drawings
 Assembly drawing of the product
 Detailed bill of materials

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