BAYERO UNIVERSITY KANO

DEPARTMENT OF CHEMICAL AND

PETROLEUM ENGINEERING

FACULTY OF ENGINEERING

TECHNICAL REPORT ON STUDENT INDUSTRIAL

WORKING SCHEME (SIWES)

VITAFOAM NIGERIA PLC

UBAIDULLAHI ABDULLAHI OBADAKI

ENG/17/CHE/00247

4TH November 2021

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 CERTIFICATION

This is to certify that, Ubaidullahi Obadaki of Chemical Engineering department in the Faculty

of Engineering participated in the Student Industrial Work Experience Scheme (SIWES 1) for

the period of 8 weeks.

DECLARATION

I, Ubaidullahi Obadaki here by declare that this report was written by me and it was based on the

knowledge and experience gained from my SIWES.

Signature Date:

2
 ACKNOWLEDGEMENT

Firstly, I will like to give all thanks and appreciation to almighty Allah for allowing me come

this far and have the experience of SIWES 1 in good health. I would also like to appreciate my

parents for supporting me throughout my SIWES program. I would also like to give thanks to my

elder sister who helped me get into the company I did my SIWES program and also advised me

on how to conduct myself at the company.

Special thanks to my industry-based supervisor Mr Sunday zakari, The entire staff of vitafoam

Nigeria Plc and my fellow SIWES students. I would like to acknowledge my friends Comfort

Abutu Joseph and Emmanuel Ebong who kept in contact with me during my SIWES program

and made things lively.

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TABLE OF CONTENTS
CHAPTER ONE..............................................................................................................................5
1.0 INTRODUCTION.................................................................................................................5
Brief History of SIWES.........................................................................................................5
CHAPTER TWO.............................................................................................................................7
2.0 GENERAL PRINCIPLES OF MANAGEMENT..................................................................7
2.1 DATA ABOUT THE COMPANY........................................................................................7
2.1.1 Name of Company..............................................................................................................7
2.1.2 Address of Company...........................................................................................................7
2.2.1 ORGANIZATIONAL SET-UP OF THE COMPANY......................................................8
2.3 PROFESSIONAL ETHICS.................................................................................................13
2.3.1 Policy Statement...............................................................................................................13
CHAPTER THREE.......................................................................................................................14
3.0 ANALYSIS OF PRODUCTION.........................................................................................14
3.1 ERGONOMICS...................................................................................................................14
3.1.1 Problems encountered during SIWES...............................................................................14
3.1.2 Provision of safe work Methods and Environment...........................................................16
3.2 Products/Services.................................................................................................................20
3.2.3 Ingredients and Composition............................................................................................24
3.2.4 Images and related data.....................................................................................................25
3.3 QUALITY ENGINEERING................................................................................................32
3.4 Maintenance Engineering....................................................................................................34
3.4.1 Maintenance policy...........................................................................................................34
3.4.2 Material Procurement........................................................................................................35
CHAPTER FOUR.........................................................................................................................37
4.0 CONCLUSION....................................................................................................................37
4.1 REFERENCE.......................................................................................................................38

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CHAPTER ONE
1.0 INTRODUCTION
Brief History of SIWES

SIWES was established by ITF (Industrial Training Funds) in the year 1973 to solve the problem

of lack of adequate proper skills for employment of tertiary institution graduates by Nigerian

Industries. The Students’ Industrial Work Experience Scheme (SIWES) was founded to be a skill

training programme to help expose and prepare students of universities, polytechnics and

colleges of education for the industrial work situation to be met after graduation. This scheme

serves as a smooth transition from the classroom to the world of work and further helps in the

application of knowledge. The scheme provides students with the opportunity of acquainting and

exposing themselves to the experience required in handling and managing of equipment and

machinery that are usually not made available in their institutions.

Before this scheme was established, there was a growing concern and trend noticed by

industrialists that graduates of higher institutions lacked sufficient practical background for

employment. It used to be that students who got into Nigerian institutions to study science and

technology were not trained in the practical know-how of their various fields of study. As a

result, they could not easily find jobs due to the lack of working experience.

Therefore, the employers thought that theoretical education going on in higher institutions was

not responsive to the needs of the employers of labour. This was a huge problem for thousands of

Nigerians until 1973. It is against this background that the fundamental reason for initiating and

designing the scheme by the fund in 1973/74 was introduced.

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The ITF organization (Industrial Training Fund) made a decision to help all interested Nigerian

students and established the SIWES program. It was officially approved and presented by the

Federal Government in 1974. The scheme was solely funded by the ITF during its formative

years but as the financial involvement became unbearable to the fund, it withdrew from the

scheme in 1978. In 1979, the federal government handed over the management of the scheme to

both the National Universities Commission (NUC) and the National Board for Technical

Education (NBTE).

Later, in November 1984, the federal government reverted the management and implementation

of the scheme to ITF. In July 1985, it was taken over by the Industrial Training Fund (ITF) while

the funding was solely borne by the federal government. (Culled from Job Specifications on

Students Industrial Work Experience Scheme).

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CHAPTER TWO
2.0 GENERAL PRINCIPLES OF MANAGEMENT

2.1 DATA ABOUT THE COMPANY

2.1.1 Name of Company

Vitafoam Nigeria Plc

2.1.2 Address of Company

Independence Road, Mai Malari street.

Commencement date

13th August 2021

Activities of The Company

Vitafoam is a foremost manufacturer of premium polyurethane foam products. Specializes in

production and sale of mattress, pillows, furniture, beddings etc.

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 2.2.1 ORGANIZATIONAL SET-UP OF THE COMPANY
ORGANOGRAM OF VITAFOAM KANO

GENERAL MANAGER

FACTORY MANAGER

SECRETARY MARKETING PRODUCTION PRODUCTION FINANCIAL

MANAGER MANAGER ENGINEER CONTROLLER

STORE KEEPER ASSISTANT KEY

MAINTENANCE
HUMAN PRODUCTION ACCOUNTANT
RESOURCES MANAGER
MARKETERS

LOGISTICS QUALITY OPERATORS

MANAGER CONTROL
DEPARTMENT

DRIVERS
ELECTRICAL MECHANICAL WORKSHOP
DEPARTMENT DEPARTMENT

GENERAL MANAGER
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Also known as managing directors or chief operating officers, general managers are tasked

with overseeing daily business activities, improving overall business functions, training heads of

departments, managing budgets, developing strategic plans, creating policies, and

communicating business goals.

FACTORY MANAGER

The factory manager oversees the workers and the equipment, and operates on the factory floor.

He is responsible for carrying out production strategy decision and supervising the production

process.

PRODUCTION MANAGER

The production manager oversees the production process and operations. He supervises all the

factory ground operations and gives detailed report on a daily bases to the factory manager. He is

also in charge of giving out work materials to the staffs.

ASSISTANT PRODUCTION MANAGER

The assistant production manager assists the production manager in carrying out his duties, he is

in charge of checking the amount of scrap generated .

PRODUCTION ENGINEER

The production engineer oversees all maintenance, repairs and fabrication in the factory. He is

the head of all the technicians and submits a daily report to the factory manager.

FINANCIAL CONTROLLER

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Also known as financial comptrollers or chief accounting officers, financial controllers are

tasked with overseeing day-to-day accounting functions, integrating finance operations,

forecasting and budgeting, handling tax matters, preparing financial reports, and ensuring

organizational financial stability.

HUMAN RESOURCE

In simplest terms, the HR (Human Resources) department is a group who is responsible

for managing the employee life cycle (i.e., recruiting, hiring, onboarding, training, and firing

employees) and administering employee benefits.

MAINTENANCE

Maintenance is the function whose objective is to ensure the fullest availability of production

equipment, utilities and related facilities at optimal cost and under satisfactory conditions of

quality, safety and protection of the environment.

MARKETING MANAGER

The marketing manager is in charge of the organization's entire marketing activities and

therefore handles formulating, directing and coordinating marketing activities so as to

influence customers to choose the organization's products over those of competitors.

SECRETARY

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 Ensuring meetings are effectively organized and minuted. Maintaining effective

records and administration. Upholding the legal requirements of governing documents,

charity law, company law etc (where relevant). Communication and correspondence

KEY ACCOUNTANT

Developing and managing a portfolio of Key Accounts, Achieving monthly sales targets by

identifying and developing new customers.

Ensuring high levels of customer satisfaction as well as up-sell and cross-sell potential within

existing customers to maximize share of wallet.

STORE KEEPER

The storekeeper is responsible for the maintenance of a department's/organization's storeroom,

performing activities such as stocking of operational materials and supplies, inventory control

and records, purchasing, and related duties as required. Responsible for packing, pricing,

labeling, and returning supplies.

MARKETERS

A Marketer, is responsible for working with other marketing staff to develop unique campaign

ideas to market the company’s products, services or overall brand identity. Their duties include

completing market research to identify target audience demographics or reviewing previously

successful marketing campaigns, working as part of a team to accomplish tasks by set deadlines

and making adjustments throughout marketing campaigns to achieve better engagement from

consumers.

LOGISTICS MANAGER

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Logistics managers are responsible for planning, coordinating, and monitoring logistics

operations such as warehousing, inventory, transportation, and supply chain processes. Logistics

managers typically supervise a team of warehouse staff or other logistics specialists.

QUALITY CONTROL DEPARTMENT

QC personnel perform the testing and compare the results to the specification requirements. They

are contractually responsible for controlling the quality of the work performed. They are

ultimately responsible for assuring the quality of the work performed. Quality control

inspectors check the quality of incoming and outgoing materials or products for a company, as

well as the production procedures. This job involves tasks such as running tests, keeping a record

of defects, analyzing products, and overseeing procedures.

OPERATORS

Machine operators set-up, operate, and maintain machinery, usually in a manufacturing setting.

They are responsible for ensuring the machine produces high quality products, runs smoothly

and at capacity, and is properly maintained. Education and training requirements depend on the

type of machinery.

DRIVERS

2.3 PROFESSIONAL ETHICS

2.3.1 Policy Statement

 The Company is committed to upholding highest ethical and moral standard in the

conduct of her business and in all dealings amongst employees and with all persons,

corporate or individual dealing with the company or any of her employees in the course

of business. This policy therefore aims to instill a culture of abhorrence of unethical

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 practices by creating securities trading procedures for management and those in

possession of market sensitive information.

 Objective of the Policy The aim of this policy is to eradicate all forms of inappropriate

conducts, fraudulent acts and unethical practices within the company as it relates to

dealings in stock on the floor of the Nigerian Stock Exchange.

 Application of the Policy This policy shall apply to anyone who by roles in the Company

come in possession of price sensitive information and who can easily use such

information to his or her advantage.

 Purpose The ordinary shares of the Company are listed on the Nigerian Stock Exchange

("NSE"). This Vitafoam Securities Trading Policy ("the Policy") regulates the sale and

purchase of shares in the Company by its Directors, Executive Management, Employees

(officers), Audit Committee Members, External Auditors, Financial Advisers and other

professional bodies and anyone who by chance has information that is price sensitive.

 Definitions In this Policy: Board means the Board of the Company; Inside Information

means information that is not disclosed or generally available and, if it were disclosed or

generally available, a reasonable person would expect it to have a material effect on the

price or value of the Company's shares. Policy means this Securities Trading Policy as

amended from time to time; and Senior Management means Executive Management

employees of the Company who manage the Company pursuant to the directions and

delegations of the Board.

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CHAPTER THREE
3.0 ANALYSIS OF PRODUCTION

3.1 ERGONOMICS

3.1.1 Problems encountered during SIWES

During my stay at Vitafoam Nigeria Plc, I have noticed that the company has a wonderful

operating system. The company has Eight major sections which are

 Production

 Conversion

 Sewing

 Bailing

 Accounting

 Marketing

 Storage

 IT section

I was mostly based at the production, conversion, IT and bailing section during my stay at the

company. From the experience I got at the company I noticed that the production and conversion

sections had the most problems. The production section is the most complicated section,

problems that arise there could cost human life and great financial loss. The problems I have

encountered at the production section is a faulty pump which is meant to pump polyol into the

mixer.

The solution to this will be to buy a new pump because the present pump has been issues over

time and has seriously deteriorated. Another problem I noticed is that during production some

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minor errors happen due to lack of focus and can have large costs e.g Due to lack of

concentration during production on a certain day, water required for production of polyurethane

(Foam) finished in the tank and was not noticed till it was too late and the mixture was

incomplete so the polyurethane (Foam) did not form and the other chemicals involved were

wasted. My solution to this will be to have more staffs in the production section to keep an eye

on key aspects while production is happening.

For the conversion section (Where the foam blocks are reduced into required sizes) the

problems I have noticed is that there is a lot of scrap generated during size reduction. The

solution to this will be making the most use of the scrap for lamination (This is a process

whereby a mattress which has a whole in it is filled by using a piece of scrap foam) purposes.

3.1.2 Provision of safe work Methods and Environment

 Ensuring all machines and equipment are in good conditions and that all safety gadgets

are in place and functioning properly.

 Providing good factory layouts, free of all hinderances

 Providing good illumination and ventilation

 Providing protective apparels to employees

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  Keeping noise, heat/cold, vibrations, fumes, solid particles etc, at safe levels. In addition

all employees must be taught the correct procedures of working safely

Safe Practices

There are very many safety precautions recommended for industries generally, for a foam

industry the shortlist of the areas of greatest importance are:

 Protective clothing and equipment

 General work environment

 Safe use of chemicals

 Electricity

 Machinery safety

 Fires

 Explosions

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 Transportation and handling of materials

 Prevention of falls

 Maintenance work

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Fig 1: safety measures

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Fig 2: Mattress

Fig 3: Pillow

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3.2 Products/Services
3.2.1 Vitafoam Nigeria Plc is Nigeria’s leading manufacturer  of flexible,

reconstituted and rigid foam products. It has the largest foam manufacturing and

distribution network which facilitates just in time delivery of finished products

throughout West African Sub region. Incorporated on 4th August, 1962 and listed

on the floor of the Nigerian Stock Exchange in 1978,  Vitafoam’s brands remain

household names in the Country. The Company’s commitment to quality in its

production process has earned it several quality awards including the  Gold

Certificate Award for most of its products . Vitafoam was the first Foam

Manufacturing Company in Nigeria to subject its quality system to the Quality

Management System championed by the Standards Organization of Nigeria (SON).

The NIS ISO 9002 Certificate was obtained in 2001 and upgraded to NIS ISO 9001:

2000 in 2004.Vitafoam is a responsible corporate citizen and it adopts best

practices in all operations.

The code of good corporate governance has been well implemented by the

company and it is committed to the continuous improvement of its operations.

The Company’s policy is determined by a  competent and dynamic Board, a mix of

executive and non-executive directors who are experts in their own fields. The

Board is supported by a robust management team. The Company is consolidating its

core business by the introduction of innovative value added products and services.

It has become a full range solution provider for bedding and allied products. Its

Comfort Centers provide a one stop shop for discerning consumers of its products.

The company has carved a niche for itself in the industry by its offer of a vast array
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of high and superior quality products  that present the customers with multiple

unique choices. Mattresses of varied resilience and hardness are available

nationwide. By use of contours cutting equipment , Vitafoam designs and constructs

custom-made mattresses and pillows. In addition, a range of profile products that

are versatile in use are offered to the market e.g Mats (Vitarest, Leisuremats etc)

and Foam sitting chairs (Vitasolid). The needs of nursing mothers are addressed by

the offering of a number of foam based baby products (Changing mat, Baby cot

mattresses, pillows etc).

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3.2.2 Vitafoam consists of certain machines which are to the functioning of the factory those
machines are listed and discussed below:

Potentiometer

This machine is used to control the flowrate of the chemicals coming into the mixer during

production. Before production begins the potentiometer is used to calibrate the flowrate of the

chemicals required for the production of different densities of Foam. This machine is operated by

the production managers and the production staffs.

Chillers

This consists of a heat exchanger which is used to cool the temperature of Polyol and TDI

(Toluene di isocynate) in the tanks. Production of foam can only take place at certain

temperatures for safety concerns e.g Polyol within the temperature range of 22-24 celcius and

TDI within the temperature range of 27-18 celcius. This machine is operated by the production

engineer and the technicians.

Rotary machine

The foam block produced from the max foam plant is large in size and has to go through size

reduction. This machine is used to reduce the size of a foam block horizontally into the desired

size. It consists of a sharp blade and a conveyor carrying the foam blocks to be cut. This machine

is operated by the form man and other trained workers.

Band knife

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The band knife serves the same purpose as the rotary machine. It cuts the foam block vertically,

According to the specified dimension. This machine is operated by the form man and other

trained workers.

Probe stick

When a foam block is produced is has to be cured for some hours for the temperature to

cool down. The probe stick is used to check the temperature of the foam block during curing. It

is inserted into the center of the foam block to check the temperature of the block and prevent the

block from reaching a temperature of 75 celcius in which the block will ignite. This device is

operated by any trained worker or staff.

Sewing machine

When the foam has been reduced into the specified size, it is then taken to the tailoring section

where the foam is covered with either a jackat or quilted cover using the sewing machine. This

device is operated by contractors .

Diothene machine

After the mattress has been covered up, it is then sealed up by the Diothene machine using nylon.

This device is operated by trained workers and technicians.

3.2.3 Ingredients and Composition

 Conventional Polyol

 Polyol

 Calcium carbonate (CalCO3)

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  Water

 Silicon

 Amine

 Stannous

 TDI

3.2.4 Images and related data

Fig 2 Chillers( Heat exchanger)

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Fig 3 Sewing machine

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26
Fig 4 Quilting machine

Fig 5: Rotary machine

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Fig 7 Gas mask

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Fig 8 Trough machine (For production)

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Fig 9 Mixing tank

3.2.5 There are four major sections in the factory which house these machines

 Production

 Conversion

 Tailoring

 Bailing

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At the production section there are certain materials required to handle the machines such as gas

masks, protective gloves, factory boots and protective .

At the conversion section we have the rotary machine which is operated with hand gloves and

glasses.

3.3 QUALITY ENGINEERING

3.3.1 The quality control department in vitafoam is responsible for checking how long the

mattresses will last and the accuracy of the density of each type of mattress. After production

some samples of foam are brought to the lab for testing, The samples are cut into small sizes and

the density is checked by measuring the dimensions of the sample and weighing it.

weight
density =
volume

The samples also undergo a compression test to determine how long they will last. The foam

sample is compressed in a compression device and put in an oven at a temperature of 72℃ for

22hours. The next day it is removed and left to cool and then the new thickness of the sample is

measured.

initial thickness−new thickness

Error= × 100
initial thickness

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3.3.2 There are certain tools used to carry out the quality control operation, they are

 Standard digital oven

 Compression device

 Vernier caliper

 Digital electronic laboratory scale

Standard digital oven

It is built for purposes such as heating and drying, standards digital ovens are built to offer

accuracy, control and safety.

Compression device
It compresses the foam and holds it in place for testing

Vernier scale

It is designed for accurate and precise measurements. It measures the linear distance of an object

such as length, thickness, outside diameter, width etc.

Digital electronic laboratory scale

It is used to measure mass or weight. It works with the use of a strain gauge load cell. Digital

scales convert the force of a weight into an electric signal

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3.4 Maintenance Engineering

3.4.1 Maintenance policy

Vitafoam Nigeria Plc is committed to the safety and health of all employees, customers,

contractors, visitors and other stakeholders in our facilities, and to preserve, protect and sustain

the development of our host community and environment at large.

The company provides necessary resources by way of information, training, technology and

encouragement for all employees to contribute positively to the implementation, maintenance

and continual improvement of our occupational health and safety management system.

The employees are committed to observing all the safety policies and procedures laid down by

the company.

We are committed to complying with all relevant environmental laws and regulations and

periodically, review our compliance for continuous suitability via full understanding of the

environmental impacts of our operations, services, equipment, products and packages. In

addition, we are committed to continually look for ways to minimize these impacts.

Our occupational health and safety management system and environmental procedures and

performances are subject to both internal and external audits and validations.

Our policy at Vitafoam Nigeria Plc. is to continually manufacture, distribute and sell

polyurethane/reconstituted foam (mattress, cushions, pillows, sheeting) and allied products that

conform to international standards, applicable statutory, regulatory and other requirements as

well as surpass customers’ expectations at a price that represents value.

Vitafoam Nigeria Plc is committed to satisfying customer, legal and our relevant interested

parties’ requirements as well as the continual improvement of the quality management system.

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3.4.2 Material Procurement
Most of the raw material used in production are imported from a company called INOV based in

south korea.

Polyurethane Foam is an essential part of the Engineering Materials category which includes all

spend related to the provision of essential industrial and engineering raw materials which are

further processed or used to produce goods, articles or structures.

A changing ecosystem within the Engineering Materials market also affects the procurement

process, cost dynamics and supplier attractiveness for the buyers of Polyurethane Foam.

Suppliers are continuously taking efforts to improve efficiencies and productivity and deploying

processes and technologies. Some of these investments are likely to increase their costs in the

shorter term, but learnings from other sectors keep the suppliers optimistic about a lean cost

structure in the longer run.

Markets across the globe are reeling under shortage of professionals and workforce that have

relevant skills and training. Minimum wages and stringent regulations are compelling suppliers

to increase their employee expenses which are expected to have an inflationary impact on buyers'

procurement cost.

For example, Buyers should engage with suppliers that have adopted a global delivery model as

it reduces buyers' risk. In this model, any disaster/emergency at any operating facility of supplier

will result in the work being transferred to a different facility, thereby ensuring continuity of the

project and reduced risk for buyers. This model also provides buyers access to skilled labor from

across the globe, thereby improving the quality of engineering products provided by the supplier.

Buyers should engage with suppliers that repurchase used products at fair market value. This
34
assists buyers to dispose of used products in a convenient manner. Also, during such

repurchases, suppliers provide credits to buyers for future purchases. This reduces overall

procurement costs for buyers.

Competitive bidding as a cost optimization tool is extremely potent but should be carefully

deployed only when there is no significant differentiation among Polyurethane Foam suppliers.

Fig 6 Polyol tank

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CHAPTER FOUR
4.0 CONCLUSION
The Student Industrial Work Experience Scheme (SIWES) is by all means the meeting point of

all activities carried out within this period of my internship. It has therefore become an

innovation that has no doubt stood the test of time and has the potential for playing an active role

in utilizing Nigerian Tertiary Institutions and students for the industrialization of her country.

Every Engineering process can be identified as a cause of change, either to human beings,

animals, plants, environment etc. Most Engineering discipline therefore incorporate some vehicle

for ensuring that a specific engineering activity or process can be carried out i.e. if it is feasible

and that it can be carried out effectively and efficiently in order to produce the required results.

For most Business Enterprise including the Engineering firms, Project management is the

technique required to ensure that an Idea generated is transformed into real life obtainable

products, services or structures that serve an initial purpose for which it was developed.

In the Chemical Engineering field, an activity scope under the name process design is employed

to see the erection of new chemical processes and plants or modification of existing ones.

Despite this, most process designs are still carried out within the framework of Project

Management therefore, both process design and economics, and project management skills

including cost engineering knowledge are important to the Chemical Engineer.

The Student Industrial Experience Scheme has provided an avenue for undergraduates as myself

to engage in such engineering activities thereby gaining required skills, practices, and knowledge

of commerce and technology required by students to become full-fledged graduates.

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4.1 REFERENCE

https://www.wiki.ng/en/wiki/history-of-siwes-student-industrial-work-experience-scheme-48125

https://vitafoamng.com/store/index.php?route=common/home

https://procurement.spendedge.com/report/polyurethane-foam-market-procurement-intelligence-

report

Vitafoam manual for producing polyurethane

Kirk-Othmer  Encyclopedia of Chemical Technology. John Wiley & Sons, 1997.

Oertel, G. Polyurethane Handbook. Second ed. Munich: Carl Hanser Publishers, 1993.

Seymour, Raymond, and Charles Carraher. Polymer Chemistry. New York: Marcel

Dekker,1992.

Ulrich, H. The Chemistry and Technology of Isocyanates. New York: John Wiley & Sons, 1996.

— Perry Romanowski

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