CHAPTER ONE

1.1 ABOUT THE INDUSTRIAL TRAINING FUND (ITF)

The Industrial Training Fund (ITF) was established by the decree 47 of 1971 constitution and
charged with the responsibility of promoting and encouraging the acquisition of industrial
skills, with the view of generating a collection of indigenous trained manpower, sufficient
enough to enhance and meet the needs of the economy so as to promote development.
Supervision of students, organization orientation programs and disbursing allowances to
student are some of the roles played by the industrial training fund in the implementation of
Student Industrial Work Experience Scheme (SIWES).

1.2 ABOUT STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

In recognition of the shortcomings and weakness in the formation of SET graduates,

particularly with respect to acquisition of relevant production skills, the Industrial Training
Fund (which was established in 1971 by decree 47) initiated the Students’ Industrial Work
Experience Scheme (SIWES) in 1973. The scheme was designed to expose students to the
industrial environment and enable them develop occupational competencies so that they can
readily contribute their quota to national economic and technological development after
graduation.

Consequently, SIWES is a planned and structured programme base on stated and specific
career objectives which are geared towards developing the occupational competencies of
participants. In spite of the challenges faced by SIWES in the four decades of its existence,
the scheme has not only raised consciousness and increased awareness about the need for
training of SET students, but has also helped in the formation of skilled and competent
indigenous manpower which has been manning and managing the technological resources
and industrial sectors of the economy. Participation in SIWES has become a necessary
condition for the award of degrees and diplomas to SET students graduating from higher
institutions in Nigeria. It is therefore, not in doubt that SIWES is a veritable means or tool for
National Economic Development.

1.3 AIM OF SIWES

The effort is aimed at helping/training students in Nigeria tertiary institutions the practical
aspect of their field of study by exposing them to machines and equipment, professional work
methods and ways of safeguarding the work areas and workers in industries and other
organizations.

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1.4 OBJECTIVES OF SIWES
The Student Industrial Training objectives are:

1. It provides an avenue for students in institutions of higher learning to acquire industrial

skills and experience during their course of study.

2. It expose students to work methods and techniques in handling equipment and machinery
that may not be available in their institutions.

3. It makes the transition from school to the world of work easier and enhance students’ contact
for later job placements and a chance to evaluate companies for which they might wish to work.

4. It provides with the opportunities to apply their educational knowledge in real work and
industrial situations, thereby bridging the gap between theory and practice.

5. The programme teaches the students on how to interact effectively with other workers and
supervisors under various conditions in the organization.

1.5 IMPORTANCE OF SIWES

1. It exposes students to more practical work methods and techniques.

2. It provides students with an opportunity to apply their theoretical knowledge to real life
situations.
3. It enables students to gain experience in handling equipment and machineries.

4. It provides an environment whereby students can develop their creativity and interpersonal
skills through software design techniques.
5. It is one of the award of Bachelors of Science/Technology Degree (B. Sc. / B. Tech.).

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 CHAPTER TWO

2.1 ESTABLISHMENT DESCRIPTION

Avon Crown-caps and Containers Nigeria Limited is a Nigeria manufacturer of metal

packaging products.

Avon manufactures crown-caps, metal containers which are used for packaging of milk
powder, beverages, insecticides, chemicals and agro based products and also metal drums
used by the oil and lubricants industry.

Avon is a member of SEDEX which provides member companies with a secure online
platform for sharing and managing information on four key compliance related areas: health
and safety, labour standards, business ethics and the environment.

Avon commenced commercial operations in 1981 at its state-of-the-art manufacturing facility

at Sango-Otta near Lagos. Since then, it has grown from strength and today, with over 70%
market share, it is the market leader in the Nigeria metal packaging industry.

Avon is part of the Enpee Group;-a diversified transnational conglomerate with interests
across the packaging, construction, energy and chemicals sectors and with over 50 years of
business experience across Africa & Asia.

2.2 ESTABLISHMENT IDEALS

2.2.1 Philosophy:

To build enduring relationships and bonds that rest on the solid foundation of mutual trust
and understanding and to adhere to the highest standards of quality and excellence.

2.2.2 Vision:

To delight customers and satisfy all other stakeholders by continual development and nurture
of people, products, process and environment.

2.2.3 Mission:

To be the customers preferred choice for quality, service, new product development and
collaboration.

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 2.3 ESTABLISHMENT OBJECTIVES/SCOPE OF SERVICE
Avon Crown-caps and Containers Nigeria Limited is committed to:
Providing the packaging industry with outstanding products and services of reliable and
consistent quality.
Producing quality products with a view to establishing itself as the most reliable supplier in
the industry.
Ensuring complete customer satisfaction.
Bringing in continuous improvement and improved organizational
effectiveness. Improving the quality of work through continuous training.
Establishing and reviewing quality objectives periodically.

2.4 ESTABLISHMENT/ORGANIZATION CHART:

2.5 QUALITY ASSURANCE

This concept covers a wide range which as an individual or collectively favours the quality of
manufactured product, it is the overall arrangement made in order to achieve consistencies in
production and standardised quality which is appropriate for it intended usage. It looks
vividly into what happens yesterday, today and tomorrow so as to appropriate and ensure
quality final product.

2.6 QUALITY CONTROL (PLACE OF PRIMARY ASSIGNMENT)

Quality control is used to describe all measures designed to ensure the uniform output of
batches of products that conform to the establishment specification. It is that part that
organises, documents and release or hold product in order to ensure that the necessary and
relevant tests are actually carried out and that the starting material, intermediate and finished
product are not accepted for use, sale or supplied to the customer until their quality has been
judged to be satisfactory.

However, quality control serve as a medium by which the manufacturer measures the actual
quality performance in regard to the standard and takes necessary steps on the courses of the
variation from specification (if there is any) to ensure good quality product.

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 CHAPTER THREE

3.1 INTRODUCTION TO THE LABORATORY

A laboratory is a facility that provides controlled conditions in which scientific activities,

researches, experiments and measurements may be performed. Hence, the crown-cap
laboratory is a laboratory where some quality tests/activities are carried out on crown samples
in other to get information about the product quality.

3.2 GOOD LABORATORY PRACTICE (GLP)

Good laboratory practice is a quality management system which ensure strict compliance to
laboratory rules and regulations. GLP ensures control on storage of chemicals, workers
dressing code, testing equipment’s calibration and do & don’ts in the laboratory environment.
A good laboratory practices follow below conditions:
•All samples in the laboratory must be labelled appropriately.
•Record keeping is essential in the laboratory.
•Do not eat or drink in the laboratory.
•All bottles and containers must be labelled.
•Visitors are not allowed into the laboratory.
•Always beware of glass especially if it is broken and then dispose-off safely.
•Keep your work area tidy and clean up any spills including water on the floor.
•If the emergency alarm sound, make your work safe and leave the building as directed.
•Report any accident you have.

3.3 LABORATORY SAFETY REQUIREMENTS

1. Safety Goggles: Always wear safety goggles to protect your eyes during any activity
involving chemical, flame or heating or the possibility of flying objects, particles or substances.

2. Lab Apron: Wear a laboratory apron to protect your skin and clothing from injury.

3. Breakage Handling: Handle breakable materials such as thermometer and glassware with
care. Do not touch broken glass.

4. Heat Resistance Gloves: Use heat resistance gloves or other hand protection when
handling hot materials. Heating plates, hot water and glassware can cause burns, never touch
hot objects with your bare hands.

5
5. Plastic Gloves: Wear disposable plastic gloves to protect yourself from contact with
chemicals or organisms that could be harmful. Keep your hands away from your face and
disposed-off the gloves safely at the end of the activity.

6. Sharp Objects: Scissors, scalpels, pins and knifes are sharps that can cut or puncture your
skin. Always direct sharp edges and points away from yourself and others. Use sharp
instruments only as directed.

7. Poison: Do not let any poisonous chemicals get to your skin and do not inhale its vapour.
Wash your hands when you have finished with the activity.

8. Flames: Tie back loose hair and clothing and put on safety goggles before working with
fire. Follow instructions from your instructor about lighting and extinguishing flames.
9. Fumes: Poisonous or unpleasant vapours may be produced, work in a ventilated area.
10. Disposal: Chemicals and other materials used in the activity must be disposed-off safely.

11. Hand Washing: Wash your hands thoroughly with soap, water and sanitize your hands
with the aid of hand drier when finished with the activity.

3.4 CROWN LABORATORY EQUIPMENTS, USES AND OPERATING

INSTRUCTIONS

1. Tumbling machine: This is use for tumbling (dust loss) test, to determine the amount of
dust loss by crowns when tumbled in the enclosed chamber with the abrasion of weight. It
has the standard revolution of 23±2 per minute.

Fig. 1: Diagram of tumbling machine

Work/Operating Instructions:

1. Clean the tumbling machine glass chamber with cotton wool.

2. Put the test samples inside the chamber.
3. ON the machine and allow it to rotate for 50 minutes.
4. STOP the machine after 50 minutes and clean the chamber again for another test.
5. If there is no sample to test off the machine.

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2. Secure Seal Tester (Leakage Tester): It is use for crown leakage/secure seal test.

Fig. 2: Diagram of Secure Seal Tester

Work/Operating Instructions:

1. Attach appropriate Fixture to hose.

2. Fill tank with water ‘½.’ From top of observation window.
3. Place Unit to be tested in tank and attach hose to Fixture. Close and latch lid.
4. Turn selector-switch of secure seal tester to TEST until the test pressure reading is
150PSI (Pound per Square Inch).
5. Turn the selector to HOLD at 150 PSI for 1 minute and observe any bubbles during
the test, bubbles indicate failure and if no bubbles test is ok.
6. Then, turn the selector to VENT before removing the bottle.
7. Do all necessary recording at the end of the experiment.

3. Weighing Scale: It is use for weighing material below 210g.

Fig. 3: Diagram of weighing scale

Work/Operating Instruction:

1. Clean the equipment with cotton wool.

2. On the machine, ensuring display shows, 0.0000g.
3. Open one side of the balance and place the material to be weighted on the weighting
container, close the open side.
4. Record the figure display on the screen.

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 5. Open one side of the balance and remove the material weighted.
6. Close the opened side and off the machine.
7. Do not weight any material above 210g on the scale.

4. Capping Machines: It is use in capping crowns for leakage test. There are three types
namely;

• Manual capping machine: This is a type of capping machine that is simple and versatile,
no power needed and fit a large range of caps.

Fig. 4: Diagram of manual capping machine

Work/Operating Instruction:
1. Adjust the capping head to the size of required bottle.
2. Position the bottle ensuring it align with capping head.
3. Put the crown to be capped inside the capping head.
4. Press the capping handle down.
5. Remove the capped bottle and check crimp diameter using crimp gauge.
6. If the crimp diameter is not okay, repeat step 4 until required diameter is got.
7. Record your observation.

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• Automatic capping machine: This is also a type of capping machine which is powered by
pneumatic (compressed air/gas) and is suitable for any size of the bottle.

Fig. 5: Diagram of automatic capping machine

Work/Operating Instructions:

1. Carefully inspect the set up and ensure that there is no gas leakage in any part of the
set up.
2. Check the capping machine if it is well set for required height of the bottle, if not,
adjust to fit the height of the bottle.
3. Carefully use capping machine to crown the bottle.
4. Check the crimp diameter by using the crimp diameter gauge.
5. If the crimp diameter is not okay, repeat step 4 until required diameter is got.
6. Record your observation.

• Semi-automatic capping machine: This is also a type of crown capping machine, it is

simple and very versatile. It is also powered by pneumatic (compressed air). Will also fit a
large of caps.

Fig.6: Diagram of semi-automatic capping machine

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 Work/Operating Instruction:

1. Adjust the machine to the size of required bottle.

2. Position the bottle ensuring it align with capping head.
3. Put the crown to be capped inside the capping head
4. Use leg to press the pedal.
5. Remove the capped bottle and check crimp diameter using crimp gauge.
6. If crimp diameter is not okay repeat step 4 & 5 until required diameter is got.
7. Record your observation.

5. Pasteurizer & Water Bath: it is use for boiling of crown samples during crown boiling test.

Fig.7: Diagram of pasteurizer and water bath

Work/Operating Instructions:
1. Fill the water bath with water up to three quarter level.
2. Switch ON the water bath and allow the water to boil (i.e.100 C)̊.
3. Get the crown samples prepared into the perforated cans.
4. Put the crown inside the boiling water with the aid of perforated can(s) and cover the
water bath.
5. Allow the crown to stay in the boiling water for 30 minute (at 100 C)̊
6. Remove the perforated cans from water bath.
7. Switch OFF the water bath.

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6. SALT SPRAY CORROSION TEST MACHINE: It is use for crown-caps corrosion test.

Fig.8: Diagram of salt spray corrosion test machine

Operating Instructions/Precautions:
1. Check Air Saturated water level before every new test & use only DM water.
2. Maintain safe distance from the chamber while opening the door.
3. After completing the test and before opening the door use air purge feature.
4. Read Instruction Manual before operating.
5. Test Air Pressure 0.7 to 1.2 Kg / Cm².
6. Required PH Value 6.5 to 7.2pH.

3.5 OTHER LABORATORY EQUIPMENTS/MATERIALS AND THEIR USES


Gas volume tester: for testing the volume of gas during CO2 retention test.

Crown height gauge: for measuring crown height.

Crown diameters gauge: for measuring crown diameters.

Crown centre panel and ring height gauge: for measuring crown centre panel and ring
height.

Crimp diameter gauge: for measuring crown crimp diameter after capping.

Flange angle tester: for measuring crown flange angle.

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3.6 CROWN PRODUCTION MACHINES, USES & OPERATING INSTRUCTION

1. Crown Punching Machine (PTC): It is use for punching printed sheet for crown
production.

Fig.9: Diagram of crown punching machine (PTC).

Work/Operating Instruction:

1. Clean the machine surrounding area, chips separator and waste box.
2. Clear all crown lying on the conveyor, tray and floor.
3. Check level of lubrication in the tray and fill if required.
4. Check the air pressure.
5. Switch ON the main motor.
6. START the machine and punch one sheet.
7. Set the deco as per design
8. Punch five sheets. There should not be any variation in deco setting.
9. After approval of quality control (Q.C) personnel run the machine in auto mode
continuously.
10. Record all the machine data in prescribed format.
11. In case of any abnormality, STOP the machine and inform the supervisor.

2. Crown Lining Machine (PMC): It is use for lining crown during production after
punching by the PTC machine.

Fig.10: Diagram of crown lining machine (PMC).

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Work/Operating Instruction:
Check the crown hopper and compound drum to ensure that the desired materials are inside.
1. START the chiller, if OFF.
2. Check the compressed air pressure: it should not be less than 6 bars
3. Switch ON the PMC machine and the cooling conveyor.
4. Switch ON the CVS camera.
5. Switch ON the extruder heater.
6. Check the temperature of the extruder zones.
7. Start the extruder motor to flush the extruder properly.
8. Set the extruder speed to the required liner weight.
9. Run the m/c in automatic mode and produce some crowns
10. Check the adhesion of the liner to the crown.
11. Visually check the profile of the liner and confirm the quality of the crowns.
12. Run the m/c for mass production, having confirmed the quality of the crowns
13. If you notice any abnormality in m/c or crown, inform the shift supervisor immediately.

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 CHAPTER FOUR

4.1 CROWN LABORATORY QUALITY ACTIVITIES/CHECKS AND THEIR

WORK INSTRUCTIONS
4.1.1 LEAKAGE (PRESSURE RESISTANCE) TEST.

Leakage test is performed to identify weak spots as well as to improve product design. The
test is performed by using high pressure (150 Pounds per Square Inch;PSI) to check if there is
a pressure to check if there is a pressure drop caused by an unintended crack or hole.

The test is carried out to improve the seals and also to determine minimum and maximum
burst pressure. Leakage tests are often performed before the distribution process in order to
meet the safety and quality standards. The test can be detected by bubbles when submerged
the pressurize object in water.

AIM: To identify weak spots as well as to improve product design. To determine minimum
and maximum burst pressure.
SAMPLE SIZE: 24 crowns for PMC 1, 2, 3 & 4 while 36 crowns for PMC 5.
FREQUENCY: one per day running job.

EQUIPMENTS/MATERIALS USED: Capping machine, crimp diameter gauge, secure seal

tester (leakage tester), stopwatch, crown opener.
WORK INSTRUCTIONS/PROCEDURE:

1. Necessary. Pick 24 crowns representing 24 punches of PMC1-4 and 36 crowns

representing 36 punches of PMC 5.
2. Take the crown to the crown laboratory.
3. Follow the steps in the attached work instruction on capping machine and secure seal
tester in the laboratory.
4. Record your observation in leakage test chart.
5. If any leakage, stop the PMC machine. Hold the lot for further actions.
6. Report to QAS/designate for immediate action.
STANDARD RESULT: No leakage at 150PSI for one minute.

4.1.2 TUMBLING (DUST LOSS) TEST

This is also a quality check/activity carrying out on product crown once per day for every
running job using 50 pieces of crown (as sample size). Tumbling is done to determine the
amount of dust loss by the sample crown and to know the durability of the product by using
Tumbling machine.

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AIM: To check for the durability of crown decoration (deco).
SAMPLE SIZE: 50 Crowns.
FREQUENCY: One per day running job.
EQUIPMENTS/MATERIALS USED: Tumbling machine, weighing scale, cotton wool.
WORK INSTRUCTIONS/PROCEDURE:
1. Select at random two sets of twenty five crowns.
2. Clean the first twenty five crowns with cotton wool/air blowing and take the initial
weight on the weighing balance.
3. Record the initial weight before tumbling.
4. Place the weighed crowns inside the tumbling machine and allow to rotate for 50
minutes.
5. Remove the crowns inside the tumbling machine and clean again with cotton wool and
record the weight obtain.
6. Subtract the second reading from the first reading and record the difference on a paper.
7. Repeat the same procedure for the remaining twenty five crowns sampled earlier.
8. Add the result of the twenty five and the second twenty five together and divide it by
two (2). The result obtain is the dust loss of the crowns.
9. Discard both sets of twenty five crowns after the test.
10. Record the result.
STANDARD RESULT: ≤35mg

4.1.3 CORROSSION TEST

This is also a daily quality check/activity that is carried out on 27 shells punch wisely using
Copper sulphate solution (CuSO4). Corrosion test is done to check for the rusting ability of
the crown when in contact with liquid i.e. corrosion resistance of materials.
AIM: To check corrosion resistance of materials (crown) and surface coatings (Lacquer).
SAMPLE SIZE: 27 shells punch wise.
FREQUENCY: Once per day running job.
EQUIPMENTS USED: Beaker
WORK INSTRUCTIONS/PROCEDURE:
1. Pick 4 crowns randomly of running job.
2. Pour a prepared copper sulphate solution in a beaker and put the crowns inside. Ensure
the crowns are submerged.

3. Shake and allow the crowns to stay for a minute. Then pour out the copper sulphate
solution and rinse the crowns with water.
4. Use cotton wool to clean/dry the crowns.

15
 5. Visual inspect for rust on both inside and outside of the crowns.
6. If rust is observed, stop production and hold the produced lot for further investigation/test.
7. Record your observation in corrosion test chart.
8. Inform QA supervisor/Designate for necessary action.
STANDARD RESULT: No rust marks after one minute inside copper sulphate solution.

4.1.4 BOILING (PASTEURIZATION) TEST

This is a quality checks/activity that is carried on crown to check for the liner adhesion and
deco adhesion when subject to boiling at 100 ̊C for 30 minutes.
AIM: To check for the liner adhesion and deco adhesion.
SAMPLE SIZE: 2 Crowns per carton. FREQUENCY:
Every carton produced. EQUIPMENT USED: Water
bath, perforated cans. WORK
INSTRUCTION/PROCEDURE:
1. Fill the water bath with water up to three quarter level.
2. ON the water bath and allow the water to boil (i.e100 C)̊.
3. Collect the lined crown from all the concerned PMCs by taking 2pcs from each carton
produced from them and number them accordingly.
4. Put the crown inside the boiling water with the aid of perforated can(s) and cover
the water bath.
5. Allow the crown to stay in the boiling water for 30 minute (at 100 ̊C)
6. Remove the cans from water bath and collect the crowns and carefully inspect them
for any PVC and print peeling or shrinking and cracking respectively.
Any peeling or cracking of PVC or print notice should be reported immediately to quality
assurance supervisor for needful.
STANDARD RESULT: No liner peeling and print peeling or shrinking and cracking
respectively.

4.1.5 PULL TEST

This is also a quality activity that is carried out to check for the liner adhesion if meet the
standard.
AIM: To check for the liner adhesion.

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SAMPLE SIZE: 24 Crowns for PMC 1, 2, 3 & 4 While 36 crowns for PMC 5
FREQUENCY: Every 2 hours.
MATERIAL USED: Knife

WORK INSTRUCTION/PROCEDURE:
1. Collect 24 samples of crowns (representing 24 punches) from each machine (PMC 1-
5), every two hours.
2. Pull the inlay with knife from the shell to know if the inlay pulls easily. If it pulls
easily, tell the production supervisor for correction.
3. Record your observation in the chart.
STANDARD RESULT: The liner should not pull easily.

4.1.6 SCOTCH TAPE TEST

This is a quality activity that is carried out to check for the durability of the printed sheet
before punching.
AIM: To check for the durability of the printed
sheet. SAMPLE SIZE: One printed sheet per
stillage. FREQUENCY: Once per day running job.
MATERIALS USED: Tape and printed sheet.
WORK INSTRUCTION/PROCEDURE:
1. Pick one sheet from the stillage.
2. Apply the tape on the printed side.
3. Forcefully pull the tape.
4. Record your observation.
STANDARD RESULT: The print should not peel with the tape.

4.1.7 CVS CAMERA CHECKING

This is a quality activity that is carried out to know the performance of the rejection camera.
The rejection camera is the camera that reject any crown with any defects either liner defect
or deco defect as well as the foreign crown.

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AIM: To know the performance/working status of the rejection camera.
SAMPLE: Introduction of foreign crowns.
FREQUENCY: Every 2 hours.
MATERIAL USE: Foreign crown.
WORK INSTRUCTION/PROCEDURE:
1. With the assistance of the operator, put 4 foreign crowns on the lining hopper
2. Collect the rejected foreign crowns from the rejected tray.
3. Do recording into the camera performance chart.
4. This checking is done at 2 hours interval.
STANDARD RESULT: The camera should reject all foreign crowns introduced.

4.1.8 LINING WEIGHT

This is a quality activity that is carried out to check if the weight of the inlay (liner) is within
the production standard.
AIM: To check for the liner weight is within standard.
SAMPLE SIZE: 4 peel-able shells. FREQUENCY: Every 2
hours. MATERIALS/EQUIPMENTS USE: Weighing scale,
forceps WORK INSTRUCTION/PROCEDURE:

1. With the assistance of the operator, put 4 peel-able shells on the lining hopper
2. Collect the lined peel-able crowns from the rejected tray.
3. Peel the inlay.
4. Weigh the inlay one after the other on the weighing scale (the 4 inlay weights got give
the actual minimum and maximum inlay weight obtainable on all the punches of the PMC)
5. Do recording of each in lining weight chart.
6. Variation should not be more than 4mg and all must fall within standard range weight.
In case of non-conforming, stop the machine and report to QAS/designate for immediate
necessary action.
7. This checking is done at 2 hours interval.
STANDARD RESULT: The weight must be within the standard (175±10kg)

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4.1.9 PROGRAMMABLE MACHINE CONTROL (PMC) COUNTER VERIFICATION

This is also a quality activity that is carry out in order to verify the machine automatic count
and to know and aware of the machine counter status/performance.
AIM: To know the working status of machine automatic count.
SAMPLE SIZE: 10 crown sheets.
FREQUENCY: One machine per day.
EQUIPMENTS/MATERIALS USED: Crown sheets, PTC machine, Sample tray,
PMC machine.
PROCEDURE:
1. Take 10 crown sheets from running job to PTC machine for punching.
2. Check PTC machine thoroughly to ensure no left over shell.
3. Punch the 10 sheets and collect them after screen at the elevator hopper.
4. Take the punched shell to PMC machine.
5. Check PMC hopper and check to ensure no left over crowns.
6. Pass the punched shells (675*10=6,750 pcs) through PMC machine.
7. Check the PMC user interface display for number of shells counted by PMC counter.
8. If the quantity display is not exactly 6,750, stop the PMC machine and inform crown
manager/maintenance department.
9. Record observation in counter verification register.
STANDARD RESULT: The quantity displayed by PMC counter must exactly be 6,750.

4.1.10 CROWN COUNTER VERIFICATION

This is a quality check that is carry out in every two weeks also to verify the machine
automatic counting.
AIM: To verify the machine automatic count.
SAMPLE SIZE: One carton in two weeks
FREQUENCY: Once in two weeks
MATERIALS USE: Hand gloves, Carton, Sample tray.
PROCEDURE:
1. Pick a completed carton of crown.
2. Count the crowns using counting trays/otherwise.

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 3. Counting must be done in a clean environment to avoid foreign crown.
4. Record your actual counting and compare with standard(machine counting)
5. Report if any variation to the Q.C. supervisor for necessary action.
STANDARD RESULT: The result must be 10,000 per carton.

4.1.11 SHELL CHECKING

This is also a quality activity that is carried out in order to check and confirm the product
(crown) height, outer diameter & flange angle is within
AIM: To check if the crown production height, outer diameter and flange angle is within
standard.
SAMPLE SIZE: 27 shells punch wise
FREQUENCY: Every two hours.
MATERIALS/EQUIPMENTS USE: Crown sheet, Permanent maker, Crown outer diameter
(OD) gauge, Crown height gauge and Flange angle tester.
WORK INSTRUCTIONS/PROCEDURE:
1. Take a crown sheet and turn it to the unprinted side.
2. Mark number 1 to 27 (represents 27 punch heads of PTC) systematically using
permanent marker and a crown sheet skeleton.
N.B: The sheets are to be marked as per the design of the PTC die.
3. Give the marked sheet to the PTC operator for punching.
4. Collect the punched shells and select the marked shells.
5. Take the marked shells to the laboratory for checking.
6. Do the checking using the OD gauge for outer diameter, height gauge for crown height
and flange angle tester for flange angle.
7. Record your recordings in shell check chart.
STANDARD RESULT: Must conform to crown production standard for height, outer
diameter and flange angle.

4.1.12 CARBON-DIOXIDE (CO2) RETENTION TEST.

This is one of the quality activity that is carried out once in a while, whenever there is
introduction of new material(s). It is carried out to know how the new product will retain the
carbon-dioxide (CO2) content of beverages after capping.
AIM: To know the new material ability to retain the CO2 gas.

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SAMPLE SIZE: 7-21 crowns.
FREQUENCY: Whenever there is introduction of new material (pvc/pvc
free/lacquer/machine).
EQUIPMENTS/MATERIALS USE: Bottles, capping machine, crimp diameter gauge, gas
volume tester, pasteurizer.

WORK INSTRUCTION/PROCEDURE:
1. Fill up seven (7) bottles 0.1N (H2S04 acid) leaving head space.
2. Add 4grams of NaHC03 to each bottles.
3. Crimp the bottle with crown-caps (ensure good crimping using appropriate crimping
gauge).
0
4. Pasteurize the bottles at 68 C and leave to cool overnight.
5. Check one bottle for initial volume by means of relevant equipment and chart
(pressure gauge and gas volume chart).
6. Record the result on C02 retention chart.
7. After one week, check two of the bottles as in method 5.
8. At the end of third week check the remaining bottles as in method 5.
9. Compare the volume got in all bottles with the initial volume and make a remark.
10. Any cap losing more than 0.2 gas volume is considered a failure.
STANDARD RESULT: Okay/ Fail.

4.1.13 FINAL INSPECTION.

This is a quality activity that is carried out on crowns to inspect for any visual defect.
AIM: Observation of any visual defect.
SAMPLE SIZE: 500 pieces of crown.
FREQUENCY: Every 3 hours of production.
WORK INSTRUCTION/PROCRDURE:
1. Randomly collect 500 pieces of crowns on running PMC machine.
2. Spread the crowns on a table/otherwise close to the PMC machine.
3. Do visual checking for deco & liner integrity parameters.
4. If a defects is observed, stop the machine from further production and order for correction.

If it is a critical or major defect, the produced lot is held for further analysis. If in-case it is
minor defect, if the sum of all minor defect is more than five crowns then the production lot
is held for further analysis.
5. Record your observation.
6. Inform QAS for necessary action.

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4.1.14 JOB LABELLING
This is also a quality activity that is carry out repeatedly for every running job so has to
release every job that has satisfy the quality specifications and requirements and to put on
hold any job that has not completely satisfied all quality specifications and requirements.
AIM: To identify a defect product from non-defect one so as to release the non-defect one for
transfer.
FREQUENCY: Every container pallet of every job.
WORK INSTRUCTIONS/PROCEDURE:
1. Place a material in-process card (Yellow card) on the container of every job that has
successfully undergone a production stage and which satisfied all quality
specifications and requirements, but which has not undergone the final production
(consumption stage) in the factory.
2. Fill all information spaces on the card-next destination, production date, job, quantity,
shift, machine, QC remarks and QC sign-completely.
3. Place a release card on the container pallet of every job that has successfully
undergone the last production stage, and which satisfies all quality specifications and
requirements.
4. Place a hold card on the container of every job at any stage, which has not completely
satisfied all quality specifications and requirements. The hold card among other
information should specify clearly the defects.

4.1.15 CERTIFICATE OF ANALYSIS (COA) PREPARATION).

COA is a document issued by Quality Control Personnel that confirms that a regulated
product meets its product specification.
It commonly contain the actual results obtained from tests performed (e.g. outer diameter,
inner diameter, boiling test, dust loss test, corrosion test etc) as part of quality control of an
individual batch of a product. Certificate of Analysis also consist of relevant batch number in
the appropriate place.
AIM: To confirm that a regulated product meets its product specification.
SAMPLE SIZE: 40 Crowns.
FREQUENCY: Every production batch.
EQUIPMENTS/MATERIALS USE: Crown height gauge, Crown OD gauge, Crown ID
gauge, weighing scale.
WORK INSTRUCTION/PROCRDURE:

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 1. Pick 40 crowns from production batch.
2. Using outer diameter gauge, inner diameter gauge and height gauge, check the OD, ID
and height respectively.
3. Record your readings on COA chart.
4. Record the ranges of your dimensional readings in the chart.
5. Use final inspection chart and visual inspection of the forty crowns picked in step 1 for
attributes observation recording.
6. Record your result of boiling test, corrosion test and dust loss test in the chart.
7. Record the quantity to be dispatched and batch in the chart.
8. Print out the duly completed COA chart.
9. The crown analyst signs and the HOD signs the print out COA.
10. Record the required information (job, quantity, etc.) in COA register.
11. Give the COA to FGS (Finish Goods Store) representative, ensure the representative
sign it.
STANDARD RESULT: Okay/Fail.

4.1.16 CHECKING/TESTING OF INCOMING CARTONS

This is also a quality check that this carried out on product packaging materials from the
suppliers to know if meet the required standard.
SAMPLE SIZE: Two cartons per lorry
FREQUENCY: Every batch of lorry supply.
WORK INSTRUCTION/PROCEDURE:
Check the following carton dimensions and compared with the QAD standard
1. The internal length of the carton; which must be within the range: 460±5mm.
2. The internal width and internal height of the carton; which must be within the range:
305±5mm.
3. Check the weight of the carton which must be within the range: 0.80±0.05kg.
4. Check the plyer of the carton, must be (5 plyers)
5. Check any visual defect on the following:
a. Stapling-should be cupper and not iron.
b. Printing (compare with the standard).

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c. Texture.
6. Carry out the parking test on the carton by using it to pack and then smoothly seal the
carton using gum tape .Carefully observe if there is any difficulty in the process.
7. Do drop test by dropping a crown filled carton flatly on the floor at height 5 feet. Pins
should not remove and not burst.
8. If all test and checks are okay, accept the cartons, if not reject.
4.1.17 CHECKING/TESTING OF INCOMING POLYBAGS
This is also a quality check that this carried out on product packaging materials from the
suppliers to know if meet the required standard.
SAMPLE SIZE: Two polybags per batch supply.
FREQUENCY: Every batch supply. WORK
INSTRUCTION/PROCEDURE:
1. Check the length of the poly bag which must be 860 ± 10mm
2. Check the breadth of the poly bag which must be 460 ± 5mm
3. Check the gusset of the poly bag, which must be 180 × 180 ±5 mm
4. Check the thickness of the poly bags which must be 0.05mm
5. Carry out packing test by using it to pack required job quantity. The nylon must not
tear.
6. If all tests proved okay accept the poly bags, if not okay hold and generate report for
disposition.

4.1.18 CHECKING/TESTING OF INCOMING GUM TAPES

This is also a quality check that this carried out on product packaging materials from the
supplier to know if meet the required standard.
SAMPLE SIZE: One gum tape per batch.
FREQUENCY: Every batch of gum tapes supply.
WORK INSTRUCTION/PROCEDURE:
1. Check the width of the gum tapes which must be within the range: 48 ± 0.2mm.
2. Apply the tape on the carton and try to remove it, it must tear along part of the carton.
3. If not satisfactory with standard, hold and report to Quality Assurance Supervisor for
needful.
4. Record observation /result.

4.2 OTHER LABORATORY QUALITY ACTIVITIES


Crown Height: During shell checking and COA preparation using crown height gauge.
Standard result; 5.95±0.1mm.

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 
Crown Outer Diameter: During shell checking and COA using crown outer diameter
gauge. Standard result; 32.05±0.2mm.

Flange angle: During shell checking using flange angle tester. Standard result; 16 ±ͦ4 ̊

Crown inner diameter: During shell checking and COA using crown inner diameter gauge.
Standard result; 26.8±0.1mm.

Crimp diameter: During leakage test using crimp diameter gauge. Standard result;
28.7±0.1mm.

Liner ring height and centre panel: During shell checking using crown centre panel and
ring height gauge.

4.3 Some Crown Quality Defects and Meaning

1. Off-Deco: when crown exterior decoration is not centred.
2. Misprint: when the crown decoration is not at the right position or when there is a slight
deviation from the print as compared to LSD.
3. Half Lining: when the interior profile of the liner has a slight cut.
4. Scratches: when a traces of forceful peel occur on the exterior part of the crown.
5. Colour variation: when the colour of the supplied stillage doesn’t match the LSD (light,
standard & dark) reference.
6. Liner peeling: the peeling of crown liner
7. Deformed crown: is any crown that has damages
8. Empty crown: crown without liner.
9. Inlay stain: stain in the liner.
10. Air pocket: enclosure of air under the liner/ an air space underneath a liner in form of
water swollen beneath it.
11. Double liner: when two liners accidentally fill one crown.
12: Spillage: spread out of liner beyond the marks.

4.4 REASONS FOR POOR QUALITY MANUFACTURED PRODUCTS

There are so many reasons why manufactured products may not attain the desired
specification. This is very important to be considered due to the impression that poor quality
may create in the market. These highlights below explain in details the concept.
1. STARTING MATERIALS: Inability to ensure proper monitoring of raw materials right
from delivery, prior production or handling of these materials before (i.e. storage condition)
goes a long way in affecting the overall quality of the production.
2. PERSONNEL: There is need for proper training of production workers in order to give them
basic knowledge about the whole production and how to ensure Good Manufacturing Practice.

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Also there is need to put in place skilled and experienced people in the field that can bring
innovation and apply their mind positively, to bring about reasonable productivity.
3. MANAGEMENT: There should be cordial relationship between the employee and the
employer, to facilitate and motivate the workers to be more productive. This encompasses the
health status of the workers, good working environment etc.
4. MACHINE: Machine must be well operated so as to obtain optimum result. Therefore, the
need for technical knowhow must come in. Also machine must be designed to suit the
manufacturing process and to be maintained under a perfect working condition.
5. PROCEDURE: Failure to strictly follow the laid down standards and due process may
result in poor quality of the products.

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 CHAPTER FIVE

5.1 SUMMARY OF ATTACHMENT ACTIVITIES

During my training period at Avon Crown caps & Containers Nigeria Limited as a SIWES
student, I was introduced to the laboratory, laboratory safety requirements, laboratory
equipment, production machines as well as the quality activities carried out in the laboratory.
I also involved in carry-out some daily quality activities/checks and imputation of the
activities result on to the server and into the chart in which I was able to grasp adequate
knowledge and understanding regarding quality assurance and quality control in production.

5.2 SIWES CHALLENGES (CHALLENGES ENCOUNTERED)

The main problem I encountered were getting placement and transportation. It was a quite
challenge for me that I live in far place to get to the organization every working day and as well
as getting back to my destination after each working day. I was not given any remuneration or
allowance, therefore, resulting to financial difficulties arises as a result of transportation.

Laziness of workers is also another challenge I experience. The high rate of laziness
exhibited by some workers in the factory where I undergo my industrial training is quite
alarming. Majority of these workers sometimes sees and takes the internship students as
servants. For instance, instead of the students to be properly taught and shown the major
activities, they’re now being instructed to carry out irrelevant jobs.

5.3 RECCOMMENDATION
In view of the relevance of the SIWES program, it is important that it is sustained by the
government through the Industrial Training Fund (ITF) as it exposes the student to work
tools, facilities and equipment that may not be available in their respective institutions in
relation to their course of study.
To this end, I recommend that the following under-listed points should be implemented:
i. Students’ Industrial Work Experience Scheme (SIWES) needs to be strengthened by all
concerned stakeholder in order for its objectives to be fully realized.
ii. Regular monthly allowances for students on attachment should be paid promptly.
iii. Organization should always accept students for SIWES and subsequently assign them to
relevant jobs.
iv. Experience staff should always be made to train the students on attachment.

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 v. Employers of labour accepting internship students should always ensure that they’re
properly monitored, taught and disciplined. The I.T Students shouldn’t be treated as servants
all because they came for training.
vi. They should be supported by the organization (no matter how small) with money probably
daily, weekly or monthly for their transportation and service.

5.4 CONCLUSION
My six months Industrial attachment with Avon Crown-caps & Containers (Nig.) Limited has
been one of the most interesting, productive, instructive and educative experience I have ever
gained. Through this training, I have gained new insight and more comprehensive
understanding about the real industrial working condition and practice and also improved my
soft and functional skills as well as industrial skills.
All these valuable experiences and knowledge that I have gained were not only acquired
through the direct involvement in task but also through other aspects of the training such as;
work observation, supervision, interaction, supervisors superior and other people related to
the field. It also exposed me to some certain things about quality control (Q.C). And from
what I have undergone, I am sure that the Industrial Training Programme has achieved its
primary objective.
I therefore conclude that SIWES is of great benefit to students in tertiary institutions, though
it is confronted with series of challenges which may have hindered the realization of the goals
and objectives of the scheme.

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