Competency Demonstration Report (CE2) - Production Expansion Project

This competency demonstration report details a mechanical engineer's involvement in the expansion of production lines at Al Rawabi Dairy Company in Dubai. The project, spanning from October 2014 to June 2015, aimed to increase production capacity and efficiency. The engineer, in the role of a Maintenance Engineer, was responsible for various tasks, including developing new production lines, improving existing ones, preparing progress reports, delegating tasks to technicians, monitoring worker performance, and managing material requisitions. The report outlines the project's background, objectives, the engineer's area of work, and their responsibilities. It describes the engineering knowledge and skills applied, including feasibility studies, problem-solving, and collaborative work with team members. The engineer faced challenges such as the unavailability of old machine parts, which was resolved through online research and manager approval for new materials. The project's successful completion resulted in increased production quantity, improved product quality, and enhanced the company's market position. The report concludes with a review of the project's outcomes and the engineer's contributions.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 2
ELZUBAIR RODWAN ABDELMAJID

CE 2.1 Project Information
Name of the project: Expansion of production with additional production lines
Location of the project: Dubai
Project Duration: October 2014 - June 2015
Organization: Al rawabi Dairy Company
Role and Designation during the time: Maintenance engineer
CE 2.2 Project Background
CE 2.2.1 Characteristics of the project
The Al rawabi Dairy Company is one of the leaders in the production of dairy and juice
products. The company is established in UAE with a wide range of functional products in their
line of work. The company has current operations in UAE, Qatar, and Oman and has more than
13,000 stores with the availability of fresh products. They have a cattle stock of 13,000 cows.
Since the establishment of the company in 1989 with a small count of 500 cows, the company
has innovation in its core working processes. The company introduced plastic bottles in the year
1991 and then became the first company to pack fresh juices in the year 1995 in GCC.
CE 2.2.2 Objectives developed for the project
The major objectives, which were followed by me, has been discussed below:
 To increase the number of production lines in the company.

 To increase the amount of production per day on the existing systems.
 To provide a periodical update to the maintenance manager about the progress of the work.
 To check the working condition of the different equipment’s present on the floor of the
production system.
 To delegate the jobs to the technicians for the project
 To monitor the working job status of each of the worker of the production floor.
CE 2.2.3 My area of work
For the completion of the project, I had worked on the process of development of new
production lines and improvement of the existing production lines in the factory. I had developed
the reports for the sharing with my maintenance manager of the project. I had helped in the
breaking down of the work for the technicians and the monitoring of the job status of the
workers. I had also raised the corrective action planning for the report based on the breakdown of
the work. I had taken care of the follow up of the parts in the stock of the warehouse and the
purchase requisitions.

CE 2.2.4 Project Group
Figure 1: Team Member associated in this project
CE 2.2.5 My responsibilities throughout the project
I was responsible for the working of the improvement in the production lines of the
production factory as well as for the implementation of the new production lines on the factory
floor. I had helped in the development of the reports of the progress of the work. The report was
shared on a timely basis with the maintenance manager. I had developed the job break down
structure for all the workers on the working grounds. I had monitored the working of the workers
and raised a corrective action plan for the report based on the breakdown of the working
structure. I had taken care for the timely follow up of the stocks of the warehouse as well as the
order requisitions for the materials required for the production line improvements.

CE 2.3 Distinctive Activity
CE 2.3.1 Comprehending the theory of the project
The company mainly works for the production of dairy products and has become one of
the leaders in the production of dairy products. The company set in UAE has a wide range of
functional products as well. With the help of their 13,000 cattle, they are able to produce enough
milk products for the sale in and around the country. Recently the company has started to drop
down on the production rate with the ageing of their machineries. I was asked to work for their
company in order to find the drawbacks in their production line and for the installation of new
production lines in the factory floor. I had worked with my team members for the completion of
the project work within the timeline as well as keeping the project within the budget provided by
the client.
CE 2.3.2 Engineering knowledge and skills applied in the project
I had used my knowledge of a mechanical engineer, which I had learned during my
bachelor degree and during my work experience. I had taken care of the work of the
development of the new production lines on the factory floor. Once I was able to produce a new
set of working production line, I shifted my work for the improvement of the old production
lines. I compared the time that was being taken by the two system. I then checked to see which
of the machines needed to be changed. I then had checked the available resources to check if
changing the new material was feasible or not. Once it was feasible, I checked the online
resources for the replacement of the old machines.

CE 2.3.3 Accomplishment and task performed
The feasibility study of the new machines and parts were shared with my managers to
make them understand as to what extent changes needed to be carried out. Once the requisition
was approved, it was easily cleared out. The new machines was able to be installed into the old
production line and the production rate increased.
CE 2.3.4 Identified issues and their solutions
2.3.4.1 Issues
The issues, which I had faced during the implementation of the new production, was the
unavailability of the old machines for the development of the new production lines. For this, I
had to conduct an online research for the finding of new machines to work with.
2.3.4.2 Solutions
The research had delayed the working of the project by quiet a lot of time. The
requisition had to be cleared out by the managers of the company before proceeding with the
placing of the order of the products. I had to make the managers understand the benefits of using
such materials and they were ready to use the requested products.
CE 2.3.5 Plan to produce creative and innovative work
I had worked on the process of making new production line on the production floor as
requested by the clients. Based on the outcome of the new machines I had studied the old
production lines for adding the new improvement for the increase in the quality as well as the
speed of the production line. Closing down of all the production lines would eventually hamper
the working of the company. This helped the company to continue their production as well as for
me to improve their production lines. For a better understanding of their production line faults, I

had compared and worked on both the new and the old production line. Based on this report I
had conducted the renovation of the production lines.
CE 2.3.6 Collaborative work
I had collaborated with my team member for the completion of the project. I had shared
the working details of the project completion procedure with my maintenance manager. I had put
together my team of workers for this project for the best quality according to the requirements of
the client. The new production lines were first installed on the production floor and then the
working for the improvement of the production lines were taken care of. The changing of the old
equipment has helped in most of the improvement procedures of the old production line of the
production floor. The team had worked for the completion of the project within the required time
line of the project as well as the approved budget for the work.
CE 2.4 Project Review
CE 2.4.1 Project Overview
After the completion of the project, I found that the purchasing of the new equipment has
allowed the company to increase its production in terms of quantity as well as production rate.
The use of the new equipment has helped in the improvement of the quality of products being
prepared. The modernization of the production line has made the new products strengthen its
position in the business market with the reinforcement in the form of sustainability. The
company has increased its growth at a rate of 15% on an annual level.

CE 2.4.2 My contribution to work
For the completion of the project, I had helped in the development of new production
lines in the production factory and for the improvement of the production line in the factory. I
had also helped in the development of the reports to be shared with the maintenance manager of
the floor. The report had been shared on a timely basis. I had looked after the working of all the
workers on the production floor who were directly related to the project. I had monitored the
working of workers based on the work break down structure created for the project. I had also
taken care of the follow up of the materials and stocks in the warehouse of the project. Apart
from this, I had helped in keeping track of the material requisitions placed for the project. I had
worked with my team members for the completion of the project on time.