Competency Demonstration Report - Career Episode 1 - Tehran Plant

This report details a mechanical engineering project undertaken at the Tehran Cement Plant, focusing on increasing productivity and reducing operational costs. The project involved a comprehensive analysis of the plant's processes, including workflow optimization, bottleneck identification, and the implementation of new technologies. The student, acting as a team member, was responsible for project scheduling, cost reduction strategies, and documentation. Key accomplishments include the development of an automated monitoring facility for shipments, the redesign of the workshop layout using AutoCAD to improve workflow, and the implementation of a new truck fleet to reduce transportation costs. The report also addresses identified issues, such as the distance between test benches, and details the solutions implemented to improve efficiency, reduce working time, and increase working space. Collaborative work with other engineers and the application of engineering knowledge and skills were critical to the project's success, leading to significant improvements in productivity and cost-effectiveness. The report highlights the student's contribution, the project's overview, and a review of the methodologies used.

COMPETENCY
DEMONSTRATION REPORT
Career Episode 1
NAME

CE 1.1 Project Information
Name of the project: Increase in the productivity of Tehran Cement Plant project
Location of the project: Iran
Project Duration: November 2011 – December 2012
Organization: Tosee Siloha Company
Role and Designation during the time: Team Member
CE 1.2 Project Background
CE 1.2.1 Background of the organisation
The Tosee Siloha Company was set up in the year 2007. The company was set up as an
EPC company. The company had working in the industrial production line in the field of wheat
silos, cement factory, power plant, cooling towers, distillation columns and various other
factories. The company is a member of United Nations Industrial Development Organization
(UNIDO). The factories are slow in the flow of adoption new technologies. This is due to the
problem off overhauling optimization processes and thus a cut is the profit is being ensured. The
Tehran cement plant has been in operation for 25 years. Due to the high operational period there
is a rising concern about the safety and the environmental factors of the organisation.
CE 1.2.2 Objectives developed for the project
For the project I had set out the following objectives to provide the client with the best
quality of work:

 To review the documentation of the project, process flow diagrams and flow charts.
 To analyse the operation of the organisation closely.
 The remove any kind of bottleneck in the operational procedures.
 The review the existing environmental standards for the operation.
 To design the allocation time and budget for the project.
 To constantly monitor the progress of the project and to suggest any kind of
suggestion for the same.
 To develop a custom workflow for the project for the use of the equipment’s and
resources for the proper optimization of the cost and procedures.
CE 1.2.3 My area of work
For the completion of the project I was completely involved in finding of better and new
ways for increasing the workflow and productivity. I was also responsible for finding a solution
to reduce the cost of production in this project because the cost of production needed to be
reduced as the long term usage had increased the cost at a constant rate. I was also responsible
for the scheduling of the project and the proper management of the workflow and the resources.
In order to maintain the assigned schedule with workers, I have taken timely follow-up with
them. As I had a good writing skills, I helped in the documentation of the project report.

CE 1.2.4 Project Group
Figure 1: The hierarchy of the project
CE 1.2.5 My responsibilities throughout the project
I was responsible for the development of the project schedule and the proper management
of the Tehran Cement Plant project. I was also responsible for the finding of new ways in which
I would be able to increase the workflow of the factory. I had worked for the reduction of the
cost of production which had continuously increased with the long productivity cycle. Apart
from this I had also helped in the documentation process of the project progress.

CE 1.3 Distinctive Activity
CE 1.3.1 Comprehending the theory of the project
Tehran cement plant factory had multiple units and many divisions which were analysed
to find the best way to increase the productive strategy. I had made a decision to inform my team
mates and supervisor of the progress that I was going to follow for the completion of the project.
I had participated in the initiation of the project and had attended the introductory meeting for the
understanding of the project. After the understanding of the project requirements I had conducted
an online research of the best ways which I would be able to implement into the project for
meeting with the project requirements.
CE 1.3.2 Engineering knowledge and skills applied in the project
I had used my engineering skills and knowledge which I had studied during my
engineering course to complete the project according to the project objectives. I had then
developed the shipment arrangement and registration of the delivery with correct follow up of
the shipments into an automated monitoring facility. I had used my AutoCAD skills to design the
floor plan in order to rearrange the tables and increase the productivity of the work shop. I had
consulted with an ECS process consulting company who helped me to understand the process
which can be implemented into the project for the meeting of the objectives.
CE 1.3.3 Accomplishment and task performed
I had firstly decided on the amount of work which I would be able to contribute to the
work. I had then followed with the working of the objectives and the activities of the project.
This process helped me to pinpoint out the areas where I would be able to use my skills for the
improvement process. I had then divided up my area of work in to further small tasks which

helped me to complete the task with ease. I had decided to find the best quality of work with the
involvement of minimum cost for the project. Thus I had worked on the area of increase in
productivity. I found that the gas and the oil was being imported by third part trucks. I found a
solution to implement the problem with the help of using own truck fleet. This helped in the
reduction of the cost. I had implemented two more sources into the same process to reduce the
cost. I had also helped in the development of the online monitoring of the equipment’s to reduce
the time required for the process. This reduced the cost by 16%.
CE 1.3.4 Identified issues and their solutions
1.3.4.1 Issues
During the evaluation of the completed project I and my team mates had found there was
a problem in multiple areas of the project. I found that there was an increase in the process of
cement creation for the shipment. This was slowing the employees as well as the workers for
their work. Eventually I found that that the test benches were far away from each other which in
turn increased the time for the workers to walk farther for the gathering of the required tools
1.3.4.2 Solutions
The cement automation system and the driver verification system can be automated
easily. The process of cement loading can also be scheduled easily. It had been seen that the
drivers often talk among themselves between the loading times. This can be reduced with the
process of automation. I had worked on the problem of repair bench distance and had a chat with
the workers of the floor and found their problems with the situation. I had then worked the
setting of the benches in AutoCAD with the help of my design skills. After the final evaluation I
found that the shipments would enter from one point of the building and then move to the end of

the work shop. I had my team relocate all the equipment’s to meet the new requirement. This
helped in reducing the working time by 25% and increased the working room by 16%.
CE 1.3.5 Plan to produce creative and innovative work
For this project I had firstly divided up the complete task into several sections for the
evaluation of the individuals working place with efficient contribution. I had implemented a
process for the automation of the loading process of the shipments which reduced the cost of
management. I had also made use of the latest technology for the project for the helping in the
process of overcoming the lag in production.
CE 1.3.6 Collaborative work
I had collaborated with my team of engineer to understand and complete the work of the
project. I had helped my team members for the following of the timeline of the project to
complete the work within the designated deadline. I had used a systematic approach for the
different sections of division helped in the clearing of the task and with clear approach of the
resources.
CE 1.4 Project Review
CE 1.4.1 Project Overview
The project provided me with a great opportunity where I was able to use my engineering
skills. The skills provided me to gain experience in many real world projects. I had divided up
my project work into several sections so that each of the sections can be tacked individually.
This also helped me to analyse the section of work which required for efficient working. I had
also used all of the latest technology for the completion of the project.

CE 1.4.2 My contribution to work
For the project I had helped in the process of scheduling the project progress report. I had
helped in the management of the progress of the project. I had also helped in the finding of the
process for the increase in the productivity and the workflow of the company. I had also helped
in the decreasing of the cost of productivity of the machines in the company. I had also helped in
the documentation of the progress report of the project.