A SURVEY AND ANALYSIS

OF TH E

KENYAN M ETALW ORKING INDUSTRY :

EQUIPMENT PRO DUCTIO N ENGINEERING AND

M A N P O W ER

MOHAMED AKRAMI KHAN

A thesis submitted in fulfilment for the

Degree of Master of Science (Engineering)
in the University of Nairobi

1973

UNIVERSITY OF NAIROBI LIBRARY

0101399 4
This thesis is my original work and has
not "been presented for a degree in any
other University.

(M.A. KHAN)

This thesis has been submitted for exa­

mination with my approval as University
supervisor.
 CONTE NTS PAGE
A Summary of the Contents., 5

PART ONE: EQUIPMENT

, CHAPTER I
Equipment Census 6
PART TWO: PRODUCTION ENGINEERING .
CHAPTER fl
Production of Metal and
Metalworking Processes - 34

CHAPTER III
Production Systems

I. location of Establishments 112

II. Plant Layout and Methods ofProduction -4 27
III. Work: Study ^9
IV# Design and Drawing Practice 4 42

CHAPTER IV
Production Planning

I. The Market Eactor 151

II. Production Scheduling andProcessing 157
III. Maintenance of Equipment 162

CHAPTER V
Quality and Material Control 165

PART THREE: MANPOWER AND WORKING / *

CONDITIONS

CHAPTER VI .
Manpower and Training 179

CHAPTER VII
. Working Conditions
arid
Industrial Safety 203
 PAGE
PART POUR: THE METALWORKING
INDUSTRY IK RETROSPECT

^ CHAPTER VIII
-
Resume and Conclusions

I. A Review: Metalworking Industry 215

II* Advisory Services and Research ' 218

III* Recommendations for Further Work . 219

Appendix.
1. Explanation of Terms 221

2. Collection of Data - 223

3* Main Results of the Survey (Table A) 228

4* Import of Metalworking Machinery 276

5. Net Imports: Raw Materials 277

6. Composition of Local Iron Ores 278

7. Approximate Capital Costs: Stee3.

Production 279

8* Cost: Materials Handling 280

9. Import Restrictions 282

10. Production Programme 284

II. Exports: 1967 and 1974 285

12. 'Preferred12
I. Jobs b y Occupational-
10
79
56
*
Categories and Provinces 286

13>- References 287

 5

A SUMMARY OF THE COUTKUTS

This study was undertaken with the intention of:

(1 ) conducting a survey to compile accurate details
of the Kenyan metalworking industry with reference
to equipment, elements of production engineering
and manpower; and (2 ) analysing the results of
this survey hy evaluating and comparing them, quanti­
tatively and qualitatively, with the established
engineering practices, standard methods and national
development objectives.
The material is presented in four parts
Part One : Equipment
Part Two : Production Engineering
Part Three: Manpower and Working Conditions
Part Four: The Metalworking Industry in
Retrospect•

The information was obtained from the known

metalworking establishments in the main towns of
Kenya. Throughout the dissertation, the data is
divided in accordance to the size of the firms (See
Para. 2, Appendix 1). The main results of the
survey appear as Table A in Appendix 3* The
appendix also contains certain data which is not
original but is cited in the dissertation.

Appropriate details of the present state of

the industry are given at the beginning of each
chapter, under Section 'A1. Section '3* of each
chapter attempts to analyse the data relevant to
the topic under question. Simple statistical
methods are used to examine the data. Conclusions
and recommendations are then given at Section ’C .
C H A P T E R I

EQUIPMENT CENSUS

xXx
 6

•EQUIPMENT CENSUS

A. THE PRESENT STATE

1 , 1 , 1 An Equipment Inventory

An inventory of the main metalworking equipment i3

recorded in the following tables:-

Table 1.1,a.; Covers the private sector of

' the metalworking industry and a few quasi­
government establishments. The latter includes
the metalwork shops of the establishments
referred to in Table A, under Section II,
No. 85 and Section III, Nos. 2, 3, 18 and
28.

Table 1.1.b,: Covers the East African

Railways Chief Mechanical Engineer’s Work­
shops, Nairobi (Table A, III, 4). These
workshops have a far greater quantity and
variety of equipment than is normally found
in other establishments in this country. Its
equipment is, therefore, shown separately in
this table.

Table 1.1 ,c.: Lists locally-made equipment.

Table 1.1 ,d,: Lists production plants.

B. AN ANALYSIS: EQUIPMENT

1.1.2:- National Equipment Inventory

Several countries organize and regularly conduct

equipment censuses on a national scale. Ashburn 1
explains how equipment'studies are undertaken in
different countries.

*v ♦
 QUANTITY OF EQUIPMENT —
T Y P E ‘OF
AGE ronm a t GRAND
EQUIPMENT

r
TOTAL

y*
a
o
LESS THA] MORS THAN 10 YEARS AGE UNKNOWN
SINE OF SM. MS. LA. SM. ME. LA. SM. ME. LA SM ME LA
ESTABLISHMENT
A. KKTAL-CUTTING \ I
EQUIPMENT
Lathe Machines
Centre Lathes H 66 25 55 170 64 8 17 19 77 253 106 436
Bench Lathes 4 4 - 11 12 1 - 2 - 15 18 1 34
Capstan/Turret
Lathes '2 1 1 4 4 — _ _ 1 6 5 12
Toolroom Lathes - 5 2 2 2 1 - - 1 2 5 4 11
Others 1 1 - 1 - - - - 1 2 - 3
Vertical Lathes - - - 2 - - - - 2 1 3
»
|
Milling Machines
Universal 1 8 1 4 24 15 - 3 1 5 35 17 57
Horizontal - 6 1 1 4 - - - - 1 10 1 12
Vertical - 4
1 2 — 1 5 — — — — 2 5 7

AN- EQUIPMENT INVENTORY OF KENYA

Table 1.1 *a
 ME LA GRAND
Shapers. Planers, SM ME LA SM ME LA SM ME LA SM
TOTAL.
& Slotters 1----
Shapers 1 20 5 5 43 13 5 - 11 11 63 29 103
Planers - 1 - ■- 1 4 - 3 - 2 7 9
Slotters - - - - 4 2 — ** 1 — 4 3 7
i
Drilling Machines
Bench* 7 23 - 11 14 - 22 13 28 40 50 28 118
Pillar/C olvunn 46 6 45 85 31 15 12 8 83 143 45 271
I23 '
Radial 2 3 1 4 14 — 1 3 1 7 20 28
.1 ■■-i
Boring Machines I
i
i
Horizontal/ j
Vertical 1 - - 3 5 >- 2 6 5 11

i
Grinding & ' !
Buffing Machines i
Bench/PedectaA 33 30 2 37 57 21 24 53 1 94 140 24 258
Universal r - V - - 2 - - 1 - 3 4
Surface 4 6 2 3 6 4 3 3 1 10 15 7 32
Tool — 3 2 1 2 2 - -4 1 1 9 5 15
Shaft 4 4 - 4 9 2 - 3 - 8 16 2 26
Others(valve,
grinding etc,) 1 3 10 1 1 16 1 8 29 3 40
4 3
1 - - 2 4 _.2s!__4 _ __17___
Buffing_________ . 2 L x 5 . 17 __ 3
gable 1 ,1.a» (contd)
Sawing Machines SM MS LA ■ SM LA SM ME LA SM HE LA IGRAND
ME TOTAL
Powered hack-saws ' 10 31 11 ' 8 29 8 3 13 8 21 73 27 121
Circular saws - 15 4 2 3 6 - 3 8 2 21 18 41
Band saws 1 ■ 1 4 1 3 2 2 5 •2 4 9 8 21
*
Broaching Machine;3
\
I M ■i
Horizontal • 1 - - - - - - - 1
Die-Sinking «Sc
Engraving Machincr *
All types* j| - - - 1 1 1 - 2 1 1 3 2 ; 6
Gear-cutting I
Machines ]
All types* - - - - - - - - - - - - -

Honing Machines
Rc-boring type* 12 15 2 2 2 1 2 7 16 24 3 43

B. MACHINES FOR j;
MITAL-FORMING I
Presses I
Hydraulic 4 14 2 4 16 4 3 16 7 11 46 13 70 •
Eccentric 5 ' 39 33 - 42 65 ! 3 19 15 8 100 113 221
Manual* : 1 17 7 7 23 30 j 9 3 18 17 43 55 115
Forging Presses t .
Upsetter3(Hot & . 2 52 11 . 11 20 20 3 83 31 117
Others Cold> 5 - - 1 4 - - - - 6 4 10
i—
Table 1,1.a. (contd)
 GRAND
Forging Hammers SM MB LA SM ME LA Sl-l ME LA SM j ME LA TOTAL1
Mechanical - - - - - - - 1 2 - i 2 3
i
Stearn/Pneumatic - - - 3 3 - 1 2 - 4 5 9
Drop - - - - - - - 1 - ■- - 1

Small-scale Rolling
Mills t

Hot Rolling - 1 - - - - - - 1 - 1 1 2

Machines for Sheet/

Plate Work
Spinning Lathe3 - 3 - - 10 10 - - - - 13 10 23
Shears, hand operated* 12 10 7 8 13 6 27 25 2 47 48 15 110
Shears, powered 1 3 - 1 - 7 9 - 4 3 2 14 12 28
Folding, hand operated 2 U 5 5 15 9 18 27 3 25 56 17 98
Folding, powered - - 3 2 3 - - - 6 2 3 9 H
Bending Rolls, hand-
operated* 2 9 5 5 10 9 17 27 1 24 46 15 85
Bending Rolls,powered - 3 3 2 6 9 1 4 - 3 13 12 28
Guillotines, hand-
operated* 3 12 2 8 11 4 15 6 2 26 29 8 63
Guillotines,powered - 4 7 - 5 2 - 1 1 - 10 10 20
Nibbling Machines 1 3 2 - - 2 - 2 - 1 5 4 10
Automatic Seaming
Machines - 4 — — — — — — — — 4 — 4
Flanging Machines mm ..1 2 1 2 3
'
----------- 1. ’
'!
Table l.l.a. (contd)
 C. PLANT FOR METAL- SM ME LA DM ME SM ME LA SM ME LA GRAND
LA TOTAL
JOINING
V
Li*6C H 1C rlbgciJL^uAC
Welding Sets 96 276 88 41 122 68 29 63 66 166 461 222 849
Oxy-acotylene
Welding Sets 18 60 16 8 20 15 18 40 7 ' 44 120 38 202
Gas-shielded
V/elding Sets 2 •6 9 — — - - - . 2 2 •6 11 19
Submerged-arc
Welding Sets 1 2 - - - - — - - 1 2 - 3
Automatic Welding
Sets 1 4 3 2 — — - - 3 4 3 10
Resistance Welding
Sets 1 17 12 3 3 1 - 1 19 4 21 32 57

D. OTHER EQUIPMENT-
Cast iron cupolas 1 - - - - 1 1 20 3 2 20 4 26
Oil fired furnaces - 3 3 - - 2 1 8 4 1 11 S 21
Electric furnaces
(for heat treatment) — 4 1 — - - - 3 4 - 7 5 12
Electroplating
Plants* 5 _ — - 4 - 3 9 - 8 13 21
Oxy-acetylene Profile
cutting* — 5 - - 1 3 - - 3 - 6 6 12
Grit blasting equip­
— — - 2 - - 1 - 2 1 3
ment
Metal spraying
Equipment* - ' 2 - - - - 1 1 1 1 3 1 5
Electro-static
Spraying Equipment - - - - - - - - 1 - - 1 1

KEYs SM a Small ME = Medium LA = Large table a.\.cl.

 12

QUANTITY !
LLCS THAN | MORE THAN ;TOTAL
EQUIPMENT 10 YBiiRS j 10 YEARS
. _
i A. METAL-CUTTING MACHINES
Lathe Machines
Centre lathes 4 53 57
Bench Lathes 1 1 2
Capstan Lathes \ 3 24 27
Turret Lathes ' - 4 4
Wheel Lathes 2 15 17
Profile/Copy Lathes 1 2 2

Killing Machines
Universal - 2 2
Horizontal - 4 4
Vertical 1 4 5'
Shapers, Planers, .
Slotters
Shapers 2 14 16
Planers - 3 3
Slotters 1 2 3
Drilling Machines
Bench* - 3 3
Pillar/Column 1 11 12
Radial 1 20 2t

Boring Machines
Vertical - 7 7 '
Horizontal 2 5 7
Others (valve, boring,etc. 1 8 9
Grinding Machines
Pedestal ./Bench 1 24 25
Centreless 1 - 1
Surface 2 5 7
Universal 1 6 7
Tool and Cutter - 2 7 9
Valve 2 3 5

EQUIPMENT INVENTORY 0? HAILWAY "WORKSHOPS , NAIROBI

Table 1.1»b«,
 13

1 -- - -- - ■■■■■
S a vins Machines •
Hack-saws (powered) 1 9 10
Circular/Friction saws 1 1 2
Band saws - 5 5

Threading Machines
All types - 5 . 5

Gear-Cutting Machines
Katt e r s o n Gear cutter 1 1

En^ravinf? Machines
All types 1 1

lapping Machines
/ All types 1 1
—

B. KETAL-FCRKING MAC H I N E S
Presses
Hydraulic 1 7 8
Eccentric 4 5 9
Manual - 3 3
Forcing Presses
. 2
Upsetters (Hot & Cold) 2
Spring Buckling & .... •*,
F i n n i n g Presses - 5 5
Forfrin^ Hammers
Mechanical 1 1
S t e am/Pne urn t ic - 6 6
Drop 1 2 3'
Machines for Sheet/Plate
Work
Shears, hand operated . 1 6 7
S h e a r s , powered 1 6 7
Fo l d i n g machines (including
tube bending) 7 7
Fo l d i n g m achines,powered - - -
B e n d i n g Rolls, hand
operated 1 3 4
B e n d i n g Rolls, powered - 2 2
Limshers - 3 3
L . . . . . . . - * - ---
Table 1.1.b. - contd»
 14

c. m e t a l -j o i n i n g p l a n t
Electric metal-arc welding 11 38- 49
Flash Welding - 1 1

D. FOUNDRY EQUIPMENT
Shell Moulding - 5* 5*
Moulding Machines - 5 5
Tropenas Converter 1* - 1*
Cupola3 - 3* 3*
Morgan Tilting Furnace
(600 lbs) 2 1 3
Morgan Furnace (250 lbs) - 3* 3*
Sand mixing plant - 2 2
Sand drier mills - 2* 2*
Corenaker 1 1
Aluminium Furnace - 1 1
Mould drying oven - 1 1
Tyre Furnaces - 2 2
Electric heating pots - 2 .2

Blacksmith Heat in? Furnace

Large 4* 4*
Small - 7* 7*
Others - 2 2

E. OTHER EQUIPMENT
Oxy-acetylene Profile
cutting 4 4
Metal Spraying - .2 2
______ t- - - --- ,
* Includes locally designed and erected units.

Tattle 1 .1 .b,(contd)
 J
» • **.

15

..... '— ■1 ■■■ ----- — ■

QUARTITY OF EQUIPMENT BY
ESTArsLISHMEHT •
EQUIPMENT TOTAL
SHALL MEDIUM LARGE
SCALE SCALE SCALE

A. KACKIHZS FOR
I-ETAL-CUTTIUG
2 l
Powered Hack-saws 3 5
Threading machines 2 - 2
Grinding machines
(Pedestral/Sench) 10 10 . 20
Surface Grinders - 1 - ; 1
Pillar drills 2 2
- "

B. MACHIRES FOR
KETAL-FCRHING
& FOR SHEET- *
METAL WORK

Automatic machine
for making springs 2 3
Automatic machine
for making channe­
ls 1 1
Folding, hand-
operated 1 4 *• . 5
Bending Rollers,
hand operated 2 5 7
Bending rollers,
powered 1. 3 4
Guillotines - 3 - 3
Rod Twisting
machines - 2 mm 2
Hydraulic presses 2 8 2 12 *
Fly-presses 3 6 - 9
Eccentric presses 3 2 5
i

LOCALLY-MADE EQUIPMEKTC
Table 1.1,c•
 T6

Q U ANTITY 0? PLAINT BY
ES?ABLISHI-_jK? , T OTAL
1
PLAKT FOR
Si'iAljj MbblUi-i LARGE
SCALE SCALE SCALE i

Wire D r a w i n g - 3 - 3
Vire Barbed. i - 2
Wire Grill - 2 - 2
Wire M e s h - 3 - 3
W e l d i n g Rods - 1 -
1
Rod & B a r Rolling - - 3 3
Cold E x t r u s i o n - - 2 2
Die C a s t i n g - - 1 1
Containers &
cans 1 3 4
Steel W o o l - 1 .- 1
Rad i a t o r Parts - 1 - 1
Sheet-Metal
Pipe _ 1 — 1
Automatic
Galvanising — OT 2 2
Automatic manu­
facture of
office pins 1 1 2
Manufacture of
Zippers 1 _ 1
Manufacture of
bed springs 1 2 1 4
Metal pressings ■ 1 1

SPECIAL PRODUCTION1 PLANTS

Table 1.1,d
 T6

QUANTITY 0? PLAI7E 3Y
E ST Ah LIS HMS NT ! TOTAL
PLAIH? FOR I'iijlJiUi'i LARGE
S;-iAlL
SCALE SC a L tj SC/iLij 1
W ire Drawing - 3 - 3
Wire Bartei - i -
2
Wire Grill - 2 - 2
Wire Mesh - 3 - 1 3
Welding Rods - 1 - »
Rod & Bar Rolling - - 3 3
Cold Extrusion - - 2 2
Die Casting - - 1 1
Containers &
cans IH .
1 3 4
Steel Wool ~ 1 .- 1
Radiator Parts - 1 - 1
Sheet-Metal
Pipe 1 1
Automatic
Galvanising —
2 2
Automatic manu­
facture of
office pin3 1 1 2
Manufacture of
Zippers 1 —
1
Manufacture of
bed springs 1 2 1 4
Metal pressings 1 1

SPECIAL PRODUCTION1 PLANTS

Table 1.1,d.
 17

In the United States of America, "American Machinist'1,

a technical publication, has been active in this sphere.
It conducted the first census in 1925 with the main aim
of providing a measure of the degree of modernisation in
the metal industry.

Ashburn^ states that in three countries (CanadaT

Great Britain and the United States), equipment studies
are undertaken on a regular basis by a publishing
company; in three (France, Italy and Japan), censuses
are taken by Government Departments; and in three others
(Argentina, Brazil and Chile), by a body of the United
Nations and agencies of the Governments. Such studies
are conducted at intervals varying from 5 to 10 years.
2
In Kenya, "Industrial Production" surveys have
been conducted in 1954, 1956 , 1957, 1961 and annually
since 1965. These surveys are conducted to compile
information for the economic planning and development
of the country. Their objective, therefore, is different
apd they cannot be applied to form a national equipment
inventory.

The inventory data collected by the author may

be utilised in any of the following ways:-

(a) In making comparisons with other firms,

countries, and results of previous,
surveys in terms of type of equipment;
degree of modernisation; and the deter­
mination of ratios of machines to workers.

* (b) In conducting market analysis for the

local manufacture or sales of equipment
and their accessories.
 V.
18

(c) In the regional and national planning

and development by the Government and
by other associations or firms. The
data can also specify the type of new
equipment in demand, and this can help
in the organisation of personnel training
programmes in the maintenance and operation
of such equipment.

The aforementioned surveys are largely conducted

by post. For accurate results, especially in a developing
country, the method of personal interview is recommended.
Such a method is necessary in Kenya, where about 43^ of
the metal-working firms are small-sised and are owned
mostly by persons having a low educational standard.

1.1.3. Displacement and Replacement

Tables 1.1,a and 1.1.b. give the age groups of

individual machines. An analysis of these age groups,
give the results shown in Table 1.1.e., for the main types
of equipment. Prom these tables the following may be
concluded:-

(a) A greater percentage of the metal-working

equipment was acquired before 1962 .
There has been a gradual displacement of
such equipment. The displacement has
taken place with a change of ownership
from larger organisations to smaller ones;
and generally with a change in the role
of the equipment. For example, a tool­
room lathe was used by the railways for
precision work. On the expiry of its life
(i.e. when the degree of wear was such that
it could not do precision work), it was
bought by a small-scale worker for main­
tenance and repair work.
 LESS THAN MORE THAN
EQUIPMENT TOTAL
10 YEARS OLD 10 YEARS OLD

METAL-CUTTING EQUIPMENT 35 65 100

METAL-FORMING EQUIPMENT 45 55 100

METAl-JOINING EQUIPMENT 68 32 100

TOTAL 47 53 100

AGE OF MAIN EQUIPMENT*

(IN PER CENT)
TABLE 1>1 ,e

♦Includes Railways Workshop, Nairobi,

 20

For the latter purpose, this machine still has

many years of service* However, the replacement
of equipment, which is displaced in this way, is
not fast enough and this explains why -over 50$
of all the main equipment is over 10* years old.
This situation may improve if the upward trend
shown by the graph (Appendix 4 ) continues,
or if local production of metalworking^is intro­
duced. 'f ' \ (

* The ten year period was chosen arbitrarily. In the

surveys mentioned in Paragraph 1.1.1., periods ranging
from less than five years to over 20 years were taken.
The author came across several items of equipment of
well over 20 years old* In any subsequent survey,
periods of less than 10 years, more than 10 years;
and less than 20 years, more than 20 years old should
be included*

(b) In the mechanism for the transfer of technology

from a developed to a developing country,
4
Cooper considers the purchase of modern
equipment as a direct method of such a
transfer. The present technological develop­
ment of Kenya is largely based on the acqui­
sition of progressively modern equipment,, With
the introduction of such equipment, the
technology is developed because more local
personnel are trained and there is an inter­
change of technical information between
foreign experts or consultants and the recipient
enterprises in Kenya.

The transfer of technology to Kenya has been going

on since the early days of its development; and although
there is an increase in the import of certain types of
metalworking equipment during the last few years
(Appendix 4 ), the progress during the last decade has
been rather slow, especially with respect to the' basic
machine tools.
 21

This is clear iron. Table 1.1.a., which shews that except

for a few items like automatic sheet-metal seaming
machines and gas-shielded welding plants, a large per­
centage of the equipment incorporates a technology
which is more than 10 years old*

This situation is different in the special pro­

duction plants like rolling mills. Kenya, being a
developing country, has the advantage of acquiring the
latest technology in this respect without the problem
which a developed country has in either modifying or
getting rid of obsolescence plant.

1.1.4. Type of Equipment

Fig. 1.1.A. (plotted from data in Table 1.1,f.),

shows the relations between the percentages of equip­
ment and the size of establishments. The 3ize of an
establishment is based on the number of workers it
employs, i*e. 1 to 10 workers constitutes a small; 11
to 50 a medium; and 51 onwards a large-scale establish­
ment. Approximate linear relations are obtained, generally
with: (1) a positive gradient from the small to middle
sized firms and, (2) a negative gradient from the middle
to the large sized firms. These relationships may be
described by the following equation*

y - c + mx
where c = intercept on the y axis .--
m = gradient j 'S'

In the case of centre lathes, for example, the

relationship may be described by:-

y = c + 1.5*
y = c - 0.52x

Radial drills and capstan/turret lathes (when

railway workshops are included) display positive
gradients only# ^
PERCENTAGE OF EQUIPMENT

SEE OF ESTABLISHMENT..

PERCENTAGE OF E Q U IP M E N T

INI R E L A T I O N TO

SI7.E OF E S T A B L I S H M E N T
FIG. 1.1.A.
 PERCENTAGES
EQUIPMENT EXCLUDING RAILWAY WORKSHOPS* INCLUDING RAILWAY WORKSHOPS
SMALL MEDIUM LARGE TOTAL SMALL MEDIUM LARGE TOTAL
Centre Lathe 17.7 58.0 24.3 100 | 14.1 46.5 39.4 100
Cap3tan/Turrets ■8.3 50.0 41.7 100 I 2-5 15.4 82.0 100
Universal Millers 8.8 61.4 29.8 100 ! 59.3 32.2 100
Shapers 10.7 61 .0 28.3 100 j 9.2 53.0 37.8 100
Planers 0.0 ’ 22.3 ! 77.7 100 0.0 16.6 83.4 100
Pillar Brills 30.6 5 2.8 16.6 100 29.3 50.5 20.2 100
M
Radial Drills 3.6. 25.0 71.4 100 2.1 14.3 83.6 100
Inclunatic Hammers 0.0 44.5 55.5 100 0.0 26.7 73.3 100
Drop Hammers 0.0 0.0 100.0 100 0.0 0.0 100.0 100
Rolling Plants 0.0. 20.0 80.0 100 0.0 20.0 80.0 100
Eccentric Presses 3.6 45.2 51.2 100 3.5 43.5 53.0 100
Electric Welding Sets 19.4 54.4 26.2 100 18.5 51.4 30.1 100-
> PERCENTAGE OF EQUIPMENT IN
#See Paragraph 1.1.1. RELATION TO SIZE OF ESTABLISHMENT
TABLE ■1.1 ,f
 24

In a paper
5 presented at a symposium on the
"Development of Metalworking Industries in Developing
Countries", curves as those shown in Fig. 1.1.A. are
traced for the Latin American countries* These curves
follow straight lines with either positive or negative
gradients only. This is due to the fact that a certain
type of equipment is distributed in proportion to the
size of the establishment* For example, the small­
sized firms have the largest number of centre lathes;
and the quantity of turret and automatic lathes is the
5
highest in the large-sized firms. The paper explains
that the stage of development in the use of a particular
equipment is indicated by the gradient of its curve.

With the aforesaid comments, an analysis of the

trends displayed in Fig. 1.1.A. follows:-

(a) The middle-scale works have the bulk of

general engineering equipment like centre
lathes, universal milling machines and
pillar drills. This situation does not
change even if the semi-automatic production
equipment like capstan and turret lathes are
accounted for, although a straight line curve
is obtained if the railway workshops are
considered.

(b) A higher percentage of heavy equipment

(Radial drills, planers, etc.) is found in
the large-scale firms* However, the quantity
of such equipment (Table 1.1.a.) is very small
This shows the lack of heavy engineering in
this country.

(c) A small percentage of equipment cf all

nature is employed by the small-scale
e stablishment s•
(d) A breakdown of the stage of development with
reference to a given type of equipment is as
follows:-
 25

(i) Universal Type (Lathes, Hillers, Welding Sets)

At present, these indicate both positive and

negative gradients. These should have a nega­
tive gradient only, which would be possible if
more units were employed by the smaller firms,
(ii) Automatic and Heavy Equipment (Capstan Lathes
Radial Drills, Presses, etc.)

Some of these equipment show favourable

trends with positive gradients. With a pro­
portional increase in their quantity, the
degree of the gradients of their curves should
increase.

The present stage of development in Kenya indicates

that there is a far greater concentration of equipment
in the medium sized firms* For further development, it
would be necessary to get rid of the "peaks11 in the
curves shown in Fig. 1.1*A. The "peaks" represent the
great disparity in the distribution of the quantity of
equipment in relation to the size of the establishment.
They also represent the disproportionate use of certain,
types of equipment. . The "peaks" could be removed by
the amalgamation or expansion of the middle sized firms
or by the implementation of the recommendations given
in sub-paragraph (d) above. On the other hand, there is
a healthy trend in the use of eccentric presses. The
significance of this becomes obvious when one notes the
development in Kenya of the can and container manu­
facturing industry (which largely employs automatic
eccentric presses)*
Frequency distribution curves of the two most common
types of equipment are plotted in Fig, 1.1.B. from data
shown in Tables 1.1.g. and 1.1.h. The distribution
shows that there is a greater frequency of one or two
items of these equipment and that the frequency of
establishments having from 5 to 10 units is in fact
loss than 15*
60 r

FREQUENCY DISTRIBUTION
OF EQUIPMENT
FIG.IJ.B
 27

1 3 4 5
2
x - No. f =
fx d=x-x fd*
of lathes frequency

1 37 37 -2,258 -83.5
2 30 60 -1.258 -37.7
3 21 63 -0.258 -5.4
4 15 60 * 0.742 11.1
5 12 60 1.742 20.9
6 10 60 2.742 27.4
7 4 28 3.742 14.9
8 6 48 4.742 28.4
9 3 27 5.742 17.2
10 1 10 6.742 6.7

TOTALS S f = 139 2fx=453 ifd = 0

Mean value = x - s fx
*f

= 3*258 (Say 3 Lathe Machines)

If all the signs in Column 5 are taken as
positive,
Mean deviation = Total of Column 5
• X f *

= ,
2.5?-2. = 1.82 (Say 2 lathe Machines)
139

* Correct to one place of decimal.

FREQUENCY DISTRIBUTION OF LATHE MACHINES

(FOE ESTABLISHMENTS WITH 1 TO 10 LATHES)

Table 1.1
 28

| x= No. of f = d-x-x fd*

fx
; Welding Sets frequency
i
1 56 56 -1.989 • -111.4
i
2 56 112 -0.989 -55*4

3 30 90 0.011 0.3

4 7 28 1.011 7.1

5 10 ‘ 50 2.011 20.1

6 14 84 3.011 42.1

7 8 56 4.011 32.1

8 5 40 5.011 25o1
/
.9 2 18 6.011 12.0

10 4 40 7.011 28.0

TOTALS •Sf=192 5fx=574 ■Efd = 0

Mean value = x = s fx = 574

Xf 192

= 2*989 (Say 3 Welding Sets),

Similar to Table 1.1«g.r

Mean deviation - 335*60

‘ 192 ' . • *

= 1.74 (Say 2 Welding Sets)

* Correct to one place of decimal.

FREQUENCY DISTRIBUTION OF ELECTRIC WELDING- SETS

(FOR ESTABLISHMENTS WITH 1 TO 10 SETS)

Table 1.1.h
 29

Most firms, therefore, have less than 5 units of these

equipment. This indicates the general trend in Kenya of
jobbing work rather than production.

1.1.5 Locally-made Equipment

As shown in Table 1.1.C, locally-made equipment was

found in only small and medium workshops. In one medium-
scale workshop (Table A, II, 65)» nearly half the large-
batch production was being carried out by locally-made
machinery. Such firms have little capital for invest­
ments in new machinery. However, as they have a need,
they use their ingenuity and workmanship to erect
machinery capable of doing reasonable amount of work.

The manufacture of local equipment should be

encouraged. In this respect, Paragraph 3.4.2. makes
some recommendations.

1.1.6 Production Plants

Production plants (Table 1.1.d.) were mainly found

in l^rge-scale firms. This is to be expected since
such firms can make large investments for the acquisition,
running and maintenance of such plants.

A few small and medium-scale firms have, however,

acquired such equipment. 'Some of these firms have been
established with the assistance of bodies like the
Industrial and Commercial Development Corporation (I.C.D.C.).
Such a trend should be confined to certain limits
because otherwise it can act as a hinderance to the
natural growth of industrial skills. Any attempt to
introduce large-batch or mass production in such firms
should be done by the use of conventional or semi­
automatic machines with a labour-intensive production
scheme. In this way, industrial skills in the country
will keep a balance with the more automatic plants used
in seme large-si~ed firms.
 30

1.1.7 Machine Tools Per Worker

The paper‘d (see Paragraph 1,1,4) presented by the

United Nations Economic Commission for Latin America,
discusses the fact that during the initial development
stages of a country, low ratios of machine tools per
worker are observed. With more industrialisation and
larger acquisition of equipment, higher ratios are
possible. Higher ratios could also be the result of a
sudden unemployment situation in the industry.

Pig. 1,1,C. presents a curve for the local metal­

working industry. The ratios are based on machine tools
per total number of workers employed. This curve may
be used for any subsequent studies in the field of
industrialisation and employment in the metal industry.

C. CONCLUSIONS AND REC OMILBNDAT IONS

1.1.8
Several countries carry out regular censuses in
order to establish their national equipment inventories.
For a developing country like Kenya, equipment censuses
could give valuable information for development and
industrialisation purposes. It is recommended that the
statistics division of the Ministry of Finance and
Economic Planning with the co-operation of bodies like
the East African Institution of Engineers, should carry
out such censuses with intervals varying from two to
five years, *

1.1.9
Over 50fo of the main metal-working equipment in
the country is at least ten years old. There is a
faster rate of displacement of equipment, generally
from larger organizations to smaller ones. The rate
of replacement has been rather slow, although in 1969,
a substantial increase in the import of metal-working
machines was noted. While in the sphere-of production
plant, Kenya is acquiring the latest technology, in
conventional machine tools, the technology is well over
ten years old.
 in

RELATION OF NO. OF METAL

CUTTING MACHINES TO SIZE OF FIRM
FIG.I.I.C.
 32

Modern technology is being introduced in certain fields

like those of metal fabrication, but in order to develop
the technology, Kenya should acquire a larger percentage
*

of modern equipment, especially with regard to the basic

metal-working tools.

1 . 1.10
The middle-scale firms have the highest percentage
of equipment. For further development, it is necessary
for larger enterprises (which may also be formed by the
expansion or amalgamation of the smaller firms) to acquire
and employ a greater percentage of equipment. While
progress in the use of eccentric presses is satisfactory,
no automatic machining equipment is employed in the
industry and also the percentage of semi-automatic
machines (like capstan lathes) is found to be lower in
the large-scale firms.

The frequency distribution of the two most common

types of equipment show that over 50 metal-working
establishments have only one or two units of such
equipment and that less than five establishments have
ten. For a more proportional distribution of equipment,
it is recommended that larger firms should acquire more
automatic and semi-automatic type of equipment; and
the smaller firms should make use of the universal type
of machines in order to undertake a large range of jobs.

1.1.11
Necessity forces some small and medium establish­
ments to employ locally-manufactured machinery*
Examples of such machines are pillar drills, he^vy duty
pedestal grinders, and eccentric presses. In an effort
to encourage local machine tool manufacture, recommendations
made in Paragraph 3.4.6. may be enforced. ■
 33

1 .1 .12
Specialist production plants were found in the
large-sized establishments* Recently some smaller
firms hav^ acquired small automatic production units*
This trend should he confined to some limits for
otherwise the use of widespread automatic plants could
hinder the development of industrial skills* In order
to maintain a balance of industrial skills, the smaller
firms should be encouraged to use more conventional
type of equipment*
 P A R T T W O

PRODUCTION ENGINEERING

■xXx
 1
\

C H A P T E R II

PRODUCTION OF METAL AND METAL­

WORKING PROCESSES

----xXx
 34

PRODUCTION OF METAL AND METALWORKING PROCESSES

A, THE PRESENT STATE

The following tables represent the present state

of engineering processes used in the metalworking
industry for refining of metal, manufacture, repair
work and engineering services*

Table 2.1.a : The Production of Metal and

Forming in the Liquid, Hot
and Cold State.
Table 2.1.b : The Machining Processes
Table 2.1.c.: Welding and Joining Methods
Table 2.1.d : Heat Treatment Methods
Table 2,1.e : Surface Treatment Methods

2.1.1. Historical Retrospect

There is evidence of prehistoric ironworking in

parts of Northern Sudan, The National Museum in
Nairobi show exhibits of iron products and records
that iron vas in use in Nubia (MeroB) from about
650 B.C. Its progress southwards to East Africa was,
however, very slow and ironworking was still in a
primitive state when the first settlers arrived.
There is mention of processes used for making tools
whereby pig iron was heated and worked on a stone
anvil with an iron hammer, welded without a flux
and barnished with stones while it was pegged on a
banana log (which substituted for a vice). The un-
tempered cutting edge was obtained by rubbing on
a stone.
Concerning iron making, Du Bois^ states
"In certain parts of Kenya and the neighbouring
countries the smelting of iron ores by the use of
charcoal and the forced draught of air from goat-
* i
skin bellows has been carried out in rural areas for
the production of sponge iron.
 MAIN APPROX NO. NORMAL
RAW OF FIRMS PRODUCTS/SERVICE
PROCESS MATERIAL USING THE MAIN CHARACTERISTICS ‘ AND
PROCESS OUTPUT CAPACITY
SM ME LA
1.PRODUCTION Production of iron not undertaken.
OF PIG IRON ' - - - -Iron ore is found in several parts
of Kenya but is not commercially -
exploited.
2.PRODUCTION hematite, Production undertaken, by the rail- ..
OP STEEL coke, 1
& scrap wayk foundry in Nairobi. Main
equipment: acid-lined tropenas
converter, capacity about 750Kgms. See Tables 2.1.a.
Main production is of steel castings (1) and (
and a small quantity of alloy steel 5fe £,i'l
ingots. These castings are sub­
jected to chemical and physical
tests.
3.PRODUCTION Kenya is endowed with several ores
o?““Fo“u- - - - - of non-ferrous metals as discussed
FERROUS
METALS in Paragraph 2.1.4. Local refining
of the netals not undertaken.
THE PRODUCTION OF METAL AND FORMING IN THE LIQUID,
HOT AND COLE STATE
Table 2,1.a
>

4.CASTING Coke, SMI HEI LT Cast iron is produced in locally-

a) Cast Iron scrap & made cupolas* Dimensions of some
small qua­ of the main cupolas are'given in
ntities Table 2.1.a(3). The constituents
of lime of the raw materials and those of See Table 2.1.a(3)
stone the finished products are based on Pi.g'-e.58
intuition and, with the exception
of the railways foundry, chemical
and mechanical tests are not
employed to establish the sound­
ness of castings.
b)Non- Wrought Wrought or scrap is melted in a
Ferrous or scrap. CTi

Metals small crucible which is heated in

Aluminium, either a coke or an oil-fired
copper,
brass & furnace. No control is kept over
bronze the constituents of the metal
and the finished casting is merely
specified as "Aluminium", "Brass",
etc. Again the .railway's foundry
is an exception to this trend*
Examples of their specifications
are shown, in Table 2.1.a(4). This
foundry employs rotary furnaces
having a combined capacity of
about £85Xgms -CP*-?* ?-?)_________
 SM [TaT" 1A
c) Sand Cast 6 20 5 Cast iron (Para. 4.a. above) is used Wheels; gear
Casting iron extensively. The castings are gene- wheels; manhole
and rally rough and have poor dimensional covers.
non- accuracy. Fine work involving holes,
fer- webs, and grooves is not in much pra-
rous ctice. Thinnest normal section is
net- about 1.Ocm. For accurate work machi-
ala ning allowance is left.
The process of casting is largely • Crushing rollers;
manual. However, the railway's railway brake
foundry has two semi-automatic pro- blocks; weighing
duction flow-lines. Their production blocks; hydraulic
capacity for brake blocks is 8,000 jack cylinders;
per week. Weight; 2-2C0Kgms
Their equipment consists of auto­ per item.
matic moulding machines, roller con­
veyors and attachments for pouring .. -
of molten metal.
--—-..In the non-ferrous metal range, Bushes; bearings;
aluminium, copper and its alloys badges.
are employed. One firm (Table A, Weight: Up to
11,71) was seen to cast intricate 1CKgs. per item.
badges of bronze or brass.
___ (CQHTiHiU}—
i

SM ■MS LA

N^
Pattern Making:- Normally made
from local timbers, the common
timbers being 'Podo1 and Cedar.
Some firms were seen to be using
a sample of the item to be manu­
factured as a pattern. Considera­
tion to shrinkage allowance is
generally not given.
Split patterns are not much used
and the practice of making baked
cores is also limited.
With the exception of the rail­
ways, sound principles of pattern
making were not observed.
Patterns for making small non-
ferrous metql items like badges
are made in lead. The pattern
is either carved by hand or made
in an engraving machine. The
work requires great skill and
only one or two firms undertake
such jobs.
(c p h -u h u e I
■ I ■
Mould Making:- Normally made
on the floor. The use of
moulding boxes is limited.
Riverbeds provide the-main
source of sand. Sometimes,
a mixture of sand and red clay
is used. Only one firm
(Table A,III,17) was seen to be
using laboratory tests to esta-
bli3h the soundness of a mould.
The normal practice is to make
"green" moulds, although some
firms reduce the moisture
content by lighting a wood fire
on the cope. Nails are often
used to strengthen the mould.
The railway's foundry has a
sand reclamation plant. Moulds
for the manufacture of fine non-
ferrous metal castings are made
from, sand ground to powder and
mixed with molasses. These
moulds are often made in small
metal boxes having the dimensions
as small as 4cm? each.
 SM ME LA
d) Die Aluminium - 5 - 1. Gravity:- Used for the manu- Small castings
Casting
& Zinc facture of small items. The dies up to about 5kg.
alloys (generally of mild steel) are in weight.
made hy a combination of machi­
ning and fabrication and are in
two halves.
- - 1 2. Pressure:- Process only found Components for
at one firm (Table A,III,1©). The casements.
machine used is the pressure or ■*
hot chamber type.
• - 1 3. Slush Casting:- Slush Spruts for
casting is done manually and is hollow-ware.
used by a firm in Mombasa
(Table A,111,20). The die is
imported.

e) Shell Cast iron The railways1 have two machines. Components

Moulding and steel 2 one of which is semi-automatic. mainly for the
They use sea sand which is pre- railways.
processed in a mill and' is mixed
with phenol resin for making the
shell.
Besides railways, only one other
firm (Table A,III,26) was found
to have equipment for shell mouldir
— -- ---- — -— -------- ^_(Co wthmue )
 1

3M ME 1 LA
5. FORGING The process is based on tra­ Decorative fences;
a) Hand Mild steel ditional methods; one black­ lampstands; furni­
. For&inc
& spring smith was found to be using a ture; gardening
steel. 38 . 50 12 bellow for blowing air into the implements; leaf
hearth; and the work is often springs.
done while squaring on the floor.
The use of dies is limited and
the practice of forge welding
was not observed* Most black­
smiths also use electric and
•
gas welding processes.
Decorative work is mostly
done by smaller firms while
larger firms use the process to
assist in the forming of thicker
plates and bars.

h Hie chemical Pins and bolts.

Forging Mild steel 3 6 Only the railway workshops
The automatic up­
(Table A fIII,3 & 4) employ drop
set forging
and steam hammers. The biggest
machine of the
capacity of the steam hammer is
railways can
about 1,000 kgm3. and 6f the drop
produce about
hammer about 1,500 kgms.
200 pieces per

h0UJ- tCOMTM-mfe)
 SM | ME ! LA
5. FORGING The process is based on tra­ Decorative fences;
a) Hand Mild steel ditional methods; one black­ lampstands; furni­
For^inf:
& spring smith was found to be using a ture; gardening
steel. 38 50 12 bellow for blowing air into the implements; leaf
hearth; and the work is often springs.
done while squaring on the floor,
The use of dies is limited and
the practice of forge welding
was not observed. Most black­
smiths also use electric and
gas welding processes.
Decorative work is mostly
done by smaller firms while
larger firms use the process to
assist in the forming of thicker
plates and bars.
t
blKechnnical Pins and bolts.
For&inf: Mild steel 3 6 Only the railway workshops
The automatic up­
(Table A,III,3 & 4) employ drop
set forging
and steam hammers. The biggest
machine of the
capacity of the steam hammer is
railways can
about 1,000 kgms. and Of the drop
produce about
hammer about 1 ,500 kgms.
200 pieces per

h 0 U r- fC O ^ T ^ U fc i
 SK MS LA
b)Mechanical Operations like automatic upset
Foivtinsr-cont. forging are also undertaken by '
these workshops.. Other firms
generally employ pneumatic hammers.
Only one establishment (Table A,'
11,49} employs mechanical hot
pressing for the manufacture of
certain items.

6.ROLLING Mild steel

billets Cold rolling of metal is not
undertaken in this country.
Hot rolling of steel rods and
bars is undertaken by three main
mills:-
1 1. The Mill at Kikuyu:- (Table A. 30,OOOKg/Day
111,16). Established around 1957. 7.35czi billets
Materials handling mostly manual. can be rolled
Five two high mills for non- to 0.62cm dia-
reversal rolling. Installed meter rods.
horsepower about 800. Oil-fired
furnace.
6 . RO LLIN G SM KE LA
C o n td . - - 1

* - 1 1
2. The Mill at Nlritini:-
(Table A,III,22). Established 60,OOOKg/Day
In 1971 and represents an invest- 8cm^ billets can
ment^ of K£ 1 million. The be rolled to bars
rolling operation is automatic, of 2-0 to 1.0cm.
although subsequent loading of diameters.
finished product is manual. Eas
two and three high mills for
reversible rolling. Installed
horsepower of the motors o nly■
is about 1,500.
3. The Mill at Dandora:-
(Table A,III,5)* Similar to 5 0 ,000 Kg/Eay
(2) above. Was under constru­ ,(Estimated)•
ction at the time of visit.
Planned total installed horse­
power about 4,000.
In addition to the above, Note:- The rods
two establishments were found to and bar3 are pri-
be doing small-scale rolling for marily used for
the manufacture of items like re-enforcing con-
hoes and matchets. Crete structures.
______C t o W T l H H E X -
 '
SM T'TE LA
7.EXTRUSION lead-based Hot extrusion of metal is not
slugs 1 practised*
* Cold or impact extrusion is From 2,800 to
carried out by one establish­ 3 #000 tubes per
ment (Table A ,111,29) for the day.
manufacture of collapsible
tubes* The process is auto­
matic and employs inter-stage
annealing.
8.WIRE 3 1. Wire Drawing:- In Kenya, One firm uses
DRAWING* & there are two establishments 6.5 mm and 5*5cm
WIRE PRO- engaged in the process of wire diameter wires to
DUCTS drawing (Table A,II,63 & 93). reduce their cross-
The process is ’'dry" and soap sectional areas
powder is used as a lubricant. - by about 15# to
Wire drawing machines with 20?S.
vertical and horizontal cap­
stans are employed*. ..Initial
annealing of the wire was founc
to be carried out by one firm
only.
Another establishment
(Table A,II,26) also uses this
process as part of the manu­
facture of welding rods.
------- Ccotizrirtul)
 L_
8. Contd. SM iME 1 LA
Bright
drawn steel 1 3 -
wire

Bright 1 4
drawn steel
wire
 “““ ■
— ^ -
2.Manufacture of Wire Springs:- Close-coiled
Bed springs are manufactured by springs; conical
automatic machines. Two esta- springs (Single
blishments (Tabic A,I, 2 and and Double).
II, 65) use locally-made
machines for this purpose.
3. Manufacture of Hails. One establish-
Rivets and Screws:- Larjre ment (Table A,II,
quantities of wire nails are 33) has a capacity
produced in Kenya. The equip— of 1,800 Kgs. of
ment used is the automatic nails per month.
nail press. Generally, dies
for these presses are initially
imported. Subsequent repair of •
these dies and manufacture of
replacement parts are carried
out locally.
' Rivets and screws are manu-
factured in a similar manner.
Kon-ferrous.rivets are not
produced and there was no evi­
dence of the production of
.bifurated rivets.
Q. Contd. SW ME LA
1 1 4. Other Wire Products:- Paper pins, clips
and stable clips
are manufactured
on automatic
machines having
production rates
of 100 to 150
items per minute.
..
? —
Wire nettinrs.
-
9. PRESS Tinplate 1 3 1. Manufacture of Can3 and Production rates:
WORK Drums:- The press work (Table A,III,29):
technology for the manufacture half million open-
of cans, tins, containers and ended cans daily.
drums is the most advanced and Firm(Table A,II,
automated in this country. The 84): 9*000 con-
two main firms (Table 'A,III,14 tainers (5 litre)
and 24) engaged in this pro- per day.
,duction have their own tool
rooms and lithographic
■
departments. They also manu­
facture some press tools and
dies. Operations like forming,
punching, blanking and piercing
are carried out.
9. Contd. SM ME I LA

Tinplate - 1 - .

Aluminium 2 1
& stain­
less steel
sheetings
The automatic units incor-
porate seaming and soldering
operations.
2. Manufacture of Crown Corks:-
The production is automatic Over 15,000
although final packing is done crown corks per
hy hand. The plant incor- hour.
porates a lithographic section
and also has machines for the
insertion of plastic sealing
material.
3. Manufacture of Domestic
Hollow-ware:- Presses Firm (Table A,
ranging from manual fly- 11,97) consumes
presses to slow speed 600 metric tons
159,000 Xgs capacity.crank- of aluminium;
presses are employed. One 200 metric tons
firm (Table A,III,20) employs of stainless
pure aluminium sheet and steel; and 100
attains, by a combination metric tons of
of pressing and deep- mild steel per
drawing processes, a 40^ year.
to 43?'» diameter reduction
of the blank in three
operations.
(c o m t a h u e )
 —

9- Contd. SM ME LA
1

Tinplate - 7 3
& alumi­
nium
sheetings.
 No inter-stage annealing is
undertaken. Some dies are
made locally.
Another firm (Table A ,11*97)
has five mechanical presses
ranging from 10,OOOKgs to ■

AOO,OOOKgs. This firm manu-

factures its own dies from
cast iron.
,
Ordinary grade of lubricating ■
oil is used in the process but
several items (especially earth
pans) were found to have
wrinkles.
4. Manufacture of other items:-
■ In coach and bus body-building, Bus and coach
window panels of sheet-metal window panels.
are formed on manually-operated
presses. The dies (made of
mild steel) are pressed home by
means of screw clamps.
9.Contd. SM l ICS I LA ------------------- 1
i
Mild steel - 5 4 ■ Presses are employed in the ,
plate | manufacture of steel casements. Brackets.
Some locally-made piercing
presses are also used-
Mild steel
plate 1 Another firm (Table A,II,58) Hinges; hasp
has some hand-operated and and staples*
• mechanical machinery for manu­
facturing pressed items.

10. PLATE & Mild steel, 1 6 4 1. Manufacture of Tanks:-

STRUCTURAL stainless Tanks for the storage of Vehicle-mounted
WORK steel; and liquids like petroleum, tanks (50,000
aluminium edible oils, milk and beverages litre capacity);
plate. are manufactured in Kenya. liquid storage
Rolled Tanks for the transportation of tanksf100,000
steel Lars. such materials are also made litre).
and mounted to vehicle
chassises.
The process is largely
manual, although use is made
of bending rollers*
______ _______________ |
10. Contd. SM ME LA

Mild steel 1 1 3
plates and
rolled
bars

■i
The rollers (both powered and
manual) are of small or medium
size. Aa a result, several
sections of plate are shaped by
a combination of bending and
hammering, and are then fabri-
cated by welding to form a tank.
$ome firms use a simple jig to
ensure that the required cur­
vature of the plate is attained.
One establishment (Table A,
1X1,9) specialises in the manu­
facture of stainless steel and
aluminium storage tanks.
2. Manufacture of Marine Vessels:
The process consists of forming Lighters; tugs;
mild steel plates in the workshop ferries. Max.
by using presses, bending rollers, deadweight .ton-
etc. The sections are then nagefdwt. tons)
welded or riveted to a frame- about 150 long
work, which is generally fabri­ tons.
cated on g slipway.
(COHTAHU.E') -
Note;- The slipway of one firm
at Honbasa (Table A,III,1.7) is
in the process of being con­
verted into a dry dock, which
will bo the largest of its
kind in the Western Indian
Ocean, north of Durban 4 v
5. Structural Work:- Several Erection and
firms are engaged in structural fabrication of
engineering, although only five steel structures
have their own yards and drawing for bridges;
office facilities. factories, ware­
Sections are cut and drilled houses; work­
in the yard and are then trans­ shops; towers
ported to the site for erection and power
either by welding or by means of stations.
nuts and bolts.
4. Manufacture of Other Items:— 1. Mechanical
These items are largely made Handling Equip­
from plates, tubes, rolled ment :-
sections and pipes which may (Table A,II,24)
be used in combination with manufactures
each other or individually. lifting jacks
& hand-operated
hydraulic fork
lift trucks. (cot-vCi
 1--- i
---
10. Contd, shlme LA
As mentioned earlier, the Firm (Table A,
process is largely manual, and II, 22) manu­
only a limited use of press and factures overhead
shearing machine tools- i3 made* gantry cranes.
A greater degree of fabrication
rather than forming is employed.;
The production, as in the case
of items above, is Jobbing or
small—batch.
2. Bodies for
lorries; \T.
ro
trailers and
wheelbarrows.
3. Tea machinery.
4. Plough frames
and other agri*
cultural equip­
ment .
5. Exhaust pipes.

11, SHEET- Tinplate 28 12 1. Tinsmith Practice:- Like Buckets; con­

METAL WORK forging, tinsmith practice is tainers ; watering
based on traditional methods: cans; measuring
cans; (
 11 • Contd. SM ME LA
i '
\
t f
I
]
i

i*

• :

'
' ■
. •

;
Tinplate & - 10 3
aluminium
she e tings
forking on the ground, use of funnels; troughs;
crude tools, and manufacturing water tanks (capa­
without the aid of drawing. city 10,000 litre
Several tinsmith shops were approximately).
found to have no facilities
for electric power. Such shops
use charcoal as a heating medium
for soldering.
Automatic and semi-automatic ..
sheetrmetal work machinery is
rarely used.
The medium-scale tinsmith
uses some power tools and conce-
trate on the manufacture of
items like water storage tanks.
Corrugated sheet-metal is gene­
rally employed for such items.
2. Manufacture of Vehicle Bodies: Sheet-metal
Bus, coach and other vehicle bodies for
hodies are manufactured in Kenya. buses & coaches;
A frame is fabricated and welded and bodies, for
to the chassis* Sheet-metal | vehicles used
sections are then shaped by j for cargo­
hammer and by manually-operated carrying.
wheeling machines.
11 , Corrtd. SM ' MS LA

1 -

Aluminium - 2 1
sheetings
These sections are then riveted Bodies for mobile
to the frame to form the skin. film units have
The floor is generally made of also been made in
marine ply-wood and covered by Xenya^.
sheet-metal.
Some firms also manufacture
their own seat frames and seat
cushions. ‘
3. Manufacture of Other Items:- .. j
Automatic production of sheet- Irrigation water
metal pipes for irrigation pipes.
purposes is undertaken by one
1
firm (Table A,II,42). The
exterior of the pipe is painted
and the interior is covered 'i
with bitumen.
Metal spinning is employed Domestic hollow-
by some medium and large- ware.■
scale firms engaged in batch 1
f
production. Aluminium is used i
but no inter-stage annealing i3 !
carried out during the process*
. -Ccort-rmuel____ i
 SM ' ME LA i
11. Contd. i

! ; Wooden blanks are used and the ■

wooden tool'employed is lubri- i

i cated with bees-wax. Only simple j

— ----- F shapes are spun. |
»
r
1 Aircraft skin repair work is j
(
l carried out at Embakasi (Table j
(
i A,III,2). The sheet-metal shop

!. i of this establishment also has •

i
facilities for the heat treatment j
i i i
| i of non-ferrous metals* ! 1

KEY:- SM - Small Table 2.1.a

ME -.Medium
LA - large
 56

*—
YEAR IRON & STEEL BRASS OR GUR-
(M-TON)* METAL (M-TOH)*

1969 1,045 121

1968 1,020 98

1967 1,220 120

1966 1,035 153

Tota3. Value of Casting for 1969:-

Ferrous C a s t i n g s . . K £ 90,218
Hon-ferrous Castings*.K£ 42,595

Total.................. K£ 152,813

OUTPUT: RAILWAY FOUNDRY, NAIROBI

* (Metric ton*i)
 51

I. TYPE: CARBON ST EliL CA STINGS

COMPOSITION AND PHYSICAL PROPERTIES

GRADE A GRADE B GRADE C

Maximum Carbon 0.25 0.35 0.45?$

Maximum Silicon 0.60 0.60 0.60?$
o.
o
Maximum Manganese 1.00 1.00;$

Co
o
o
Maximum Sulphur 0.06 0.06
Maximum Phosphorus 0.06 0.06 0.06$
Minimum Tensile Strength 28.00 32.00 35.00 ton/Sq"
Minimum Yield " 14.00 16.00 17.50 ”
Minimum Elongation 22.CO 20.00 15.00 " "
oo
VO

Minimum Angle of Bend 120° Ho test

i

II. TYPE: "20" CARBON STE EL

COMPOSITION AND PHYSICAL PROPERTIES

KIN. MAX. DESIRABLE

Carbon 0.15 0.25 ' 0.20$

Silicon 0.06 0.35 0.25$
Manganese 0.06 1.00 0.75-r» i
VO
o
o*

i
o>.

Sulphur - -
Phosphorus - - 0.06?$ Max.
Tensile Strength 25.00 35.00 30.00 ton/Sq"
Elongation 25.00 — 25°/$

EXAKPLES OF STEEL PRODUCED BY THS RAILWAY POUKDRY ,

NAIROBI

Table 2.1.a,(2)
 ESTABLISHMENT MAXIMUM DIAMETER MAXIMUM PRODUCTION RATE*
(REFERENCE) (Cm) HEIGHT (m) (METRIC TON)

TABLE A, 111,17 90 7.5 —

TABLE A,III, 30 — - 1.5

TABLE A, II, 71 , 60 4 1 - 1.25

TABLE AV II, 43 90 5.7 2 ■

* Por an 8-hour shift; . including preparation and heating.

APPROXIMATE CUPOLA DIMENSIONS

Table 2.1.a.(5)
 59

i&i
!a

—i
,o
COMPOS]
|
i

PHOSPHORUS
03 COMMON
H g ;
COPPER

hi
H s o NAME
EH <4 o
h
LEAD

g M is; H
& o P .o Hi
M M
g Hi g M
tsl Eh < 3 HH CO
r

Cu Pb Zn Sn Ni Ai Sb Ph Mn Fe si !
i
- Tr­
87 2 2 9 -
ace
- — [&UNMETA1
ji
ii
CO

- H - - - - - {BRONZE
i^

60 0.1 0,1 - 1 — - 1 1 iMANGANESE _1

37 ilBRONZE !
i ii i
88 ! - — 11 - - - 1 -
ilPHOSPHO- j
IIrous bronze
•f T

Q :jLEAD '!
80 1 9 1 - - - - -
IlBRONZE i
...;j .......
58 - 1-
PROP STAMP I
5 39 Jb r a s s j
I
5.8 - 0.1 90 3.8 0.2 VBIHEmTAL

____i — __!

EXAMPLES OF NON-FERROUS ALLOTS

Table 2.1.a . (4)

 APPROX NO.
MAIN
OF FIRMS „ NORMAL
RAW
PROCESS USING THE MAIN CHARACTERISTICS IpRODUCTG/SERVICE
MATERIAL PROCESS AND
- OUTPUT CAPACITY
1 MACHINING SH ME LA M a c h in in g i s a w id e ly u s e d p r o -
M ild s t e e l;
PROCESSES ce ss in K enya.
a llo y
The m a c h in e s an d t h e c u t t i n g
s te e l;
to o ls a re im p o r te d * M ost fir m s
b ro n z e &
h a v e a h e a v y a n n u a l e x p e n d it u r e
b ra s s
on c u t t i n g t o o l s . The c u t t i n g
flu id is made l o c a l l y b y m ix in g
o r d i n a r y g ra d e l u b r i c a t i n g o il
an d w a t e r .
47 73 28 1 . L a th e W o r k :- C e n tr e l a t h e N o rm a l c e n t r e
tu r n in g is a w id e s p re a d p r a c ­ la th e w o rk c a r r i e d
tic e . M ost fir m s a ls o a t t e m p t o u t on s m a ll and
to u se t h e c e n t r e l a t h e fo r m e d iu m -s iz e d
to o lro o m a n d p r e c i s i o n tu r n in g * machines.
T h e re i s a la c k o f t o o lr o o m and
c a p s t a n / t u r r e t la t h e w o rk i n
th is c o u n tr y . M ost tu r n e r s a re
h ig h ly s k ille d in t h e i r w o rk .
1 5 6 C u ttin g t o o ls com m only i n N o rm a l c a p s t a n /
u se a r e o f th e h ig h sp e e d t u r r e t la t h e w o rk ,
s te e l ty p e . a ls o c a r r ie d on
*
s m a ll an d m e d iu m -
THE MACHINING PROCESSES
Table 2.1.b
 SM ME LA
C o n td .

90 80 27
t
t

i
I
t

3 8

i
I

7 35 H
 - s i z e d m a c h in e s .
2. D r illin g and B o r i n g : - P o r t a b le
d r i l l m a c h in e s a r e u s e d i n th e
v e h ic le b o d y - b u ild in g in d u s tr y *
F o r w o rk s h o p p r a c t i c e th e p i l l a r N o rm a l d r i l l i n g
v e r tic a l d r i l l is t h e m o s t common. p r a c tic e w ith
B ox c o lu m n ty p e o f d r i l l s and m edium s iz e d
r a d ia l d r i l l s a r e n o t much i n use. p illa r d r ills .
A ls o , th e u se o f d r i l l i n g jig s
and f i x t u r e s i s l i m i t e d .
P r e c is i o n d r i l l i n g w i t h th e
u se o f re a m e rs was n o t o b s e r v e d .
l
R a d ia l d r i l l i n g is m a in ly \
u n d e r ta k e n i n m a r in e a n d s t r u -
c t u r a l e n g in e e r in g w o r k .
B o r in g i s o n ly u n d e r ta k e n
f o r fin is h in g la r g e m a r in e
r a i l w a y and b e a r in g s ( T a b le A ,
III, 17 a n d 4).
3 . M i l l i n g : - The n r a c t i c e of N o rm a l m i l l i n g
m illin g is lim it e d . One f i r m p r a c tic e c a r r ie d
( T a b le A , 1 1 , 8 3 ) a t t r i b u t e d o u t on s m a ll and
th is to th e l a c k o f s k i l l e d m edium s iz e d
m anpow er. m a c h in e s . P ro -
The p ro c e s s i s g e n e r a lly d u c ts in c lu d e
u s e d f o r t h e m a n u fa c tu r e o f s p u r ,h e lic a l &
g e a rs . worm g e a r s . ( cowt.) ,
 SM ME LA
C o rrtd .

90 80 27

35 U
 - s i z e d m a c h in e s .
2. D r illin g and B o r i n a : - P o r t a b le
d r i l l m a c h in e s a r e u s e d i n th e
v e h ic le b o d y - b u ild in g in d u s tr y .
F o r w o rk s h o p p r a c t i c e th e p illa r N o rm a l d r i l l i n g
v e r tic a l d r i l l is t h e m o s t common. p r a c tic e w ith
B ox c o lu m n t y p e o f d r i l l s a nd m edium s iz e d
r a d ia l d r i l l s a r e n o t much i n use. p illa r d r ills .
A ls o , th e u se o f d r i l l i n g jig s
and f i x t u r e s i s l i m i t e d .
P r e c is i o n d r i l l i n g w i t h th e
u s e o f re a m e rs was n o t o b s e r v e d . \
R a d ia l d r i l l i n g is m a in ly \
u n d e r ta k e n i n m a r in e a n d s t r u - \
c t u r a l e n g in e e r in g w o r k .
B o r in g i s o n ly u n d e r ta k e n
f o r fin is h in g la r g e m a r in e
r a i l w a y an d b e a r in g s ( T a b le A ,
III, 17 and 4 ) .
3 . K i l l i n g : - The p r a c t i c e of N o rm a l m i l l i n g
m illin g is lim ite d . One f i r m p r a c tic e c a r r ie d
( T a b le A , I I , 8 3 ) a t t r i b u t e d o u t o n s m a ll and
th is to th e la c k o f s k i l l e d m edium s iz e d
m a n p o w e r. m a c h in e s . P ro -
The p ro c e s s i s g e n e r a lly d u c ts in c lu d e
u s e d f o r t h e m a n u fa c tu r e o f s p u r ,h e lic a l &
g e a rs . worm g e a r s , (cowx)
t
4 . G r in d in g and H o n in g : - B ench
g r in d e r s a r e u s e d e x t e n s i v e l y ,
e v e n f o r t o o l and c u t t e r g r i n d i n g .
T he use o f t o o l and c u t t e r g r in d e r s
is ra re .
S p e c ia l t y p e o f c r a n k s h a f t R e - g r in d in g
g r i n d e r s and s u r f a c e g r i n d e r s o f a u t o m a t iv e
a re used f o r g r in d in g c r a n k - e n g in e co m p o -
s h a f t s an d e n g in e c y l i n d e r b l o c k s , n e n ts .
F in n s d o in g t h i s ty p e o f w o rk a ls o
u n d e r ta k e h o n in g o f c y l i n d e r w a l l s .
T he p r o c e s s i s done b y h a n d b y
a t t a c h i n g a h o n in g b i t to an
e le c tr ic hand d r i l l .
5 . S h a p in g ; - C ra n k -ty p e s h a p e rs N o rm a l w o r k -
a r e g e n e r a lly , e m p lo y e d , shop p r a c t ic e .
6 , Powered S a w in g : - M ost fir m s
e m p lo y p o w e re d h a c k -s a w s .
L a rg e f r i c t i o n saws a r e u s e d
by f ir m s enga g e d i n s te e l s tru c ­
t u r a l w o r k ; and c i r c u l a r saws
f o r c u t t i n g a lu m in iu m , a r e b e in g
in t r o d u c e d .
(cO fATiH U t)
 SM 1ME LA
7. Planing and Slotting:- Mainly
used for railway and marine engi­
neering purposes.
- 1 8 . B r o a c h in g : - O n ly one f i r m
( T a b le A , I I ,4 9 ) h a s a s m a ll
h o r iz o n t a l h y d r a u lic b r o a c h in g
u n it.
9. Diosinking and Engraving*:-
The p r o c e s s i s c a r r ie d o u t by Name plates; dies.
t h e u se o f p a n to g ra p h d i e -
s i n k i n g and e n g r a v in g m a c h in e .
e>
1 0 ' P o lis h in g * : - E l e c t r i c hand
g r i n d i n g an d b u f f i n g m a c h in e s a r e
u s e d f o r c le a n in g w e ld e d J o i n t s .
H e a v y - d u ty b u f f i n g m a c h in e s
a re used f o r p o lis h in g house­
h o ld s i l v e r and h o llo w - w a r e .

KEY:- SM - Small
ME - Medium
LA - Large (size of firm)
* The number of firms shewn are those which have special
equipment/facilities for the process*
T a b le 2 . 1 . b
 'APPROX NO.
MAIN NORMAL
RAW OF FIRMS
PROCESS USING THE MAIN CHARACTERISTICS PRODUCT3 / SERVICE
MATERIAL PROCESS AND
OUTPUT CAPACITT
1 .WELDING & M ild s te e l SM M2 LA
JO IN IN G and a l i m i - 03 89 29 1. E le c tr ic M e t a l- A r c W e ld in g : -
t e d am ount The p r a c t i c e o f e le c tr ic m e t a l- The m a j o r i t y of
o f a llo y a r c w e ld in g i s w id e s p r e a d i n th e p r o d u c t s shown
s t e e l and Kenya. A lte r n a tin g c u rre n t in P a ra . 10,
c a s t ir o n . (A .C .) s e ts a re g e n e r a lly T a b le 2 . 1 . a . a r e
u s e d , a lt h o u g h d i r e c t c u r r e n t fa b r ic a te d b y th e
o n e s a r e a ls o e m p lo y e d b y some e le c tr ic m e t a l- a r c
fir m s . The n o rm a l c u r r e n t w e ld in g p r o c e s s .
O'
ra n g e i s fr o m 70 t o 3 0 0 -a m p 3 .
A lt h o u g h w e ld in g r o d s a r e
lo c a lly m ade, la r g e q u a n titie s
a re s t i l l im p o r t e d . A v e ra g e
m o n th ly c o n s u m p tio n o f w e ld in g
ro d 3 v a r ie s fr o m 50 t o over
1 ,0 0 0 K g s . p e r e s t a b lis h m e n t .
M ild s t e e l 33 69 27 2 . O x v - a c e ty le n e W e ld in g : - •
an d n o n - G e n e r a lly u se d f o r w e ld in g o f R e p a ir w o r k .
fe rro u s n o n - f e r r o u s m e t a ls . E q u ip -
m e ta ls m ent a ls o e m p lo ye d f o r c u t t i n g .
( C O U tlH U t) ____
WELDING AND JOINING- I4ETH0D3
T a b le 2 . 1 . c
 SM ME LA
S t a in le s s - 2 4
s t e e l and
a lu m in iu m
s h e e t in g s
- 1 -

. *■
1 2 -
3 . M IG * and T lS * W e ld in g : - MIG S to r a g e ta n k s
a n d T IG w e ld in g t e c h n iq u e s a r e f o r t h e fo o d and
new t o K e n y a . b e v e ra g e in d u -
s tr ie s .
I n d u s t r i a l P la n t ( T a b le A ,
1 1 1 ,9 ) i s th e l e a d i n g f i r m in
t h e use o f th e s e t e c h n iq u e s ,
f o r w e ld in g o f n o n - f e r r o u s
m e ta ls a n d f o r s t a i n l e s s s te e ls .
The i n e r t g a s e s u se d a r e A rg o n
f o r T IG an d c a r b o n - d io x id e fo r
M IG .
4 . S ubm erged A r c W e l d i n g : - The B u ild in g - u p o f
" G le a s o n ” su b m e rg e d a r c w e ld in g w o rn s t e e l corapo-
p ro c e s s i s u se d f o r b u i l d i n g up n e n ts .
w o rn c r a n k s h a f t s .
A n o th e r f i r m ( T a b le A , I I , 1 4 ) P r o d u c t io n r a t e
e m p lo y s th e p r o c e s s f o r b u i l d i n g a b o u t 5 0 c m s /m in .
u p c r a w le r t r a c t o r t r a c k r o lle r s
and sh o e s .
•M e ta l in e r t- g a s - s h ie ld e d a rc .
* * T u n g s te n i n e r t - g a s - s h i e l d e d
a rc .
- / c g H m r t u E ) , ,,
Mild steel

Cast
ir o n
M ild s te e l
plate and
vire .
5 . R e s is ta n c e W e ld in g : - The use S h e e t- m e ta l
o f s p o t w e ld in g i s l i m i t e d , Ndume c a s in g s ; m e ta l
L im it e d ( T a b le A ,1 1 1 , 3 0 ) was th e fu r n itu r e ; and
o n ly f i r m o b s e rv e d t o be u s in g i t c a s e m e n ts .
f o r s h e e t-m e ta l w o rk .
L a rg e n u m b e r o f f l a s h and
r e s is t a n c e b u t t w e ld in g u n i t s a re
e m p lo y e d b y f i r m s m a n u f a c t u r in g
s te e l fu r n itu r e an d c a s e m e n ts .
6 . M e ta lo c k in g :- E m p lo y e d f o r R e p a ir w o r k .
w e ld in g o f c r a c k e d c a s t i n g s .
7 . A u to m a t ic W e ld in g : - M u l t i - W ir e m e s h ;d ru m s .
p o i n t a u t o m a t ic s p o t - w e l d i n g
•
m a c h in e s a r e u se d f o r t h e m anu-
fa e tu re o f w i r e m e s h .'
Two f i r m s ( T a b le A , I I I , 9 & 27)
w e re fo u n d t o h a v e a u t o m a t ic
seam w e ld in g e q u ip m e n t f o r t a n k s ,
•
a lt h o u g h n o t i n much u s e .
A u to m a t ic seam w e ld in g i s - a l s o
used in t h e m a n u fa c tu r e o f d ru m s
b y one f i r m ( T a b le A , 1 1 1 , 2 4 ) .
2. OTHER SM ME
JOINING Tinplate 29 13

METHODS

- 1

Tinplate
and alumi­
nium
sheetings

KEY:- SM - Small
ME - Medium
LA - Large
LA
Soft soldering process is used by
tinsmiths in the manufacture of
tin products including down pipes
and roofing gutters for buildings.
One firm (Table A , I ,8 4 ) consumes
i
about 100 Kgs of soft solder per
year.
The only commercial use of
brazing was observed in the manu­
facture of bicycle frames (Table
A,II, 8 6 );
CT\
Ferrous and non-ferrous rivets
are mainly used in the manufacture
of bus and coach bodies. Both
reaction and bifurated rivets
are used. The process is manual
and the use of pneumatic riveting
tools is limited.
Rivets are also used in the re­
pair of aircraft skin (Table A,III
2).

Table 2,1,c
 MAIN APPROX NO.
RAW OF FIRMS NORMAL
PROCESS
MATERIAL USINS THE MAIN CHARACTERISTICS PRODUCTS/SERVICE
PROCESS AND
OUTPUT CAPACITY
■HEAT SM ME LA
1, Hardening and Tempering:- The
TREATMENT
common process of hardening is
rather crude and is largely based
on experience: the Smith's hearth
is used as the furnace and the
temperature is judged by the eye
before dipping the item in cold
water.
Tempering was found to be even cr
CP
less understood and its application
is limited.
Electric furnaces for controlled
hardening and tempering are
used by firms which make press'
tools and dies.
2. Annealing and Normalizing:-
There are few examples of annealing
and normalizing practice. One
firm (Table A,II,63) anneals wire
rolls before drawing.
(Con-nsUlE^
HEAT TREATMENT METHODS
Table 2.1.d
I
I
Gm a i l cast Ir o n h o usings are
g e n e r a l l y a n nealed a f ter w e l d i n g
them. The rail w a y ' s w o r k s h o p s in
N a i r o b i n o r m a l i z e all t h e i r steel
ca s t i n g s at t e m p e r a t u r e s v a r y i n g
b e t w e e n 880°C to 900°C.
Stress relieving of welded
steel tanks is done by one
, establishment (Table A,III,27).
It has a stress relieving room
(Size 6m x 4m x 4m high) main­
tained at a temperature of about
5 00 °P .
The practice of annealing and
normalizing sheet-metal is also
rare. The only place where the
stress relieving of non-ferrous
metals was found to be undertaken
is the engineering base of the
East African Airways Corporation
(Table A,III,2).

TablC- £.1.dL
 MAIN APPROX NO*
OF FIRMS NORMAL
RAW PRODUCTS/SERVICE
PROCESS USING THE MAIN CHARACTERISTICS
MATERIAL AND
PROCESS
OUTPUT CAPACITY
SM T4
IJ*H!?
* T
JjAA
SURFACE 1. Galvanizing;- Galvanizing Containers; du3t
Lead and 1
TREATMENT was a jobbing process. One firm bins.
zinc is
(Table A,II,15)* for example,
employed
galvanise items by dipping them
for galva­
into a pit of molten zinc.
nizing mild
Kenya now has two mass pro- Corrugated iron
steel sheets
2 duction galvanizing plants sheets.
(Table A,III, 12 and 26) for
coating corrugated iron sheets*
Ferrous and 4 2 1 2. Electroplating:- There is a Plat ing; cad ium;
non-ferrous greater degree of specialisation copperjchrome;
metals are in this process than is generally nickel; silver;
electro­ found in other processes: out of dalle;tin; gold;
plated the five main private firms having brass*
facilities for electroplating,
three specialise in the process.
Both transformer/rectifier and
motor generators are used to •
obtain D.C. current. One firm
(Table A,IIf28) uses a pressure
of 5-volts and an amperage of 15
for general work.
SURFACE TREATMENT METHODS
Table 2.1 ,e
Ferrous and
non-ferrous
metals are
used as
metallizing
agents.
 Processes like anodizing are Anodizing;
also carried out. The engi- parkerizing.
neering base of the East
African Airways (Table A,IIIf2)
produce work to a high standard^.
3. Grit Blasting:- The grit used For preparing
is imported, although locally items like
available sand is also used. coffee pulp
discs for
metalizing.
4. Metallizing:- One firm For building-
(Table A,lilt'd metallize up bearings
large marine bearings by and coffee
feeding molten metal to the pulp discs.
bearing surface,- The process
is hand-operated and the metal
is fed with* the guidance of a
dis* *

Generally, metal spraying is

done with a hand-operated spray
gun. CCQH TU4UE1
 SM KS LA I
i
1 5**Painting and Enamelling:- Casements* i
4
Paint coatings are applied to i
i
casements and metal furniture l
by dipping them in a bath of j
paint. i
2 3 Two firms (Table A, 111,14 Casements|
and 21) do electrostatic metal furniture
spraying and enamel painting and kitchen-
on their products. They employ ware.
overhead conveyors and electric
furnaces for these processes.
Another firm (Table A,III,15)
uses a manual process for the
enamelling of kitchen-ware.

M ---- i ■ ■ I

KEY: SM- Snail Table 2.1.e.

KS- Medina
LA- large
* Painting: o n l y includes firms manufacturing casements.
 73

This material has been used to make primitive imple­

ments and weapons but the craft has practically died
out as the re stilt of increased trade with the indu­
strialised countries which are able to supply tools
and other necessities at comparatively low prices”*
The National Museum shows exhibits of iron,
brass and aluminium ornaments but these are items
which were made after the introduction of metal into
Kenya by the early traders. The railways introduced
organised metalworking techniques to Kenya. In this
2
context, the following report made by a railway
authority in 1903 is worth noting:-
"The employment of Swahilis, Kikuyu and other
natives of Africa in the shops as hammermen, riveters
and coolies is a pleasing feature, but I think that
the employment of a small number of Africans as
apprentices is desirable, so that they may be trained
to become artisans and eventually replace the skilled
labour now obtained from India. The eventual result
would be economy"«
The above quotation is an illustration of the
beginning of workshop practice in Kenya. The acqui­
sition of skilled labour from abroad a n d 'the type of
training mentioned above formed the foundation on
which the present engineering practices are based,

B • AN ANALYSIS; PRODUCTION OF METAL AND METAL­

WORKING PROCESSES
With the exception of scrap,'raw materials for
metalworking are imported by Kenya* As shown in
Appendix 5, the quantity of imports of metal shows
an increasing trend over the past years*
The following analysis discusses the possible
methods of local production of metal; and the
trends in the application and in the local techno­
logy of metalworking processes.
 74

I. The Production of Metal and Forming in the Linuid

Hot and Cold State

2.1.2. Production of Pig Iron

u i _ Raw Materials
(a) Local Iron Ores

There are several iron ore deposits in the country.

7
The Geological Survey of Kenya lists these ores as
"Other Minerals of Economic Importance".
Besides other small deposits in South Machakos;
in parts of the coastal region; and in the Hyanza
Province, the authors of "Minerals of Kenya"^consider
the following reserves to have considerable economic
potential (Numbers in parentheses refer to the map in
Pig. 2,1.A.). Appendix .6....... gives an indication
of the composition of some of these ores.

(i*) At Krima Hill (1), South of Mombasa, an

estimated 3 to 15 million ton3 of Perric
oxide, occurs as Goethite and to a
lesser extent as Magnetite. The ore is said
to contain from 10 to over 50 percent FezOj*

(ii) At Bukuru (2), ten miles south w'est of

Kakamega, a body of pyrite lode to a depth
of 88 metres has been found. The lode is
estimated to contain 17 million tons of ore.
This figure may be exceeded because lateral
extensions are likely to be in existence.

(iii) In the Uyoma Peninsular (3)» Titaniferrous

Magnetite occurs. ;The amount is not known
but samples containing magnetite concentrations
of up to 90 percent have been analysed.

(iv) At the Macalder Mine (4) in Nyanza Province,

considerable deposits of banded ironstones
are known to be in existence.
L O C A L IRON ORE DEPOSITS
 •
76

In addition to the above, a reserve containing

millions of tons of massive iron ore was recently
discovered near Mariraante (5)* The ore is believed
to contain up to 51 percent of iton. However, the
high percentage of titanium (from to 1 5/» of
titanium oxide, TiC^) makes it uneconomical as a use­
ful ore for making iron.

From the above summary, it is?clear that there are

prospects of iron ore mining in Kenya, but their true
economical value can only be known if feasibility
studies are carried out and factors like location,
availability of fuel, and methods of production are
considered,
(b) Imported Iron Ores

In the event that the production of iron from

local ores proves to be uneconomical or insufficient
to meet the demand, the question of importation may
be considered.

The nearest foreign reserves to Kenya are in

8
Tanzania. In the deposits around Livingstone Mountains
(between the towns of Songea and Njombe, Southern
Tanzania), 130 million tons of ore and 200 million tons
of coal have been estimated. It is understood that
Tanzania is to mine these deposits and smelt the ores,
These reserves' are linked to Kenya both by road and
rail (the main rail connection is from Morogoro, about
550 kilometres north of Hjombe). An alternate route
could be by sea from Bar es Salaam. Tf these ores are
offerred to Kenya for import, their economical value
should be assessed.
Q
Another source is Hhodesia. According to Voskuil
it has the largest deposit in Africa and totals
millions of tons. Coking coal is also available in.
Rhodesia. However, the present political situation
and the land-locked situation of this source makes it
an uneconomical proposition.
 J

77 *

A similar political situation exists with regard to

South Africa, although in this case, a sea route for
transport could be established*

The most economical method of transport of ore

is considered to be by sea. Alexandersson1^
explains the growth of the ore-carrying ships in the
world market. For a 20,000 ton dead-weight motor-
ship, Bashforth11 gives the annual fixed charges
(i.e. interest and depreciation on capital, insurance,
maintenance, repairs, wages, port charges and other
overheads)as £ 195,000. He states that this is about
60fo to 705$ of the total cost, the rest being pro­
portional costs (mostly fuel and lubricants).

Based on the year 1970 when Kenya imported

12
129,693 metric tons of iron and steel , a ship of
20,000 ton dead-weight would hava to make at least
13 trips to transport sufficient ore for local
production*. Vest Africa and India may prove
suitable sources for sea transportation1 The
cost prize of one metric ton of medium grade Indian
ore was estimated** to be about KShs 90/= free on
board, Mombasa.

Such ore-carrying ships could play a dual-role

in the import 'of ores and in the export of commodities
like cement which are produced in Kenya.

The importance of road transport, however, should

not be overlooked by Kenya. Vhen the Trans-African
Highway1*^ (linking Mombasa to Lagos in Nigeria) is
completed, the possibility of importing .iron ore from
Vest Africa should be considered.

II. Methods of Production

(a) Blast Furnace

The fuel for the normal blast furnace method

consists of:-
(i) Coking Coal:- Coal deposits of commercial
valve are not found in Kenya.
 78
12
(ii) Limestone:-Large deposits of limestone
exist in Kenya.
*.Assuming that 2 tons of ore give one ton of pig
iron; see citation II, page 10.
** Estimated by the Commercial Secretary, High
Commission of India.
As shown below, the use of imported coal would
prove uneconomical*
One ton of ore requires nearly one ton of coke
for its smelting*. With the year 1970 as a reference,
the total amount of iron and steel imported - 259,396
Metric tons*
Assuming that this tonnage were to be produced
from ore. Tonnage of coke required = 259r396 Metric
tons. Cost**of one metric ton of coke = K£ 23.
Total cost of coke = K£5»966,10S#
This is over 65^ the value of all the iron and
steel imported
12 in 1970#
*Refer citation 26, page 12.9*
** Based on the cost used bj East African Railways,
largest users of coke, refer to railway's "Standard
Price Stock Catalogue", February 1971#
(b) Electric Reduction Furnaces

Electric reduction furnaces have shovm. conside­

rable progress in countries with cheap power gene­
rated by systems like low pressure natural steam,and
water power*
The first stage development ^ of the natural
steam emissions in the Rift. Valley province of Kenya
consists of a possible capacity of 30 MW.
Ignoring the smaller hydro schemes, the main
source of hydraulic power is the Tana River with a
total potential capacity of about 1 ,CQQMW. As rivers
in Kenya are seasonal, this capacity will be adversely
affected in a dry season.
 79

The 1570-1964 Development P l a n ^ aims for an

additional installed capacity of 5Ct?.f at Karaburu,
Tana River. This scheme with the addition of other
thermal units aim for a growth rate of electricity
of 9f* of maximum demand and Sfo of average demand*
According to the plan, the capacity at the end of
1974, will he 40?° above the projected average demand*
On the performance of an electric furnace, it is
11
stated "the furnace can he economically operated
at reduced capacity, whereby it can become a consumer
of surplus electric power and avoid heavy consumption
of power during peak load hours"*
This is an important factor and should be conside­
red in view of the fact that the maximum capacity of
t

electricity in 1974 would be 40>£ in excess of the

average demand, and especially if the project for the
use of natural steam for the production of electricity
materialises*
11
For economical production, the same source
recommends that the price of 1 lb. of coke should
equal 1*8 times the cost of 1 Kwh of power. For off
peak electrical supply, the cost J of 1 Kwh of power
is Kenya cents —/12. For economical use of an ele­
ctric furnace, the local price of 1 lb. of coke should,
therefore, be Kenya cents —/12*6. The price of the
coke used by. the railways (see page. D A . ) is -/23 cents
per pound, which is cents -/1.4 per pound more than
the optimum price.
11
Electric furnaces are known to consume between
2,400 to 2,600 Kwh of power per ton of pig iron
produced, ^ith an average consumption of 2,500 Kwh
at a cost of cents -/12 per Kwh, this works out to be
K£15 per ton of pig iron. The pig iron (imported)
used by the railways costs between K£26 and K£34 per
ton depending on tho quality. Hence, the power-
charges for the local production of one ton of pig
iron would be as much as 5Qfo of the cost of a ton of
imported iron.
 80

For economical production, therefore, there is a

requirement for the availability of cheaper electric
power.
•

Another advantage of the electric furnace is that

the coke. is used merely as a reducing agent. Compared
with a blast furnace, there is a 60fi reduction in the
consumption of coke. Moreover, this process produces
a better quality of product.

(C) The Charcoal Blast Furnace

The charcoal blast furnace can produce a better

grade of iron, especially with regard to the sulphur
content which can safely be kept under 0.015^. Some
countries like India and Brazil, however, use this
process because they lack local supplies of suitable
coking coal. Brazil uses Eucalyptus trees for the
manufacture of charcoal used in the iron and steel
industry with an annual pig iron production of 800,000
. IS
tons
12
In 1970, Kenya produced 153 thousand stacked
cubic metres of charcoal. It is not known if any
special trees were used for the production of this
charcoal. The main requirement for charcoal suitable
for iron making is that it should have a high density.
Bengough states that Eucalyptus Saligna (common name
Saligna, Gum) is readily available from the plantations
of Kenya highlands. He gives a specific weight of
'Z
48 lbs/ft. at 12fo moisture ^content. According to
18
Rowe , these trees mature in about 10 years. Also,
19
it is known that about 0.107 tons of coal can be
produced per nr of wood.

The fuel consumption depends on the grade of the

charcoal. As Eucalyptus trees give a good grade of
charcoal, consideration should be given to their value
as a local blast furnace fuel.
 81
However, a charcoal blast furnace is considered to be
suitable for ores of a higher grade,

2,1,5. Production of Steel

(a) Electric Arc Furnace

20
The electric arc furnace is better known for
the manufacture of high grade steels. However, recent
practice indicates that it is also being used for the
production of commercial steel in bulk ingot form. The
process may be basic or acidic. The former, when used
21
as a single slag , is recommended for making commercial
steel. When basic, the hearth is bricked with either
magnesite or dolomite. Both of these minerals are in
plentiful supplies in Kenya*

The main material for the electric arc furnace is

scrap metal* The supply from this source is said to be
dependent on the capital investment made twenty to
22
twenty five years ago . This source is, therefore,
proportional to the development of the country.
1 2
In 1970, Kenya exported ferrous and non-ferrous
scrap metal to the value of K£ 519,000. This was only
Q.lfo of the total value of all exports . The quantity
of scrap metal can be increased by an improvement in
the methods of collection, handling and classification.
There is a requirement for the expansion and mechani­
sation of the scrap metal industry in Kenya. Besides
obsolete capital equipment, waste from machining, etc.
should be collected from larger workshops, The rail­
ways' workshopSjfor example, have an annual machine
shawings tonnage of about 900 tons.

For a large electric arc furnace the power

21
consumption is about 500 to 550 kwh per ingot ton.
Compared with the electric reduction furnace (Para. 2,1,2
(b) ), used for the manufacture of pig iron, the power
consumption is nearly five times less.
 82

The cost of production depends upon the price of

electricity and the facts on electric power given in
Para. 11.2.1.2(b) are equally applicable to the
electric arc furnace.
*
In 1971, a report J from one firm (Table A,III,
23 ) indicated that they were planning to erect an
electric furnace for the production of ingots for
cold rolling. When commissioned, this furnace should
provide valuable information for future development
in this field. However, past experience shows
(Appendix 7) that the capital cost of the electric
furnace is of a low order.

0>) Bessemer Process

/The Bessemer process can be modified as a side-

blow process. It is then known as a Tropenas Con­
verter and is suitable for the manufacture of steel
castings. The railways have successfully used this
process (Table 2.1.a). Their recommended composition^
for a charge is:-

Selected SteelScrap...... ........ 240 lbs.

Hematite PigIron................ 160 lbs.
Limestone.... ............ 5 lbs.
Silicon.... .................... 1 lb.
Coke b e d ........... 700 lb3.

The.economy of the above process is probably

due to the use of a high percentage of scrap, which
is locally available.

The normal Bessemer processes, both basic and

acid-lined, require large percentage of pig iron.
Such processes, therefore, will not be economical
unless there is a production of pig iron in this
country.
 S3

Previously, the railways used the crucible

process for the manufacture of a small quantity of
high grade steel for making jigs and tools. This
process, was successful except that it could not
produce sufficient quantities of steel. Such a
process could be established in this country for the
production of a small quantity of high grade steel.

(c) Open-Hearth Process

The capital cost of the open-hearth process

is comparatively high ( A p p e n d i x . 7 . . Moreover,
the raw materials are expensive because the pig
iron and scrap metal must have low phosphorus and
sulphur contents.

2.1.4* Production of Non-ferrous Metals

Kenya has reserves of some non-ferroUs metals.

The following is a brief description of the occurance
of two non-ferrous metals of interest to metalworking

(a) Copper^
Pound in parts of Central Province, Eastern
Province and in West Pokot. The main production
of copper has been from the Macalder-Nyansa mine,
South Nyanza. Copper and zinc concentrates were
mined in 1951* Cement copper was mined from 1956
to 1966 along with gold and silver.
At the present state of development, it is
considered that all the known high grade deposits
.of copper are exhausted^ In 1961, 2,564 metric
12
ton3 of copper were mined f;but in 1970, this
tonnage had dropped to only 79 tons. Kenya, there­
fore, has to import copper. For this reason,
pc
Zambia is considered to be an economical source .
There is a good road connection between the
copper belt in Zambia and Ear es Salaam, which has
road, rail and sea connections with Kenya,
 84

0>) Lead and Zinc^

Mining was started recently in the Kilifi

District for lead and zinc minerals. In 1952,
the maximum values obtained during drilling were:
lead 11?», copper 6for zinc 9fo, gold 0.3 dead-weight
per short ton, silver 30.2 dead-weight per short
ton.
The smelting of these minerals for the
production metal for commercial use is not
26
undertaken. According to one authority , smelting
of copper involves a large investment and should
only be undertaken if the supply of ores and
concentrates are available for a number of years.
At present, therefore, the prospects of smelting
copper in Kenya are not favourable.
Although lead and sine minerals are mined,
it is understood that they are not smelted for
local commercial use.
In comparison with ferrous metals, Kenya
relies more on imported non-ferrous metals than
ferrous metals,

2.1 ,5. Casting

(a) Sand Casting

With an improvement in the standard of casting,
several items which are now imported could be manu­
factured in the country.
An investigation was carried out to relate the
cost of an imported casting .to a similar one assumed
to be manufactured locally. The item considered was
a transmission case (sump) used on the 11Caterpillar”
diesel engine which powers the 920 Series of front-
ended wheel loader of the same make. The results of
the investigation were as follows:-
 85

Weight of the imported item = 79• 5 Kgrns

Material of the imported item = Cast iron*
Cost price in Nairobi = KShs 1,755/55
♦Exact specification not known.
For comparison, an establishment (Table A,II,71)
was approached. This establishment gave the following
quotation for the production of 10 similar transmission
cases:-
Cost of pattern(labour + material) = KShs 160.00
Cost of cast iron................. = KShs 256.11
Cost of coke....................... = KShs 150.00
Cost of labour: Mould making...... = KShs 512.00
Other............................... = KShs 148.00

Total........ = SShsJ^OOS^ll

Therefore cost for one article = KShs 100.61

This is more than 15 times cheaper than the imported

article. However, this cost will be more if the over­
heads are considered and if better material, metallurgi­
cal and production control is maintained in its pro­
duction. Even with the addition of those costs, the
locally-made articles should be cheaper, especially if
made in larger quantities.
Quality products, like the one mentioned above, can
only be manufactured if careful consideration is given
to the following points:-
a) Pattern Making
Good timber is available, in Kenya for the manu-
27
facture of modern patterns. Wimbush gives details
of a large number of Kenya timbers several of which can
be used for pattern making.
Podo (Podocarpus Gracilior and P. Milanjianus) and
pencil cedar (Juniperus Procera) are the main coniferous
woods of Kenya. Several firms make patterns out of
these woods, possibly because they are easily available
for commercial use, * *
 86

In addition, the following, are example of two

timbers which have the prospects to make good
patterns:-
1. African Blackwood or Ebony: extremely
fine texture and can be easily worked
with tools. Used for hand-carving
figure s , ornament s .
2. "Mutondo" (Funtunia Latifolia): non-
textured, works clearly and without
difficulty.

For an improvement in the dimensional accuracy

of castings, there is a requirement for a higher
degree of skill in the method of pattern making.
Pattern making must be recognized as an essential
important factor in the production of castings. Firms
should provide the correct tools and facilities' to
fulfil thi3 function.
The use of metal for the production of patterns
should only be considered if large-batch production
of casting is undertaken. At present, the casting in
Kenya is undertaken on the basis of one-off or small-
batch.
(ii) Mould Making

As with the rest of the process, no standard

method is used for the preparation of sand. Large
7
quantities of sand are available in Kenya. For
Nairobi, the main source is the rivers between Athi
River and Konza; for coast, the Voi River;.and for
Western Kenya, the supplies are obtained from the
rivers in Maragoli and near Kisii.
The main requirements for moulding sand are:-
1. "Refractoriness^?- For normal sand casting,
the sands available provide sufficient
refractoriness.
 87
OA
For shell moulding, the railways*4 found that the
refractoriness of the sand was not sufficient. They
added from 5^ to 10^ of silica flour to improve this
property•
28
2. "Bond1 1 De Garmo recommends the addition of
clays, such as bentonite, kaolinite or illite to
improve the cohesiveness. Several firms were found
to be using "red" clay for this purpose. Bentoni-
7
tic clays are available in Kenya and their cohesive
effect in moulding sand should be investigated.
Some firms use molasses for small moulds (Table 2.1.a.
Paragraph 4(c). According to De Garmo, furfural
alcohols are used in modern foundry practice to give
strength to the mould.

3. "Permeability"s- Some firms were found to be using

slaves for obtaining the required grain size, but
the TiJtdespread practice seems to ignore this property.

Generally, no modern equipment is used for grading

and preparing sand for casting. Also, the testing
of sand is generally left to intuition.

(b) Other Methods of Casting

As most castings of good quality are imported,

the requirements for the practice of precision invest­
ment casting and die casting have not been felt in
Kenya. The only establishment (Table A, III, 10)>known
to be using the pressure die casting machine manu­
facturers components for casements. Several other
items, however can be produced locally and there is a
requirement for at least one such foundry in each major
industrial centre of the country. The idea of having
a specialist foundry to serve a number of establxsh-
pq*
ments is recommended by Sakharov .
However, gravity die casting should continue to
provide a certain degree of self-sufficiency to the
small-scale works. If such firms improve the dimen­
sional accuracy of their dies, they can manufacture
several items which are not made locally at present.
 88

2 ,1 ,6 . Forging
She skill of hand-forging available in the country
should be better utilised in the production of more
decorative wrought iron items. The smaller firms
should be given guidance on the design and marketing
problems (Para. 3*4*3. and 4.1*5.) in order to
create an interest in this craft.
The manufacture of leaf springs for motor vehicles
is undertaken by hand-forging. The use of simple
spring buckling presses is recommended for this
process.
Drop-forging is only used by the railways. With
the exception of a few components, board hammers
may be erected locally by some of the larger firms
for the manufacture of drop forgings.
■zp
Press forging is recommended for large compo­
nents since it ensures that the metal is squeezed
right through to its core to minimise anisotrophy.
One establishment (Table A,II,49) was found to be
using this process for small items. Por such items,
the production would be more economical with steam
hammers.
2.1.7 Rolling
The three main rolling mills in Kenya (Table 2.1,a,
Para. 6) do hot rolling for the production of rods
and bars. • These mills should extend the range of
their production by cold drawing of bars and wire.
At least one of the rolling mills should intro­
duce a blooming and slabbing mill. This vail be
essential if a start is made for the production of
steel in Kenya. With such a mill and subsequent
plate and strip rolling, the metalworking industry
in Kenya could get the raw material from local
resources.
Hot rolling is an important process because it
forms part of the initial steps for the production
of raw material for the metalworking industry.
Consideration, therefore, should be given to incx^ease
its role in the metal industry of Kenya,
 69

The possibilities of hot rolling plate, strip,

t
structural beams, rails and tubes should be
investigated. Even if slabs and blooms are imported,
the local production of such items could save valuable
foreign exchange.

There is a plan for the manufacture of a few

items by cold rolling. An agreement^ has been signed
between the Industrial and Commercial Development
Corporation of Kenya and the Erollo Group of Italy for
a K£ 2,5 million project for the manufacture of galva­
nised water pipes, tubes, hollow sections, steel plates
and sheets by mean3 of cold rolling. The factory will
be established in Mombasa and will employ over 350 men*
It is understood that construction for the first phase
of the project has already started*

2.1,8. Extrusion

The extrusion of hard metals involve large invest-*

31
ments, Pearson describes presses of capacities
ranging from 1,000 tons to 20.000 tons for the extru­
sion of such metals. The normal presses used in Kenya
do not exceed 100 tons, A jump to capacities ten times
as much for extrusion presses would involve large
capital for the production of only a few articles.
However, the extrusion of aluminium, magnesium and
sine alloys may be considered as they require presses
ranging from 500 to 6,000 ton capacity. The use of the
right type of lubricant and metallurgical composition
no
are important. According to De Garmo^ , the cost of
extrusion dies is relatively small.

If the mining of lead (Paragraph 2.1.4) proves a

commercial success, the use of this metal should be
made for the extrusion of lead pipes which have a wide
application in Kenya for the distribution of water and
in the field of chemical engineering.
 90

The Robertson press could be used for this process*

The economy of this process should also be considered
if lead has to be imported.

Most countries do large-scale extrusion of cable­

sheathing of electrical conductors. The sheathing of
imported conductors should be considered. There is
25
one establishment in Kenya for the manufacture of
cables but the processes they use are not known.

2.1.9. Wire Drawing and Wire Products

(a) Wire Drawing:- In wire drawing, the reduction

32
in area is given by:-

r . ' - <A2/A) >

Where A 2 = Pinal cross-sectional area

A^ = Initial cross-sectional area

For fine wires, the value of is between 15 and

20$ and for coarse, 20 to 45$. In Kenya, one firm
(Table 2,1.a. Paragraph 8) is known to be producing
fine steel wire.

Wire drawing should follow from the rods produced

in a rolling mill (Paragraph 2.1.7)* It should then
be passible for a billet (which may be imported) to
be rolled and drawn down to wire of various diameters.
Such wire is already used for the manufacture of many
products but mostly from imported wire.

Ron-ferrous metal wire drawing is not practised

in Kenya* This process should be introduced to meet
the demand, particularly of electrical conductors*
32
This will involve the "wet11 method of wire drawing.
(b) Other Wire Products:- There is an annual require­
ment for about 5 metric ton3 of nails. It is understood
that the present production is sufficient to meet this
demand.
* With the exception of one firm2** which is known
to have the facilities for this process.
 91

The finish of the rivets and screws is of a

low standard. This is probably due to poor die
design and die maintenance. This accounts for the
fact that rivets and screws are still imported*
The sheet-metal industry uses large quantities
of non-ferrous metal rivets. Such rivets are at
present imported. There is, therefore, scope for
the manufacture of non-ferrous metal rivets*
2.1.10. Press Work

Press work is highly mechanised because it

meets a big demand for cans, crown corks and con­
tainers. This demand is created by the primary
industry of Kenya - agriculture* The oil refinery
at Mombasa is the second main market for the can
and drum technology of Kenya. With the further
development of the refinery, this market should
also expand*
Press work in the vehicle body building industry
is largely manual and the standard of the process ia
poor. Moderate amount of mechanization was found in
the manufacture of domestic hollow-ware and in the
production of items like hasp and staples.
A better understanding of pressing and deep
drawing is essential for firms engaged in this pro­
cess. Several products made by these processes were
' 32
found to have wrinkles. Alexander differentiates
between drawing and pressing. He states that in the
latter method, the sheet must be gripped firmly.
Some products, therefore, may be improved by investi­
gating and correcting such points.

2.1*11, Plate and Structural Work

In the manufacture of tanks, there is a require­
ment for the use of better bending and materials
handling equipment. Improvised bending rollers are
generally used and a large part of the process con­
sists of bending by hand hammering of plate sections.
There are several modern bending presses and rollers^
which could find an application in the Kenya tank
building industry.
 m U

92

Tanks are generally poorly calibrated. .This is

mainly due to the fact that they are not made in
accordance to pre-drawn engineering plans.
Several plate components for equipment like
materials handling devices and tractors can be manu­
factured in Kenya. It is understood that the East
African Agriculture and Forestry Research Organi-
34
zation^T has developed a local tractor. For the
production of such a tractor, a high percentage of
plate members should be made locally. One establish­
ment (Table A,11,22) is already engaged in the manu­
facture of overhead gantry cranes for which the plate
and structural work is done in Kenya and only a few
items are imported. For large-scale production of
such items, there will be a requirement for plate
work in the hot state. In this way, thicker plate3
32
could be worked more economically *

The manufacture of small marine craft has

shown considerable progress. There is, however,
a lack of local design practice (Para. 3*4<>8) and
of facilities for materials testing (Para. 5.1 *7).

Structural work for buildings is based on

good design practice (Para. 3.4.1.), especially
in the large-sized firms. Some smaller firms,
however, do not have good facilities for such work.
 93

2,1*12 Sheet-Metal Work

(a) Tinsmith Practice

The widespread use of this process (Table 2.1.a,,
Paragraph II) is mainly due to:-
(i) Snail capital investment for tools. Little
or no power requirement because several
firms use charcoal for heating,
(ii) The products made are in demand,
(iii) The nature of the work is simple.

There is, however, only a limited amount of

decorative work of copper or brass undertaken. This
craft should be encouraged and, as in hand-forging
(Paragraph 3*4.3.), guidance should be given on design
and marketing problems.

(b) Manufacture of Vehicle Bodies

The manufacture of coach, bus and cargo­

handling bodies represents the largest sheet-metal
industry in Kenya, The use of several manually operated
hand tools is made, but this technology could imx>rove
with the use of more powered tools, especially pneu­
matic ones.

In addition, there is a requirement for the

application of larger sheet-metal panels, Larger
panels of different shapes could be obtained by the
expansion of press work in this industry. The use of
such panels will result in the reduction of the frame
members and in the number of rivets used.

(c ) Manufacture of Other Items

The manufacture of sheet-metal pipes is

understood to be unsatisfactory. This is possibly
because seam welding is done by the oxy-acetylene
method, Future expansion in this field should be based
on equipment incorporating resistance seam welding' .
 94

The process of metal spinning is at present

used for hatch production. It is however, suitable for
snail-scale works and can provide a valuable addition
to the crafts. With a suitable material -(generally
aluminium), items having many shapes may be spun.
The firms using this process for batch production
should avoid it and concentrate on deep drawing and
pressing for the manufacture of simple domestic hollow-
ware. This should prove more economical and should
increase their rate of production.

II* The Machining Processes

2,1,13. Application

The machining processes in general and lathe work

in particular, have a widespread application in Kenya
(Table 2.1.b.). This is mainly due to the fact that
a large number of firms are general engineering works.
32
A versatile process like machining, therefore, has
the right application for such firms. Another factor
is the cheapness and the low cost of its operation.
The entrepreneur .can pick from a wide range of sizes
and types of machines. Moreover, at present there is
a large distribution of second-hand machines (Paragraph
1.1.3) in the industry. These may therefore be obtained
cheaply, i

There is very little batch and mass production

of items by machining. Hence, the lack of automatic
machining equipment in this .country. With the use of
more semi-automatic machines and the principles of
Group Technology (Paragraph 3*2.2), local production
of machined components is possible.

Precision machining, grinding and honing are under­

taken by some firms but their metrological standards
are poor (Paragraph 5*1.4).
 • V.

95

Processes like planing and slotting are not in

much use. This is mainly due to the lack of heavy
engineering in this country. At the present stage
of its development, such processes are not considered
essential to the metal-working industry.

2.1.14 Operation

While the skill of turners is of a sufficiently

high grade, the full utilisation of machining equip­
ment is generally not made. This is mainly due to
the lack of knowledge on' the part of operators on
factors like speeds, feeds, type of tool and cutting
angles, and the use of cutting fluids. Such factors
are generally left to intuition. With a better
utilisation of these factors, machining of alloy
steels and non-ferrous metals, particularly aluminium
could be done to a higher standard.

III. Fabrication and Joining Methods

2.1,15. Electric Metal-Arc Welding

The process of electric metal-arc welding finds

a widespread application (Table 2,1.c.). This is
mainly for the reason that it has an equal application
for both production and repair purposes.

Alternating Current (A.C.) is used for welding mild

steel but several firms were also found to-be using A.C*
for welding cast iron and thin metallic sheets. For
56
cast iron Chapman^ recommends a Direct Current (D.C.)
:
power source and the same is reiterated by Houldcroft
for welding of thin metal, although other methods are
available for welding the latter (Table 2,1.f).

Several firms use the wrong type of welding rods,

particularly for cast iron and stainless steel welding.
This may be due to the high cost of "Ferroloid" and
"Chromoid” welding rods (Table 2.1 '*£).
 | TYPE AND WELDING ROD/WIRE 1 GAS
AVERAGE KShs* KEhs*
PROCESS SUITABLE FOR VALUE TYPE PRICE TYPE PRICE,
CP CURRENT (PER KG) PER V?

Metal-arc I-Iild steel' 80 amps A.C. "VITEMAX" in the

100 amps 11 following sizes:
plates and
140 amps " ; 2,5 m 5/50
beams 120 amps n 5.25 mm 4/40 - —
4.0 mm 4/00 - -
5.0 mm 3/05 - -

Cast iron. "Perroloid" 5.25m 82/= - - ■

Stainless
Steel ;nChromoid" 3.25mm 45/= - -
•
Aluminium
Alloy i"Alumoid" 3.25mm 100/= — -

Oxy-acetylene Mild steel ■

sheets - 1I a c ' dia. copper
lo coated 4/90 Oxygen =/62
Brazing — l/jg" dia. rod 37/50 Acetylene 13/90
Aluminium
sheets - 1/^g11 dia. rod 40/=

TIG- Thin metal DCEN*** Same as for -metal-

sheets X amp-2Samp arc - Argon 55/=
Plates & 25~5S0amps
beams A.C. (with It — It
55/=
current osci
H a t or) | tC O M T lM u O

PARAMETERS FOR LOCAL WELDING BRACTICE

 MIG Non-ferrous Up fritO "B05TRAKD"~~VIRE
sheets up to 250 amp A.C 1.1/.I. in the
0.3675 cas. following sizes:
■"thick 1/^ 2 " <**
ia. 10/60 Argon 55/-
3/64" dla. 9/90 c o 2g © 4/60

PAEAKSTNR3 FOR LOCAL WELDING PRACTICE

Table 2,1.ft.

* Prices obtained from E.A. Oxygen Co., Nairobi (June 1972), except where otherwise stated.
** Only typical values are shown.
*** D.C.„ electrode positive. ^3
© Source: HOULDCRCFF, P.T., Welding Processes, University Press, Cambridge 1967.
@© Price fron Carbacid, (1961) limited, Nairobi.
i
 98

35
Flash welding is recommended ' for the fabrication
of the following products
Flanges, housings, tie bars, buffer ends, metal
casements, track rails, beams, bolts.

In Kenya, only metal casements are fabricated by

flash welding.

Submerged arc welding is a highly mechanised

process and as used by one establishment (Table A,II,14)
has useful application in the reclamation of worn
tractor undercarriage components. For ferrous and non-
ferrous metal plate and sheet welding, the semi­
automatic processes of TIG- and MIG are recommended,
For a high production rate as in the mnnufacture of
drums;, resistance seam welding is a suitable method,
and is used by one establishment (Table A,III,24)*

Welding is a complex process and has many variables.

For a better utilization of this process, comprehensive
training is essential for those engaged in its practical
use. One training course was organized by the Depart-
37
ment of Mechanical Engineering, University of Nairobi ,
38
and the Eutectic Welding Company have held some
courses on welding. More courses of this nature should
be arranged.

IV, Heat Treatment

2.1.16, Application

In general, the metalworking industry has a low

standard in the application of the science of metallurgy.
This probably is due to:-
(a) Almost complete reliance on imported materials.
This results in a reduction of opportunities to
undertake processes like heat treatment.
(b) A lack of knowledge of the advantages of heat
treatment. This is partly due to the small
number of engineers employed in the industry
(Paragraph 6,1.1,).
 9.9

More stress should be laid on the application

of heat treatment methods by the local industrial
training. The manufacture of cutting tools by the
heat treatment of alloy and high carbon steels should
be encouraged. This may be done in conjunction with
the recommendations made for the production of local
steel by the crucible method (Paragraph 2.1.21 (cj.

Certain items like structures and v/elded compo­

nents should be the subject of inspection before use
to ascertain that correct stress-relieving processes
are employed in their manufacture.

V. Surface Treatment

2.1.17. Galvanising

With the establishment of two automatic galvanising

plants (Table 2.1.e), the import of corrugated sheets
has been reduced from 3*066 tons in 1960 to 979 tons in
1970. For the same period, however, the import of tin­
plate has increased from 7,651 to 17,959 tons. There
is, therefore, a requirement for the production of tin­
plate.

Small-scale galvanising is
practised only by one establishment (Table A,XI,13).
Firms engaged in production of sheet-metal items could
galvanise their products by maintaining small pits
containing molten lead and zinc for galvanising purposes,

2.1.18. Electroplating

The amperages for the process practised locally

are of a low order (Table 2,1.e). For Chromium,
•3/*
Chapman*3 recommends 75 to 100 amps, per sq. ft. of
area deposited with a voltage of about 6 volts.
As electroplating requires specialist knowledge,
it is recommended that at least one good electroplating
firm should be developed in each major industrial
centre of Kenya.
 V,

100

The use of this process for the reclamation of worn

parts is not wide spread and this is a field which could
he expanded.

2.1.19. Other Methods of Surface Treatment

The process of metallising by using metal

spraying could be extended to cover the reclamation of
worn parts, including worn crankshafts. The equipment
required is inexpensive and is simple to operate. For
the reclamation of crankshafts, the "Gleason” submerged
arc welding method is employed by two establishments
(Table A,1,61 and XI, 32). This method is expensive
and it often distorts the metal. The application of
metal spraying should,therefore,be extended to cover a
wider field.

A high standard of enamelling, especially for

metal furniture, was observed. This standard should
be maintained, and a wider range of sheet-metal products
should be enamelled to improve the appearance of the
final product•
 * *.
101

C. CONCLUSIONS AND RECOMMENDATIONS

I. The Production of Ketal and Forming in the liouid,
Hot and Cold State

2.1.20. Production of Pig Iron

(a) There are no establishments in Kenya for the

production of pig iron from ores. The occurance of
iron minerals is widespread in the country. The depo­
sits at Mrima Hill, Bukuru, Uyoma Peninsular and
Kacalder Mine are considered to have economic potential.
Their commercial exploitation should be instigated with
a view to local iron production.

(b) Detailed studies should be carried out to

find out the economic benefits of making iron from
imported ores. Sources in Rhodesia and South Africa are
near, but due to the present political situation, these
reserves cannot be considered. If the exploitation
of the ore deposits in the Livingstone Mountains in
Tanzania proves successful, the economical value of
importing ores from these deposits should be considered
by Kenya. These reserves are linked to Kenya by road
and partially by rail. When the Trans-African Highway
is completed, the prospects of acquiring iron ores
from West Africa by road should also be investigated.

(c) Several countries import ores by sea trans-.

port. Special- ore-carrying ships are employed and
there is now sufficient experience in this field to
obtain accurate costs in the operation and maintenance
of such vessels. Feasibility studies should be carried
out to ascertain the economy of obtaining iron ores
from reserves in India and Vest Africa for local iron
production.

(d) If iron ores are obtainable, a suitable

method for the production of iron should be selected.
With the high cost of coke, the operation of a blast
furnace is apparently uneconomical. The electric
reduction furnace offers many advantages.
 • i.
102

With the further development of electric power

resources, the erection and operation of such a
furnace may be feasible provided coke is available
at a price comparable to the cost of electric power.
An alternate method for the production of iron is
by using the charcoal blast furnace. This method
gives a better grade of steel and could prove econo­
mical for the production of small quantities of iron
from local ores. Cheap timbers like Eucalyptus may
be used for the production of charcoal.

2.1.21. Production of Steel

(a) With the exception of railways, steel making

is not practised in Kenya, and almost all the steel
used is imported. The railways foundry operate a
770 Kgm capacity tropenas converter for the production
of steel castings and ingots. This converter was manu­
factured locally and in 1969 had a production output of
2.0JO metric tons. This is only about of the
total amount of iron and steel imported in the same
year. The steel produced is subjected to chemical and
physical tests.

(b) Recent practice indicates that the electric

arc furnace can produce steel from scrap as the main
raw material. With an improvement on the collection
and classification of scrap, this process offers a
good opportunity for local steel production. As the
Bessemer process relies on large quantities of pig
iron, it is not recommended Unless there is production
of pig iron in Kenya.

(c) The crucible process has been used by the

railways for the manufacture of small quantities of
high grade steel. This process is recommended for
the small-scale production of steel for jig and tool
making. This steel will be cheaper than the open-
hearth steel.
 103

2.1.22. Production of Non-Ferrous Metals

(a) :'. The mineral welath of Kenya is endowed with

several non-ferrous metal mineral deposits. High grade
copper deposits are now considered to he exhausted. In
the Kilifi district, lead and zinc mining is being
carried out. It is not known if there are any plans
for the production of commercial metal from these mine­
rals,

(b) The railways produce a number of non-ferrous

alloys like gunmetal and several types of brasses. To
attain a certain degree of self-sufficiency, establish­
ments having furnaces should follow this practice,

2.1.23, Casting

(a) Cast iron is produced from local scrap.

Establishments operate cupolas which are made and
erected locally. These cupolas are lined with refra­
ctory bricks which are available in Kenya. The cupolas
are small and generally have the capacity to produce
about 2 metric tons of cast iron per day. The process
for the production of cast iron is crude. Manufacturers
normally rely on experience and intuition for the
selection of the raw materials and for establishing
the soundness of the final product. The majority of
the cast iron is used for sand casting*

(b) To improve the quality of cast iron, it is

recommended that simple laboratory methods for the
determination of constituents like carbon should.be
carried out. As most establishments do not have
competent personnel or facilities for conducting this
type of tests, samples may be sent to other labora­
tories .like the railways.

(c) Sand casting has the most widespread

application* The heaviest castings made by this
process are of the order of 300 Kgms, although simple
castings of around one ton have been made.
 104 •

The dimensional accuracy, surface finish and the

soundness of the finished product is normally poor.

(d) No standard methods are used for the pre­

paration of suitable patterns, which are generally
made with the intention of obtaining surplus material
in the finished product for machining. Several
timbers are available in Kenya for making better
patterns. More skill and the use of the better
tools and measuring instruments are required to
improve the standard of pattern making.

(e) No advanced techniques are employed for

the selection, gx-ading, preparation and use of sand
for /'making moulds. Normally, no methods for testing
the compaction, permeability and moisture content of
moulds are used. Sands, bentonitic clays and
molasses are available locally. Investigations
should be carried out to establish the correct
proportions of these constituents and their use
should be encouraged.

(f) The pressure die-casting machine is known

to be operated by only one establishment for the
production of non-ferrous metal (mostly mine alloys)
castings; and shell moulding is undertaken by a
couple of establishments. Such casting methods are
recommended for a few centrally situated foundries,
which may serve a number of firms in each industrial
area; while the use of small-scale gravity die-casting
should continue to give the smaller establishments a
measure of self-sufficiency.

2,1.24. Forging

(a) The skill of hand forging should be maintained

and developed by training craftsmen in the art of
forging. The small-scale entrepreneurs should be given
guidance in design and marketing problems to help them
create products which would sell in a wider market.

f,
 105

This may be done by the method outlined in Paragraph

•• fir * * »1* , 5 *

(b) Mechanical devices like buckling presses and

roll-forging machines are rarely used* Small-scale
works could improve their production by the use of
such machinery. The process of drop-forging is
restricted to the railways only, Some of the larger
establishments should develop this process and
consider the erection of board hammers. At present,
there are no applications of press forging, although
one establishment is known to be using this process;
but its application may become necessary if the pro­
duction of large-scale forgings is commenced in Kenya.
/
2,1.25. Rolling

(a) Hot rolling of billets for the production of

rods and bars is undertaken ty three establishments
in Eenya. The production of two of these firms is
highly mechanized; while the third relies on manual
materials handling. In addition, there are only two
other establishments which have simple equipment for
c
rolling.

(b) The products of these rolling mill3 should

be subjected to bar and wire drawing. In this way,
bright drawn steel could be produced locally from
imported billets. Investigations should also be '
carried out to ascertain the economical benefits
of rollling imported ingot3 into blooms and slabs,
with subsequent plate and strip rolling (hot and cold)
for the local production of metallic plates and sheets.
This would form an important process for the pro­
duction of raw material for the whole of the metal­
working industry. However, if iron and steel pro­
duction commences in Kenya, the introduction of
blooming and slabbing mills should be a logical step.
 • u

106

2,1,26 Extrusion

(a) Impact extrusion of lead is carried out in

Kenya for the production of collapsible tubes. The
extrusion of steel and other hard metals is not
recommended because it requires heavy equipment with
large investments for only a few applications. The
extrusion of aluminium and other non-ferrous metals
should, however, be considered.
(b) With the development of lead mining in Kenya,
the possibility of using the Robertson press for the
manufacture of lead pipes should be investigated.
Consideration should also be given to the process of
cable-sheathing of electrical conductors.

2,1 p27 Wire Drawing and Wire Production

(a) The "dry11 process of wire drawing is employed
by three establishments. The reduction in the cross-
sectional area of the drawn wire is kept between
15/5 to 2G?o. Only steel wires are drawn. Further
application of this process should be made in the
drawing of bar and wire produced from the local
rolling mills (Para, 2.1.25(b). To meet the demand
for electric conductors, the possibility of drawing
non-ferrous metal wires and bars by the "wet" pro­
cess should be considered.
(b) The production of nails is mechanized and the
home demand is adequately met. An improvement in
the quality and production rates of rivets and screws
is essential in order to cut down.their import. The
production of non-ferrous rivets should also be
introduced. Several other wire products are manu­
factured and the production of the close-coiled bed
springs is one of the few processes in which some
establishments employ locally-made automatic machines.
2.1,28 Press Work
(a) The application of press work in the manu­
facture of cans, containers, drums and bottle crown
corks represents a highly mechanized process.
 1Q7

The daily production capacity of one establishment

is half a million open-ended cans* The process meets
a large demand created for containers by processed
agricultural products; and by oil and petroleum
products. The production is carried out by a
large number of semi-skilled men operating automatic
and semi-automatic machines,

(b) Locally-made hydraulic and mechanical presses

are used in the manufacture of bus and other vehicle
bodies from sheet-metal. The presses are mainly used
for the production of window■■ panels. Their appli­
cation should be extended to make other panels a3
explained in Paragraph 2.1.12(b).1 Moreover, the
design of the presses and dies should be improved.

(c) Three establishments are known to be manu­

facturing domestic hollow-ware of aluminium and stain­
less steel. The finish of some of these products
should be improved. This may be done by improving the
design of the dies and by using the operations of
deep drawing and pressing.

2,1,29. Plate and Structural Work

(a) Plate and structural work contributes to many

important products and projects in Kenya. Many establish­
ments, however, use improvised equipment in their.manu­
facture. The employment of modern techniques in forming,
fabrication and in materials handling should be
encouraged in the field of plate and structural work.

(b) For the working of plates more press work

should be introduced in order to reduce the amount of
fabrication. In many cases, this should result in better
economy. For thicker plates, hot-working methods may
be used. In this way, import substitution of several
plate components may be effected.
 108

2.1,30. Sheet-Metal Work

(a) The practice of tinsmith is widespread in

Kenya. Although based on traditional methods, the
products made by tinsmiths have a reasonable demand.
As the process requires small investment and little
or no power is required (several tinsmiths only use -i
charcoal for heating), it is suitable for rural
areas. The process should be extended to include
decorative work, especially in copper and brass.

(b) The main use of sheet-metal is in the

building of coach, bus and other cargo-carrying
bodies for vehicles. Joining is primarily done by
riveting but only a few firms use pneumatic tools
for this purpose. Also, the use of press work is
limited (I5aragraph 2.1.28(b). This should be
extended to manufacture more sheet-metal panels with
different sizes and shapes.

(c) Metal spinning is used as part of small

and large-batch production of domestic hollow-ware
of aluminium. For such production, pressing and
deep drawing methods are more suitable. Metal spinning
is an inexpensive process and can form part of the
crafts for small-scale works.

II. The, Machining Processes

(a) The common machining processes consist of lathe

work; drilling and boring; milling; grinding and
honing; shaping; powered sawing; die-sinking and
engraving; polishing; and to a lesser extent, planing;
slotting and broaching. These processes have a wide­
spread application, mainly because of their cheapness
and versatility. The practice of machining, however,
is barely up to the normal workshop standard; there
is very little small-batch production of machined
components and no large-batch or mass production.
 109

Hence, machining is mainly done with the aid of

conventional equipment. At the present stage of
its development, metalworking in Kenya does not*
have a great need for processes like planing and
slotting.

(b) It was observed that the standard of metrology

in machining is generally poor (Paragraph 5*1.3)*
Moreover, the application of these processes consists
of routine work and generally no attempt is made to
fully utilise a machine in terms of speeds, feed3
and type of cutting tools* Hence, the lack of
machining of some alloy steels and non-ferrous metals.
This observation becomes more significant when one
considers that several milling machines are known
to be out of operation for this reason. Training
of operators in this respect is, therefore, an
essential requirement.

(c) Batch a’
nd mass production of machined components
may be done by the method recommended in Paragraph 3*2,2.

III. Fabrication and Joining Methods

(a) The electric metal-arc welding process is the most

common method for fabrication in the metalworking industry
of Kenya* It-is used both for repair and production
purposes* The process utilises a large quantity of
welding rods* In some cases it was observed that
parameters like type and value of current and type
of welding rods with respect to a given material are
incorrectly used. This calls for more industrial
training in the field of Yielding*

(b) Oxy-acetylene welding is the next most common

method of joining metals* Its principal application
is in the welding of thin metals and in repair work*
This type of welding is known to be suitable for alloy
steels and its use in this repsect should be investi­
gated in the local industry. •
 110

(c) Recently, gas-shielded welding methods like

TIG- and MIG have been introduced to the local metal­
working industry. At present, these processes are
practised by only a few establishments, one of which
fabricates stainless steel and aluminium tanks.
Carbon dioxide has been successfully used with the
MIG process as a shielding agent; and as this gas
is produced locally (from natural, emissions in the
Rift Valley), it is in plentiful supply. TIG, with
Argon as the shielding gas, is recommended for thin
sheets, but it is more expensive than the MIG process.
However, both of these processes are semi-automatic
and should find more application in production work.
/
I V . ^Heat Treatment

(a) The practice of heat treatment is not very

common in the local metalworking industry. This is
partly due to the fact that components which arc
normally heat-treated (tools, jigs, and dies) a^e
largely imported; and partly because there is a
lack of knowledge of this process. With the increase
in production engineering, a few establishments have
now began to manufacture and heat treat their own
jigs and dies. In several of these establishments,
however, the practice is based on intuition.

w There is only one establishment with facilities

of stress-relieving of large welded sections. Also,
the practice of heat treatment of non-ferrous metals is
rare. It is essential that certain items like welded
gas tanks should undergo heat treatment before being
approved for use,

(c) There is some application of resistance and

flash welding. Several other items could be produced
with the aid of flash welding. The main other
joining methods consist of riveting and soldering,
both of which are used in the sheet-metal practice.*
No hot-riyeting was observed.
 111

V. Surface Treatment

(a) Automatic production of galvanising metal sheets

is undertaken in Kenya. This process has helped in
cutting down the import of galvanized sheets but at
the seme time, the import of tinplate has increased.
The process of metal coating should, therefore, be
extended to the production of tinplate* Y/hilst the
mass production of galvanising sheets has increased,
small-scale methods of metal coating are rare. Small-
scale galvanizing should be practised by firms engaged
in the production of sheet-metal articles.

f
(b) Electroplating is a specialised process which
is undertaken by a few firms. Apparently, the main
application of the process is for re-electroplating
household silverware. Its use should cover the re­
clamation of worn machine components. Also, there
is a requirement for increasing the normal amperages
used. Other methods of surface treatment consist of
metal spraying and enamelling. The application of
both of these processes should be increased to cover
a wider range of engineering services and metal
products.
 C H A P T E R III

PRODUCTION SYSTEMS
I LOCATION OF ESTABLISHMENTS

II PLANT LAYOUT & METHODS OF PRODUCTION

III WORK STUDY

III DESIGN & DRAWING PRACTICE

 U2

I. LOCATION OF ESTABLISHMENTS

A. THE PRESENT STATE

- The following data represents the present state

of the location of metalworking establishments in Kenya:-

Fig. 3.1.A. - Geographical Distribution of

Establishments

Table 3.1.a. - Location of Establishments and

their Size

Table 3.1.b. - Geographical Distribution of

Labour

Fig. 3.1.C. - Geographical Distribution of

Skills

B• AN ANALYSIS: LOCATION OE ESTABLISHMENTS

3* 1°1, Development

Development started in Kenya with the building

of the railways system early this century, Hill^ states
that Vhitehouse, the first chief engineer of the rail­
ways, bought 372 acres of land at Kilindini iri early
1896 to establish the first railways base and, conceivably
the first engineering workshop in Kenya, On 30th May,
1899# the raiJ.s reached Nairobi where, subsequently,
workshops and living quarters were established, In
1903# an inspector of railways^, described the locomotive
shops in Nairobi as ’’very completely equipped".
The contribution of the railways to the develop­
ment of industrial centres like Nairobi is evident from
2
the following statement made in 1948:-
"Mairobi started as a railway town and to this
day the Kenya and Uganda Railway is the largest under­
taking in the country and is still adding to its size.
It is natural that the integration of so important a
concern into the expanding town is a matter of importance".
 35 40

G E O G R A P H IC A L D IS T R IB U T IO N O F F IR M S

F IG . 3.1.A
 • £.
m

ESTABLISHMENTS
CENTKE
SMALL MEDIUM LARGE TOTAL

Nairobi 71 82 16 169

j Mombasa 20 15 11 46

Kisumu 8 7 1 16

Nakuru 3 2 - 5

Eldoret 1 4 - 5

Kitale 2 2 - 4
Thika 2 - 1 3
Kaivasha 1 - - 1

Gilgil -
- I > 1
Grand
Total
108 112 } 30 250

LOCATION OF ESTABLISHMENTS AND THEIR SIZE

Table
 1-15

PERCENT
METALWORKING **
NO. OF EMPLOYED
FIRMS TOTAL
METAL* WORKERS IN METAL
CENTRE EMPLOYED
WORKERS INDUSTRY
NUMBER PER
FIRM TO TOTAL
EMPLOYED

Nairobi 5,302 169 32 28,984 18.4

t
| Mombasa 1,661 j 46 37 1 1 ,3 3 3 14.6

E
Kisumu 282 16 18 2,099 I 13.5
I
!
| Nakuru 25 5 5 2,877 0.87 j

!Eldoret 44 5 9 2,665 1.6

l / t
( /; 1
j Kitale 54 4 14 428 12.6

f
j Thika 263 3 90 2,834 9.4

Naivasha 5 1 3 556 0.54

Gilgil 65 1 65 112 59.0

GEOGRAPHIC AL,DISTRIBUTION OF LABOUR .

Iable 3.1.b.
* Excludes foremen and technicians. Humber of
unskilled workers is estimated*
Includes private and public sectors.*
** Total employed in the manufacturing industry,
1967 (including non-metal industry;;
Source: "Employment and'Earnings", 1963-1967*
Ministry of finance and Economic Planning,
November 1971, Page 20*
 11.6

The trend of the location of metalworking establish­

ments in relation to the size of tovms is presented in
Table 3*1*c.y from which a linear relation is apparent
with a heavy concentration in the two main centres of
Nairobi and Mombasa. In order to evaluate this trend
the method of least squares may be used:-
Assuming a linear trend (i.e. Y = a + bx)„ the
two equations for this method are,
S(Y) = Na + b (X) ....... (1)
2.(XY) = a (X) + b (X2 ) .... (2)

Where X and Y are the values under consideration

a, b constants and N, the number of times the
above values are considered (for Table 3.1.C.,
N = 9) •

Evaluating the above equations (1 ) and (2) from

the values in Table 3*1.c.,

250 » 9a + 176b ........ (3)

19336 = 176a + 12556b........ (4)

From these equations ( 3 and 4),

a = -3c4
b = 1.6
The equation of the linear relationship is,
therefore, as follows:-
Y = -3.4 + 1 «6X........ (5)
Equation (5) is plotted in Fig. 3*1•&«» from which
it becomes clear that there is a concentration of
establishments in a couple of industrial centres and '
that the rest of the main towns in Kenya only have a
few firms each. The trend indicates that towns of
population smaller than Kitale (Population 11,573) may
not have any metalworking establishment, although
Gilgil and Naivasha were found to have one each. The
former presents a unique example of a large-scale firm
(Table A,III,30) which has been successfully developed
in a rural area.
 1.17

.TOTAL POPU­ NO. OF

NAME LATION ESTABLI­
OF POPU­
(NAIROBI SHMENTS
TOWN LATION*
AS 100**;
X Y XY X2

Gllgil 5000 1 i 1 1
/

j Naivasha 6920 1 1 1 1
I

Kitale 11573 2 4 8 4

Eldoret 18196 4 5 20 16

j Thika 18587 4 3 j 12 16

Kisumu 32431 6 16 j 96 36
i
Nakuru !47151 9 5 45 81
I

Mom'faaoa ' 247073 49 46 2303 2401

I
i
Nairobi 509286 100 169 16900 10000

£x=176 j-z_Y=250 ,-XYr,19386 |/:X2=12556

TREND OF NUMBER OF ESTABLISHMENTS IN RELATION

* TO SIZE OF TOWNS
(Tatlo 3 .1 .c.)
* tinw
-miii iiiB^rai m M f t r

* Population census, 1969

** Rounded off to first significant numbers.
 SIZE OF TOWNS
-* P P P U L ftT tO H . VIM ROW ftS IP O )
FIG. 3 i.B.
 .1-19

5.1.2* Geographical Inertia

A description of geographical inertia is given by

Estall^ who states
"For various reasons - a raw material supply, a
power supply, a nodal location for existing transport
services and so on - an area may be cone an important
centre of industrial production"*
In Kenya, the distribution of metalworking
industry is due to the development, brought about by
geographical inertia, of certain centres. As stated
earlier, Nairobi started as a railway town*and developed
to become a centre for transport and Government, admini­
stration. Nakuru, for example, developed because of the
surrounding farming areas; and 'workshops were establi­
shed there to help repair farm machinery and to manu­
facture items of use on farms.
Once established, such centres benefited from
further progress. This is made clear in the following
paragraphs
(a) Supply of Materials
Except for scrap metal, raw material for the
metalworking industry is imported. Dealers have their
markets in the main industrial centres and, contribute

to the industrial concentration of such centres.

(b) The Market

A certain industrial centre may not have a
market for a given product. However, due to the re­
sources of such a centre, it may create a market for
that product. Such a market is known as a derived
a
market . Certain centres in Kenya have a number of
derived markets. An example is the manufacture of oil
cans in. Nairobi for the oil industry in Mombasa. The
former has derived a market for the manufacture of
oil cans.
 120

However, the market does have some influence in the

distribution of firms as shown by the manufacture of
marine craft at the coast and the production of con­
tainers for processed fruit at Thika.

(c) Supply of Water

As with other systems, the industrial centres
have benefited from larger supplies of water, Dixon
states that in Nairobi the water supply was 150,000
gallons per day in 1907 and he estimates that in 1980
it will be well over 10 million gallons per day. In
contrast to this, only 15 ?S of the rural areas get
piped water,

(d) Availability of Power

// With the development of industrial, centres,

there is a greater requirement for power resources.
This is^. therefore, another factor for the geographical
inertia of such centres. According to the figures
given by Bradley^, Nairobi and Western Kenya has an
installed capacity of electricity of 63 MW and an
additional standby and peak value of 27MW; whereas
Nanyuki, Kitalo, Meru, Homa Bay and Lamu only have a
capacity of 4.2MW. Other sources-of power like petro­
leum products are also available in the main centres.

(e ) Availability of Labour

The trend in the availability of labour (Table

3.1*b. and Fig, 3*1 *B.) is also similar to that which
effects other factors like power and so on. In this
instance, however, there are one or two towns (like
Gilgil) where the percentage of metal workers is much
higher. This is discussed further in Paragraph 3.1.3(a).

(f) Mutual Benefits

An outcome of a developing centre is the mutual
dependence and benefits which firms have amongst each
other. For example, in Nairobi, several firms depend
on the East African Foundry Works (Table A ,11,23) for
their casting requirements.
 121

This results in firms clinging together.

3»1.3. Dispersion of Industry

The previous paragraphs have outlined several

factors which contributed to the development of several
economic nuclei in Kenya- All these factors can be
attributed to the geographical inertia of such centres.
Although such centres have several advantages, their
further development poses a threat to the prosperity
of other areas in Kenya* The requirements of the
developed areas in terms of factors like the projected
growth of power and water supply must be met but a
simultaneous effort must be made for a dispersal of
(
the industry to other areas- This will decrease the
population and congestion in the main centres and, at
the same time, provide the rural areas with the benefits
of industrialisation. In the strategy of industriali­
sation, the Development Plan^ (1970-1974), stresses the
importance of the dispersal of industry. In line
Q
with this strategy several projects have been started
but_mostly with a bias to agriculture.

This is logical since agriculture is the primary

industry of Kenya. The development of agricultural
industry can create a local demand for metal products
like water storage tanks and charcoal kilns. Such a
demand should be met by the rural industry. Dandekar^
explains how the traditional industry and the small-
scale industry are organized in India for the self-
sufficiency of village communities. Por such projects,
he mentions, "It was obvious that the village industries
could not be preserved or promoted without a national
policy to protect them” . Detailed planning by the
Government in such matters, therefore, is essential.
A strategy suggested by Staley10 in respect of such
industry could prove useful in Kenya. Briefly, he
states that certain urban points should be developed.
 T22

Such points should then have linkages downwards to

villages and upwards to major industrial centres.
Some problems associated with the development of
urban points in Kenya are discussed in the following
paragraphs.

(a ) Availability of Labour

(i) Supply of labour:- As stated earlier,

this is normally proportional to the development
of the area (Table 3«1.b). However, the establish-
.ment of a big workshop near Gilgil (Table A,III,50)
has shown that in a reasonable period of time, a
large number of workers can be trained to do skill­
ful jobs (Pig. 3.1.C), In due course of time, the
supply of such workers increased and at the tine
of this survey, they represented 59f° of those
employed in total manufacturing (i.e. including
non-metal manufacturing) at Gilgil.

(ii) Coat of labour:- According to the

Kenya Engineering Workers Union (Nairobi Head­
quarters: City Mansion, Tom Mboya Street), the
cost of labour in the main industrial centres is
about the same, However, the income from rural
traditional activities in Kenya is about 1/7 to
1/Sth the income derived: by those in the modern
sector"* ^ . The establishment of industry in such
areas could offer a better wage structure and
act as a stimulus to the employment of workers.

(iii) Availability of Skills:- Fig,3.1.C

shows that in Thika, a large number of machine
operators have.been trained. It is easier to
introduce this class of skill to new development
ardas than to train workers to a higher degree
of skill. However, automation requires a
stable and large market which may not be available
in the rural areas, although in Thika the market
for metal containers (see Para.3.1.2(b) is created
by the agricultural industry.
G ILQ L

N A IV A S H A

TH IKA

K IT A L E

ELDORET

NAKURU

K IS U M U

M O M BASA

N A IR O B I

tu ^

D IS T R IB U T IO N OF S K IL L S

FIG. 3.1C.
 124

As the traditional skills in metalworking were

not developed, the skills available in a parti­
cular area are the direct result of the establish­
ment of the industry in that area. With more
industrialisation, it is conceivable that parti­
cular skills will develop in certain areas. At
present, however, the distribution of general
metalworking skills is in relation to the develop­
ment of a given area.
7
The Development Plan 1970-1974 mentions about
the introduction of a training programme based on
the concept of Village Polytechnics. Such a pro­
gramme may help in extending the traditional rural
skills to the basic metalworking principles.

(b) Availability of Power

g
According to Bradley , wind and solar power in
Kenya do not have sufficient energy for most industrial
purposes. However, his suggestion for the use of dual­
fuel engines which may be a*un on locally-grown and
processed fuel is worthy of consideration.
The use of engines run on gas produced from the
treatment of sewage should also be considered. Such
19
a plant has proved successful in New Zealand . At
their Whangarei plantt 45,460,000 litres of sewage
(wet weather capacity) is treated for the production
of 764m of gas per day. V/ith two engines, about '
27,500KWh of power is generated per month. This sewage
plant is for a population equivalent to 25,000 people.
With the installation of modern sewage systems,
a number of larger towns in Kenya could benefit from
such schemes. Such towns may form part of the potential
urban points as referred to in Para. 5*1*3*

(c) Transport

With the present situation of having raw materials

in the main industrial centres, village workshops could
incur large transport costs. With the "development of
potential urban points, raw material could be made
available at such points at controlled prices.
 >25

In this way, the village workshops will have the

benefit of obtaining raw material from a near-by
source.
As mentioned earlier, the finished products
should primarily fulfil the local demand. ?or out­
side markets, the goods should be handled by other
agencies, preferably assisted by the Government.

C. CONCLUSIONS AND RECOMMENDATIONS

5 *l-»-4>
The establishment of the railway system in East
Africa set the original pattern for the concentration
of industry in certain centres. The momentum of the
geographical inertia of these centres increased with
their further development. As a result of this, over
90f<> of the firms are concentrated in the three main
centres of Nairobi, Kombasa and Kisumu, There is a
linear trend between the relationship of the number
of establishments to the size of towns, but the
disparity in the number of firms located in the two
main industrial towns (Nairobi and Iiombasa) and the
rest of the towns in Kenya, is of a high degree. The
general trend shows that towns with a population less
than about 11,500 people may not have a single metal­
working establishment.

In some cases, the market has helped in the

distribution of the industry* but some highly developed
centres like Nairobi have created a limited amount of
their own markets. Other factors from which such
centres have benefited are the availability of power,
water and labour,
5.1.6.
Several national plans are in hand for the dis­
persal of industry to the rural areas. Resources like
the supply of water and power should be* developed in
such areas.
 126

The possibility of using power produced from thermal

units run on locally-grown and processed fuel and on
gas produced from sewage waste should be investigated.
For the development of such areas, detailed national
plans (which should include the training of manpower)
and the development of a few nodal points, with
linkages to villages and the main industrial towns are
recommended.
 \ 2 1

II, PLANT LAYOUT AND PRODUCTION METHODS

A. THE PRESENT STATE

The following tables represent the data collected

on the subject of plant layout and production methods
practised in this country.
Table 3.2.a. - Type of Layout
Table 3*2.b. - Materials Handling Methods

B. AN ANALYSIS: PLANT LAYOUT AND PRODUCTION

5*2.1. Small-scale Works

Small sized firms have few items of equipment and

do not have any particular pattern (this is referred to
as “mixed” layout in Table 3*2.a.) of layout* Depending
on the' type of work undertaken, such establishments may
be divided as follows
(a) Blacksmith Type:-* Generally have a floor space
2
of about 50m , one work bench, a portable hear-ch
and at least one electric welding unit. The shop
is crowded with material stored along the walls or
on an overhead gallery* Generally, without an
office.
(b) Machinist Type:- Similar to above but with
less working space because of the area taken by
machines. Besides machines, such shops also have
electric, welding units.
.(c) Tinsmith Type:-
(i) Crafts:- Have no power tools. Work is
carried out on floor for manufacture of items
like trunks and boxes.’
(ii) Tank Manufacture:- Besides tanks, they
manufacture buckets, drain pipes and so on. Layout
similar to blacksmith's but tend to have less
space for the storage of large tank3.

The small handicraft and machine shops are generally

overcrowded. For example, a typical shop (Table A,I,45)
o
had an area of 2,33m to each worker. This is less than
2 15
by about 1 .27m as that recommended by Greene o
SIZE OF TYPE OF LAYOUT
FIRM
MIXED BAYS HEAVY GROUPED LIKE OTHER TOTAL

Small 81 .6 9*3 0.93 1.9 3.6 2.7 100

Medium 30.4 11.6 15.2 20.5 16.1 6.2 100

<

128
large — 6.6

o
o
26.7 36.7 26.7 3.3

TYPE OF LAYOUT
(Per- cent of firms)

(Table 5 .2.a )
 SIZE
Ur
. - -- MATERIALS HANDLING METHODS i
!Manual ilTrolleys Fork Lift I Mobile j Overhead Con­ Other Total
FIRM only Trucks Cranes cranes & veyors Methods
'
j Lifting »
l
! j Tackle
\
i ■ i
1 l 1
1 j
Snail 96 .4 0 .9 [ 1 ©8 — j 0 .9 : 100
I "

Medium : 7 5 . 4 | 2*7 2*7 | 0 .9 1 15.6 1.8 ; o© 9 100

!

j
!
i
Large 2 .5 | 19.1 7.1 11.9 55 .4 1 9 .1 7.1 100
*

MATERIALS HANDLING METHODS

(In per cent of firms)

Table 5©2.b
 130

Moreover, the use of open electric metal-arc welding is

a constant hazard in such shops. This is discussed in
nore detail in Para. 7.1*3*
y
3.2.2, Group Layout

The words group layout and"baysM are almost synony­

mous. The former term is used where grouping of machines
is more distinct.
The equipment is generally grouped for convenience
and not necessarily for batch production. This is
partly due to the shortage of large batch production in
this country.
Even for batch production, some of the grouped
layouts were found to be arranged in incorrect
sequences. Pig. 3.2.A. is an example of such mal­
practice fouled iv, o-w,*. *Lr>v\, (yraVte. AjUS-.io)
14 M
Ivanou outlines theA known principles of
Gr o u p Technology which can bring mass production
principles within the reach of small and medium-batch
15
enterprises. According to Thornley , Group Technology
ca n be used for the production of parts more efficiently
an d economically. Ee states that this type of
production may bo done by grouping machines together.
I n Kenya, there is very little batch production of
components, although they are in great demand. This
d e m a n d is met by importation. For their local manu­
facture a project for Group Technology could be considered
by a body like the Industrial and Development Corporation
(I.C.D.C.) and established at an industrial estate.

3.2.3. Heavy Product Layout

Heavy product layout is mostly found in larger

firms (Table 3.2.a.), although some small works
fabricate heavy products (e,g. structures, vehicle bodies,
etc.). A suitable layout is a covered yard with an
over-head travelling gantry and a platform of steel
plate.
 POUSrtVMG

finished
PRODUCT
St o r e

F L O W D IA G R A M : P R O D U C T IO N O F K E T T L E
 *32

H. Young & Company (Table A,III,8) has such a yard.

Several workshops doing heavy production were found
to be without such facilities.
For items which can move under their own power
(like lorries), or those which can be moved by materials
handling devices, the principle of continuous production
can be introduced by maintaining a number of stations
for undertaking different steps in the manufacture of
the item. Greene ^ explains how such a method was
used in the manufacture of a ship. Figs. 5,2.B(1) and
(2) are based on approximate distances obtained from
one establishment (Table A,III,15). The advantages of
the latter method are obvious,

5.2.4. line Layout

/
This term denotes a layout established for the
production of a certain item only. In Kenya, continuous
production with various degrees of mechanisation was
found in the following industries
(a) Containers, crown seals and drum manufacture
(b) Manufacture of wire products
(c) Impact extrusion of collapsible tubes
(d) Hot rolling of bars and rods
(e) Limited amount of casting and forging
(f) Coating of corrugated iron sheets

In several cases, continuous production is achieved

by the use of single units. For example, a single unit
i3 sufficient for the automatic production of nails.
The principal advantage of a line layout is in the
mass production of a given item. For better productivity,
such production lines are genera iiy automated. The
basic steps in the progress towards automation are
16
explained in a report on "Automation". Although
published in 1956, the following developments towards
automation mentioned in the report are still valid:-
(a) An increase in the mechanisation of transfer
devices,
(b) Introduction of numerically-controlled machines.
•x
 S T A T IO N 3 STATION 2 ST A T IO N I
MATERIAL SW EET-METAL BE^M S, BRACKETS
FOR. SEATS

FA&RlCKTC COT TO SIZE CUT TO S1Z.E

SEAT FRAMES

FlN\SV\ Fl&RE. INSPECT INSPECT

WORK «
INSPECT

JT. TO PRODUCTIOH J*L TO p r o d u c t i o n TO PRODUCTION

FiNAL VZ'Vw ljjs[£ Lime ^ — V LIME
INSPECTION DRILL FRAME A Z 'W*.
- O O ■ O ---- 0 - 0 - 0 o — o — H m — o — 0 “ “0 * o -
AWWT SPRAY INSTALL RIVET ADD WELD LINE m o v e m e m e n t
DLL!VERY PM M T SEATS SKIN FLOOR FRAME (CHASSIS MOVING)

SUMMARY
MO. OF O P tR K H O K S O IO
MO. OF STO RA GES V 3
N O . OF TEMPORARY STOR.ES D 1
M o. OF INSPECTIONS □ 7 IM P R O V E D ASSEM BLY PRO CESS CHART
MO. CF TR A N SPO R TA TIO N S ❖ 5 COACH B O D Y B U IL D IN G
TOTAL TRAVEL 78 F IG . 3.2.B.C2)
METRE
 135

(c) Use of computers- for automatic-processing

of technical and "business information.

In Kenya (a) is used in the manufacture of one

or two items only and (c) is used by some large-scale
firms, but (b) has still to be introduced.
17
A report tabled by the Parliamentary Select
Committee on Unemployment stressed the need for
employing more men than machines and recommended a
duty on the import of all capital ipachines. The.
report argues that by doing so more employment
opportunities would be created. However, the Develop-
ment Plan 1970-1974 projects a growth rate of l +5f<>
in the manufacture of metal products. Moreover,
industrialisation in Kenya, as in any other developing
country, must move at a faster pace-as -recommended by
the Secretary-General of the United Nations Conference
on Trade and Development (UNCTAD) . To achieve this,
a moderate progress towards more mechanization should
be made. The local technology and the market available
are not ready to accept and utilise ultra-modern equip­
ment like numerically-controlled machines, but an
increase in the use of more semi-automatic and, in
some cases, automatic machines is inevitable.
Principles like those of Group Technology (Para.3*2.2.)
and other labour-intensive piece-work schemes should
be introduced to reduce the risks of unemployment.
Also, automation demands a large and steady market for
the products. This question is discussed further in
Chapter IV.

3.2.9. Materials Handling Methods

Materials Handling is still predominantly manual

(Table 3*2.b.). In the very small shops, this is in
order; but in the majority of the cases, the provision,
maintenance and use of materials handling devices needs
improvement.
 • ^

136

Several light engineering firms have changed over to

heavy work but their materials handling methods have
not changed. This is partly due to the availability
of cheap labour. Such labour, however, would be better
utilised in the type of production outlined at the
end of Para. 3*2.4. Por moving materials, firms should
make more use of hand-drawn trolleys. In spite of
being An inexpensive and simple method, its use was
found to be very limited.
In some firms with modern production equipment, it
was noticed that their materials handling devices were
far inferior to the standard of their equipment. A
system of this nature can easily impair the efficiency
19
of such equipment. Lingard observes that some
developing countries get financial help and buy ultra­
modern machinery without paying attention to the problem
of feeding raw material to the machine and taking away
the finished product. Firms should avoid falling into
such a pitfall,
A study carried out by the East African Industries
Limited (Appendix,....?.... ) shows that in the long run
it is cheaper to employ a fork lift truck than manual
labour. By introducing a fork lift truck, twelve men
would become redundant and one *driver would have to be
employed. This is a problem which the industry has to
face but in the metalworking industry, there are some
items which, because of their size and weight, have to
be moved by mechanical materials handling devices.

G* CONCLUSIONS AND RECOMMBNDAT IONS

■*■5.3.6.
Small works are generally overcrowded, They should
either increase their work floor or reduce the amount
of equipment and raw material. Basic principles of
human engineering should be used in the layout of tools,
welding booths, raw material storage and in the use of
work benches.
 V

\
137

2 - U
Over 25/S of large, 15^ of medium and about \% of
small-scale works are engaged in heavy engineering
practice. Several of these firms have unsuitable sites
and do not have adequate lifting equipment. Firms
engaged in the large-batch production of certain heavy
items may benefit by the introduction of continuous-
production principle.

3.2.8
Group layout and the use of "bays” were mostly
found in the medium and large-scale works. The
grouping of machines is generally done for convenience
and not in reference to any production procedures.
Firms engaged in large-batch production should examine
and re-arrange their equipment in accordance with their
production sequences by using principles of method study.

2*2*2
For import substitution of components, bodies like the
Industrial and Commercial Development Corporation (I.C.D.C,)
should consider a project for the introduction of the
principles of Group Technology, preferably for an
establishment in the industrial estate. Experts from
the I.C.D.C. should organize and give advice on the
production management for such an establishment.

3.2.10
At the present stage of development, the industry
is not ready to accept ultra-modern production equipment.
However, to achieve the 7.3/6 growth rate in the manu­
facture of metal products as envisaged by the current
Development Flan 1970-1974, the use of more machines
should be encouraged and also a certain degree of
automation should be introduced. Wherever possible,
assembly and piece-work should be organized on a
labour-intensive basis.
 138

3.2,11
Over 95^ small and over 757* medium-sc ale firms
were found to be using only manual materials handling
methods. While in some small light engineering firms
there may not be any requirement for such 'devices,
several firms could improve their production by the use
of simple materials handling devices. For heavy
engineering, there is a requirement for better lifting
equipment.
 139

III. WORK STUDY

A. THE PRESENT STATE

The present state of the practice of work study

methods is shown in Table 3.3.a.

B. AIT ANALYSIS: WORK STUDY PRACTICE

3.3*1, Method Study

Section II of this chapter analysed the question

of method study with reference to layout and sequence
of production. This is the basic step for work simpli-
20
fication as defined by Lehrer .

3.3.2. Introduction of Work Study Methods

TJae use of work study methods, and particularly

of time study, is restricted in the metalworking industry.
The question of using work study methods was probably
never considered for the following reasons
(a) Lack of batch and mass production methods
(b) The availability of cheap labour
(c) Variation in the technical skill of the workers

Recently with the increase in production and the

standardization of technical skills, through industrial
training, some firn3 are becoming aware of the usefulness
of work study methods. However, at the present stage of
its development, the metalworking industry is not ,
sufficiently advanced to make full use of modern work
study methods. A good deal of technological progress
is necessary before the industry could benefit from work
study methods, and in particular from the practice of
time and motion study.

3.3.3. Work Measurement

The main purpose of work-measurement is two-fold

(a) For rate fixing and incentive wage schemes
(b) For planning and scheduling purposes
 WORK STUDY METHODS
SIZE
OF Compa- Time & Synthe­ No Calcu­
Total
rat ive* Motion tic Method
FIRM lation
Method Study Method

Small 16.3 — 8.1 75.6 - 100.0

140
Medium 29*8 - 13.5 56.7 - 100.0

Large 38.0 - 24.1 34.5 3.4 100.0

WORK STUDY METHODS

(In per cent of firms)

Table 3.3 -a.

* Based on experience from similar jobs previously done.
 141

In the metalworking industry, schemes as those at

(a) above are not in use* The only schemes used are
overtime payments and shift differentials. These are
generally based on the monthly salary of the workers.
In the absence of piece-work and general mass pro­
duction principles, the present systems in use are
satisfactory. With the introduction of piece-work,
firms will have to use standards based on work-measurement
practice.
The methods used for work study are generally for
purpose (b). As mentioned in Para. 4.2.2., firms
engaged in automatic production can measure their out­
put from a knowledge of the efficiency of their
machines. Although such firms work on output constants,
21
they do not maintain records of their "Synthetics" .
Also, several firms with this type of production were
found to be ignoring the measurement of work done by
the manual packers.
When discussing work-measurement, one comes back
to the question of standards, which as pointed out in
Para. 5.2.5., are hardly used in the local industry*
For example, several firms use the comparative method
(Table 3*3.a*), but they do not maintain any records of
previous jobs. Therefore, no standards are maintained.
For jobbing and small-batch production especially
for welding, machining and forging, the method of-
finding production rates by calculating speeds, feeds,
etc. could be used. For such methods, allowances for
fatigue and for materials handling should be made.
However, several entrepreneurs would be unable to achieve
this because of their low standard of education (Para.6.1.2),

3*3.4 Training;:

Until recently, there was no evidence of taining on

22
work study methods. The first course of this nature
was organised by the United Nations Special Fund and
East African Railways & ‘Harbours' project in April 1970. *
 J.

142

Since then the Management Training and Advisory Centre,

Nairobi, has held a number of courses on this subject*
Training of workers in the art of using tools and
in implementing work simplification should also be
encouraged. In Japanese factories this is a regular
practice ' in the training of their workers.

C. CONCLUSIONS AMD RECOMMENDATIONS

UxS.
The use of method study principles in establishing
the sequence of production, especially in batch and mass
production; and in the simplification of work, should
be encouraged in the metalworking industry*

L M
No firm was found to be using stop-watch methods for
time and motion 3tudy* At the present stage of its
development, the industry does not require such methods.
Other methods of work-measurement can be useful but these
must be based on the standards developed by individual
firms* There is a requirement for the preservation of
such standards by the firms concerned.

1 l2iI
Both internal and external training schemes are
essential in order to extend the scope of work 3tudy
practice in the Kenyan metalworking industry. .

IY. DESIGN AND DRAWING PRACTICE

A. THE PRESENT STATE

A small percentage of establishments were found to
be using engineering drawing methods in their production*
Table 3*4«a. shows that a mere 29 firms (about 12^) had
drawing offices of any description. Several of these
offices had out-dated drawing tables, with a few drawing
instruments, often not in use.
The practice of engineering design is also restricted,
although it is employed in the manufacture of structures,
most of which are designed by consulting engineers
specialising in civil or structural engineering.
 PER CENT OF FIRMS No. of Esti­ Products for
SIZE firms mated No. which dra­
0? with With Without Un­ Total regularly of wings nor­
Drawing Drawing Drawing known using out­ draughts­ mally used
ESTAB1I- Offices Boards/ Facili­ side dra­ men
ME1JT Tables ties wings

Small Nil 2.8 97.2 Mil ICO 11 1 Small struc­

tural steel­
works
j

143
Medium 11.6 15.2 65.2 8.0 100 27 17 Structural j
steel-works |
and vehicle
bod ies
large 40.0 16.7 50 13.3 100 18 50 Structural
steel-works,
vehicle
bodies and .
trailers
DESIGN AND -DRAWING- PRACTICE
Table 3 .4.a.
 144

B . AH ANALYSIS: DESIGN AND DRAWING PRACTICE

3,4*1* General Trends

Most of the design and drawing practice is carried

out on a trial and error'basis* The following example
illustrates this trend* An establishment (Table A ,11,14)
decided to use locally-made overhead canopies for their
new tractors* By doing this, they contemplated a large
saving in foreign exchange. The order for the manu­
facture of about 70 canopies was given to a local firm
(Table A,II,35). The design consisted of free-hand
sketches with the dimensions of the frame-work based on
intuition* The first canopy was fitted on a tractor
delivered to a road construction project near Gilgil.
After ^only a few hours of running, the canopy began to
develop cracks* In due course, most of the other
canopies ended up the same way. As a result, all the
canopies had to be modified but there was still no
guarantee that they would be strong enough*
Some small workshops, engaged in non-manufacturing
work, may not require the services of a drawing office,
but those engaged even in the manufacture of articles
like forged lamp-stands could benefit by improving the
standard of their design. Several small-scale establish­
ments fabricate structures, but it was found that they
are often not made in accordance with specified drawings.
In fact, several entrepreneurs were found to be unable
to read simple drawings.
However, it was found that generally items which are
covered by Government or other legislation are made, in
accordance with the design and drawings approved by
qualified engineers and after completion, these items
are checked and approved by independent inspectors.
One of the few examples where approved design is
used is that where firms make items according to
registered specifications of certain well-known machines.
 145

For example, one firm (Table A ,11,45) make tea

machinery in accordance to the design and drawings
issued by their principals, George Williamson Africa
Limited, Nairobi*
Marine Engineering establishments (Table A,III,17
and 24) have small but well equipped drawing offices.
The former does no design work but has two draughts­
men for assessing the material required and for making
workshop drawings from drawings made abroad by quali­
fied naval architects. For the manufacture of small
sections of a marine vessel, the workshop drawings
are made to full scale on large sheets of paper, from
which wooden templets are made to assist in the shaping
of the metal. The latter claim to have two qualified
naval architects engaged in the design of small marine
vessels.
The "Tool and Jig Design Office", of the railway*s
Chief Mechanical Engineer*s Workshop, Nairobi (Table
A,III,4) is, perhaps, the best example in Kenya of a
drawing office working in conjunction with the pro­
duction department and the work-floor. It has a
supervisor and a staff of four. Jigs and fixtures
are designed in this office and the sequence of their
production (processing) is established. The design
of templets, gauges and machine spare-parts is also
undertaken. Standard drawing procedures are maintained
for all their vrork.
There was little evidence of component design. Ono
firm (Table A,II, 49) was found to have a qualified
engineer working on design of items like bicycle
locks, matchets, etc. Generally, however, the trend
seems to be to copy the design of imported items and,
in some cases, to adapt them for local production*
For example, a firm (Table A,II, 74) was found to get
their castings made by using imported components as
patterns. Tho plough frames made by one establishment
(Table A,II, 51) are understood to be -copied from
imported ones. Several'of the locally-made coaches
were originally copied, although the coach building
has shown some creativity lately.
 It was found that engineering drawings are rarely
used even for the calculation of material required for
a particular job*
Sound, practical design has many features. Vallance
and Doughtie^ sum these features as follows
(a) Technical factors
(b) Experience factors
(c) Kum&n factors

By "technical" factors is meant the ability of the

designer to put his engineering knowledge to practical
purposes* The experience of the designer with existing
designs contribute to the "experience" factors. And by
"human" factors is meant that elements should be designed
with the view that they are to be used by human beings*
Comparing these factors with the state of design
practice in Kenya, there seems to be a lack of technical
factors* As stated earlier, the use of engineering
knowledge in calculating forces, in recommending the
correct materials and so on, is used in the manufacture
of items like structural steel-works, and to a very
small-scale in the mechanical engineering industry*
The "experience" factor is responsible for the
bulk of engineering manufacture in JUenya* The practice
of copying existing designs and relying on the word of
the "fundi"*is quite conkion, This trend hinders creative
work.
In copying existing designs, no special consideration
is given to the human factors. This point can again
be illustrated by the locally-made canopies for tractors
(Page ]44____ ) These canopies only provide a shade for
sun but do not shield the driver from dust, wind or rain,

'3.4.2, Introduction of Design Practice

In spite of a lack of engineering drawing and

design practice, workshops in Kenya carry out their
business without any apparent handicaps. The intro­
duction of a new production method like design and
drawing is, therefore, a difficult problem.
* Swahili word for craftsman.
 147

One method of tackling this is by promoting an interest

in this field in the metalworking community of Kenya®
In India, bodies like ’’Inventions Promotions and Imports
Substitution Board" and the Ministry of Industrial
Development have launched a strong campaign in promoting
interest for the manufacture of local products td sub­
stitute imported ones. This campaign has paid off good
dividends and as reported in ’’World Construction"^,
Indian engineers have designed and manufactured devices
like bending rolls for cold forming girders, conical
drilling bits, vibratory rollers, concrete pumps,
transit mixers, etc. A 40-ton capacity revolving gantry
won cash awards fox' its designers from the "Inventions
Promotions and Imparts Substitution Board", This
design saved for India about Rs2 million in foreign ex­
change .
Import restriction can create a necessity for
certain items. Such a necessity is essential for the
development of an interest in design and creative work*
oc
The recent measures taken by the Kenya Government
brings to light an example where necessity may help in
the design and manufacture of a local product: hydraulic
hand palleti trucks were being imported to Kenya fx’om
Denmark. With the introduction of import restrictions,
a firm in Nairobi (Table A,II,22) got the stimulus to
manufacture the same item locally with a few.imported
components for it. This will involve the design of jigs
and fixtures and, pei'haps, an improvement in the existing
design so that it may be better adapted for the local
market. If the manufacture of such a truck materialises,
the effort will be worthwhile both in introducing a
design function in Kenya and in saving some foreign
exchange for the country.
This is an example of an engineering firm having
the foresight a M the resources to introduce a home­
made product to the local market. This may not be the
case with most other firms because they fail to under­
stand the market and,, the importance which the design
function has on such a market.
 148

Such firms should "be given assistance as discussed in

Para. 3*4*3*
Another way of introducing the design practice is
by encouraging engineers to take a greater interest in
processes for reclaiming worn machine parts by re­
conditioning them. Re-conditioning methods like sub­
merged-arc welding and "-wtetAlo eking" are used in
Kenya* Such methods are in great demand because
several components, which ordinarily would be imported
from abroad, can be back in service in a few days and
at a fraction of the cost of new ones. Effective re­
clamation requires sound design and workshop practice
27
as stated ^"Conservation”

3.4.3. Establishment of the Design Function

Para. 3.4.2, made remarks on the benefits of

obtaining assistance from the Government in an endeavour
to improve the standard of the design practice in the
metalworking industry. This can best be done by form­
ing a national design council* Such a council may
comprise of members dravm from the industry, the
University and the East African Institution 'of Engineers;
and should act both as a policy-making and as a
consultancy body* The terms of reference and the organi-
oo
nation of such a council are described by Whitfield
with reference' to the United States of America*
Whitfield points out that in America, the National
Inventors’ Council works in the field of patent law;
taxation; and provides incentives for invention and re­
search activities.
The proposed design council would work effectively
only if it is fully aware of the problems facing the
industry, The council could obtain information from the
29
industry by making regular surveys. Maddock explains
the methods used by the Engineering Group of the Ministry
of Technology of Britain in carrying out regular surveys
with the aim to stimulate technical advance in the industry.
 149

Kost design offices were found to have inadequate

reference material* While some firms had handbooks on
general mechanical engineering, data on local design
"50
practice is generally not available* Pitts' shows how
the information needs of a designer should be fulfilled.
He describes various services and publications which
can help a designer. Such a stheme, at least in an
elementary form, may be maintained by the proposed
national design council,
Agbasiere' explains how design can contribute to
the improvement of activities like traditional forging
and tinsmith practice as undertaken in Africa, With
scientific assistance in matters related to design,
metallurgy and processes, these skills could contribute
to the technological development of a nation,

C. CONCLUSIONS AND RECOMMENDATIONS

Very little use of engineering design and drawing

practice is made by the metalworking industry. Design
is generally based on the knowledge of previous designs
of parts which are imported and on the experience of the
worker. While the knowledge of these factors is essential
to a designer, the situation in Kenya is such that too
much dependence on past experience is hindering
creativity both in the crafts and in the field of -pro­
duction engineering. The value of good engineering
design is often not appreciated* This is partly because
the metalworking industry does not fully participate in
the market which largely depends on imported goods designed
abroad•

As in the building industry, the construction of

certain items should not be approved unless they are
made in accordance to specified drawings. Such drawings
should only be approved by qualified engineers. In this
way, the usefulness of good engineering design and drawing
practice could be extended to the industry.
 1*50

3.4. 6 .
It is recommended that a national design council,
with members drawn from the industry, the University and
the East African Institution of Engineers, should be
established with assistance from the Government. The
council should play both a policy-making and a consul­
tancy role. It should provide incentives to designers
and inventors by awarding annual prizes for the best
industrial design in the country and for the design and
manufacture of items which substitute imported ones* It
should conduct regular surveys to assist the industry
in improving their products to a standard capable of
competing in the local and world markets. The proposed
council should also maintain an information centre for
engineers and designers*

The practice of reclaiming worn machine parts is

becoming common in this country. The practice can be
extended to reclaim other components by using sound
engineering design principles.

Kenya has started manufacturing small marine vessels

but there is a-lack of qualified naval architects in
this country. The possibility of training a small
number of naval architects should be considered by the
University of Nairobi and by other technical institutions
in Kenya.
PRODUCTION PLANNING

1. MARKET FACTOR
2. PRODUCTION SCHEDULING AND
PROCESSING

3. MAINTENANCE OF EQUIPMENT
 1-51

PRODUCT IPIT PLAIIDING-

I. THE MARKET FACTOR

A. THE PRRSEKT STATE

The information collected on marketing techniques

is shown in Table 4.1 *a.

3. AU ANALYSIS; THE MARKET FACTOR

4.1*1.:™ The influence of market on engineering

production is the single most important factor. The
type of production, the quality and quantities of the
items produced; the type of equipment used and the
type of training necessary for the manpower, all
depends on this factor. Eor example, in Kenya the
market has a big demand for containers. This has
resulted in the establishment of automatic plants
for theix* production with the use of special equipment;
and the training of personnel to operate and maintain
such equipment.

The influence of the market fact ox* on plant

location is covered under Paragraph 5*1*2. The
Development PlarJ 1970-1974 calls for the following
action to expand the market for manufactured goods

(a) Import Substitution

Import substitution in the manufacturing
industry of Kenya is not considered to be as
important as it used to be previously. If
import restrictions are put on consumer goods,
it will not make much improvement in the economy
because such goods only account for about 2\fo of
the total manufactured goods in Kenya. Inter­
mediate goods, however, account for about 5o?S
but are considered to present technical problems
and hence are difficult to manufacture locally,
A total ban on import of manufactured goods
is not economically feasible at the present state'
of development in the country.
 SIZE J.T I f'J Q . IECNNIQUES
u j ;

PIRM PERSONAL SALES SELLING

CONTACT DEPARTMENTS AGLETS

■SMALL 90 .65$ 5.6$ 3.8?S

MEDIUM 50.0r
/° 36.4 5$ 1 3 .65-5

152
i

LARC-E * 1 2 .05$ 83.0^** - .

IIAKKETING- 'TECHNIQUES
Table 4.1.a.
* Sxclud.es the quasi-governnent establishments
** Includes firms' having selling agents also*
 153

(b ) Established Markets
There are uncertainties regarding access
to old markets in the neighbouring countires.
Exports to such countries are bound to suffer
as a result of their industrialisation plans,
ITew markets, therefore, must be found in
Africa and in the Indian Ocean area.

(c) Growth Hate

The projected growth rate of export is
between 5 and (although for metal pro­
ducts the situation is not so encouraging,
see Paragraph 4.1.3*)« However, if factors
like the costs and prices of Kenyan manu-
j factured goods could compete with overseas
counterparts, a much higher growth rate can
be expected,

4 .1 .2,_Import 3institution

A p p e n d i x . 9... gives details of import restri- i

ctions applicable to Kenya at the time of writing. .

* Items shown under schedules A and C are imported, ■ j
Their local manufacture presents a challenge to the j
Kenyan metalworking industry. This challenge should j
be met by a national effort by investing more in the j
s
industry and by the acquisition of technical knowledge j
and skills, ' \
fjj
Several of the items which are manufactured in |
Kenya are still being imported. Some of the examples
are razor blades, barbed wirve and hydraulic jacks. ”
!
Their import is.still continued because the quality
I,
of the local products is poor. The development and
practice of engineering standards are, tnerefore, nece­
ssary to bring about more effective import substitution.
Another drawback is the lack of raw materials.
Although Kenya relies heavily on the raw materials
obtained from. abroad, a-certain amount _of import
substitution is possible. This is discussed further
in Chapter II. ?;
 i.
1-54

More detailed planning by the government in

training, financing and in the protection of the
industry is required. The development approach
2
suggested by Staley may prove suitable for Kenya.
»

Briefly, his approach aims at making small industries

more efficient; to change to the production of more
profitable items; and to enlarge the size and the
production capacity of the plants.

4.1,?. Established Markets

The majority of the metal products made in the
country are consumed by the local market. Berna^
suggests certain points in the improvement of a
domestic market. According to him, firstly, the
efficient development of, marketing techniques
'-.^eaulsjfc^n widening the market; and secondly, for
effective marketing, there must be "low-cost chan­
nels of commerce through which goods can move
expeditiously from factory to final user.." In a
study of small-scale entrepreneurship, he found
three methods of marketing:-
(i) Personal contact with the buyer at the
work-floor level
(ii) Establishment of sales departments or
branches as distinct from the factory.
(iii) Employment of selling agents

Table 4*1*a. shows the marketing methods.used in

the metalworking industry of Kenya, from which it is
clear that the marketing effort is largely based on
traditional methods. This ds mainly due to the large
number of small and medium sized firms which are
engaged in jobbing and work according to the personal
orders they get.
Concerning export, some firms are known to be
manufacturing and exporting goods to the neighbouring
East African countries* Compared with agricultural
products, (Appendix 11), the export of metal products
is very low.
 <- 155

The projected export figures for 1974 show that the

export of metal products will drop by 1fo. This trend
will have an adverse effect on the metal-working
industry. It is, therefore, important that new export
markets be found. At the UNCTAD III Conference^,
Kenya called for a new world commodity arrangement and
suggested methods for the transfer of technology from
the developed to the developing countries and for the
formation of a market within the block of developing
ChuntireSsattending the conference. An attempt should
be m a d e ^ o put such methods into practice.

C . CONCLUSIONS AND RNCOMKSIU)ATIONS: THE MARKET FACTOR

4.U4»

The market has a strong influence on the practice

of metalworking. The quality and quantity of products;
the mode of manufacture; the choice of equipment; and
the training of the personnel are some of the factors
which depend upon the size and type of the market. The
Development Plan 1970-1974* suggests several ways for
the widening of the existing markets and the acquisi­
tion of new ones. Over the years, the import of a
number of products has been stopped. This has helped
stimulate local manufacture* However, a total ban on
some capital and intermediate goods is not economically
feasible at present. Compared with consumer goods, a
greater percentage of intermediate goods are used in
Kenya. Their local manufacture, therefore, would
benefit the economy more. The production of inter­
mediate goods present complex technical problems, which
could only be overcome by the acquisition of specialised
knowledge and skills. More detailed planning by the
government in the fields of technical training and in
the financing, could result in potential projects for
the manufacture of such goods.
4* 1*5
Nearly 51^ of the local marketing of metal products
is based on traditional methods. An improvement of
marketing techniques can help widen the domestic market
and create a greater demand for metal products. The
establishment of marketing techniques could assist in
this matter. I-letal products account for about 3# of
the total exports from Kenya. This is a small per­
centage when compared with agricultural products which
account for about 6Q;$ of the total export. By 1974?
the export of metal products is expected to drop by 1^.
This would have an adverse effect on the whole industry.
The importance of finding new export markets, therefore,
cannot
j be stressed further.
 •157

II. PRODUCTION, SCHEDULING AND PROCESSING

A. THE PRESENT STATE /
The data collected on the use of production .
planning methods is presented in the following
tables
Table 4*2.a. - Production Scheduling and
Processing Methods.
Table 4*2.b. - Example of Processing and
Scheduling.
B. AN ANALYSIS: PRODUCTION SCHEDULING- AND PROCESSING
4.2.1. Jobbing and Small-hatch Production
In jobbing (Table 4.2.a.) very few small and medium
sized ^irms apply planning methods in their routine
work. Such firms do general mechanical engineering work
and a considerable amount of their activity involves
repair and other non-manufacturing type of work.
5
According to Ellon the main purpose of production
planning is "to make effective use of the resources
available ,to the enterprise". He considers manpower-;
materials; machines; money; and methods as the main
resources. The co-ordination of these factors contri­
bute to effective production planning.
In the local small-scale job-shop, the entrepreneur,
himself, a skilled man, is often in direct control of
the first four factors* His main drawback is in tho
use of methods. These methods may concern the use of
engineering standards (Paragraph S’-1 .k); the training
of his workers (Paragraph 6.1.2); or the layout of his
equipment (Paragraph 3.2.1).
In the larger firms, especially those employing
over 25 workers, there is a requirement for scheduling,
The method suggested by Gillespie^ is recommended for
such shops in Kenya. The method consists of estimating
the labour cost for the manufacture of the item.
 .
SIZE OF JOBBING/SMALL-BATCH PRODUCTION LARGE-BATCH/MASS p r o d u c t i o n
FIRM Methods Methods Not Methods Methods Not
Total Total
used Not used Confined used Not used 'Confined
• f

SMALL 5.0 97.0 100.0 j

25.0 75.0 — 100.0
I ! I
t
I
MEDIUM 16.7 70.0 13.5 100.0 | 40.0 35.0 25.0 100.0

SSI
i
! LARGS | 61.0 | 53.4 5.6 100.0 66.7 16.7 16.7 100.0
I ; “I
1------------- !---------- !-------------

USB OF PRODUCTION SCHEDULING/FROCESSING METHODS

(In percentage of firms)

Table 4.2.a .
 1*59

This cost is broken dcvn with respect to the

different shop3 and is then converted into hours.
Once the hours are obtained, they may be used for
scheduling. Besides scheduling, this method can
indicate whether the labour is being used effectively*

For the manufacture of products requiring several

processes, processing (i.e. deciding the sequence
of manufacture) is also applicable. In the local
industry processing is generally done by the word
of mouth. While this is acceptable for the smaller
establishments, the larger ones should make use of
processing charts. A simple scheduling and processing
chart as used by one establishment (Table A,II,8) is
shown /in Table 4*2.b, The railways'workshop in Nairobi
i3 perhaps the only establishment in Kenya which uses
detailed processing charts.

4.2,2. Large-batch and Mass Production

Large-batch production is mainly confined to the

manufacture of office and domestic metal furniture
production. In this field only one establishment
(Table A*III,13) was found to be using scheduling and
processing methods based on the principles of pro­
duction planning. Their method consists of finding
an economical batch size for a one month production
run. Scheduling is then done and is based on
"Synthetics'1 (Paragraph 3*5*5*)» from which the man­
hours required for a particular run are known. Week­
ends are generally not scheduled and are left for any
late orders*

In mass production, planning is based on the pro­

duction rates of the machines. Most establishments
work towards a weekly or a monthly production target.
 r

1.60

PRODUCT: Bracket
QUANTITY: 5,000.

PROCESS OPEHATIOK/PIECES HOURS

Guillotine 10,000 pieces 18

Crop ends 20,000 operations 24
Pierce hole3 5,000 operations 8
Porm small section 5,000 operations 10
Form one end - 12
Form two ends - 12
Spot Veld — 42

Total Hours......... .. 126

Instructions:- When job commences, report to the

Works Manager. Then daily with
quantities done and time on each
operation.

EXAMPLE OP PROCESSING AND SCHEDULING

Table 4.2,b.
 161

Appendix* .19... chows a production programme for one

establishment (Table A,III,24). Most establishments,
however, make no analytical programmes for their- pro­
duction planning*
In a number of establishments, elaborate methods
of production planning are not applicable. This Is
due to either the small size of such establisiiment3
or to the lack of regular large-batch production
throughout the year and due to the non-manufacturing
activities of several firms. Such establishments may
have several slack periods in a year. Hence, the use
of production planning aids like Gnat Charts and route
cards are not strictly applicable unless there is an
expansion in the production of metal products. However,
as discussed in Paragraph 4.2.1., there is a requirement
for simple methods of production planning.

G* CONCLUSIONS x m BECOMILENLATIONS

4.2,^:- Most of the small sized establishments are

engaged in repair and non-manufacturing type of work.
Production planning methods are, therefore, not
applicable to such firms, although there is a require­
ment for them to develop, maintain and practise general
engineering standards. Lai’ger firms with jobbing or
small-batch production rarely use production planning
methods. To make a better use of their resources such
firms should employ simple production scheduling and
processing methods.

4 .2.4:- Establishments engaged in mass production roly

on the production rates of their machines for the pur~
pose of scheduling. While this is an acceptable prac­
tice, most firms do not carry out analytical studies
to improve on their overall production. Out of the
firms engaged in large-batch production only one was
found to be using production planning methods* It is
recommended that for large-batch production, the deter­
mination of an economical batch size should be a pre-
requisit.
 162

III. MAINTENANCE OF EQUIPMENT

A. THE PRESENT STATE

Table 4.3.a. shows the present trend of

maintenance of metalworking equipment.

B. ANALYSIS: MAINTENANCE PH ACT ICE

4.3*1. Conventional Machinery

No standard methods are used in the maintenance of

local metalworking equipment (Table 4*3.a*)* Main­
tenance is generally undertaken on finding a fault.
Out of the establishments using conventional machinery,
only 24^ were found to be performing simple maintenance
operations, and none was using planned maintenance
7
methods. On the cost of maintenance, PrcKikov states:

11.... the cost of maintaining and servicing a

tool during one maintenance cycle (i.e. up to
and including a major overhaul) is greater than
the cost of a new machine, and if maintenance and
repair are badly organized, it can be several
times greater” .

The situation in Kenya is different because moot

conventional machines are not used continuously. In
spite of this, there is a requirement for the'intro­
duction of simple maintenance procedures, especially
for establishments having larger outputs* Such
procedures should be part of -engineering standards
(paragraph 5*1 *6).

4.3*2. Automatic Machinery

The situation with plants having automatic

machinery is much better (Table 4.3*a). There is a
greater awareness in such plants for the benefits of
preventive maintenance.
 METHOD OF MAINTENANCE
!
---------
On Fault
Casual
Type of Machinery Finding Planned TOTAL
Method
only

Convent i onal 76 — 24 100

163
.Automatic - 43 57 100

MAINTENANCE PRACTICE
(In percentage of firms)

Table 4 «3. a.
 J,

164

Firms having automatic machines were found to have

maintenance departments, but few of them had well
organized teams working in accordance with established
maintenance programmes, i.e. programmes which take
into account the effect of maintenance on production.
Standards for the maintenance of automatic machinery
7
should be established. Pronikov gives useful
information on the repair and maintenance of machine
tools in developing countries.

C. CONCLUSIONS AND RECOMMENDATIONS

4.3.3:- No definite procedures or standards are

used in the maintenance of conventional metalworking
equipment. A certain degree of maintenance of pro­
duction equipment is undertaken but there is a require­
ment for the use of better preventive maintenance
programmes. Standards for the maintenance of conve­
ntional and automatic machinery should be developed
and used by the Kenyan metalworking industry.
C H A P T E R V

QUALITY
AND
MATERIAL CONTROL

---xXx---
I QUALITY AND MATERIAL CONTROL

A. THE PRESENT STATE

5.1.1. Quality Control

The following tables show the present state of

quality control practice in the Kenyan metalworking
industry.
Table 5.1.a:~ Use and Inspection of Tools of
Quality Control
Table 5. K b : - Inspection Procedures
Table 5.1.c:- Standards

5.1.2. Material Control

In the smaller workshops, material control is

generally well organised, although many firms were
observed to be ignoring the practice of using racks0
Material control practice in the larger firms is
generally poor. Most establishments use no material
control procedures. A typical example is of a firm
(Table A,II,31) which had 46 workers and foremen at
the time the survey was conducted. It had no store-
men and the material was just piled up in certain places
and was picked up by the workers as and when it was
required.

B . AIT ANALYSIS: QUALITY AND MATERIAL CONTROL

5.1.3. Tools of Quality Control
Table 5.1.a. gives somo statistical data about
the use of measuring instruments. The standard of
their general storage, maintenance, inspection and
usage is of a low degree. This is clear from the
table which shows that no small sized firm does
inpsection of their instruments; and that only 197^
and 28% of the medium and large sized firms inspect
their instruments.
 SIZE USE OF TOOLS OF QUALITY CONTROL INSPECTION
0? OF TOOLS
Micrometer Slip Vernier Surface
FIRM Total OF QUALITY
Screw Gauge s Calipers Plates
Gauge s CONTROL

Small 35.6 NIL 54.8 9.6 100.0 NIL

991
Medium 59.5 5.9 - 36.6 100.0 19.0

large 22.8 7.4 40.0 29.8 100.0 28.0

USE AND INSPECTION OP TOOLS OF QUALITY CONTROL

(In per cent of firms)

Table 5.1»a.
1 Left with Responsibility
1 Specially
owner, of Engineering Not
SIZE Total
foremen Employed
Management Confirtn..
OP Inspectors a<3U
or
FIRM
workers

Small 100.0 - - - 100.0

167
Medium 66*6 25.2 1 .0 7.2 100.0

Large 46.7 25.3 16.7 13.3 100.0

INSPECTION PROCEDURES IN PRODUCTION- *

(In per cent, of firms)

Table 5.1 .b.

* Includes jobbing work*
 SIZE FIRMS USING M E T R I C A T I O N
0? STANDARDS'
Not Transi­ Not
Completed Total
FIRM BOOKS
Started tional Confirnv.e(L

Small 23 92.6 5.6 1.8 - 100

Medium 47 56.2 26.8 13.4 3.6 100

891-
Large 81 53.3 16.7 16.7 13.3 100

Total - 71.6 16.4 8.8 3*2 100

i __________!__________ . ■■ I.l. . . . . . .
.. — 1
STANDARDS
(In per cent of firms)

Table 5.1 *c
 4 .

169
1
Rice states that it is normal for a workshop
without an organized system for the maintenance and
inspection of measuring equipment, to have from 30
to 50^ of their equipment giving defective answers.
From this it could be concluded that most of the tools
of quality control in use in the metalworking industry
of Kenya may be defective.
Individual firms should give top priority for
establishing correct procedures for the maintenance
2
and inspection of such tools. Juran gives some
details of a procedure for such maintenance. However,
most firms, would be unable to inspect their instru­
ments even if they followed a procedure because of the
lack of "master” or inspection gauges. In fact, the
majority do not possess even workshop grade slip
gauges as indicated in Table 5.1.a. In this respect,
the establishment of a national materials testing
laboratory (Paragraph 5.1*7) should prove invaluable.
With the poor maintenance standard of measuring
instruments, precision engineering in Kenya can only
produce articles whose dimensional accuracy is not
even up to the standard which a well maintained
micrometer screw gauge could help to attain.

5.1.4. Inspection Procedures

In the small sized firms inspection is left

with the workers (Table 5.1*b.). Since most of these
firms are engaged in craft practice, this is in order;
although those engaged in precision grinding and
structural work should use other means of inspection.
Central inspection on a table arranged for inspection
and under the supervision of either a senior worker
or the entrepreneur himself could prove the best
method.
As with the smaller firms, a high percentage
of medium and large sized establishments do not use
any particular inspection procedures.
 170

This is partly because of a lack of high quality

production* However, even in jobbing, there are
several factors where inspection can improve the
%
quality of production. Seder mentions five such
factors as the set-up of the job; the condition of
the machine; the skill of the operator; and the
type of material* To improve the quality of the
local products, inspection procedures should pay
careful attention to such factors.

In jobbing and small-batch production, there

is no requirement for the employment of inspectors,
although independent inspection by the entrepreneur
or a foreman is recommended. As stated earlier, the
method of having a central inspection station would
be the most suitable.

More establishments with large-batch and mass

production should employ inspectors. Such establish­
ments should use planned inspection procedures.

5*1.5. Kenya National Standards

For the last few years, discussions have been

going on for the establishment of an Hast African
Bureau of Standards for the objective of establishing
standards for local application. In January 1970,
Phillips^ writing in the "East African Report on
Trade & Industry" mentioned about the formation of
a Standards Office and the establishment of the
East African Metric Standing Committee, From recent
reports , however, it is apparent that no official
document has been issued on engineering standards.
£
In Kenya, there have been Government notifications
for general standards for industrial use, but apart
from the progress reported above, there are no official
regulations* The normal practice is still to refer to
the British Standards Specifications.
 1.71

These standards may not he compulsory and are, therefore,

7
often used voluntarily . The Weights and Measures Act,
Chapter 513 of the "Laws of Kenya", give legal details
of the establishment of Standards, and their enforce­
ment. When the local engineering standard’s are
established, this Act should make their enforcement
compulsory.

During the last few years, Kenya has been going

through the process of metrication. The Metric System
Act 1968 (Act No. 63 of 1968) commenced on 20th
December, 1968 and it gives the Minister the power to
order any sector of the industry and to specify the
date for the conversion to the metric system.

In the metalworking industry, it was found that

those/concerned with weights (like the px'oduction of
nails) had changed over to the metric system. On the
side of measurements, however, very little progress
is being made* This is clear from Table 5.1.c. In
fact, nearly all the firms which reported as having
converted to the metric system were either dealing in
items which are weighed or were merely capable of
working from drawings (generally of structures) having
metric dimensions. Moreover, nearly all the equipment
va3 found to be in the British System.

Prom the aforesaid and especially from the

fact that most of the equipment will have to be
converted or replaced, the cost to the industry will
be phenomenal. In Britain, the Government decided in
May 1965 to gradually change over to the metric system
Q
by 1975# V/eston describes how the British Government
and the industry are tackling this problem together.
The Government has based its plan on the recommendations
received from the industry.
 172

This type of communication is essential for the success

of such a plan, especially in calculating the time in
which the industry could economically be converted to
use the metric system,
»

At the present rate of progress, only 8.8fo of the

total metalworking establishments have changed over to
metric system. Considering a uniform progress per year,
this gives a 2.2?$ growth per year for the period 1969
to 1972 (inclusive). At this rate of growth, the
number of years required for complete metrication may
be found from the following equation:-

Sn = So (1

Where, gn _ xotal number of firms which should.

use metric system after n years*
So = Number of firms which already use
the metric system.
r - Percentage increase in the number
of firms using the metric system.

Evaluating the above equation,

250 = 22(1 -h 2,2sn

100;

From, which n 11 years.

At the present percentage increase, therefore,

it would take over 11 years to convert the metalworking
industry to use the metric system. After 11 years,
however, most of the equipment would be obsolete
(Paragraph 1.1*3) and could be replaced by their metric
counterparts. This is a long period for the conversions
and also there i3 no guarantee that the present rate of
increase would continue. Hence, the requirements for
more effective and less tixie-consuming methods for
conversion are imperative.
 173

At a seminar
9 on metrication held at the factory
of Whiteby Lang & Neill Limited, Liverpool (United
Kingdom), the following equipment for converting-
machines to the metric system were mentioneds-
Simple dual reading dials for lead screws
Re-engraving of existing dials
Use of metric-reading optics

The use of such conversion equipment and the

replacement of old machinery (Paragraph 1.1.3) should
be the bas*s of metric conversion in Kenya. The
Kenyan branch of the East African Metric Standing
Committee should invite representatives from the
industry, the University and other professional bodies
to discuss this conversion before issuing any regulations
A recommended outline network analysis for the con­
version of the Kenyan metalworking industry to the use
of the metric system is given in Pig*. 5*1 .A.

A sub^-committee to deal with the conversion in

the engineering and construction industries, was
reported^ to have been formed by the Ministry of Works
in 1967. It consisted of members from the East African
Institution of Engineers; Ministry of Works; and
from the Institute of Architects and Chartered Surveyors,
It is not known how much progress this sub-committee-
has made, but the author found that it had not created
any practical influence in the metalworking industry.

5.1.6, Use of Standards

*
The use of engineering standards in metal industry
of Kenya is severely limited. There are many instances
where no standards are used. As shown in Table 5.1.c.
even the application of engineering books is rare,
especially in the small and medium sized firms. The
percentages shown consist of firms many of which had
only one book. This factor seriously limits the scope
of such firms to produce work to any given standards.

i
 pncPnQF PlM-t POg;
WHOLb vKOUST^

IM PLEM ENT P l-M * . USE

DEKOKSTftVHOK EQUIPMENT
S* R E P l_K C £M E H T P O U C ^

TRKtN MEH CiP

*e*ST A-FPJCkN
Ms-T R l C ST t%ND vts 0 EVENT l. FORMATION OF POLICY.
. C-OMMITIEE'1 2., C O M PLETIO N OF P L A N N IN G .
■b.COMPLETION OF EXPERIMENTS
A. COMPLETION OP METRICATION
EDUCATTONfkL MEDIA, programme.

N E T W O R K A N A LY SrS F O R M E T R IC A T IO N
 175

This situation deteriorates when the question of

individual company standards are considered. It is
estimated that no more than about ten firms in Kenya
maintain and enforce the use of engineering standards.
Firms generally have a loose pattern of traditional
engineering practice and rules for workers and other
staff members. But these are rarely defined and are
not maintained in a written form.

Standards for tho following factors are

recommended for the local metalworking firms:-

Measuring Instruments
Limits and Fits
Drawing Practice
Material Identification and Control
Stores Procedure
Equipment
Safety and Security

Wilson® describes in detail the importance of

industrial standardization in developing countries,

f In this context, engineering standards cover all

aspects of engineering practice, i,e. metrology;
discipline and regulations for workers, safety, etc,

5*1*7. Materials Testing

In the commercial sector of the metalworking,
industry, only two instances were found where materials
testing equipment was being used. In both these cases
the equipment was for hardness testing, and was used
by large-scale firms. This is insignificant in an
industry having well over two hundred firms and shows
the lack of the practice of materials testing.
In the Government and quasi-government sector,
the Materials Branch of the Ministry of Works maintainns
a materials testing centre at Commercial Street, Nairobi
and the railways workshops in Nairobi use materials
testing techniques.
 176

The former is the only materials testing laboratory in

Kenya, apart from the facilities offered by the Univer­
sity of Nairobi. Thi3 laboratory is better equipped
for testing of materials used in buildings and road-
making projects. However, in view of the age of some
of the testing machines and the fact that it is
housed in an old wooden building without means of
controlling the temperature or humidity, makes it un­
suitable as an institution where national standards
could be maintained and materials tested. The
establishment of a national laboratory with modern
metrological equipment is, therefore, an essential
requirement.:
As mentioned in Section A of this chapter, the
practice of material control is poor. This is mainly
due to:-
(a) Manufacture without the use of detailed
drawings.
(b) A lack of storemen.
(c) Poor storage facilities and procedures.

G. CONCLUSIONS AND RECOMMENDATIONS

5* K 8 :- The normal tools of quality control are
applied in the metalworking industry of Kenya. The
quantities of slip and plug gauges were found to ba
considerably low. No standard methods are used for
the storage, maintenance, and inspection of gauges
and in most cases, measuring instruments are treated
in the same way as metalworking hand tools. With
such malpractice, it would be normal for a firm to
have between 30 to 50C
,Z of their instruments giving
wrong results. Individual establishments should be
more conscious of quality control and should establish
methods for the care and inspection of their measuring
instruments* More application of simple surface'
plates should be made.
 177

Firms should use slip gauges both for precision work

and for the routine inspection of their normal gauges.
The Inspectorate of Factories should make it compulsory
for the inspection of certain gauges at least once a
year.

5.1.9s- A large percentage of establishments use no

inspection procedures in their routine production and
non-manufacturing activities. For small sized firm3
engaged in craft practice, this is in order; but
those manufacturing other articles and doing precision
machining, a centralized system of inspection under
the supervision of the entrepreneur is recommended.
Larger establishments, engaged in large-batch and mass
production should employ inspectors and should use
planned inspection procedures.

5.1.10:- There has been much discussion about the

establishment of engineering standards applicable to
the East African countries. In spite of this, no
local standards have been formed. Establishments rely
on specifications like the British Standards Specifi­
cations, For the local metalworking industry to follow
a code of specifications, it is essential that national
standards be established and enforced by an act of the
"Laws of Kenya*'. Moreover, individual firms rarely
apply general engineering standards. It is recommended
that firms should develop and apply their own standards
for factors like production costs; material control;
drawing practice; maintenance practice and safety
procedures. :

5.1.11:- "The Metric System Act" commenced on 20th

December, 1968. Since then some weight and measure
systems used in Kenya have been converted to the metric
system, but the situation in the metalworking industry
is such that a large percentage of establishments (over
90# small; over 55# medium and over 50# large sized)
have not even commenced to use the metric system of
measurement;
 170

and at the present rate of progress, the industry

may take about 11 years to obtain complete metrication*
The conversion to the metric system poses many
problems but they could be tackled by a gradual process
with the co-operation of the industry, the Government
and professional institutions.

5.1*12;- In Kenya, there are only two commercial

institutions for material testing. The main materials
testing laboratory occupies an unsuitable building and
does not have the equipment for accurate testing of
materials* There is a requirement for a national
materials and standards laboratory wxth modern equip­
ment and good facilities. Such a laboratory should
be staffed by qualified engineers and other trained
personnel and it should operate branches in the major
industrial centres of Kenya.

5.1*13?" Metalworking establishments rarely use

materials control and storage procedures. Materials
control can be improved if more use of detailed
engineering drawings for estimating is made; and
better storage procedures can be introduced if establish­
ments employ at least one storeman (or delegate the
duties of storekeeping to a member of the staff) and
use batter physical means of storing and identifying
materials.
P A R T T H R E E

MANPOWER

"AND
WORKING CONDITIONS
-----X -----
CHAP T E R VI

MANPOWER & TRAINING-

— X—
 179

I. MANPOWER
A. THE PRESENT STATE

The present manpower state in the metalworking

industry is represented by the following tables
Table 6.1 .a : Manpower in the Metalworking Industry
Table 6.K b : Comparison of Grades of Manpower
Table 6,1*c : Employment of Engineers According
to Field of Work
Table 6.1.d i Manpower Employed According to
Field of Work
Table 6.1.0 : Industrial Training
Table 6.1.f : Demand & Supply for Manpower for the
Metalworking Industry (1970/71 - 1974)
B. AN ANALYSIS: MANPOWER

6.1.1. Demand
(a) Engineers:- There is a small percentage of
engineers employed in the metalworking industry of Kenya
(Table 6.1.b). As discussed in Para. 6.1.4., this is
mainly due to a poor utilisation of engineers. However*
based on the numbers employed, estimates show that a
situation may arise in 1974 when the demand for engineers
will exceed the supply (Table 6.1.f). The difference
between the demand and supply will largely depend upon
the growth of the industry and upon its ability to uti­
lise more engineers than it does at the present stage.
The type of work which attracts most engineers is
in the field of batch oz* mass production of metal articles
(Table 6.1.c). This i3 followed by structural work;
general mechanical engineering; marine-craft manufacture
and repair; and railway* repair work. The employment of
engineers in any of the above fields depend upon the
development of that particular field. For example, in
the field of production, Kenya has a big market to serve
(products include cans, collapsible tubes, and wire pro­
ducts). This culls for specialist machinery (mostly
automatic) and highly trained engineers. Similarly,
structural work, vrhich relies on the rapidly expanding
building industry of Kenya, requires engineers'.
*Grly includes the railway workshops in Nairobi.
 Q U A N T I T Y
's i z e
Engi­ Draught Entre­ Mana­ Techni­ Fore­ Clerks Skilled Semi­ Mach­ Un­
OP
neers smen • pre­ gers cians men V/orkers skilled ine skilled
FIRM -a- neurs workers Op rra- workers
■x* tors
*-**

j Snail 1 . 1 112 9 3 3 3 178 217 7 40

f
I
i Medium
i
24 10 32 164 7 35 128 ■ 878 1051 234 297
1

'180
| Large
(Private) 33 26 Ml 57 33 78 195 604 793 748 562

Large - ■i
(Public) 10 4 | - - - 68 - 676 4 13 - 420
f
I
1 Total 6S 41 144 250 43 | 252 325 2336 2474 989 1319
i
MANPOWER IN THE METALWORKING- IINDUSTRY
Table 6»1.a.
* With, formal or professional qualifications.
** Owner-managers, mostly highly skilled.
*** Operators of automatic or semi-auto:
machinery.
 Q U A N T I T Y ( P E R C E N T A G E S )
SIZE
Managers* Engi­ Tech­ Fore­ Clerks MANUAL WORKEFLS
AND and neers nicians men Semi- Un- ' Mach­
Entrepre­ * Skilled
FIRM Skilled Skilled ine Total
neurs % Opera­
tors

18 1
Snail 21 .1 0.1 0.7 0.52 0.52 31.0 37.8 7.0 1.3 100.0

Medium 6.6 0.7 0.3 2.8 4.6 28.6 34.4 14.4 7.6 100.0

Large 2.1 0.9 1.3 2.4 6.2 17.6 23.1 24.6 21.8 100.0

COMPARISON OF GRADES OP MANPOWER

(Private Sector Only)
Table 6,1eb.
* Estimated for firms from which
quantitative data was“not
obtained.
 182.

PERCENTAGE
FIELD OF WORK
EMPLOYED
•

Structural Work 20.3

€ .

Batch and Mass Production 45.8

Marine-craft*: Manufacture
and repair work 8.5

Railways*: Repair Work 11.8

General Mechanical Engineering 13.6

EMPLOYMENT OP ENGINEERS ACCORDING

TO FIELD OF WORK

Tabic 6.1.c.

* Workshop personnel only.

 M A N P O W E R ( P E R C E N T A G E S )
!
{ FIELD MANUAL WORKERS
Mana­ Engi­ Tech­ Fore­ Clerks
i OF gers neers nicians men Skilled
Semi­ Un­ Mach­
I skilled skilled ine Total
j WORK ■K- Opera­
tors
\
| General
; Mechanical 3.5 2.1 2.1 0.0 9.1 52.4 15.4 15.4 0.0 100.0
Engineering

Structural
Work 2.1 0.8 0.8 1.7 6.3 12.6 33.7 42.0 00.0 100.6'

T(
X? o*o
Production 1 06 1.6 1 a2 5.0 12.3 5.6 11.2 5.6 55.9 100.0

MANPOWER EMPLOYED ACCORDING TO FIELD OF WORK

Table 6,1.d.
* Estimated.
The above results are from three firms, each successfully
established in one of the above fields of works(Reference: Table A,III,6,24 & 27)*
—
PERCENT AGE OP FIRES NUMBER OF NUMBER OF
| SIZE 1. ____ FIRMS
! OF On-the-job 1 Other* APPRENTICES**
No Total EMPLOYING
Methods of APPRENTICES
FIRM Training Training
Training
.
Small 26*5 2.5 71.0 100.0 26 13

Kediuri 42.3 25*6 32.1 100.0 38

■
1 "

Large - 79.2s 20.8 100.0 146***

I "
—

INDUSTRIAL TRAINING

Table 6<,1 ,e.

* Includes evening classes at Polytechnics.

** Includes apprentices not employed in accordance vith the
Industrial Training Act. *
*** Estimated* Excludes the public sector.
x Includes On-the-job training.
 DEMAND SUPPLY
Grade of Total
For For From From From Industry & Cumula­
Emp­ tive
Manpower Kenya- gro­ Univer­ Over­ other Kenyan
loyed ni ca­
wth & Total sity of seas Training Pro­
Total
Total
tion was­ Nairobi grammes
tage

Engineers 58 15 24 59 17 10 - 27 -12

Managers &
Entrepreneurs 398 75 27 102 - - 10* -92

185
i
| Technicians &
: Draughtsmen 97 11 42 53 16 28 44 -9

I Skilled
;’Workers 2336 223 1 ,100 1323 — — 720 720 -603

Foremen 174 24 36 60 - - 23 > 23 -57

— — ..... —...

DEMAND AND SUPPLY FOR MANPOWER FOR THE METALWORKING- INDUSTRY (1970/71 TO 1974)
(PRIVATE SECTOR ONLY)
Table 6.1.f.
N o t e s 1. Unless otherwise stated, the projections are in proportion to the
national requirements ("Development Plan, 1970-1974", Republic of
Kenya, page 120).
* In proportion to the Affiliated & Student members of the Kenya Institute
of Management (refer K.I.A. Development Plan, 13th December, 1972).
 186

On the other hand, general mechanical engineering,

although practised by most establishments, lack3 the
standard of design and quality to attract a large number
of engineers.
i
The Manpower Survey , 1967* found nearly 91/° of all
(total employed were 374) the mechanical engineers as
non-citizens. With the employment of more Kenyans this
situation has improved since then. However, complete
Kenyanization for the period ending in 1974 would create
a great shortage of engineers.
(b) Managers:- All the small sized firms are one-
man businesses. They are run on a family pattern, the
son picking up a trade from hi3 father. Such firms
represent over AOfo of the total but they have no demand
for the employment of managers. However, nearly 90^
of such firms were found to be owned by non-citizens.
Kenyanization, therefore, would produce the greatest
demand in such firms.
Several middle sized firms are also run on the
aforementioned pattern. Larger firms employ a number
of managers and there is a definite demand for managers
in such firms. At the end of 1974* the total estimated
demand may bo 1^2 (Table 6.1*f.). This is a conservative
figure and the actual demand when one takes into consi­
deration. the- broader aspects of management, may well be
twice as much.

(c) Technicians and Draughtsmen:- In the metal-

2
working industry, Jackson recommends the ratio of
technicians to professionally qualified men as 3=>8:1,
In the Kenyan metalworking industry, the number of tech­
nicians employed per engineer is much smaller. This is
clear from Table 6.1.f., which gives a ratio of 1*67:1
when technicians and draughtsmen are considered together;
and from Table 601ob. the ratio of technicians to engi­
neers is 1*03:1. In specified establishments with
different fields (Table 6.1.d.), this ratio is 1:1,
e howing even a lesser degree of employment of technicians
per engineer,
 167

Draughtsmen are generally employed on structural

work. Firms manufacturing casements also employ draughts
men for general drawing duties and for liaison with
architects. Due to the general lack of mechanical engi­
neering design practice (Para. 3«4.1)f very few draughts­
men are employed for the design of either products,
or jigs and tools.
The demand for technicians is more than that for
engineers. More school-leavers should, therefore, be
encouraged to pursue training leading to a technician's

■3 has
career. To do this, there is a requirement for the
recognition of the status of a technician, Varley
made some recommendations on this subject and has also
made suggestions for the recognition of the status of
the technician and the technician engineer.

(d.) Foremens- Although few foremen are employed

in the smaller firms (Table 6.1«a), their demand in
the metalworking industry is more than that for tech­
nicians (Table 6«1.£). Most foremen were observed to
be working in the Kenyan metalworking industry.
In a study conducted in the United States of
America, Waite^ found the following percentages of fore­
men
Small Plants 6.4$ (100 to 249 workers)
Medium Plants 5*6?S (250 to 999 workers)
Lai'go Plants 5.0i» (1,000 or more)

With the large number of workers shown above,

these percentages cannot be equated to the industry
in Fenya. However, the small, and medium plants mentioned
above correspond to the large plants in this country.
Comparing this with Table 6,1»b*, the percentage of
foremen in the large-scale firms is very small, although
in production engineering, the trend is different and
there are sufficient foremen employed in some firms
(Table 6 . I.d).
The management pattern of one general engineering
firm is worth noting (Table 6.1.d). This firm has no
foremen.
 1 6 8

Instead, they have appointed work floor managers who,

they consider, play a better supervisory ana training
role*
For the plants mentioned above, b’aite4, gives the
following percentages for clerical workers:-
Small Plants 3o3fo
Medium Plants 3.9?£
Large Plants 3*3^

In Kenya, there seems to be a surplus of clerical

workers in the medium and large-scale works (Table
6 . 1 *b).

(o) Manual Workers:- The greatest demand in the

industry is for skilled workers. It is over 30 tines
the demand for engineers (Table 6*1.f). On the
national scale with all the industries combined, there
will be a demand^ for 12,82 6 skilled workers at the end
of 1974.
Table 601.b. gives a breakdown of the categories
of manual workers* In the large-scale firms, the trend
is changing in that mors machine operators are being
employed. This is due to the increase in the use of
more semi-automatic and automatic machines. This is
clear from Table 6*1od. which shows that one establish­
ment has over 50^ machine operators and only about
skilled 'workers. This trend is reversed for general
engineering; and for structural work, a large per­
centage of unskilled workers is mainly employed for
materials handling purposes.■. The percentage of skilled
’
workers is highest in the small si~e<l firms. In such
job-shops, the entrepreneur depends entirely upon his
own skill and on the skill of his workers for oho
existence of his business.
Williams^ states that ’’the proportion of skilled
workers needed in any industry varies, thercioro,
according to the degree by which mass production notnods
can be introduced”.
 189

The introduction of mass production methods has

reduced the requirement for skilled workers. Such
methods of production, however, require markets.for
a large number of identical goods. As markets for
this nature are restricted at present the demand for
skilled workers will continue, especially in general
mechanical engineering. This is obvious from the
distribution curves (Pig. 6.1.A.) which shows that
160 firms employ from one to eleven skilled workers
and only thirteen firms employ the same number of
machine operators. The known number of firms which
employ the same number of unskilled workers is 42.

6.1.2, Training and Supply

(a) Skilled Workers:- The Industrial Training

Act (Chapter 237 of the "Laws of Kenya") stipulates
the legal requirements of industrial training in Kenya.
The Act has appointed an Apprenticeship Board with a
Director (previously known as Controller) of apprentices.
It defines an apprentice as:»
"A person who is bound by a written contract to
serve an employer for a determined period of
not less than four years, or such lesser period
as the Director shall determine under Sub-
Section^) of Section 20 of this Act, with a
view of.acquiring knowledge, including theory
and practice, of a trade in which the employer
is reciprocally bound to instruct that person".

for an "indentured learner” , the Act gives a

similar definition as above but the training is for
a "determined period of les3 than fear years".

Table 6.1.e. shows the trend in industrial training

in the metalworking industry. The appointment of the
majority of the apprentices does not conform to the
stipulations of the above Act.
FREQUENCY

DiSTRiBUTiQN OF WORKERS IN
RELATION TO NO. OF FIRMS
F IG . 6.1.A.
 V.

191

This is mainly due to the fact that all the small

and most of the medium and some large-scale establish­
ments neither have the facilities nor the instructors
to fulfil the requirements of the Act. Jn fact, the
standard of education of most of the entrepreneurs is
very low. This situation is similar to that in India
g
for which Chandrakant writes;-
"....a large number of our people are engaged
in industrial occupations in big and small
factories, construction works, power generation,
communication systems, transport organization and
in a host of other entrepreneurs, as skilled and
semi-skilled workers, artisans, craftsmen opera­
tives. Many of them are practically illiterate;
they learnt their trade from their fathers or
on the job. As the industrial development of
a country progresses and modern technology is
introduced, all these industrial worke.wshould be
made functionally literate'1*

The first requirement, therefore, is for a broad

education of entrepreneurs. Such an education scheme
should be phased in with Kenyanization. Most of the
entrepreneurs are non-citizens; their replacement should
consist of persons having a specified minimum standard
of education.
The difficulty of training apprentices in such
7
establishments is also expressed by Getahi , who
recommends the following amendments in the Industrial
Training Act:-
(i) Firms which employ apprentices should also
have members of staff responsible for
apprentice training only*
(ii) Craftsmen who give on-the-job training to
apprentices, should attend short courses on
methods of teaching apprentices. In this
way, they will be better equipped to under­
take apprentice training* Such courses should'
be organized by the Ministry of labour.
 192

The above recommendations are valid but a3

pointed out earlier, unless there is an improvement
in the basic education, such schemes will not bear
fruit*
In accordance with Section 5 of the Industrial
Training Act, in 1966 the Apprenticeship Board
recommended the establishment of a group of training
7
scheme based on particular industries. Getahi reports
the formation Of four groups. Out of these, the group
applicable to the metalworking industry covers general
engineering, building and civil engineering trades. It
is understood that some apprentices were recruited from
the industry under this scheme to be trained at the
national Industrial Vocational Training Centre, Nairobi*

Acting on the advice of an expert from the Inter­

national Labour Organization, in 1964, the Kenya Govern­
ment established the National Industrial Vocational
Training Scheme®. The Development Plan 1970-1974, has
a programme for the expansion of the industrial training
centre at Nairobi and for the establishment of a new
centre at Kisumu. The Nairobi centre has a planned
annual output of 40 instructors, 100 supervisors and
400 workmen, in addition to a normal training of 50
to 100 apprentices.

It is not known how far the above mentioned scheme

has progressed. The author, however, found a lack of
communication between this training organisation and
the metalworking industry, as most firms were apparently
not aware of the facilities ‘
w hich exist at such centres.
It is recommended that raining should be done oxi the
premises of the firm by having instructors who should
be sent out to the industry. In this way, towns which
do not have training centres can also benefit.
 »

1.93

Such a scheme will have to be well organised and

financed. For the latter, the method suggested by
7
Getahi whereby the industry shares the cost of training
with future reimbursements, could prove useful*
Q
Edokpayi writing on "Industrialisation and Man­
power Development in Africa", stressed the need for
careful planning of training schemes* The group
training scheme mentioned earlier has specified the
field of study but it still includes the building and civil
engineering trades, , It is proposed that more
detailed syllabi for trades in the metal industry
should be introduced* In this respect, the views
10
expressed by Vellen3 should be noted
(a) Precise job description of the trade
(b) Establishment of syllabi
(c) The duration of apprenticeship to be
based on the syllabi.

According to this method, the training for

certain trades may take less than four years (which
is at present the period set by the Industrial Training,
Act), and for others more than four years* In this way,
the period of training for a particular trade can be
better utilised. As shown in Table 6.1*e., over 200
apprentices were found to be under training, most of
them without former contracts* A flexible approach ... f
for such training would be more acceptable than the
present four years system which is not followed any-how.

(b) Engineers:- With the projected rate of

growth and of Kenyanization, there may be a shortage
of engineers in 1974 in the metalworking industry
(Table 6.1.f). This shortage, however, may be met
if the industry could provide better opportunities for
engineers because on the national scale, the supply^
of engineers in 1974 is estimated to be over 170,
 194

In addition to the graduates from the University,

the industry should encourage professional training.
11
The recent scheme started by the Institution of
Mechanical Engineers whereby the student .engineer
spends four years under the general supervision of a
Principal Industrial Tutor (who will be a member of the
staff for which the student engineer works and will be
appointed by the Institution) could provide a good
opportunity for people in industry aspiring to become
engineers. The East African Institution of Engineers
should consider such a training programme.
The supply of engineers may be adequate for the
purpose of Kenyanization, but will the local engineers
have sufficient practical experience? While discussing
/ i?
a paper on "The Practical Training in East Africa of
Mechanical and Electrical Engineering Graduates", the
chairman gave the following conclusion:-
"....the problem was that the young engineer
was conscious of his status symbol and was not
prepared to undertake practical training....".

This type of attitude must be changed if the

country is to have practical engineers to develop its
technology. In this respect, the suggestions made by
17
Palmer ^ are worth considering. He recommends:-
(i) An introduction to craft practice at an
apprentice training school for a period
of six to nine months.
(ii) A period to gain work from experience in a
normal production plant. This will help
the student gain an insight to human problems,
(iii) Introduction and attachment for short periods
to different departments of a large engineering
establishment.

(c ) Managers:- The greatest demand for high level

manpower is that for managers and entrepreneurs.
 195

In this context, managers in general and entrepreneurs

in particular, are considered to be experienced men
who, while managing their own businesses, could also
do practical work whenever necessary. For the supply
of entrepreneurs, a suggestion is made in Para. 6.1.4(a).

However, there are several schemes for the

training of managers. The training facilities mentioned
by the Development Plan 1970-1974, includes the Kenya
Institution of Administration; The Management Training .
and Advisory Centre; and the East African Staff College.
The Management Training and Advisory Centre holds
regular courses for personnel drawn from the industry*
In addition, the East African Institute of Management
runs training schemes and a regular programme of lectures.

6.1.3. The Bias Towards Technical Training*

A survey conducted in 1966 (Appendix..)?...) show
that the opinion of primary school pupils towards the
technical profession is favourable. However, in the
central province, pupils were not inclined towards jobs
requiring skilled labour, and were more biased to cleri­
cal work. The impact of this is not known but judging
from the results of one well known secondary school
(Fig. 6.1.B) far more pre-engineering pupils were
admitted, although their rate of failure was very high.
In 1964, 33 pupils were admitted and only 13 passed*
The rate of failure of art students was not so high.
This trend of having more pre-engineering students
than art students continues1at the Kenya Polytechnic
when one compares the admission statistics of engineering
to commerce students (Fig. 6*1 ,C). At the University
however, this trend changes and there are far more art
students admitted than engineering students.
Lately, the country has shown a trend towards the
development of.a number of technical colleges^. These
colleges can open a potential method for raising the
general technical standard of the nation; and for
providing specialists in several fields.
 A. SCIENCE STUDENTS ADMITTED
B. SCIENCE STUDENTS PASSED
C . A R T S S T U D E N T S A D M IT T E D
D . ARTS STUDENTS PASSED
STUDENTS
NO. OF

SECONDARY SCHOOL :
COMPARISON OF SUBJECTS
FIG- 6.I.B.
source: samhuri man school,
nmrobi
 A UNIVERSITY OF NAIROBI .
B KENYA POLYTECHNIC

MIDDLE AND HIGHER EDUCATION

ENROLMENT
(souflCEtSWTtfTlCM. NBSTftkCT
FIG. 6.1.C,
 1-98

Their establishment, however, pose a gigantic admini­

strative problem*, These colleges must be co-ordinated,
and their syllabi and intake controlled in accordance
with the national policy of the development of manpower.

6*1,4. Utilization of Engineers

Table 6.1*b* shows the small percentage of

engineers which are employed in the metalworking industry.
This is due to the lack of opportunities which the
industry can offer graduate-engineers* This problem
affects even highly industrialised countries as analysed
15
by Turner , who suggests some remedies for the British
Industry for which a survey in 1968 found 60,000 graduates
employed as technicians or technician engineers. The
British Industry is large enough to employ, although at
a lower grade, such large numbers of graduates. In Kenya,
however, the industry is so small that in most instances,
situations for engineers do not exist. Such trends and
the possibilities of creating better employment opportu­
nities are discussed in the following paragraphs.

(i) Engineering; Background of Entrepreneurs

16
In a survey carried out in India, the number of
firms (in a particular category) established by graduate
engineers was found to be the highest. Compared with
this trend, the situation in Kenya is completely different
only one or two firmQ were found to be established and
managed by graduate engineers. Small entrepreneurship,
therefore, should provide a good opportunity for graduate
engineers.
(ii) Employment for Engineers

All small and most medium sized establishments

cannot afford to employ an engineer and offer him the
salary and conditions of service consistent with his
profession. The engineers are, therefore, attracted
to larger firms where the employment situation is much
better.
 199

In addition, there are apparently more opportu­

nities for mechanical engineers in the public sector.
This is clear from Table 6.1.a. which shows that 10
engineers were employed by only two establishments*
Considering manpower generally, there are more people
employed in the public sector. In 1966, for example,
the public sector had over 200,000 more employees than
17
the private sector . This in turn creates more posts
for higher manpower, including engineers.

(ill) Design and Development

As revealed in Para. 3.4.2. the practice of product

design and development is restricted to very few firms*
18
Banjo discusses the role of the design engineer in the
development of a country. He points out that the
cultural environment of a modern society depends a lot
on the activities of the design engineer. In Kenya,
the role of such activities ID clear in the structural
engineering (building and architecture) sphere. In
metal products, however, there is very little manufacturing
activity. Hence, opportunities for engineers will be
restricted unless manufacturing is expanded.

(iv) Engineering Research

Engineers can be usefully employed in research; but

there is no engineering research practice in the industry.
19
The suggestion made by Palmer in this connection is
worth noting. He suggests that research problems of the
industry should be token up by the University which
should have the engineers and resources to work on such
projects.

(v) Administration and Consultancy

20
In a survey conducted in Britain, it was found
that in the British Industry, 29.3?$ of the professional
engineers were employed in general technical admini­
stration and 5.4/S in consultancy. For the Kenyan metal­
working industry, censuses of engineers working in
these roles were not obtained.
 200

However, it is known that a number of engineers work

as technical administrators, especially in the public
sector; and as consultants, especially in the field
of civil and structural engineering. With the future
development in the metalworking industry, the field of
technical administration and consultancy could offer
employment opportunities for mechanical engineers.

C. CONCLUSIONS AND RECOMMEKDATIONS

/

6.1.5.
The engineers employed in the metalworking industry
represent less than 2Q& of the mechanical engineers in
Kenya. The demand for engineers is highest in the large-
scale production engineering plants. In 1967, over 90/5
i
of all mechanical engineers were found to be non-citizens
The main demand for engineers for the next few years will
therefore, be created by the process of Kenyanisation.
This process should be applied gradually, for otherwise
there may be a great shortage of engineers. At the
projected rate of growth and Kenyaniaation, the demand
for engineers at the end of 1974 may be more than the
supply This shortage could be overcome by creating
better opportunities for engineers in the metalworking
industry and by encouraging professional training in the '
industry. Graduate engineers should be invited and
given financial help to take up small entrepreneurships
which at present are mainly in the hands of non-citizens,
many of whom have a low standard of education. This
would uplift the general standard of engineering. As
graduate engineers, the entrepreneurs would be well
equipped to assist in the training of their apprentices.
The introduction and expansion of functions like
design, development, research, technical administration
and mechanical engineering consultancy should assist in
attracting more engineers to the metalworking industry.
 201

6»1 .6
lloarly 507$ of the establishments are small
entrepreneurships which are either self-managed or have
one or two managers. The requirement for managers is
mostly felt by large-scale firms, which represent 127$
of the total. As in the case of engineers, most managers
are non-citizens and their replacement must follow
similar lines as for the former* There are three main
training institutions for managers, out of which one wa3
found to be actively engaged in assisting the industry.
Large sized firms have resources for training and can,
therefore, assist in the development of local managers*
6.1.7.
The ratio of technicians to engineers was found to
be 1.05:1 * When draughtsmen & tq included, this ratio
increases to 1.67:1. Compared with the ratio of 3*0:1
advocated by one authority, the number of technicians
employed by the industry is low. There is, therefore,
a requirement to fill this gap.
jjg.1_p.8-»

The percentago of foremen employed in the industry

is low. Most foremen are skilled workers. In the
medium and large sized firms, there is a larger per­
centage of clerks. Although clerks are essential to
the industry, their numbers could be reduced by giving
a few selected clerks technical training. Such tech­
nical clerks could then hold superviosry positions
which require a large amount of technical documentation-.

6.1.9.
The greatest demand in the metalworking industry
ia for skilled workers. This trend is changing to a
small extent by the introduction and expansion of mass-
production plants, which are employing large numbers of
machine operators. These machine operators are essentially
semi-skilled workers but they operate machines which
require the repetition of the same function. However,
all- the entrepreneurships depend on the industrial-
skill of the people of this country.
 202

Also, there Is a great demand for specific ski3JLs

in the large organisations. Such skills include metal
fabrication, structural and plate work. Kenya is in
the midst of a training revolution to meet the demand
of the industry for skilled workers. The Industrial
Training Act stipulates the legal requirements for
the training of apprentices. This scheme is based on
traditional methods. For a more effective training
programme, it should be amended to include job descri­
ptions of each industry and the period of training
should be changed accordingly. About 19# of the
establishments had apprentices, most of whom wero not
bound in accordance with the above Act, To improve
this situation, the National Industrial Vocational
Training Centre should establish a class of roving
instructors who should be sent out to the industry
to assist in the training of apprentices. On-the-job
training for small-scale works will only be successful
if the general standard of education of the entrepreneur-
ship is improved. This may be achieved by a careful pro­
cess of Kenyanisaticn and by a broad policy of intro­
ducing functional literacy.

6 »1.10
In basic education, the opinion of primary school
pupils show that they favour technical work. In
results obtained from a well-established school, pupils
taking A-level examinations prefer engineering subjects
to arts, although the rate qf failure was observed to
be higher amongst those taking engineering subjects. In
the University, however, the trend of admission show
that far more art students are admitted than engineering
students. In 1970, only 181 engineering students joined
the University but the number of art students was as
high as 593* On the national scale, the intake of
students in different faculties should be observed from
secondary school onwards and should be'geared to the
national manpower requirements. The same objective should
be applied in the co-ordination and development of the
various technical colleges now being built in this country.
C H A P T E R VXI

WORKING CONDITIONS

AND

INDUSTRIAL SAFETY

-----xXx-----
 203

I. WORKING CONDITIONS AND INDUSTRIAL SAFETY

A. THE PRESENT STATS

Information collected on the state of working

conditions and industrial safety in the local metal­
working industry is presented by the following tables:-

Table 7.1.a: Proximity of Industrial Areas to

City Centre: Nairobi
Table 7.1.b: Proximity of Industrial Areas to
City Centre: Mombasa
Table 7.1.c: Type of Buildings /
Table 7.1 Working Environment */
Fig. 7.1.G : Reportable A c c i d e n t s R a i l w a y
Workshops, Nairobi

AN ANALYSIS: WORKING CONDITIONS AND INDUSTRIAL

SAPt/H

7 .1.1. Congested State of Industrial Areas

In the main two industrial centres of Kenya (namely

llairobi and Mombasa), it was found that there are heavy
concentrations of metalworking establishments near the
city centres* Such concentrations cause congestion
resulting in adverse environmental and working conditions.
This situation is primarily caused by the small-scale
establishments, as is evident from the frequency distri­
bution curves, Figs. 7.1.A and 7.1 <>B. The distributions
seem to bo "normal” only in the case of medium sized
(in llairobi) and large sized firms (in Mombasa).
The mean values of the distance from the city centre
to the metalworking complex for Nairobi and Mombasa
may be computed from Tables 7*1 ca, and 7*1*b., which
are tabulated in conjunction with Figs, 7.1 *A and 7.1.B*
These values arc:-
(a) Nairobi (Table 7.1*a)
Mean value = x = t-f_x

=JL2fi!iix 100)
165
■
2 .t 5 .3 .5 .
FREQUENCY CNO. OF FIRMS)

PROXIMITY OF INDUSTRIAL AREAS

 DISTANCE FR O M CITY C E N TR E (M E TR E S X IO O O )

PROXIMITY OF INDUSTRIAL AREAS

TO CITY CENTRE-MOMBASA
FIG . 7.1. B
 206

1 2 3 4 5 6

Dis­ Mid­ No. of

fx d=(x-x) fd
tance* point firms
(Class * X (fre­ (x100) (x100) (x100)
Interval) *(x100) quency
f

8-16 12 73 876 -13.349 -974.4

16-24 20 16 320 -5.349 -85.6

24-32 28 25 700 2.651 66.2

32-40 36 38 1368 10.651 404.7

40-48 44 0 0 18.651 j 0

48-56 52 0 0 26.651 0

56-64 60 17 * 1020 34.651 589.1

<H

£i~1 69
w

£ fX a
M

4284

PROXIMITY OF INDUSTRIAL AREAS TO CITY CENTRE:

' NAIROBI

Table 7 •I*a.

- Distance in metres (xlOO) from the city centre,

x « 25.349 *(x 100) - See Para. 7.1.1. and Fig. 7.1.A.
 20 7

If all the values in column 6 are taken as positive,

£fd = 2120.0
Therefore, Mean Deviation = 2120.0 (x 100)
2t
= 2120.0 (x 100)
1 69
1fP-54 metres

(b) Momhasa (Table 7.1.b)

Mean value = x - y fx
xf
= 928 (x 1000)
46
” 20.173 metres
Again, taking positive signs in Column 6,
Mean Deviation = 242 (x 1000)
46
-n-. 3.261 metres

The mean values as calculated above give a measure

of the congestion of the industrial areas in Hairobi and
Mombasa, and show that tho former has metalworking
establishments crowded nearer to the city centre than
the latter.
At present, the situation in the other industrial
centres of Kenya is much bettor, although they have a
tendency to follow the same trend as found in Hairobi
and Mombasa.
Although the idea of building industrial estates
in Kenya was advocated^ as long ago as 1948, the first
estate was built only a few years back. The industrial
estate in Nairobi has helped in the dispersion of small
sized firms from the areas neighbouring the city centre.
 208

1 2 3 4 5 6
c
Distance Mid­ No. of £x d=(x-x) fd
(Class point firms (x1C00)
(fre­ (x1COO) .(x1000)
Interval) X
(x1000) quency)
f ■
12-20 16 29 464 -4.173 -121.0

20-28 24 10 240 3.827 38.2

28-36 32 7 224 11.827 82.8

~z£x-
2 X = 72 j&C=46 rifd = o
928
• j

PROXIMITY 0? INDUSTRIAL AREAS TO CITY CENTRE;

MOMBASA
Table 7.1.b.
* Distance in metres (x1000) from the city centre*
x = 20.173(*1 000) - See Para. 7.1.1. and Fig. 7.1.B.
 209

The upward trend of the curve for small sized firms in

Fig. 7 * U A . is merely due to the fact that there are
seven such establishments in the Nairobi industrial
estate. Besides good environment, firms in an industrial
estate have other advantages like assistance in the
maintenance of plant and in the problems associated with
the marketing of the product.

7.1.2. Type of Buildings and Working Environment

Most buildings were found to be unsuitable for

engineering work. Table 7.1*c. shows that about 64f°
small and 13^ medium si^ed establishments occupy small
shops at the basements of multi-storey buildings; others
occupy,.sheds, go-downs, garages and so on. The main
reason for the use of such buildings is initial low cost.
However, as pointed out by Hempel'1, such buildings may
be easily available, but in the long run they cost more
and prove unsafe.
As with other factors, the utilisation of space and
illumination improves with the size of the firm (Table
7.1 »d.).
Fara. 3.2.1, pointed out the overcrowded situation in
several firms which present a hazard to the safety of
workers. This is contrary to the Factories Act
(Chapter 514, "Laws of Kenya") which specifies 350 cubic
feet of space for every person employed not counting
space more than 14 ft. from the floor. Most small and
some medium scale works would not qualify for this
condition. The maintenance of floors in general was
observed to be very poor. Cracked floors are common
but several un-cemented and a few water-logged floors
■5
were seen. Heinrick states that, "Floors receive less
attention with regard to safe and efficient maintenance
than any other industrial item of equal cost". This
trend is certainly found in several shops in Kenya.
The state of illumination shown in Table 7 J .d. is
for normal day-light. For night work and dull weather,
les3 establishments would qualify for the "good" remark.
&
 SIZE Yard &
Well
Other Mot ^ .
OP Basement*’ Shed Shed or Total
Designed t
Shop Type Confirmed
FIRM

Small 64.0 7.6 15.2 — 6.6 6.6 100 t

'

Medium 11.6 40.2 14.2 3.6

210
13.4 17.0 100

Large — - 73.4 13.3 13.3 - 100

TYPE OF BUILDINGS
(In per cent of firms)

Table 7,1.c,
* Basement of large buildings
** G-odowns, garagesf etc.: generally
unsuitable for metalworking purposes.
 U T 11 i s a t ic :: C? CPAC2 r, X lC.» \

0? Pot ! ( I.’ o t
P oo r* i Good T o ta l Poor G ood T o ta l j
C c r.d lrz e d j j C c r.d ir._ c d
» IV. | 1
1 I 1
4- - O 1
, 5 3 .5 | 3 4 .0 7.5 : 1C G.C ■ 4G .2 4 4 .3 S .5 1 C 3 .0 |
I !
i
' c i 11 ! 5 3 .4 j 57 .1 4 .5 i 1C 0.C 3 7 .3 5 6 .3 5 .4 1 C 0 .0 |
1
] | \
L o r ;o j *6 .7 j 3 3 .3 ‘ ^ 0 * V/ , 1 C .0 : C4-> r. tW |
!
| • i

c - r-'r * - 4- '>
 212

7.1.3. Accidents and Other Hazards

Statistical figures for accidents were not obtained

but Fig. 7»1*C. shows the accident rate of one of the
biggest workshops in Kenya, the railway workshops in
Nairobi. In the opinion of the Railway's Security
and Safety Officer, the rate of accidents was decreasing
because of an increase in the general education of the
workers.
Most firms in Kenya neither have the tradition nor
encourage the use of eye protection lenses and goggles.
In welding, the welder uses means of eye protection but
his helpers and other workers around the area do not
wear goggles, The use of welding bays with black en­
closures is also very limited. The main effect of
actinic conjunctivitis ("flash") is described by Kuhn^
who states that exposure to it creates a feeling of sand
in the eye. The way welding is carried out in this
country many workers must be suffering from this complaint.
While means of eye protection are used by welders,
it is almost non-existent in machining and forge work.
The Factories Act sets down the regulations for
industrial health and safety. These regulations are
largely generalised. Supplementary regulations should
be published to give more details about particular type
of work. This may be done through professional bodies.
Fire fighting appliances and first aid kits were
often not observed. Most firms having such appliances
did not seem to pay much attention to their maintenance.
Reports indicate that there is a shortage of
factory inspectors. From the general standard observed,
such reports are apparently correct. There is a require­
ment for strict inspection procedures in order to improve
the working environment.
NO. OF ACCIDENTS

ACCIDENTS
RAILWAY WORKSHOPS

FIG. 7.I.C.
G. CONCLUSIONS AND RECOMMENDATIONS

jLl IjA
’*
A greater number of small and medium sized firms
are situated in the congested areas of the main indu­
strial towns of Kenya, The mean value of the distance
from the city centre to the metalworking complex was
calculated to he approximately 2,535 metres for Nairobi
and 20,173 metres for Mombasa, A similar trend was
observed in other towns but due to a lack of industria-
lisation, the congestion of metalworking establishments
is not obvious at present in such towns. In Nairobi,
the development of an industrial estate has shown a
change in this trend in that some firms have moved to '
a suitable location with a better built environment,
In towns, trades like tinsmith may be allowed; while
those doing heavier work should move to better sites.
The trend with larger firms is generally favourable
because they are situated away from congested areas.

Over 6Q/$ of the small and 1C$ of the medium sized

firms occupy buildings which are unsuitable for engi­
neering work* New small-scale entrepreneurship should
only be allowed if better accommodation is available,
A gradual policy should be adopted by the Inspectorate
of Factories to improve the condition cf the existing
es tabli shme nt s . '
Factors like illumination and batter maintenance
of floors improve with the size of the firm, although
several large-scale firms were found to have poor workin
floors,
ItL-i*
Reports indicate that there is a shortage of factory
inspectors. The industry requires qualified inspectors
who should help the firms and suggest practical solution
to improve the standard of safety. The Factories Act
covers most aspects of safety but it needs to be inter­
preted for different industries. This may be done by
professional bodies like the East African Institution of
Engineers.
 C H A P T E R VIII

RESUME AND CONCLUSIONS

I. A REVIEW: METALWORKING INDUSTRY

II. ADVISORY SERVICES AND RESEARCH

III. RECOMMENDATIONS FOR FURTHER WORK

-----xXx-----
 215

I. A REVIEW: KBTALWORKINS INDUSTRY

8,1>1 * Development

The building of the railways at the beginning of

this century resulted in an inflow of a large number
of artisans, mostly from India. In due course, some
of these artisans started their own samll blacksmith,
repair-worlc and carpentry shops. Later, their depe­
ndants joined them and the process of the introduction
of crafts continued.
Such small workshops still exist, and they
represent about 43/S of the total number of establish­
ments. In the course of time, several of these work­
shops were enlarged or amalgamated into larger units,
resulting in about 45/^ of firms having between 11 to
50 workers, The contribution of such establishments
in terms of tonnage output is small but they present
a sector of the industry having the most industrial
skills. Also, this sector forms a foundation for
entrepreneurship in this country. Industrial surveys
generally ignore firms with less than 10 workers. In
contrast, it is considered that such firms and the
mediimv-sised ones should receive more attention in
development plans. Methods should be found to use
the principles like those of cottage industry to*
enable these firms to make a substantial contribution
to the gross national product.
Out of the large sized firms (employing over 50
workers), which represent 12?& of the total, 2.0^ are
in the public, sector*; 3.2^ have overseas connections
and the rest (6.8^)have been developed locally.

8,1,2, Production

The railway’s workshop in Nairobi is still the

largest and the best equipped general engineering
enterprise in this country,

* East African Community.

It has made good progress during the last 70 years,
especially in foundry practice and in the design,
manufacture and use of jigs and tools. However, it
is still not established for the production of items
like railway vagons. In 1970, Kenya imported rail­
way rolling stock worth ££303,000 from countries like
Japan and India, Considerable amount of foreign ex­
change, however, may be saved by manufacturing such
items in the railway workshops, which have the re­
sources and the capacity for this type of production.
Great stress is being put on the training of
skilled workers and high level manpower. There is a
requirement for skilled workers and technicians, but
the industry should improve and broaden its outlook
in order to employ more engineers. This basically
depends on the market which should be expanded both
internally and by finding more export channels. The
metalworking community will keep on playing the role
of repair work and jobbing production, unless the
question of the extension of the market is fully
exploited,
A trend is developing with some small entrepreneur
to import automatic production equipment. In order to
preserve industrial skills, this should be discouraged
Any attempt at large-batch and mass production, should
be directed, whenever possible, to the use of conven­
tional and serai-automatic machinery with a labour-
intensive system. The principle of Group Technology
(Para. 3*2,2,), for example,, should be considered.
This wilX result in creating more opportunities for
skilled workers and qualified production engineers.

8r103. Processes and Equipment

Kenya has some mineral wealth in iron ores. These

reserves should be exploited and their economic value
ascertained. The import of supplementary supply of
ore3 from overseas should be considered vrith a view
of future export of refined metal.
 2M

A better use of scrap metal should be made. The

collection, separation and refining of scrap metal
should be undertaken on a larger scale. In this-
respect, the electric-arc method of smelting may
prove most economical for the production of steel.
Although light equipment for machining and
welding will keep on playing an important role, a
selective amount of heavy engineering processes
should be introduced with a view to curtail the .
import of certain forms of raw materials. Such
processes should include strip and bloom rolling
which could locally manufacture sheet-metal and
plates from imported and possibly locally produced
(by electric-arc furnace, for example) billets.
The process of casting is rather crude. There
is a requirement for the establishment of a few
foundries in each industrial centre. Such foundries
may not have ultra-modern equipment, but should
incorporate better foundry practice.
There is no shortage of craft3 in' this country
but this branch of the industry is ailing. To
prevent their natural death, national assistance in
terms of industrial design and marketing must be
given to this section of the industry.
The industry is expanding by employing equipment
displaced by a few larger organizations. In order to
keep pace with modern technology, a certain amount of
replacement of equipment i3 necessary. Nearly 55f9 of
the main equipment was found *to be over ten years old.
If this trend continues, the industry may end up with
an out-dated technology.

8.1,4. Manpower

The metalworking industry is small In its size;

in its resources; and in the number of people it
employs. In the United States of America, one author
(Para. 6.1.1(d) considers firms with 100 to 249 workers
as small.
 2 1 8

In India, firms employing more than fifty and les 3

than 250 workers are considered to be medium-scale
Few metalworking firms employ as many as three hundred
workers in Kenya*. The total employment in. the industry
(excluding labourers) was found to be 5,961 which 13
only 7 *25 ^ of the total industrial employment for the
year 19701 .
The industry is in a transitional stage in that
it has attained a good measure of progress in the
training of local people* With independence and the
policy of Kenyanization, a progressively larger sector
of the economy must be placed in the hands of the local
people* This is a healthy trend in that it gives a
good opportunity for the replacement of entrepreneurs
with men of a higher qualification* Thi3 will result
in raising the overall standard of the. industry*

8*1*5* Conclusion

The metalworking industry has been fulfilling an

essential engineering requirement for the country.
Right from the early day3 of development to the intro­
duction of entrepreneurship3 for the repair of vehicles
and agricultural machinery and for the manufacture of
small items, lately this need has brought in mass
production of containers and wire products and widened
the field of structural engineering. For the future
development, this need 3 ho aid be extended by the
examination and improvement of factors like introduction
of suitable equipment and technology; the extension of
the domestic and export markets; and the training of
manpower *

IX, ADVISORY 'AND

For the attainment of the aforesaid, national
assistance is essential. This fact has been stressed
several times in this study.
Bodies like the Industrial and Commercial Development
Corporation (I.C.D.C.) have made good progress in
carrying out feasibility studies and in establishing
new projects. However, what is required i's the
development and expansion of the existing industry
along with the new projects.
In this respect, a "technical group" should be
introduced in the Ministry of Commerce and Industry.
Such a group should have close liaison with the
industry, professional engineering bodies and the
University. This group should have terms of reference

■5 states 2-
similar to those of the Engineering Croup of the Ministry
of Technology in Britain, for which Haddock
"The Engineering Croup of the Ministry of Technology
is concerned with stimulating technological
innovation in industry. This involves surveying
the scene, diagnostic steps and actions taken to
bring about improvements. Ways have been found
to stimulate technological advance in industry
without impairing the prerogatives of management".

Ill * FJ'COHHENDATIONS POE FURTHER WORK

This study has made an attempt to collect infor­
mation and to draw certain conclusions on the metal­
working technology of Kenya. The results of this survey,
however, may be used for further research work as
discussed below,
(a) Each chapter of this dissertation may be
treated as reference for project ’work for
undergraduate students at University level.
In this way, further discussion could be invited
and more conclusions drown.

(b) A detailed study should be made of the locally-

manufactured machine-tools (Para, 1,1*5)*
The trends in the manufacture of such machine-
tools should be noted and recommendations made
for the development of a machine-tool manu­
facture plant in Kenya.
 220

(c) Para. 2.2.2 gives details of a large reserve of

iron ore in Kenya* This reserve is said to be
uneconomical for iron production because of a
high percentage of titanium content. The metal­
lurgical section of the Department of* Mechanical
Engineering of the University of Nairobi should
make inquiries and invite research to develop a
method to refine this type of ore for the econo­
mical production of iron and steel.

(d) The polymer or plastic-working industry is

developing in Kenya and employs a large number
of automatic machines. Inquiries should be made
to find out what proportion of manpower and
economic benefits this industry will have and at
what cost to the metalworking industry. Such
studies will help in future development plans*

(e) The type of contribution made to the metalworking

industry by the consulting engineers practising
in this country was not ascertained. The i^ole of
the consulting engineer in the development of the
metalworking technology should be investigated in
order to make recommendations for a better utili­
sation of engineers in the industry.
 A P P E If D J C X

1. EXPLANATION OF TERMS

2. COLLECTION OF DATA

3. MAIN RESULTS OF THE SURVEY (TABLE A)

4. IMPORT OF METALWORKING MACHINERY

5. NET IMPORTS: RAW MATERIALS

6. COMPOSITION OF LOCAL IRON ORES

7. APPROXIMATE CAPITAL COSTS : • STEEL PRODUCTION

8. COST: MATERIALS HANDLING

9. IMPORT RESTRICTIONS

10. PRODUCTION PROGRAMME

11. EXPORTS: 1967 AND 1974

12. 'PREFERRED' JOBS BY OCCUPATIONAL

CATEGORIES AND PROVINCES

13. REFERENCES

■xXx.
 221

APPENDIX 1
EXPLANATION OP TERMS

1• Metalworking Industry
(a) Metalworking industry includes:- .

Establishments engaged in the smelting; refining

and alloying of ferrous and non-ferrous metals from pig
scrap and ore; in the rolling and drawing of ferrous
metals; in the manufacture of castings, forgings, and
other related products of ferrous and non-ferrous
metals; and in the heat treating of steels and non-
ferrous metals*
Those engaged in the forming and fabrication, of
sheet-metal products like tinware, water storage tanks,
measuring cans, vehicle bodies and non-electric heating
apparatus*
Pirns engaged in the machining processes of turning,
milling, shaping, planing, grinding, screw cutting
and other related methods.
Firms using fabrication methods for metal products,
including fabricated iron, steel or other metal structu­
res for bridges, buildings, doors and sections for
ships, boats and ferries; and for plate work for the
manufacture of steel and aluminium storage tanks for
beverages, milk and petroleum products.
Establishments manufacturing steel beds; bed
springs; furniture; casements of steel and aluminium;
aluminium hol'low-ware ana ladders: barbed wire; chain
link fencing; wire'mesh; nails; rivets and screws;
crown seals; and containers and drums,
Those manufacturing pipes, pipe fittings and
agricultural implements of ferrous and non-ferrous
metals; tea machinery and parts of coffee and dairy
equipment; plough frames; wheel-barrows; maize
grinding and hammer mills; and parts of cotton
ginnery equipment.
Manufacturers of sheet-metal products by spinning
and pressing; and establishments engaged in the suxv
face treating of electroplating, galvanizing, polishing
and engraving.
 222

Establishments engaged in the repair of the afore­

said products,

(b) Metalworking industry excludes:- .

Firms primarily engaged in the production of non-

netallic articles. The maintenance workshops of such
firms are also excluded.

2. Establishment, Firm, Workshop, Works

These terms are interchangeable and denote business,

company or partnership primarily engaged in metal­
working. Each establishment, firm, workshop or works
is divided in accordance to its size, namely
Small-scale - Employing from 1 to 10 workers;

medium-scale - employing from 11 to 50 workers;

large-scale - employing from 51 and over,workers.

3. Table A

References to the main results of the survey are

made as Table A. This table appears in Appendix 3»
For example, (Table A,I,8) means refer to Table A,
Section I, Serial No. 8.
 J

223

APPENDIX 2
COLLECTION OF DATA

, This study is a part-time project* The author,

who is a full-time employee, collected the data in the
evenings, on Saturdays and during his leave periods.
Due to the large number of smaller works owned by
people of a low educational standard, it was decided
to carry out a personal survey instead of a postal one.
This was an effort and time-con3uning exercise but it
resulted in the accummulation of more accurate infor­
mation. Por larger firms, it became necessary to
obtain an appointment. A letter (Appendix 2A) was
used for this purpose. Appendix 2B is an example of
a typical reply, Por arranging personal interviews, a
letter of introduction (Appendix 2C) from the University
of Nairobi was used.
Regarding the questionnaire, the author learned by
experience that a check list (Appendix 2D) along
with a pocket-sized notebook proved the best method.
The survey wa3 mainly confined to the private
sector in the towns known to have engineering establish­
ments. In addition, a few quasi-G-overnment establish­
ments were covered, mainly because of their importance
in the development of the country. The initial addresses
of the firms were obtained from "Index to Manufacturers
and Products*', Ministry of Commerce & Industry, 1966*
The decision to visit the towns covered by this survey
was based on the addresses given in this publication.
While conducting the survey the author, however, came
accross several firms whose addresses were not listed
in the above index.
The main interviews were conducted between January
1970 and April 1972. The response from the industry
was excellent as only a small percentage of firms refused
to give information. Por non-respondents, the main
parameters were estimated.
 224
APPENDIX 2A

P.O. Box 920.

Hairobi,
Kenya*

Bear Sir,

PRODUCTION CAPABILITY AITB HECIIANICAL ENGINEERING POTENTIAL

op keiiya

I* I am persuing part-time post-graduate study with the Faculty of

Engineering, University College, Nairobi. The topic of study is as
follows
" A Survey of Mechanical Engineering complex of Kenya, with
emphasis on production, equipment, process and roan-power"*
2* With this object in view, I would be much obliged to you if
you could allow roc to visit your Works and gain information.
3. As it is a part-time study, I am only available on certain
Wednesday afternoons, Saturdays, and after 16.30 hours on week-days*
I would be most grateful if you could indicate on the enclosed
"stamped" card, a time and dato when I could visit your firro.
4* Thanking you in advance for any assistance which you may be
able to afford me.

|V|
(M.A. Khan)
B.Sc (Eng); AMSLAET.
 APPENDIX L B

I N D U S T R I A L P L A N T (E.A.) LTD.
D > E C T O *V FOSTAL ADDRESS
TELEPHONE; 33741
v. h F A h * E N H O L T Z ( D t n ih ) P.O. B O X 4717, N A IR O B I
l » Q N U A K £ » H t E l M ( S * ( ( iiiS )
KENYA
CABLES : AZRA
A. 1 A H V E E O T M O L lE R U B ( O in n S )
E A S T A F R IC A TELEX No. : *20131 O lH $ S '
• i m m •
E *. B'.O CX ( B /.w h ) National 4GRinOiat*Sawic L*0
TCU R BEE: OUR KEF: DJG/07/1012G. DATE; 28th A u^U St, 1970

Kr, H.A. Khnn,

?.0. Box 920,
r! A I ? 0 11 I,

Boar I'r. Khan,

He* Production Capability and TTechanical
Pnyinceriny Potential of Kenya,
V/c aeknov/ledye receipt of your letter of 24th August, 1970, and would
aok you to nuke it any afternoon convenient to your studios.
If you will telephone the Production I'enarer (l.r. H. Board) a day or
so ahead rivinn an indication what tine you will arrive.

Yours faithfully.
for I1IDU397.IAI. PLA:;i (chi; II;"liBD.

l-EM -H F t C F THE A S S O C IA T IO N O f EAST A F R IC A N IN D U S T R IE S C ? ; ( '^ ; ,' pcoF s -;.‘- - is 3 i > ?EC‘, r .'* c - i f e e r s r :
K IN G S T O N RQ . IN D U S T R . A ; A ^ f A . N A lJ lO J I
 APPENDIX 2C

U N IV E R S ITY O F N A IR O B I
d epa rtm ent o f mechanical engineering
Telegram*: " V a r s i t y ' ' N a iro b i P .O . B O X 3 0 1 9 7 .
T elep hone: N a iro b i 27441 N A I R O B I
PROFESSOR W. B, P A L M E R , M.A , Ph.O. KENYA,
C. En£., F E A IE , F.I.Mech, E„ N, In st. N.C.

YOUR REF:
o u r r e f : January ,1970

TO WHOM IT MAY CONCERN

This is to certify that Mr* H. A* Khan has

registered for hin M,Sc* Engineering Degree on this
department and he has been allocated a thesis on "A
Survey of Mechanical Engineering Technology and Potential
in Kenya"•
In this capacity, he has to visit several
workshops in this field and make enquires needed for his
survey. Any help from your side in this respect
would be highly appreciated*

Dr0 A. A, Hrabovec
 227

APPENDIX 2D
CHECK LIST

Established
Building, area
Management
Manpower
Employment System
Training
Equipment
Processes
Materials
Production Rates
Products
Layout
Planning

CARD :__ FRONT

Materials Handling
Costing
Estimating
Quality Control
Metric System
• Materials Testing ■
Drawing Office
Tools and Tooling
Standards
Welding Rods
Machine Maintenance
Work Study
Power Consumption

CARD : REVERSE
 APPENDIX 5

MAIN RESULTS OF A__ SURVEY

OF THE

KENYAN METALWORKING INDUSTRY

TABLE A
 ‘2 28 '7
I
TABES A
NOTES ON READING THE TABLE

/
1. Table A mainly contains quantitative information.
It is divided into four part3. Each metalworking
firm from which data was obtained appears against
a serial number in Part A/' Further information on
any particular firm nay be found against the same
serial number in Part B (Main Equipment); Fart G
(Production Engineering) and/or Part D (Manpower .
and Working Conditions).

2, In each par'fc,the data is divided according to the

size of establishments, i.e. I: Small; II: Medium;
and III: Large-scale.

3. hevend

; COLUMN 1 SYMBOL
\
1 MEANING
_ , i y Affirmative but quantity not
1
t ,
confirmed.

- i X No; nil ; ne gat ive .

- - Hot known or not applicable.

- 0 Quantity counted elsewhere.

PART B QUANTITY OF MAIN EQUIPMENT '

i
1 N0 ' Serial number as allocated in
Part A*

2 L Lathe machines: all types.

\

\ 3 S Shapers: all types.

j 4 D Drill machines: bench and pillar

5 a Grinders: all types*

6 M Milling machines : all types.

7 GT Guillotines and Shears: manual

s and powered.
: ___ ____
 2'29

8 R Bending Rollers: manual and powered

9 W Electric Metal-arc welding units.

10 .G Oxy-acetylene and gas-shielded

Welding Units.

11 SM S m i t h s hearths and foundries as

indicated.

12 P Powered and manual presses.

15 F Powered and manual Bending and

Folding machines.

14 H Powered circular, band and hack-

saws •

15 3.T. Special Production Equipment

(roiling mills; wire drawing,etc).

PART C ELEMENTS OF PRODUCTION ENGINEERING

1 No. Serial number as allocated in Part

2 Processes (prindipal process prac­

tised)

M Machining

F Forming

FB Fabrication

G Casting

?R Forging

0 Others(electroplating and heat

treatment)♦

3 Type of production

0 Jobbing

B Batch production

M Mass production
 250

4 P Production planning

C Production control •

EN Undertaken by the entrepreneur

W Left to a worker

M Undertaken by a manager

F Undertaken by a foreman

T Undertaken by a technician

I Undertaken by inspectors

0 Based on orders only

5 L Type of Layout

M Mixed

B Bays

K Heavy

G Grouped

L Line

0 Others

6 D Drawing Office

t Drawing table only

7 M Type of ravr material used

1 Steel only, normally mild steel

2 Steel and non-ferrous metal alloys

like aluminium

3 3teel and cast iron and a snail

percentage of non-ferrous metal
alloys

4 Non-ferrous metals only as used

in electroplating

6 Q Normal capacity output per

month (Kgms)
 2?1

A Up to 1,000 Kgm.

B 1,000 to 2,000 Kgm.

C 2,000 to 4,000 Kgm.

D 4,000 to 5,000 Kgm.

E 5,000 to 10,000 Kgm.

F ’Up to 50,000 Kgm.

Q Over 50,000 Kgm.

9 H Materials handling devices:

all types.

10 P' Main services and products

a Grills; gates; and other forged

items.

b Bus and coach bodies.

c Cans and drums

d Metal beds; bed springs and other

metal furniture.
//
e Electroplating /
/
f Fabricated structures, frames.

g Castings

m Casements

P Agricultural engineering products.

r Hot rolling of rods and bars.

s Engineering services like grinding

small-scale welding for repairs
and occasional manufacture of an
•
item.

S A wide variety of engineering

services and some manufacture,
including production of iron.
 2;$2

t Manufacture of items from sheet-

netal, tinplate and heavy gauge
plate*
11 m Change to the Metric*System of
Measurement.
T Transitional stage.

PART D QUANTITY OP MANPOWER AND WORKING

CONDITIONS

1 No. Serial number as allocated in

Part A.
2 M Managers
C Clerical workers
3 ■ s Qualified engineers
D Draughtsmen
4 EN Entrepreneurs (skilled owner-
managers)
5 T Technicians
6 S Skilled workers
7 ss Semi-skilled workers
8 L Labourers; unskilled workers
9 C Machine operators - generally auto
matic machines
10 F Foremen
11 A Apprentices
12 T . Methods of Trainings-
0 On-the-job
13 Working Conditions:-
3 Utilization of space
I Intensity of illumination)

G Good
P Poor (congested, bad illumination)
T Type of Building:-
B Basements
D Type of accommodation generally
used by small-scale consumer goods*
traders
 2d3

V Well-designed workshop
S Shed
Y Yard with a shed or shop, generally
well designed
 J,
» V.

234

NO NAME OP ESTABLISHMENT ADDRESS

I. Small-Scale Establishments
(a) Nairobi •

1 Abdullah's Blacksmith ' Varma Road

2 Allied Enterprise Enterprise Road
5 All Round Engineers Ring Road
• 4 Arrow Engineering &
V/elding Works Newark Road
5 Bansal Engineering Works Kirinyaga Road
6 Battan Engineering Works Battersea Road
7 Blacksmith Khan Road
8 Blacksmith Virjee Road
9 Bunyala Engineering Works Industrial Estate
10 Charger Engineers Cross Road
11 City Blacksmith Bengal Road
12 Cloth Clip Manufacturers Industrial Estate
13 Eastern Metal V/orks Newark Road
U G.S. Engineering Works Bengal Road
15 Gurdial Engineering Works Kirinyaga Road
16 Guru Mechanical Engineers Kirinyaga Road
17 Hamid Vali Mohamed Tom Mboya Street
18 Harnam Engineering Works Kirinyaga Road
19 Ideal Steel V/orks Kirinyaga Road
20 Iron Craft Virjee Road
21 Iron Decor & Engineering Newark Road
22 Ismail Ahmed Kirinyaga Road
23 J.K. Kavia Bros. Kalot Road
24 J.H. Engineering Works-. Pakpattan Road
25 J.N. Kavia Newark Road .
26 J.3. Matharu & Sons Kirinyaga Road
27 Juttala & Son3 New Pumwani Road
28 K. Ravji & Sons Bengal Road

NAMES AND__ADDRESSES
TABLE A: PART A
 255

29 Karatina Wire Manufacturers Industrial Estate

50 Kartar Singh Newark Hoad

31 Kav.ia Engineering Works Bengal Hoad

32 Kav.ia Iron & Steel Works Bengal Hoad

33 Kenya Gas Services Company Kirinyaga Road

34 K.Y.G. Mechanical Engineers Tamvorth Road

35 K.K.V. Engineering Industry Industrial Estate

36 London Furniture Company Rehmatullah Road

37 Machineways Virjee Road

38 Magre Metal Work3 Port Hall Road

39 Maraj Din & Sons Rehmatullah Road

40 Masacau Industries Limited Industrial Estate

41 Metal Equipment Company Kirinyaga Road

42 Modern Engineering Works Gurdwara Road

43 Mohan Singh & Bros. Bengal Road

44 Muchatha Tinsmiths Park Road

45 Mudher Engineering Works Tamworth Road

46 Mughal & Company Tamworth Road

47 Mutlashi Engineering Works Kirinyaga Road

48 Mutiti & Bros* Newark Road

49 Nairobi African Tinsmith &

Blacksmith Co-op. Society New Pumwani Road

50 Nairobi Mechanical Engineers Bengal Road

51 Nairobi Shaft Grinders Bengal Road

52 Nazar Singh & Bros. New Pumwani Road

53 Neptune Industry Industrial Estate

 j, :
• i.

236

54 Noorbhai Alibhai & Company Burton Road

55. Pigeon Slide Works Industrial Estate

56 Raaji Lada & Company Varma Road

57 Saddal Engineering Works Khan Road

*58 Sagoo Trunk Works Tom Mboya Street

59 Sehmi General Engineering Co Bengal Road

60 Shanti Lai Varma Road

61* Sohan Singh Joshi & Sons Bengal Road

62 Steel & Metal Works Bengal Road

63 Super Body Builders Burnley Road

64 Super Engineering Works Kirinyaga Road '

65 Super Plumbing Kirinyaga Road

66 Thakarbhai Panjal & Company Kirinyaga Road

67 Tinsmiths (Six small esta-

blishments) Kirinyaga Road ■

63 Tinsmith Park Road

69 United Metal Works Kirinyaga Road

70 Vekaria Engineering Works Bengal Road

71 Win & Company New Pumwani Road

(b) Mombasa ;

72 Aboo*s Engineering &

Welding V/orks Pandya Road

73 Blacksmith Govind Liwatoni Road

74 Clyde Engineering V/orks Pandya Road

75 Coast Tinsmith Liwatoni Road

 J,
.»

237

76 Coronate Grinding Works LivatonI Road

77 Dada General Workshop A. Visram Road

•
78 Haraka Engineering Works Livatoni Road

79 Jai Engineering Works livatoni Road

80 Juneja Engineering Works Liwatoni Road

81 Latif Woodworks (Steel

Section) Razarali Street

82 Metal Fabricators &

Refrigeration Limited Sheriff Bhai St,

83 Micro Engineering Works Joinery Street

84 Mombasa Tinsmiths M w a t o n i Road

35 Mombasa Welding & Engi-

neering Works Pandya Road

86 Rational Engineering Works Joinery Road

»
87 Kichrome Electroplating
Works Miritini

88 • O.K. Engineers Liwatoni Road

89 Station Engineering Works Kazerali Street

90 Universal Steel Workers Pandya Road

91 Yousafi Trunk Works Jomo Kenyatta' Road

(c) Kisumu

92 Amar Engineering Works Junction Road

93 Chohan Engineering Works Makasembo Road

94 Eagle Engineering Works Obote Road

95 Kisumu Tinsmiths Obote Road

96 M&gan Engineering Works Obote Road

97 Re^pid Engineering Works Makasembo Road

98 S.S. Rupera Obote Road

99 Shaker Bros, Obote Road
 238

(d) Nakuru

100 Agrimacfil Service Industrial Area

101 Farmers Engineering Works Kufanya Road

102 Suberwal Engineering Works Kufanya Road

(e) Eldoret

103 Best Engineering Works Uganda Road

(f) Kitale

104 Kitale Tinsmiths

105 Western Garage & Engineering C. Elgon Road

(k ) Thika

106 Punjab Engineering Works Garage Road

*107 Thika General Workshop Workshop Road

(h) Naivasha

108 Mehbub Alam Naivasha

II, Medium-Scale Establish-

ments ,

(a) Nairobi

1 African Bodybuilders . Newark Road

2 African Radiators Doncaster Road

3 Alif Din & Sons Varna Road

4 Bachu Engineering Works Battersea Road

5. Bir Singh Atma Singh London. Road

6 Booth Manufacturing Company Kilmarnock Road

7 Brett & Company Limited Leeds Road

 8 Burns & Blane (Kenya) Ltd. Kingston Road

9 Burns & Blane (Kenya) Ltd. Kingston Road

10 Cassini & Tonolo Limited Belfast Road

11 Central Workshop Limited Jarrow Road

12 Choda Bros. Enterprise Road

13 City Engineering Works Bristol Road

14 Construction Equipment Woolwich Road

15 Continental Engineering Ltd. Burton Road

16 Cottongton & Partners Saldhana Road

17 Crown Cork Co*.(E.A.) Ltd. Falkirk Road

18 Darshan Singh & Company Kirinyaga Road

19 Dawning Africano Enter­

prises Industrial Estate

*20 Dhiman & Sons Dudley Road

21 Dominion Engineering Works Bristol Road

22 East African Engineering

Works Doncaster Road

23 E.A. Foundry Works Bristol Road

24 E.A. Hydraulic & Metal

Industries Darlington Road

25 E.A. Metal Works Coventry Road

26 E.A. Oxygen Limited Kilmarnock Road

27 Eastern Engineering Works Enterprise Road

28 Electroplating Limited Enterprise Road

29 Empire Engineering Works Doncaster Road

30 European Engineering
Workshop Darlington Road
 j.

240

31 General Engineering Workshop Enterprise Road

32 General Engineering Works

Limited Shoreditch Road

33 Ghelani Industries (Wires)

Limited Huddersfield Road

34 Hari Singh & Company Limited Coventry Road

35 H.R* Owen Darlington Road

36 Hughes Ltd. (Grinding

Machine Shop) Dagenham Road

37 Hughes Ltd. (Plough Section) Dagenham Road

38 Hydro Engineers Burton Road

39 Ideal Steel Fabricators Burton Road

40 Jagat Singh & Sons Ltd. Enterprise Road

41 Jagjivan Hirji & Bros, Shoreditch Road

42 James Warren & Co(Africa)

Limited .Ruaraka

43 Jandu Workshop Burnley Road

44 J.M. Bosh Engineering

Works Jeevanjee Road

45 J.S. Davis & Co. Falkirk Road

46 Karaal Engineering Works Coventry Road

47 Kehar Singh & Co, Ltd. Buckleys Road

43 Kenya Box-Body Builders Virjee Road

49 Kenya Engineering Industries Ludlow Road

50 Kenya Steel Fabricators Bristol Road

51 Leading Engineering Works Dagenham Road

52 Lotus Engineering Works New Pumwani Road

 55 Kalmont Electroplating Co. Buckleys Road.

54 Mangal Singh. & Sons Commercial Street

55 Mann Manufacturing Co. Ltd* Battersea Road

56 Marshall Fowler (Engineers)

Limited Palkirk Road

57 Mars, Mechanical Engineers Camberwell Road

58 Metal Pressings Limited Industrial Estate

59 Metco Battersea Road

60 Morman Engineering Works Swindon Road

61 Morris & Company Limited Ashton Road

62 Mughal Engineering Works Newark Road

63 Kalin Nail V/orks London Road

64 Najam-ud-Din' & Sons Birmingham Road

65 Nanji Jairam & Company Newark Road

66 Pier Point Engineers Doncaster Road

*67 Precision Industries

(Africa) Limited Enterprise Road

68 Premier Engineers & Manu­

facturers Burnley Road

69 Easheed .Bros* Cardiff Road

70 R '& G Engineering Co. Battersea Road

71 Rubani Engineering Works Enterprise Road

72 Sarwan Singh Bansal Burton Road

73 Sehmi Engineering Works Newark Road

74 Sihra Engineering Works Virjee Road •

75 Steel Wool Limited Shoreditch Road

76 Technova Limited Poplar Road

77 Universal Metal Enterprises Belfast Road

 242

78 Wall Mohamed & Co, Dandee Road

79 Wigglesworth (Kenya) Ltd. Kingston Road

80 Wire Products Limited Enterprise Road

81 Yousaf Joiner Works Bengal Road

82 Yusuf Garage Limited Pakpattan Road

(b) Mombasa

83 Asodia Steel Fabricators Pandya Road

84 Betacans Limited Refinery Street

85 Chandaria Industries Ltd. Magongo Road

/ (Wire Section)
86 ' Cycle Industry (FJl) Ltd. Joinery Street

87 Brumeon Limited

88 E.A. Motor Industry Ltd. Kwa Shibu Road

89 E.A, Railways Corporation

(Machine shop only) Station Road

SO* Hirani Manufacturers Workshop Road

91 Kenya Shell Limited

(Can factory) Makande Road

92 Kenya United Steel Co. Ltd.

(Kail factory) Hull Street
, A

93 Kenya United Steel Co. Ltd.

(V/ire factory) Newcastle Road

94 Marino Engineering Works Pandya Road

95 Metro; Engineering Works Liwatoni Hoad

96 Motherstar Engineering
Works London Road

97 Narshidas & Company Seyyid Said St.

 ■J.

. • 4.

'2 4 3

(c) Kisumu

98 Charan Singh Bhamra Makasembo Road

99 Kisumu Engineering Works Obote'Road

100 Mangal Singh Engineering

Works Mackinnon Street

*101 Nyanza Containers Mackinnon Street

102 Nyanza Engineering Works Obate Road

103 Paramount Engineering Works Obote Road

104 Reliance Engineering Works Mumias Road

(d ) Nakuru

105 Rift Valley Engineering Works Industrial Area

106 Settler Engineering Works Industrial Area

(e) Eldoret

107 Kalsi Engineering Work3 Industrial Area

108 Panesar Engineering Works Birmingham Road

109 Singh Engineering Works Northey Street

no Sihra Engineering Works Birmingham Road

(£) Kitala

m Elgon Engineering Works Industrial Area

112 Suan Engineering Works, Industrial Area

III. Large-Scale Esta­

blishments

(a) Nairobi

1 A* J* Main & Co. Ltd Enterprise Road

 J,
•>
244

2 E.A. Airways Corporation

(Metalworking Shops) Embakasi

3 E.A, Railways Chief Civil Workshop Road

Engineering Workshops Enterprise Road

4 E.A. Railways Chief Mecha-

t

nical Engineer's Workshop Workshop Road

* 5 EMCQ Steel Works (Kenya) Ltd. Dandora

6 Harrtz & Bell Limited Workshop Road

7 Heat Exchangers Limited Kilmarnock Road

8 H. Young & Co, Ltd. Falkirk Road

9 Industrial Plant Limited Kingston Road

10 Ideal Casement (EA) Ltd. London Road

11 L.S. Harnam Singh Ltd. Aberdeen Road

12 Mabati Limited Oldham Road

13 Mecol Limited Commercial Street

U Metal Box Company of

Kenya Limited Newcastle Road

15 Nanak Bodybuilders Doncaster Road

18 Steel Rolling Mills Ltd. Kikuyu

(b) Mombasa ■

17 African Marine & General

Engineering Co. Ltd. langana Road

18 E.A. Harbours Corporation

Port Workshops Kilindini Harbour

19 H. Suleman, H.L. & Sons London Road

20 : Kaluworks Limited Whitehouse Road

*21 Kenya Bolts & Nuts Manu­

facturing Co. Limited ICahawa Road

22 Kenya Casements Limited Shimanzi Road

23 Kenya United Steel Co.

(Rolling Mill) Miritini
 j,
» 4.
245

24 Metal Containers Limited Glasgow Street

25 Southern Engineering Co.Ltd. Mbaraki *

26 Steel Africa Limited Refinery Road

27 SCOEE (EA) Limited Magongo Road

(c) Xisumu

28 E.A, Railways Corporation,

Marine Section

(d) Thika

29 Metal Box Company Thika

(e) GilSil
*
30 Kdume Limited Gilgil
I

* Establishments not visited but information

obtained from other sources,
 246

i 1 i2 3 FT 5 7! 8 9 ! 10; 11 12 13 H 15 I
t6
- No. s D G M GT R
!l w l g i: SM P F H S.T.j
1 i
i j I
♦ ,I. Small-Scale Establishments
t
i i I
(a) Nairobi
i I
j
l
1 M 1 2 2 X X ; x
i
2 ; X 1 X X 1 X
i
* 2 IX X 2 X X 1 2 ' X X X x X X
x 1
i
3 11 x 1 4 X X■ X X ; X X; 1 X X X
i
4 1 x 1 X X: 1 3 i X 1| 1 X 1
x i x
I i
5 1 X 1 1 i x
1i x X X 1 X X
i x 1 I
6 1 X 1 1 X X : x x | X 1 1 X X
1 i
I
7 X X 1 X X X i 1 ; x 1 X X i
i i x x * I
8 X X X X X j X 1 X 1 X X X x !
1 I
1 I
1
9 X X 2 X X 1 2 1 X X 2 X !
1 x i
10 ■1 X 2 1 X . X i X p 1 X X 1 X |
I 2 x
11 X X 1 1 X X X x X
1 X X X X 1
:
12 1 X 1 _ _
1 y ,

I
X lx 12 2 X 2 ■- X 4 X X X 1 x ;
13 I ? * i
6 ;x X 2 X X : X 1 X
x X X 1 X
f ;
i 14 i

!
1
15 X ;x :1
-
X X 2 X 3 X 1 X X X X

16 4 X 4 4 X X X X X X X X
x *
■

17 2 ;x ;1 2 X X X 1 1 1® X X X X
\ I x
I
18 4 X 1 2 X X X :2 1 X X X X
■

19 2 ;x 'X 1 X X X !2 2 1 2 1 1 X
i
20 X :x 1 X X 1 X 1 1
i5 i i
X X X
i i
21 1 ‘X i1 1 X 1 x! 1
i
X 1 1 X X
1 ' \

j
t
■—
22
---------------. —
X ‘X
I1 1 1 x |2 X 1 X X .
*
X

QUANTITY OF MAIN EQUIPMENT

TABLE A: PART B
 247

Ho. L S D G M 0? R V/ G SM p F H S.T.

23 X X 1 2 X X X 1 X 1 X X X X

24 2 X 2 X X 1 X 2 X X X X X . X

25 X X 1 3 X 1 '1 5 1 1 X X X X

26 X X 2 X X X X 2 X X X 1 1 X

27 X X 1 1 X X X 3 X X X X X X

28 X X 1 2 X 1 X 2 X 1 X X X X

•-
29 1 - y
30 X X y 3 X 1 X 3 1 1 X X 1 X

31 X X 1 1 X 1 X 5 X 1 1 X. 1 X

32 lx
//
X 1 1 X 1 X 1 X 1 X X X X

33 1 X 2 2 X 1 X 2 1 X X 1 X X

34 X X 1 X X 1 X 2 X 1 X X X X

35 X X X 2 X 2 X 4 X X X X 1 X

36 1. X 1 X X X X X X X 3 X X y
37 1 1 2 1 X 1 1 2 4 X 1 1 1 X

38 3 X 1 1 X 1 1 1 1 1 1 X 1 X

39 X X X 1 X 4 1 2 3 X X 1 X V

40 X X X 2 X 1 X 2 2 X X X 1 X

41 1 X 1 2 X 1 X 1 '1 X 1 1 X X

42 X X 1 1 X 3 X 1 X 1 1 X X X

43 X X 1 1 X X X X 1 1 X X X X

44 X X y 1 X X 1 1 X X X X X X

A1
45 3 X 1 X X X 2 X X X X X X

46 2 X 1 2 1 2 X 1 X 2 X X 1 X

47 2 X 1 1 X X X 2 X X X 1 1 X

48 X X 1 1 X 1 1 1 X 1 X 1 X X

49 X X 1 1 X 2 1 2 2 1 X 1 X X

50 3 X 1 3 1 .x X X X X X X X X
 248

Ho. L S D G M GT R w G SM p F H S.T.

51 5 X 1 5 X X X 1 1 X 1 X ■ X X
•
52 1 X 2 1 X X X X X 1 X 1 X

55 y
54 1 X 1 1 X 4 5 1 X -X 8 2 X X

55 y
56 X X 1 1 X 2 X 5 XL 1 X X X X

57 X X 1 1 X 2 X 2 X 1 X X X X

58 X X 1 1 X 5 1 1 1 X X 1 X X

59 2 X 1 4 X X X 1 1 1 1 X X X

/
60 / /X X 1 1 X X X 1 X 1 X X X X

61 5 X 1 9 X X X 1 X X 1 X X X

62 X X 2 X X y X 5 1 1 X 1 1 X

65 X X 1 1 X 1 X 5 1 X X X X X

64 1 X 1 1 X i X y X t X X X X

65 X X 1 X X 2 X y 1 X X 1 X X

66 X X 1 1 X X X 1 1 1 X X X X

67 X X 2 y X 5 X 2 X X X y X X

68 X X 1 - X X X X X X X X X X X

69 X X 1 1 X 1 1 2 ' X X X 2 X X

70 1 X 1 1 X 1 X 7 X 1 2 X y X

71 X X X X X X 1 1 X 1 X X X X

0>) Mombasa

72 X X 1 X X X X 1 X X X X X X

75 X X X X X 1 X 2 X 1 X X X X

74 1 X 1 1 X y X 2 X X X X 1 X

75 X X X X X X . X 1 X t X 1 X X

76' 2 X 2 y X X X X X X X X X • X
 J,

249

no L s D G M GT R W G SM p F H S.T.

77 4 1 y 1 1 2 1 1 , X 1 - 2 1 X

78 - X 1 X X 1 X 2 X X X 1 X X

79 X X 1 1 X X X 2 X X X X X X

80 1 X y 3 X X X 1 1 X X X X X

81 1 X 1 X X X X 2 X X X 1 1 X

82 X X 1 X X X 1 X X 1 X X X X

83 2 X 1 1 1 X X 1 1 1 X X 1 X

84 1 X y 1 X 2 1 2 1 1 2 X X X

85 2 X 1 1 X 2 X 2 2 X X X X X

86 X X 1 X X 1 2 X X 1 . X X 1 X

87 y
88 2 1 •1 1 X X X 2 X 1 X X 1 X

89 2 1 i 1 X X X 2 1 1 1 X X X

90 1 X 1 y X 1 X 2 1 X X X 1 X

91 X X 1 1 X 1 X X X V X 1 X X

(c) Kisurau

92 5 2 1 5 X X X 1 X X 1 X X X

93 2 1 1 1 X X X 2 X 1 X X X X

94 1 1 2 1 1 X X X X X X X X X

95 X X 1 X X 1 2 X X 1 X 1 X X

96 X X 2 1 X X X 2 1 1 X X X X

97 1 1 X 1 X X X 2 X 1 X X X X

98 X X 1 X X 1 X 1 X 1 X X X X

99 X X 1 X X 1 1 1 X 1 X 1 X X

(a) Nakuru

100 X x y 3 X X X 2 X 1 1 X . X X

101 1 X 1 1 X X X 1 1 X X X X X
 250

No 1 S D G M GT R W a SM p P H S.T.

102 2 1 y 2 X X X 1 1 X 1 X X X

♦
(e) Eldoret

103 1 X y 3 X X X X X X 1 X X X

(£) Kitale

104 X X X X X y 2 X X X X X X X

105 3 X 1 1 X 1 X 7 X 1 2 X y X

(«> Thika

106 4 . 1 1 1 1 X X 4 2 1 X X 1 X

107 */ X 1 1 X 1 1 2 2 - - -
- -

(h) Naivasha

108 X X 1 1 X 1 1 2 1 X X X X X

II. Middle(-Scale Establishments

(a ) Nairobi

1 X X 2 1 X 1 X 6 1 X X X X X

2 X X X X X 1 X 1 1 y 1 X X y
3 1 X 2 2 X 2 X 2 1 1 1 1 1 X

4 3 1 ;2 -2 X 2 2 8 2 1 1 1 X X

5 5 1 3 2 X 2 1 6 2 y 1 X 1 X

6 X X 2 1 X X X 1 X X 1 1 4 X

7 X X 1 1 X 3 1 6 1 1 1 V
3 X

8 5 1 3 2 1 1 X 3 4 1 7 1 X X

9 4 X 4 2 X 1 1 27 4 1 X 2 X X

10 X X 3 1 3 1 1 10 V
Jk
y X I 1 X

11 X X 1 2 X 2 X 7 12 X 2 X X X

12 X X X 1 X 1 . — 6 X X .3 X 1 X
f

251

CO
No 1 S D G M GT R w G p p H S.T

13 13 2 6 5 2 — 5 10 2 2 15 - 2 X
«
U 2 X 4 3 1 1 X 6 y y X X X y
15 8 2 3 3 2 3 - 20 3 1 3 5 2 X

16 4 1 2 2 X X 1 J 2 1 1 X 2 X

17 X 1 1 X X X 1 1 - - - - y
18 6 1 4 2 1 1 X 10 2 1 X X 2 X

19 y
20 4 1 X 3 1 X X 12 2 1 X X X X

21 3 2 X 2 X X X 1 1 X 2 X 3 X

22 6 1 3 3 1 4 3 7 1 X 1 6 4 y
23 1 X X 1 X X X X X 1® X X X X

24 1 1 1 2 2@ 1
5 4 5 X 7 X 1 X

25 2 X 2 2 1 3 8 4 X X 5 4 X X

26 2 X 1 X 1 X X X X X - 1 2 y
27 6 1 3 3 1 4 3 7 1 X 1 6 4 X

28 - - -
- - 4 - - - - - - X y
29 3 X 1 3 1 X X 2 1 2* 1 X 1 X

30 8 2 2 -3 3 X X 2 1 1 1 X 6 X

31 X X 2 2 X 1 X 16 X X 2 4 3 X

32-. 7 2 2 1 - - 2 1 - * - 2
3 - X

2 1 1 1 1 1 12 -
33 X X X X - y
34 6 1 4 5 2 2 1 10 5 2 1 X 1 X

35 X X 1 2 X 2 X 2 1 X 1 1 X X

36 2 X 2 5 X X X X X X y X X X

37 1 X 1 X X X X 1 X 1 y X 1 X

38 2 1 1 2 X X . X 2 1 2 1 X 1 X

39 X X 1 1 X 2 X 6 X X X 1 1 X •

40 X X X 2 X 1 1 8 X X y X 1 X
 J. ;
•
' 252

No L S D G M GT R w G SM p F H S.T.

41 3 1 2 2 X 2 1 3 X 1 i X i: X

42 1 .X 2 2 X 2 3 5 2 1 1. 3 3 X

43 9 1 4 6 X X 1 5 y 2 X X 1 X

44 2 X X 3 X X X 2 1 X 1 X 1 X

45 2 1 1 X X X X 1 1 X X X 1 X

46 1 X 1 1 X 1 X 5 y y X X X X

47 X X 2 2 X X X 9 X 1 1 X 1 X

48 X X 1 2 X 2 X 3 X X X X X X

49 3 X 9 13 4 X 1 1 X 1 18 X X 2

50 7 1 4 X X 1 4 22 3 2 2 1 2 X

51 8 2 4 4 1 2 X 8 2 X y X 2 X

52 3 1 1 1 X X 1 3 1 X X X 1 X

53 X X X 4 X X X X 1 y X X X y
54 X X 2 2 X 2 X 9 2 y 1 1 X X

55 2 X 4 2 X 2 2 8 3 X 3 y y X

56 X X 1 2 X X X 3 X X X X 1 X

57 3 1 1 1 X 2 X 2 2 y 1 X 1 X

58 X X 1 X X X X X X X 3 X X y
59 X X 1 2 X 3 1 2 1 X - 1 1 ' X

60 X X 1 1 X X X 5 X X X X 1 X

61 X X 1 X X 2 X 6 1 X X 5 2 y
62 5 2 2 3 X X 1 8 X y X X 1 X '

63 2 1 3 1 X X 2 1 y 2 X 2 X

64 X X 1 2 X 4 y 1 X y X X X X

65 1 1 X 3 X 6 1 5 1 X 9 2 1 X

66 4 X 2 2 X 1 X 2 X y X X 1 X

67 — - - y
 253

No L S D G M GT R W G *Jl’l ‘ P P H o m
W • X •

68 (2) 1 2 1 1 X X 1 X X 5 X (2) X
69 X X 3 2 X 2 4 1 1 1, x .y . 1 X
TO 1 X 1 1 - 2 2 1 3 1 1 1 1 X
71 5 1 2 2 1 1 - 1 - 2 2 1 - X
72 X X y 1 X X X 12 3 X 1 1 J X
73 7 X 2 3 1 X X 1 1 X X X 1 X
74 5 1 2 2 X 1 X 3 1 y X X X X
75 X X X 1 X X X X X X X X X y
76 X X 1 1 X X X 6 X X 2 X 1 X
77 J X X X X 1 6 X X y
78 5 1 X 1 X X 2 1 2 1 2 1 X X
79 1 X 3 4 X 1 X 2 2 y X y 1 V

80 2 1 1 1 X X X X 1 y 2 X X X
01 X 2 1 X 1 y 3 X y X 1 X X
02 4 X 6 6 X X 2 1 X y 2 X 2 X
00i Mombasa

03 X X 1 1 2 2 X 6 2 X 1 X 1 X
84 X IX X X X X 1 X X ■v X X y
85 X X X 1 X X 1 X X X X X' y
86 X X X X X X X X X 1 X 1 X y
07 X X X X X X X 1 1 X X X X y
88 1 X 1 X X 1 1 X X X 3 X 1 X
09 3 1 2 1 X X X X X X ■ X X X X
90 - y
91 2 X 2 2 1 3 X X X X (12) X 1 y
92 3 2 2 y X - - 3 y X 18 y 1 y
(3) (2) (3 (4) X . y (2) X y
93 — -
(3) (1) y
 254

No L S D G H G2 R G SM p p H S.T.

94 4 1 1 1 1 X X 3 2 1 X X X X
95 4 1 2 4 X 1 X 6 5 2 X. 2 1 X
96 8 3 3 5 1 3 2 19 8 1 1 1 1 X
97 1 5* 1 1 15 1 y X 1 1 X 5 X X X
(c) Klsumu

98 4 1 1 X X X X 2 X 2 X 1 1 X
99 5 2 4 X X X X 2 1 2 1 X 1 X

100 6 3 2 3 X X X 2 y 2 1 X 1 X
101 - y - - y
102 «/ 2 6 X 1 X X 4 1 2 3 X 2 X
7/
105 '4 2 2 2 1 X X 3 1 2 X X X X
104 4 1 5 3 2 2 X 4 3 y® 2 y 3 X

(d) Nakuru

105 5 1 2 1 1 X X 3 1 X X X X X
106 6 X 3 5 X 1 1 5 y y® 1 X 1 X

(e) Kldoret

107 6 X 3 4 1 y X 6 3 2 1 X X X
108 2 1i 3 1 X 2 X 3 1 2 X X 1' X

109 5 1 3 3 1 1 1 4 1 y® X X 1 X
1 10 2 X 1 3 X X X 2 X y X X y X

(f) Kitale

111 6 1 2 5 1 1 X 3 2 2 1 X 1 X
112 4 1 3 4 1 1 X 2 1 y X X 1 X

III • Lar^e-Scale Establis hment3

(a) Nairobi

1 X X 2 2 X 2 X 7 y X X X ■ 1 .X
 255

Ho 1 S D G M GT R V/ G sn p F H S.T

2 8 1 7 7 2 3 2 3 2 y 2 3 2 X

5 3 3 5 3 1 1 x 3 2 y 2. 2 4 y
@
4 109 '16 36 54 11 14 6 49 - y 17 7 12 y
5 2 1 2 1 X X (7) y y y X X X y
11 ©
6 9 1 10 y 2 4 7 4 y 5 1 5 y
7 1 1 2 3 X 3 2 17 3 y 1 6 3 X
8 X X 4 2 X 2 X 16 y y 2 X 2 X

9 3 X 2 2 X 2 3 5 y X X X 2 y
10 5 2 2 y 4 6 1 12 y y 30 - 3 y
11 X X 2 2 X y 2 25 1 y 3 y 2 X
12 - y y
■
Av
15 2 1 4 3 1 2 X 5 2 3 y 3 y
14 5 2 3 y 2 10 - 1 1 X 60 y X y
15 X X X X X 7 y 20 X X 2 2 4 X
16 3 1 1 1 X X (5) 1 1 X X X X y
M Morfoaaa
© -
17 18 1 6 y X 3 1 20 12 y 3 2 4

18 7 3 6 3 1 2 X 3 y y 2 X 1 X

19 3 X 2 2 X 6 y 6 2 X - y 2' X
20 14* 2 2 2 1 X X 2 1 15 X jC
y
21 y y
©
22 3 1 1 5 - 2 - 6 y y 25 y 2 y
25 X X X X X X (6) X y y X y 1 y
24 2 1 2 2 1 y - 2 1 X 15 y X y
25 5 1 3 2 V
3 1 6 y y 2 y 2 X
26 1 1 1 X X X X 1 1 X 3 X 1 y
27 9 1 6 3 2 2 3 20 y y ’1 1 3 y
 256

liO L S D G GT R W G SM p p H S.T
(c) Kisunu
28 10 1 7 3 1 2 3 20 y y 2 2 y
*
(d) Ihika
29 8 3 5 y 3 y — 3 y y y y y

(e)
30 6 1 6 - 2 4 2 7 y y 3 2 2 y

* Includes 10 Lathes for metal spinning

© Includes foundries.
 257

1
1 1
F
2
C FR
I
1
0!
3 *
4 5 j6 7 F !9 ito ii
No. | H F3 *j B K L D M io p' n
; I. Small -Scale Establishments •|
1 1 •
i i
(a) Nairobi 1 i
i
1 i
t
x/
| 1 y X y X y X y X X -'EN- M X 1 A !x ;a X
{
! 2 X y y X X X X X X tl M X 1 it
!x ;d X
3 y X X X X X y X X It tl X 1 - 1x ; s X
; i-
\
4 y X y X y X y X X M ,, X 1 i
A
;x i
f X
5 y X y X X X y X X It Tl X 1 it 1x ;f X
j i
I
6 y X X X X X y X X n B X 1
N
S X
| 7 X X X X y X y X X H M X 1 A U :a X
1 ;
i X X y X X y X X " » X 1 It
' i x ;a X
l 8 y
i i
X X » n tt X t
1
t 9 X y X X y X y x
1 i
If 'x t X
i
10 y X y X X X y X x - " x
1
» tl X 1 It X
11 X X X X y X y X X a

i
12 y y X X X X X X y .. L X 1 It X ■d X
'
| 13 X X y X X X y X X -> M X 1 •• X f X
X .. it X
! 14
y X y X X y X X 1 lx :s X
j 15 X X y X y *rr
y X X It n

.
1 A !x !f X
»
i 16 y X X X X X y X X *
Y 1 -
x -
s y
,
17 y X y y X y y X X y^N B t 3 -
X S X
18 y X y X X X y X X X/E1T M X 1 - x ! s X

19 y y y X y X y y X ft " X 1 - X s x

11
20 X X y X y X y X X B X 1 A X f X
21 y X y X X X y X X It M I* 1 it X f ix
tt 1 X 1 tt X a X
22 X X y X X X y y X II
tt x 1 tt X t X
23 X X y X y X y X X M
24 y X y X X X y X X tt
It lx 2
1 - X Q X
ELEMENTS OF PRODUCTION ENGINEERING ‘
TABLE A: PART C
 258

No. M F FB 0 FR 0 J B M% L D H 0 H p m

25 X X y X X X y X X B X 1 A X f X
26 X X X X X X X 11 - X 1 - X s X
y y
27 X X X X X X X II M X 1 A X f X
y y
28 X X X X X X tt M X 1 tt X f
y y y X

29 X X X X X X 11 L X 1 n X VI y
y y y
30 X X X X X X It M X 1 tt X f T
y y y
31 X X X X X X 11 B X 1 tt X f X
y y y

32 X X X X X X 11 - X 1 tt X f X
y y y
33 X X X X It M X 1 it X t T
y y y y y

34 X X X X X X 11 tt X 1 i> X f X
y y y
35 X X X X X tt *t X 1 n X f T
y y y
36 X X X X X 11 Gr X 2 - X e X
y y y y
37 X X X X X n M X 1 tt X t X
y y y y
38 X X X X X X It B t 2 - X s X
y y y

39 X X X X X X It M X 1 A X t X
y y y
40 X X X X X X 11 n X 1 B X t X
y y y

41 X X X X X tt tt X 1 A X t X
y y y y
42 X X X X X n tt X it X t X
y y y y 3
X X X X X X X ii it X - - s X
43 y y y
44 X X X X X X ft it X 1 A X t X
y y y
X X X X X X it it X 1 - X 3 X
45 y y y
46 X X X X tt it X 1 A X a X
y y y y y

47 X X X X X X ti » X 1 - X 3 X
y y y

48 X X X X X X n it X 1 A V a X
y y y
X X X X ii it X 1 it X t X
49 X y y y y
50 X X X X X X X it tt X 1 - X 3 X
y y

X X X X X X it tt X - 3 X
51 y y y 1 y
 259

No M F FB c FR 0 J B M p/c L D I’l Q H p m

52 y X -X X y X y X X l M X 1 _ X s X
53 X y X X X X X X y yEN L X 1. A X w X
54 X y y X — X y X X M X 1 n X t X
X y X X X X X X y L X 1 ti X w X
55
%

56 X X y X y X y X X II M X 1 n X f X
X X tt it
57 y X y X y y X =7
*w X 1 X f X
58 X y y X X X y X X x/'EH t> X 1 ti X t X

59 y X X X X X y X X It B X 1 - X s X
X y u 1
60 X X y X y X X M X A X f X
x /y
61 y X y X X X y X X EN M X 1 - X s T
X X/ it 1
62 X /* y X y X y X X A X f X
7w
//
X y X X X X X H X 1 n X b X
63 y y 'EN
X X y X X It M X 1 ti X f X
64 y X y y
X X X X y X X n tt X 1 It X t X
65 y y
X X X X X II tt X 1 It X X
66 y y X y a
It tt X 1 It t X
67 X y y X X X y y X X
X tt n X 1 II t X
68 y y X X X y y X X
X X it X 1 II X t X
69 X y y X X X y x7
/V •

70 X X y X y X y X X X7/ EN it X 1 II X f T

X X It tt X 1 II X
71 X y y X X X y t X

*
(b ) Mombasa X/
72 X X y X y X y X X 7 EN M X 1 A X f X
X X II 11 X 1 n X X
73 X X y X y X y a
X X It tt t - X X
74 y X y X y X X 1 3

X X It tt X 1
75 X y y X y X y A X t A
It tt
76 y X X X X X y X X X 1 - X S X
It
77 y X y y y X y X X G X 3 - X s X

X X X X 11 X 1 - X
78 y X y X y M 3 X

X X X It u X 1 - X e
79 X X y X X y X

80 y X y X X X y X X II tt
X 1 - X 3 X
tt
81 X X y X X X X y X y/ X 1 A X a X
y
82 11 1 tt
-t ■
X y y X y X y y X
7 EN
X X X
 ■260

Ho M F FB C FR 0 J B H. P/c L D H Q H p m

X y X y X y X X xi X 1 - X .s X
83 y x 'e h M
84 y y y X X X y X X " ‘it X 1 ’A X t X
ii 1 u
85 y X y X X X y X X " X X f X
it -
86 y X y X y X y X X “ X 1 X s X
X X X X X y X X tt X X X
87 y 4 - e
X X " n
88 y X y y X X y X 1 - X s X
89 y X y X y X y X X x/W it X 1 - X s X
tt
90 y y y X X X y y X " X 1 - X 3 X
tt
91 X y y X X X y y x X 1 A X t X

(c) Kisumu
f =7
92 y /X y X X X y X x 'EH M X 1 - X s X
it X 1 - X
93 r 1 X y X y X y X X M s X
X X y X X X X " tt X 3 - X s X
94 y y
n X 1 A X X
95 X y y X X X y X X " t
X X X it X 1 - X X
96 X y X y X y " s
X X X ii X 1 A X X
97 y y X y X y " t
X y X tt X 1 - X X
98 y X y X y * x/w
s
X n X 1 A X X
39: X y y X X X y x ^EH
t

(d) Hakuru
x/ - X
100 X X y X y X y X x 'EH B X 1 s X
101 y X y X X X y X X " M X 1 - X s X
102 y X y X X X y X ■A* It tt X 1 - 'X s X

(e) Eldoret
103 y X X X X X y y x 'EH B X 1 - X s T

(f) Kitale
X x/ X 1 X
104 X y y X X X y x 7EN M A t X
105 y X y X y X y X x « n X 1 tt y X

(g) Thika
xi
106 y X y y X X y X x 'EH B X 3 - X 8. X
107 X y y X y X y X x n - X 1 A X t X

(h) Haivasha
— xj
l 0 8 x y y x x x y x x ' E N M x 1 A x x
 261

F FB c FR 0 J B L D M Q H pm
Ko M M
%
(n ) Medium-Scale Establishments
(a) Nairobi *
X/
1 X y X X y X y X X 'M PI X 2 A X b X
2 X X X tl L X 2 n X t X
X y y y y X
3 y X y X y X y y X II M X 1 B X a X
4 y X y X y X y X X It H t 1 E y t I
5 y X y X X X y X X x/ M X 1 A y d X
/EN
6 y X y X X X y y X % G y 2 E X t X
7 X X y X X X y X X H y 1 A y f T
hi

8 y y y X y X y y X G y 1 D y t T
ii ii 1 D
9 y X y X y X y y X y y t T

10 X y y X y X y y X X/ H y 2 A y b•y
'M
11 X X X X X it ti t 2 A X b T
X y y y
12 X y X X X X X x/ n X 2 it X b I
y y /F
13 y X y X y y y y X 7 G t 2 F y t T
'y

14 y X y X X y y X X 'f B t 1 - y s T

15 X X II 1 F
y y y y y y X G t y t y
16 y X y X y X y X X 7- B X 2 - X a X
17 X y X X X X X X y y/M Ii - 1 E y c X
18 y X y X y X y y X y/F G X 1 D X t X
19 X X X X X 7 II X 1 A X w
X y X y f y
20 y X y X X y y X 1X °/f - X 1 - X s X
21 y X y X X X y X X X/F G t 2 A t y
22 y y y X y X y y X °/F B t 1 n y t T

23 X X X y X X y y X x/EN it t 3 it X
S T

24 y X y y X X y y X X/M M X 3 E X g y
x/w it 1
25 X y y X X X y ■y X X A X t T

26 y y y X X X X y X 7B Ii X 1 F X y
27 y y y X X X y X X X/F G A 1 A* X t y
 262

No M F FB 0 FR 0 J B M P/C L D M Q H p m

28 X X X X X y y X X X/ F G X 4 - X e T

29 y X y y y X y X X X/E N M X 3 - X 3 X
30 y X y X y X y X X tl it X 1 - X S T

31 X y y X X X y y X X/F H t 2 D y b X
32 y X y X X X y X X x/w M X 1 - y s T

33 X y X X X X X X y T/ p L X 1 B X w y
34 y X y y y X y X X X/F B t 2 F X t X
35 X y y X X X y y X y /F X 1 A X t X
36 y X X X X X y y X M M X 1 - y s a?

37 y X y X y X X y X 7y L X 1 A - p X
38 y X y X y X V X X 7- M X 2 - s T
39 X X y X X X y X X tt H t 1 A X t T

40 X X X X X X X/ F tt X 2 ti X f X
y y y
41 X X y X X X X/W M X 1 it X f X
y y y
42 X y X X y/M G 1 tt X
y y y y y y y p
43 X X X x/y tt X 1 tt t X
y y y y y y y

44 X X X X X X X/E N H X 1 - X G T
y y y

45 y X y X X X y X X y/ y - y 1 - y s X
46 y X y X X X y X X X/E N H X 1 A X f T

47 X y y X y X y X X x/ y H X 1 - X b X

48 X X X X X X X X/M u X 1 A X b X
y y

49 X y X X X y/y G 3
n t
y y y y y y y
50 X X y X X X X/ F ti X 1 F f X
y y y y
X X y X X X tl »t X 1 A X X
51 y y y &
52 y X y y X X y y X X/E N M X 2 - X s y

53 X X X X X y y X X X/M B X 4 - X e X

54 X y y X y X y y X 7- H X 2 - X b T

55 y y y X X X y y X x /m - t 1 E X t T

56 X X y X X X y X X 7r M y 1 A X t T
 '26 3

No K F FB C FR 0 J B M p/c L D M Q K p m

57 X y X X X y X V X/M G X 1 - X s X
y
*
58 X y X X X X X y y T/y L 2 E X t y

59 X y y X X X y X X X/M M t 1 A X t X

60 X X XX X X X H X 1 u X £ X
y y 7-

61 X X X X X X H 1 u X f T
y y y y/y y
62 y X y X y X y X X X/M B X 1 - X s X

63 y y X X X y X y y x/y L X 1 A y w T

64 X X y X y X y X X X/F M X 1 - X t X
X X y X X ii L X 1 A X t X
65 y y y y
66 y/ X y X y X y X X X/W M X 1 - X s X
/;
67 y X X y X/F - - 1 - — t

68 X X X X X X x/w — X n t X
y y y 3 X
69 X X X y X X X X/F M X 1 it X t X
y y

70 X X y X X x/w tt X 1 n X t X
y y y y
71 X X X II B it X t X
y y y y y y y 3
ii
72 X y y X X X y X X 7 m M X 3 X b X

X X X X X x/w n X 1 - s T
73 y y y y

74 X X y X X X 7 f it X 1 - X s X
y y y
i
75 y X *x X X X X X y 7 m L X 1 E y 1w y
76 X X y X X X X y y x/ f M X 1 A X d X

X X X X X X y/x G X 1 tt d X
77 y y y y

78 y X y y y. X y X X 7 f M X 3 - X S X

79 y X y X y X y X X y/F M y 2 - X S X

80 X y X X X y X y y X/F L X 1 E X W X
81 X y y X X X y X X X/EN H X 2 0 X b X
82 y X X X X X y y X °/M M X 1 - X s X
!

(b) Mombasa
83 X y y X X X y X X H t 1 B •X t I'

84 y X X X X X X X y y/y L - 1 A‘ y X y
 264

No M F FB C FR 0 J b ‘ M P/ C L D M Q H p m

85 X y X X X X X y y X/ M L X 1 A X -

n
86 X X y x X X X X y 7 ? L X •
1 X t X

87 X X y x X X - - - ° /F B X 1 - X s -

88 X X y x X X y X X X/ M M X 1 A X t X

89 y X y x X X y X X /X B - 1 - X s X

90 X y X X X X X X y 7 - - X 1 A - d X
It 1 n
91 X y y x X X X X y L - y c -

92 1 tt
y y y * X y X X y t/f L X X w y
It tt 1 tt
93 X y y x X X X X y X y w y
94 y X y y X X y X X 7y M t 1 - X Q T
ll 1 - S T
95 y X y y y X y y X B X X

96 y X y x y X y y X y/y G y 1 A y t T
n 2 F
97 y y y ^ X X X X y L t X P X

(o ) Kisumu
98 y X y y X X y X X 7 f M X 1 - X s X

tt
99 y X y y y X y X X 7w X 3 - X 8 X

100 y X y y y X y y 7 m G t 3 c y P X

101 X y y * X X X X y 7 - L X 1 A - C X

102 y X y y y X y X X Vw M X 1 - y 8 X

103 it ii 1 - S
y X y y y X y X X X X X

104 y X y y y X y y X 7r B X 3 D X t T

(a) Nakuru
105 y X y y X X y X X Tv M X 3 - X S X

106 y X y y y X y X X x/E N G X 3 - X s X

(e ) E ldoret
107 y X y y y X y X X 7 f M X 2 - X s X

108 y X y y y X y X X 7 m G X 1 - X s X

109 y X y y y X y X X 7 ek m X 1 — X 8 X
110 -JL. X _^y._* JL- X 14 X 1 - X s X
(f) Kitale
111 y x y y y x y x x X/F G t 3 - x S X'
II
112 y x y x y x y x x M x 1 D X t X
 265

Ho M f . FB G PR 0 J B M P/C L D M Q H p m

III. Lar^e- Scale Establishments

Nairobi
(a) •'
1 X X y x X X y y X x/ y h y 1 F y f X
2 y y y x y y y X X y/y o y 2 - y s I

3 y y y x y X ^y y 'X y/l G y 3 - y s X
X ft It 1 s X
4 y y y y y y y y y - y
m
5 X y X X X X X X y 1/M L - 1 G y r y
6 y y y y y y y y X/M G y 3 A y t y
7 X y y x y X y X X y/F H y 1 F y t
X 11 fl
8 X X y x .y X y X y 1 G y £
It It
9 X ./* y x X X y y X y 2 E y t y
i
10 y y y y y X y y X y/E G y 2 - y m i

11 X X y x X y y y X/W H X 2 E y b X

12 X X X X X y X X y 7- L X 2 - y e -

13 X y y x X y X y y y/l G t 1 - y d X
14 X y y x X y X y y " L t 1 - y c X

X y ITW X
<* X 7y h t 2 F X b X
15 y x y y
16 X X X X X X X y X 1 - X r X
y 7- L

Mombasa
17 y y y r y y y y X y/M G y 3 F y t X

18 X y X X X y/ y o - 1 - y s -
y x y y
19 X y y x X X y y X X/F H X 2 E X b X

20 X y x y X X X y y y/M G X 3 F y t X
21 y y y x X X X y y 7 - - - 1 - - t -

22 X y y x X y X y y X/F G X 1 G y m X

23 X y X X X X X X y y/E I X 1 G y r y
24 X y y x X y X y y y/M L t 1 - y c y
y X X X y 1 - y t X
25 y X y x y y/ y b
26 X y X X X y X X y " L X 2 F y e T

27 y X y x y X y y X y/F H y 1 F •y t. X
 266

No M ■F FB G FR 0 j B ■M P/a L D M Q H p in

(c ) Kisumu , •

28 y- x y x y X y X X ■/- 0 - 1 - - t -

(d) Thika

29 X y y * X y X X y y/l L X 1 G y C X

(e) G llg ll
30 y x y y y x y y X/F B t 1 F - t x
 267

2 13 5 |6 ' !7' '8 j 9 ! 10 'll |12 13

e/d ■EN ; T :S SS L j o :P s
No M/ c j i A :T I T
t
(I) S m all-S ca le E stablishm en ts
I i
N a iro b i: j j i i
(a) ;" ! i | ! !
s i ■ . i i
1 X- X 1 1 I x 'x 1 x . X x X X a G B
1 i

CM
2 ; X x jx : X X p W

x
I X
X

1/ x p
3 x II x i | x x 3 x • X Ix |X X !g B
I
4 x ! 1 I x x 2 x |x !x i X X G V
x ! i
i i i
5 X | X j 1 ! X ■2 X X :X |x X X p P D
I
'6 x !t 1 ! X X X X i X I X- X X
,Q
G D.
x
7 x ! X 1 ! X 1 ;1 X X X X - p P B
1
j
X iX X — p P n
8 X X 1 ! X 1 X X

I X
X ; x iX X X p G
9 X. 1 3 1 5 IV
10 X X 1 j x 2 3 x ! X ■x I X X p B
1 p
11 X I X x ; x :2 x 1 x :X X - p P ;B
12 2/ x X X x x 2 x 1 X X - G G iW
i
13 X X 1 j x x 3 x X X X X G G |D

14 X X. 1 (1 )1 3 1 X X X X ? G iD
15 X X 1 ; x .2 6 x X X X p D
x p i
X X V X X p i n
16 X 1 ; x 5 6 ;X

17 X X 1 i x 6 1 1 X X X 0 G G Iw

18 X X 1 i X X 1 x X X X X P G (D
19 X X 2 i x 1 2 x X X X X 3? * I
D

20 X X 1 ! x 1 2 lx X X X X G | J>
J i P
21 ! * X X
i
1 x x ;2 X X X 0 G P ; S
, t
22 j X X 1 x ;x 1 x X X 1 0 G o : D
23 ! x .X 1 x j1 2 jx X X X X P 0 I D

24 X 1 x x 3 x X X X X G P' j B
x I ' I
25 x X 1 x. i6 2 x X X X - G G ! S
26 ! x X 1 x !x
j
,8
i
lx
i
X X X X P P ! D

27 X ; x 1 x 4 2 ix X * X X P p ! S
28 ! x * X 1 x lx
l
;2 |1 X x X X P P I I)

29 f/x X ; x X [x 'x |4 2 X X X G G j V
S j
30 X X 1 x ;5 ;x jX x
x
X X G s
31 X X 1 X :2 |2 j x !x X X X G o I D
j
X X ■11 Ix jx :X 2 -
32 X 1 J 0 ! f -

QUANTITY OF MANPOWER AMD WORKIHS CONDITIONS

TAISLE A: PJlRT D° .
 \

2§8

K/c ^/D Elf k

No X E SS L 0 F A T 3 I T

33 X X 2 X 2 X X X X 1 0 P P D
34 X X 1 X 2 X X X X 3 0 •P P B
35 X X 1 X 4 5 X X X X X 0 G W
36 X X 2 X 1 2 X X X X X p P D
37 X X 1 - 7 4 4 X X X 0 p P B
38 X 1/1 1 1 3 X X X X X - G G B
39 x X 2 X 4 2 y X X X X P P B
40 X X 1 X 2 1 X X X X X P G ¥
41 X X 1 X 1 2 X X X X - P P B
42 X X 1 X 1 2 2 X X X X P P B
43 X X 1 X 1 3 1 X X X 0 P P B
44 X X 1 X 3 X X X X X X P P B
45 X X 1 X X X X X X 3 0 P P B
46 X X 1 X 2 2 X X X X 0 P P T
47 X X 1 X X 2 X X X X X P G B
48 X X 1 X X 1 X X X X X P P B
49 X X 1 X 3 3 - X X X - P G T
50 X X 1 X 1 X X X X 1 0 G P B
51 X X 1 X 1 1 X X X 4 0 P G T
52 X X 1 X X 1 X X X X X P P T
1 2 1 V
riuh. X X - G W
53 .X X (1) X G
.54 1/ x X 1 X. 3 X X X X X X G P -
55 V * X X X X X 1 4 X X - P G W
56 X X 1. X 3 3 X X X X X P P B
57 X X 1 X X 3 X X X X 0 P P B
53 X X 1 X 3 3 X X X X - - — -
59 X X 2 X X 2 X X 2 0 G G B
60 X X 1 X 1 X X X X X X P P B
61 X X 1 (1) 3 2 X X X 1 y P P B
62 1/x X X 1 1 1 X X X 3 y G P T
63'' X X 1 X 2 3 X X X X X G G V
64 X X 1 X 1 2 X X X X - - - -
65 X X 1 X X X 2 X X X X G G B
66 X X 1 X 2 2 X X X X X P P B
67 X X 6 X 9 19 1 X X X - P - B
68 X ■X 1 X X X X X X X X P G B ■
69 X X 1 X 1 5 X X X X X P P 3B
70 X X 1 V 2 4 2 X X 1 0 P G B
 269

ffo K/C K/D E N T S S3 L 0 F A T S I T

71 x x 1 x 3 x 2 x x x x -P •P ■ B

(b) Mombasa

72 X X 1 X 2 X X X X X X p P S
73 X X 1 X 1 2 X X X X p G D
74 x/2 X 4 X 2 2 X X X X - p * G B
75 X X 1 X X 1 2 X X X 0 - - D
76 X X 1 X 1 3 X X X X X a G B
77 X X 1 X 3 2 X X X X X G P- B
78 X X 1 X 1 1 X X X X X p - B
79 X X 1 X X 4 X X X X X p* G .D
80 X X 1 X 1 1 X X X X X p G B
81 y / X X X 3 3 X X 1 X 0 p P S
82 V 1X 1 (1) 2 2 X X 1 X X. G P S
83 X X 2 X X 2 X X X X X G G B
84 X X 1 1 1 5 2 X X X - G G W
n
vCjO

X X 1 X 1 2 X X X X - G P s
86 X X 1 X 1 2 X X X X - - - -
87 X X 1 X X 2 X X X X 0 G G w
88 X X 1 X 2 3 X X X X “ P P E
89 X X 1 X 2 X X X X 1 0 G G T
90 X X 1 X 1 3 X X X X X P G B.
91 1/x X X X 1 2 X X 1 X ■- P G -
(c) Klsumu
92 X X 1 X 2 1 X X X X X p G B
93 X X 1 X X 3 X X X X X p G B
94 X X 1 X 1 3 X :X X X 0 G G B
95 X X 1 X 3 X 2 X X X X G P -
96 X X 1 1 X X X X X - ~ B
X 1
97 X X 1 X 2 1 X X X X X p P B
98 X X 1 X 1 2 X X X X X p P B
99 X X 1 X 1 5 X X X X - G P B

(d) Haknru
100 X X 1 X 2 1 .X X X X 0 G G W
101 X X 1 (1) 1 1 X X X X X G G W
102 X X 1 X 2 3 X X X X X P ' G ■T
 J,
• s.
270

Xo ‘V c /D EH T s S3 L 0 F A T s I T

(e) Eldoret
(1) X 1 X 1 X X 0
103 1/x X 3 •G G W

(f) Kitale
104 X X 1 X 1 2 X X X X X P G D

105 X X 1 X 5 3 X X X X - - - -
• (g) Thika
106 X X 1 X 3 2 X X X X - P P B
107 X X 1 X 4 3 X X X X - - - -

<h) Naivasha
108 X X 1 X 1 1 X X X X X P G D

II. Medium-Scale Es tablis laments

(a) Nairobi -
1 1/x X X X 15 V5, 15 X X X X P G T

2 X X X X 12 X X ■i
t X 0
Vx Q & W

3 V* X 1 X 5 5 X X X X 0 P P B

4 X X X 15 X y X y X X G G ¥
2/x

5 X X 1 X 9 5 4 X 1 X X G G Y

6 3/2 1/X X X H 3 X X X X - G G T

7 2/- 1/2 .X X 14 4 y X X X - G G Y

8 6/19 (2)/4 X X 3 15 y X 1 2 y G G ¥

9 ("> (") X X 35 7 y X 3 (’•) y G G W

10 5/2 X X (2) 10 20 13 X y X 0 G G Y

11 1/2 X X X 5 10 40 X 1 X - G G S

12 Vi X X X 5 10 15 X 1 X X G G Y

13 6/1 X X (1) 30 15 y X (8) y y G G W

14 2/y X X 1 7 4 y X 1 y y G G ¥

15 2/3 X X X 30 .15 y X 2 X 0 P G ¥

16 X 1/x 1 X 7 8 y X 1 (1) y G P S
 J,
• t
271/

No H/c /D EN T s S3 L 0 P A T s I T

17 3/3 X X X 5 X y 10 y X y G G W
18 X X. 1 X 11 8 X X 1 X . X P P B
19 2/x X X X X X 3 4 1 X - G G W
20* X X X 35 10 y X 1 X 0 - - W
21 2a X X X 12 8 2 X 1 X 0 G P W
22 4/3 V x X X 8 12 12 X 1 X - P G ¥
23 X X 2 X X 15 X X X X 0 P P y
24 2/5 X X X 10 30 6 X 2 X - P P w

25 5/1 X (2) X 6 19 5 X (2) X 0 P G w

26 y 1/x X X 6 8 X 8 1 X y G G w

27 1/1 X X X 8 4 y X 1 X 0 P P T

28 X X 1 (1) 1 10 X X 1 X X G P ¥

29 X X 1 X 1 3 X X X X X G P S

30 X X 2 X 4 2 2 X X X 0 G G T

31 1/4 X X X 18 19 3 X 6 X X G G Y

32 7v X X X 5 3 X X X X 0 P G T

33 2/i X X X 1 2 X 6 1 X y G G W

34 2/i X X X 20 25 X X 1 X 0 P P V

35 X X 1 X 4 16 X X 1 X 0 G G' Y

36 y 1/x X X 5 9 X ■X 1 y y P G S

37 y X X X 7 X ;X X 1 y y G G I

38 ■/i X X X 6 5 X X 1 X — P G T

39 2a X X X 5 15 y X X X X G G Y

40 3/1 X X X 7 15 y X 1 X X G G Y

41 y X X X 10 6 y X - X 0 P P T

42 1/3 X X X 8 13. 6 X 1 X 0 G G YS

43 V - X X 1 25 10 to X y X - G P ¥
r

272

Wo H/c ^/D EN T s S3 L 0 V A T S I T

44 X X 2 X 6 6 X X X. X - P' G B

45 y/3 X/4 X X 10 23 y • X 1 1 y 0 G W

46 X X 1 X 4 15 X X 1 X X p P T

47 3a X X X 15 28 y X 1 X 0 p P Y

48 X X 2 X X 12 y’ X X X X p P S

49 5/8 4/2 1 X 6 30 y X 3 y y 0 G W

50 - - - - (2 )(30 ) - - (D - - a P T

51 5/1 X X X 10 30 8 X y X X G P W

52 X X 3 X X 10 3 X X X - p P B

53 7* X X (1) 10 1 X X X X 0 G P V

54 3/* X X X 14 10 3 X y X 0 G G s

55 2/3 X X X 10 15 5 X y X - - - -

56 y 3/1 X 1 6 X y X 0) X - G G V

57 7x X X X 6 2 X X X 2 0 G G tf

58 1/i X X X (D 30 5 X 1 X - G G w

59 1/x 1 X 2 8 X X 1 X X G P I

60 y / y X X X 2 y y X 0) X X P G Y

61 y Vi X X 10 7 48 X 2 X 0 .G ,G W

62 1/1 X 1 X 10 15 X X 1 X X G P B

63 3/ y X X X 6 10 8 6 y X 0 G P V/

64 2/i X X 5 17 y X 1 X 0 P G W

65 2/ > lV * X (1) 25 19 X X 1 X 0 P P B

66 2/i X X X 2 4 2 X X X X P P V

67 - “ - - 3 5 y 5 - - - - - B

68 < 7 * X X 1 3 10 5 5 X X - G G W

69 y/x X X X 3 4 6 X X *X - G P s

70 X X 1 X 4 6 X X X X — G P. T
 27 3

No H/C S/D EN T ’ s S3 L 0, F A T s I T
A
71 1/2 1A t X 10 10 15 X - X. X 0 0 G W.
72 V x X X X 10 •10 10 X X 5 0 p P B
73 X X 1 X 4 6 X X X X X p P T
74 X X 1 X 9 5 4 X 1 X x ■p P B

75 3/y X X X 1 ' 2 3 9 X X - G G W
76 1/1 X X X 19 10, X. X 1 X X G P v;
77 3/8 X X (1) (3) 36 13 10 3 X y P G w.
78 V i X X X 6 11 X X 1 X 0 G G w
79 y/y 2’/ (2) X 1 10 6 8 X o) X y P G s

80 2/2 X X 1 5 X X 25 (D X 0 P G w
81 1/x X 1 X 6 10 X X 0) X X G G B
82 3/1 X X X 5 5 5 X X X X P G B

(b) Mombasa

83 1/x X X X 11 7 X X X X WV*
P P T
CM

84 X X X 12 X y 35 3 X - G G W

85 1/x X X X X X y 17 1 X - P P X
86 3/1 X X X X 14 X X 1 X 0 G G B

87 3/2 X 'X X 3 15 X X 1 X X G.G Y

88 1/x X X X 8 4 X X 1 X X P G B

89 « y/- X X 6 6 - X 1 - y G P W
90 V i X X X X X y 10 1 X - — - -

91 - - - - 3 15 - 15 0 ) - G P T
92 X X 5 y 25 3 X X G P I

93 2/ 2 3 (V x X X 3 X y 30 7 X X G P I1

94 2/x (‘ V x X X 4 6 X X 0) 2 0 P G B

95 y X X X 7 20 X X 1 . X -
P P W
96 3/3 V- X X 10 19 y X 1 y y .
G G V

97 3/x 1
(V x X X 8 5 y y X 3 0 G G V
 274

TPT\T T s SS L 0 F A T s I X
Ho W/C ^/D

(c) Kisunu

98 1/x x X X 4 5 X X 1 X .x G G W

99 2/x X X X 10 4 10 X 1 X X P P' T

100 3/x X X X 14 10 3 X y X - 0 G Y

101 y/y - - - 4 8 - - - - - -
4 9

102 2/1 X X X 6 6 4 X 1 X X P P W

103 3/1 X y X 5 (12) X X X 12 y P G B:

104 2/x X X 1 8 20 X X 1 X 0 P P S

(d) Nakuru

105 y/x X X X 4 3 5 X X X 0 G Y
//
106 x X 2 X 6 20 X X X X y P P T

(e) Eldorefc

107 2/2 X (2) X 8 (3) 3 X X 3 y P P S

108 3/x X (2) X 6 (4) X X 1 4 y G G Y

109 X/1 X 2 X 5 y X X X X 0 P P S
110 x X 1 X 4 4 4 X (1) X 0 G G s

(f) Kit ale

111 2/2 X X X 10 17 X X 1 4 y p G B

112 V x X X X 10 4 X X 1 X - G - W

III. Large-Scale Establishments

(a.) Nairobi i

1 3/5 3/3 X . X 45 35 y X 2 y y G G W

2 y/y y/x X (6) 34 28 y X 6 y y G' G w

3 y/y y/y X y 40 30 180 X 4 y y G G Y

4 y/y 7/4 X y 582 335 199 - 55 y y G G W

5 5/1 2 1/ x X 6 10 20 30 X y y y G G W

6 5/13 (3>y X 3 75 22 22 X X y y G G tf

7 y/y 1/1 X 3 10 30 30 X y - y G G •T
 275

3 M/C 2 /D EN T 8 S3 L 0 P A m S
•4m I T

8 y/y 2/ 5 X - 12 6 y X 1 y y 0 G y

9 y/y 2/ 3 X 10 y 15 y X 1 6 y G G w
10 4/ l 2 1/ 5 X y 10 50 40 30 6 - - G G V!
11 4/2 X X X 40 35 y X y X X G G V
12 y/y "/x X y 10 20 30 y 3 - - G G w

13 5/ 2 0 7x X 1 20 y y 78 5 - - P G w

H 5/2 0 2A X y 20 y 70 250 12 11 y ' G G tf

15 2h X X X 76 76 y X y X X G G V

16 y /5 X X X 7 20 60 X 2 - X G P V

(b) Honih as a

17 y/ y 2/ 2 X y 72 42 y X 6 - 0 G G Y

18 y/y y/ x X 2 21 50 30 X 4 - y G G T

19 2/ 5 X X 2 18 60 30 X 1 - X P G T

20 4/ 7 2/ ( 1 ) X 3 24 29 20 18 4 X X G P W

21 - - X - 20 25 y 30 — - - G G W

22 y/y X X 1 15 30 y 20 y “ - P P w

23 3/1 3 2/x X y 15 15 y 2 3 y y G G V

24 ^ /2 2 Vx ■X 2 10 20 y 100 9 y y G .G V/

25 2/ U (V i X y 25 20 y X 5 y y P G w

26 y/y x/x X 4' 5 100 y 2 y y G G w

27 5 / 1 5 2/6 X (2 ) 30 80 100 X 4 y y G G w

(c) Ivisumu

28 y/y 3/x X y 20 53 41 X 3 y y G G Y

(d) Thika

29 3/l 5 V* y 10 y y 200 7 53 y G G V/

(e) Oii^il

30 2/2 1/y x y 5 55 y x 1 y y- P P T
 1600 _ APPENDIX 4

1200
METRIC TONS
00
O
O

a J

400

\ y

O . . ■ 1 ..... t - *----------!---------- J---------- >---------- 1

195! 63 65 67 69 7
YEAR

IMPORT OF
MFTAI. WORK. MACHINERY
SOURCE
S T A T IS T IC A L ABSTRACT 19T l
 APPENDIX 5

SOURCE RAW MATERIALS

5TNT1STICNL ABS^RNCT 19*11
 *278

APPENDIX__6
PYRITE

(i) (ii) (iii)

percent percent percent

si°2... 6.19 5.67 5.22

s ....... 34.65 46,18 37.15
As■•••••• trace trace trace
Cu..... trace
Ni..... trace trace trace
Pe,etc, '
(By diffe
rence).. 59.16 48.15 57.65
i 100.00 100.00 100.00
i
(i),'(ii) , (iii), Bukuru (See Para. 2,1.2. - a(i:

NYANZIAN IRONSTONES

(i) (ii) (iii)

percent percent percent
i

i°
!o
i

Si02•*** 39.10 62.10

Fe?0^... 55.31 33.36 64.72
Ti02___ 0.085 0.12 Trace
PpO^* •». 0o23 0.12 0.17
3 1 •1 1 1 t• 0.076 0.09
o
o
o

COMPOSITION OF LOCAL IRON ORES

Source: "Minerals of Kenya"f Bulletin Ho. 11 of the

Ministry of Natural Resources, Geological
Survey of Kenya, page 37.
 279

APPENDIX 7

PROCESS OPEE-HEAKTH1 BESSEMER** ELECTRIC FURMACE5

Cost (£) 12 to 14 11 8 to 10

APPROXIMATE CAPITAL COSTS

(Per ton of annual output)
NOTES:-
1. Includes fixed furnaces with inactive mixers, cranes,
gantries, firing and control equipment, instru­
mentation, raw material handling facilities, mould
preparation and stripping equipment, metal and slag
handling facilities, waste heat boilers, buildings
,and ancilliaries.
2, Includes mixer3 , cars, ladles, blowers, lime and
dolomite plant, basic slag plant, oxygen services
and buildings*
3* Includes furnace plant complete with all ancilliaries
and buildings.

Source: Bashforth, G.R., "The Manufacture of Iron

and 8teel", Volume II, 1963, page 353.
 9- ***

280

APPENDIX 8
TRANSFER 0? FINISHED PRODUCTS AND PACKING- MATERIALS
TO AND FROM THE WAREHOUSE AND FACTORY RESPECTIVELY*3
2

LABOUR NO. RATE ANNUAL COST TOTAL COST

(SALARIES)
L Horn (SAIAEI3S) FOR SEVEN
KShs K£ YEARS(IN
K£)
1 t
Factory j | \
Packers 6 ‘ 459 33*048 1652.4 ' 11566.8
Warehouse : j
Packers \ 6 1 459 33*048 1632*4 : 11566.8
i j i

I TOTAL : 12 6 6 .09 6 3 3 0 4 .8 2 3 1 3 3 .6 i
I : i ' !

COST: MATERIALS HANDLING;

Note:- 1, The rate of manual loading and unloading

is not known*
2. The trailer maximum load is 8*1 tons*
3. Such products as edible drums and some
chemicals cannot be conveniently loaded
manually•

Source: Work Study Department, East African Industries

Limited, Nairobi.
 201

APPENDIX 8A.

TRANSFER OP FINISHED PRODUCTS AND PACKINC MATERIALS

TO Aim FROM THE WAREHOUSE AND FACTORY RESPECTIVELY
(a) Extra Labour Involved:
j ANNUAL COST : TOTAL COST
iK o - I S (SALARIES) ; (SALARIES)
' MONTH - FOR SEVEN
i I ■ YEARS (IN
: !
! \ KShs K£ KX)

Pork Lift j . j
Driver '1 *628 '7,536'376.8 | 2,637„6

(b) Pork Lift (6,COO lb Capacity);

DESCRIPTION ANNUAL COST I TOTAL COST

T+
7.4
7 kQjTjT.
TryLu
j 'Trr
ii
KShs KX YEARS (K£)
Buying Price ' 4,685
Cost of Diesel 3,000 150 1,050
Estimated Repair
Charges 14,480 724 5,068
TOTAL 10,803

(c) Total Cost for (a) and (b) covering

Seven Years: K£ 13,440*6
COST OP BUYIPO AY EXTRA DIESEL PORK LIFT

1. The cost of diesel is calculated at the rate of

-/73 cents per litre and using I3°6 litres per day.
2. The repair charge is based on the total charges
incurred in the year 1971 for the existing Hyster
Pork Lifts.
TYPE CP IMPORT
RESTRICTIONS PRODUCTS TO WHICH IMPORT RESTRICTIONS APPLY
i
Schedule A Plat iron sheets (ungalvanised or uncoated); iron and steel
Import allowed wire including nickelplated wires; roofing nails, tacks and
under license fencing staples*; other screws, rivets and similar articles*;
Baser blades; Butt hinges; Tower bolts (brass and aluminium);
Disc ploughs; water meters; Bicycles; Tricycles; Bicycle parts.

Schedule B Wire rods and bars oi iron and steel; Corrugated iron
Import not sheets; Steel windows and doors; Parts of fully fabricated
allowed steel works, including buildings and bridges; Aluminium
windows and doors; Gauze; griff; netting, fencing and rein­
forcing fabrics of iron or steel wire; Round wTire nails;
Wood screws; Kocs; Katchets; Axes; Shovels and spades; wood
band saw blades; Charcoal irons; Cooking pans; Crown corks;
Earth pans; Gcmplete low-speed agricultural trailers (other
than road trailers).

IMPORT RESTRICTIONS
 TYPE OF IMPORT
PRODUCTS TO WHICH IMPORT RESTRICTIONS APPLY
RESTRICTIONS

Schedule C G-as cylinders; Barbed wire of iron and steel; Other fencing
Import licence wire of iron and steel; Screw-drivers; Domestic utensils of
required and onl^ stainless steel; Tinned and enamel tea trays, spray guns
granted under and charcoal irons; Padlocks, locks including "bicycles and
special circum­ furniture locks; Shoe eyelets; Bead wire rings and rat traps;
stances. Grinding mills and single furrow hand ploughs; Hydraulic pipe
benders; Hydraulic rams; Air compressors; Hydraulic jacks;
Hydraulic elevating tables; Airlifters for workshops; Mounted
mini-cranes; Hydraulic fork lifts; Metric weights; Fire
extinguishers; Hydraulic presses.

* Other than these covered by a manufacturer's part number.

Source: Extracted from the Exchange Control Circular Eos. 10 & 11,
Central Bank of Kenya, dated 6th January, 1972.

APPENDIX 9 A
i 1 i.
! . '* *
 PRODUCTION PROGRAMME - WEEK ENDING ...... -fe?-- # ^ U 1 7/
Monday 3 /5 Tuesday 4 /5 Wednesday 5/5 Thursday 6/5 Friday 7 /5 Saturday 8/5
2 1 OL drua 5548 210L Shell 5629 21OL Agip 5548 21OL Shell
5629 5*2; 210L Agip Grey White 425 HO/Yellov 1125
A^p 450 Grey/White 1125 RO/Yellov 112 5
with FI Sc; sen
FI screen deliver to Esso
>543 2 1 QL Shell to he deliv ;re& (Complete E300)
" EO/Yallov 60 0 to Euao 5594 20OL 02
w Enso 12 0
w 5132 2 0 0 L OB
n Caltcx
.-3 Multifok 2 u
2 0 0 L OS
Shell 18 0

TOTAL 1C>0 TOTAL 1125 TOTAL 1125 TOTAL 736 TOTAL 1125 TOTAL I
’.'fork up "to 4.15 Work up to 4.15 Work up to 4-15 Work up to 4.15 Work up to 4.15 Work no to
.
Compioto Couplet© 5615 35D pail
5593 2 1 L pail —
i 21L pail 5583 2 1 L pail-L- Loubil Henkel 10 0
5606
Sadolino 4077 Sadolina Walpamur 18 8 1
5493 21L pail L OE
M 5546 2 1 L pail—lr 5517 21L pail ‘ Galaxy 300 5 6 1 6 6 0
Henkel
*-♦ Coates Eoso 300 10 0
10 0 0 5361 16L pail • » * 60L OE
5601 2 1 L pail—L- 5623 2 1 L pail Twigs) gree a 5 0 0 Mobil 50
Robbidao 5 0 0 Mobil 5330 20L Mobil 5605 6 0 L OS
5497 2 1 L pail-L- All available.a ieeto 20L Esso Shull ^50
•>4 Galnxy 200 All available e lhets. 6 0 L OS Easo
C'.O'u OE Caite 1
pliiL 5OL_0L’ Cd.tr ______________ t
TOTAL 4077 TOTAL 1700 TOTAL 2181 TOTAL 4902 40
Work up "to 6 * 1 5 Work up to 6 .1 5 Work up to 6.15 Work up to 6.15 Work up to 6.15 Work up to
Cleaning ou' * «« 21L pail ««• 6 0 L 0E Lugcovers Lugoovere
23L Mobil Esso 300 Mobil 50
Y- Blaok

01 XldN3ddY'
'J - 2 1 L Mobil 561^ 60L O H -Y- Blue
Ro .lorcoating Euso 135 V- RO o*0 (i G.M.
t. ^ 60L Grease 2 8 0 -Y- Mobil W 1 Lite W.X. <£_
6 0 L Grease 50 5125 6 0 L 0 2 Mult- Prod. Eng.
‘ 75 K&int.Eng.
n^ n<r 490; fa is a ^3S p 40
rr-^ao Sales Aoa*
Despatch
Work up -to 4.15 DidO ROb bnXTD*----TrT
Work up to 4»15 Work 30 Work up to Work tip to Store*
m File 19/i-V)
MU —r- - ; Running Gaskets Running Gaskets - Running Gaskets
up to 6 . 1 5 up to 6 . 1 5 up to 6 . 1 5
*G
£6
• • a «•

tfarka Ifen4^«r
 285

appendix 11

EXPORT VALUES SHARE OP TOTAL

INDUSTRY £ 1000 Per cent
1967 1974 1967 1974

Agricultural Products 34,360 54,950 43.1 45.8

Total Processed
Agricultural Products 12,464 15,400 15.6 12.8

Total Agricultural
Products 46,824 70,350 58.7 50.6

i
Metal' Products, and
/.
Machinery 2,961 3,250 3.7 2.7

EXPORTS: 1967 AND 1974

Source: Development plan, 1970-1974, Republic of

Kenya, page 153-
 286 i

APP3NDIX 12

CATE- P R O V I K C E
GORY TOTAL TOTAL
WEST 1JYAHZA EIFT CENTRAL EAST COAST RURAL URBAN
Ear­
ning 12 9 11 5 2 2 7 13

Skil­
led
Labour 15 19 14 8 16 13 14 19

Cleri­
cal 20 21 14 27 21 36 23 20
Tea­
ching 13 13 22 20 15 34 19 14

Poli­
tics 5 10 11 11 8 6 9 5

Medi­
cal 16 10 3 15 17 2 12 17

Tech­
nical/
Profe­
ssional 20 18 24 15 20 8 17 11
TOTAL 101 100 99 101 99 101 101 99

1PREFERRED 1 JOBS BY OCCUPATIONAL CATEGORIES

• AMD PROVINCES
(In per cent)
Source: Koff, D.R.- "Prospectives of Kenya Primary
Pupils", "Education, Employment and Rural
Development", Report of the Kericho(Kenya)
Conference, 25th September - 1st October,
1966 , page 401*
*
 APPSi.TOX 1^

R E F E R E N C E S
 287

CHAPTER I

1• Ashburn, A "Organization of a Machinery Census

and Use of Census Data with Special Deference
to Industrially Developing Countries", paper
presented at the United Nations Interregional
Symposium, Moscow, 7th September to 6th October,
1966, United Nations Publications, No. 3.69,11.
B.2., entitled "Development of Metalworking
Industries in Developing Countries", page 109®

2 "Industrial Production Surveys of Large-Scale

Firms", 1964-1966, Statistics Division, Ministry
of Finance and Economic Planning, page 1 »

3. Jelen, F.C, "Cost and Optimization Engineers"^

McGraw-Hill Book Company, 1970, page 102*

4 Cooper, C. "The Channels and Mechanisms for the

Transfer of Technology from a Developing
Country", United Nations Conference on Trade and
Development, TD/B/AC•11/ 5 > 27th April, 1971 *
page 1 9 .

5. "Methodological and Operation Aspects of Machine

Tool Studies in Developing Countries", paper
presented by the Secretariat of the United
Nations Economic Commission for Latin America
at the same symposium as citation 1 above,
page 203.
 ^288

chapter ii

1. Du Bois, C.G.B. and Y/alsh, J., '‘Minerals of Kenya”

Bulletin Mo* 11, Ministry of Natural Resources,
page;? 35,13,4V

2* Hill, M . F . , ."permanent Way”, East African Rail­

ways and Harbours, page 239 0

3* "Sunday Nation", E.A. Newspapers (Nation Series)

limited, January 17, 1971, page 26„

4o "East African Report on Trade and Industry",

Official journal of the Kenya Association of
Manufacturers, July 1970, page 30«

5* "Daily Nation", E.A. Newspapers (Nation Series)

Limited, Financial News, January 13, 1971.

6 <> "Tech A i r " , The Journal of the Society of

Licensed Aircraft Engineers and feehaologi t
Hay 1971, page c (iii).

7. Pulfrey, W. and Walsh, J., "The Geology and

Mineral Resources of Kenya” , Bulletin No. 9,
Ministry of Natural Resources, 1969, pages 26*.
27, 30, 24.
8 . Same as citation 3 above, December 13, 1970,
Business Section.

9. Voskuil, W.H., "Minerals in World Industry", ,

McGraw-Hill Book Company, Inc., 1935, pages
76, 73*
10o Alexandersson, G., "World Shipping", John Wiley
and Sons, New York/London, 1963, page 81.

11. Bashforth, G.R., “The Manufacture of Iron and

Steel” , Volume I, Chapman and Hall Limited,
1963, page* 11 ,2.10, 2.75
12. "Statistical Abstract, 1971", Ministry of Finance
and Planning, pages 61, 114, 58, 97, 47, 49.
 289

13. Same as citation 5 above, January 28, 1972,

page 17.

14. "Development Plan, 1970-1974", Republic of ■

Kenya, pages 352, 353, 357 *

15. Tariff catalogue, East African Power and

Lighting Company Limited,Pa.to-

16. "The Chartered Mechanical Engineer", Journal

of the Institution of Mechanical Engineers,
London, January 1972, page 51*

17. Eengough, C.C,, "Commercial Timbers of Kenya" ,

Ministry of Natural Resources, 1971.

18. Rowe, R.D.H., "Rotes on Forestry and F a m i n g

iij the Kenya Highlands", Forest Department
Pamphlet Ho. (Second Series) 1, page 3.

19. "Eucalyptus for Planting", Food and Agricul­

tural Organisation of the United Nations,
Forestry and Forest Products Studies No. 11,
page 146.

20. Rollason, B.C., "Metallurgy for Engineers"

Edward Arnold (Publishers) Limited, Third
Edition, 1961, page 146.

21. Bashforth, G-.R., "The Manufacture of Iron and

Steel", Volume II, Chapman and Hall Limited,
1963, pages 297, 3 1 2 . '

22. Singh, M . , "India's Export Trends", Oxford

University Press, 1964, page 114*

23. Same citation as 3 above, January 17, 1971, but

page 26.

24. "Instruction Manual on SteeJ. Manufacture" T

Chief Mechanical Engineer's Railway Workshop,
Nairobi, 1959, Sections 5.20 and 18.00.

25* "East African Standard", East African Standard

(Newspapers) Limited, Nairobi, January 11, 1973,
page 5.
 2g)0

26. "Economic Geography of Industrial Materials'1,

edited by Albert S. Carlson, Chapman and Hall
Limited, London, 1956, page tT f .

27* Wimbush, S.H., "Catalogue of Kenya Timbers” ,

Government Printer, Nairobi, 1957, pages 51?
41, 45 and 47*

28. De Garmo, E.P., "Materials and Processes in

Manufacturing", The MacMillan Company, London,
1969, pages 255, 5 18 , 529«

29. Sakharov,. G.M., "Design of Machine Tool Plants

for Developing Countries", same symposium as
stated in citation'1, Chapter I, but page 185.

30 * Same citation as 5 above,but issue o* 11 ,

te>.
51. Pearson, C.E., "The Extrusion of Metals",
Chapman and Hall Limited, I960, pages 75, 31
and 163 *

32. Alexander, J.M., and Brewer, R.C.,"Manufacturing

Properties of Materials", D. Van ITosbrand
Company, 1968, pages 86 , 290 and 301, 514*

33. Same citation as 16, October 1972, page 94*

34. Same citation as 25 above, May 16, 1972, page 2 .

35. Houldcroff, P.T*, "Welding Processes",

Cambridge at the University Press, 1967, pages
23, 35, 135, 150.
36. Chapman, W.A.J., "Workshop Technology", Part III,
Edward Arnold (Publishers) Limited, 1961, page 56

37. Department of Mechanical Engineering1, University

of Nairobi.

38. Sane citation as 4 above, June 1970, page 12<>

 291

CHAPTER III
I. Same citation as 2 of Chapter II, but pages
148, 190, 239.

2* White, L.W. Thornton, SilbermanL.,

Anderson P.R., "Nairobi blaster Plan for a
Colonial Capital11, His M a j e s t y ^ Stationery
Office, 1948, pages 2, 38.

3. Arkirt, H . , and Colton, R.R. , "Statistical

Methods", Barnes and Noble, New York, 1963*
page 50 .

4. Estall, R.C. and Buchanan, R . O . , "Industrial

Activity and Economic Geography", Hutchinson
University Library, 1966, pages 27, 97.

5. Dixon, H.H., "Nairobi Water Supply", Journal

of the East African Institute of Engineers,
Volume 17, No. 1, March 1968, page 13*

6 . Bradley, D . , "Fuel and Power in Kenya",

University of Nairobi, Department of Mecha­
nical Engineering, Technical Report M70/1(1970).

7. Same citation as 14 of Chapter II but pages

173, 305, 3 H , 324, 353, 366.

8 . Same citation as 25 of Chapter- II but issue of

13th June,-1971.

9. Dandekar, V.M., "The Role of the Small-scale

Industry in the Indian Experience", "Education,
Employment and Rural Development", Report of
the Kericho (Kenya) Conference, 25th September
to 1st October, 1966, page 152.

10. Staley, E. and Morse, R . , "Modern Small Industry

for Developing Countries", Stanford Research
Institute, McGraw-Hill Book Company, 1965,
page 301 .

II. Same citation as 25 of Chapter II but issue of

13th May, 1971.
 292

12. "Energy", published by the Caterpillar Tractor

Company, Peoria, Illinois, U.S.A., Volume 6 ,
No. 1, page 5.

13* Greene, D.E., "Production Technology"-, Chapman

and Hall Limited, 1962, page 58*

14* Ivanov, E.K., "Group Production Organisation",

Business Publications Limited, 1968*

15* Thornley, R.H., "Group Technology - a Complete

Manufacturing System", same citation as 16 of
Chapter II but issue of January 1972, page 46.

16. "Automation", Department of Scientific and

Industrial Research, Her Majesty's Stationery
Office, 1956.

17* Same citation as 25 of Chapter II but issue of

19th December, 1970, page 1.

18. Same citation as 25 of Chapter II but issue of

17th March, 1972, page 2.

19. Lingard, "Materials Handling in the Deve­

loping Countries", "Materials Handling and
Management", Official Journal of the Institute
of Materials Handling", March 1970, page 27.

20. Lehrer, R.N., "Work Simplification", Prentice-

Hall, 1957, page 8 .

21. Lockyer, K.G., "Factory Management", Pitman

Publishing, 1968, page 117.

22. Same citation as 3 of Chapter II, but issue of

June 1970, page 25.

23. "Management Today", Journal of the British

Institute of Management, July 1969, page 71.

24. Vallance and Doughtie, "Design of Machine

Members", McGraw-Hill Book Company, 1951, page 1.
 293

25* "World Construction", February 1972 -

Volume 25, No. 2, Dun-Donnelley Publishing
Corporation, 466 Lexington Avenue, New York.

26. Exchange Control Circular No. 1/1972’, dated

6th January, 1972.
27. "Conservation", Caterpillar Tractor Company,
Peoria, Illinois, U.S.A. , 1951*

28. Whitfield, P.R., "Creativity and Design",

same citation as 16 of Chapter II, but
issue of January 1969, page 3*

29. Haddock, I., "Stimulating Innovation In

Industry", same citation as 16 of Chapter
J.I, but issue of September 1968, page 353®

30. //Pitts, Go, "Design and Developments", same

citation as 16 of Chapter II, but issue of
Hay 1972, page 72.

31. Agbasiere, J.A., and Chukvujekwu, S.E.,

"Teaching Mechanical Engineering Design in
Africa", same citation as 16 of Chapter II,
but issue of October 1972.
 294

CHAPTER IV
1. Sane citation as 14 of Chapter II but page 311*

2. Same citation as 10 of Chapter III, but page 318.

3. Berna, J.J., "Industrial Entrepreneurship in

Madras State", Stanford Research Institute,
Asia Publishing House, London, I960, pages 171 •

4. Same citation as 3 of Chapter II, but issue of

January 1972, page XI.

5. Eilon, S . , "Production Management for Developing

Countries", same citation as 1 of Chapter I, but
page 409®

6 . Gillespie, "Engineering Reorganisation", Sir

Isaac Pitman and Sons Limited, London, page 194.
//
7. Pronikov, A.S., "Repair and Maintenance of
Machine Tools in Developing Countries", same
citation as 1 of Chapter I, but page 507.

\
 295

CHAPTER V
1* Rice, W.B., "Calibration Requirements for
Government Contractors", American Society for
Quality Control, Annual Convention Transactions,
I960, page 87-93.

2* Juran, J.M., "Measurement", Quality Control

Handbook, McGraw-Hill Book Company, 1962,
page 9-16*

3o Seder, L.A., "Quality Control in the Job Shop",

same as citation 2, Section 26*

4. Phillips, P.E., "How the East African Bureau

of Standards Will Operate", same citation as
4 of Chapter II, but issue of January 1970, page
12*

5. Same citation as 25 of Chapter II, but issue

of 27th July, 1972, page 5.

6. "Kenya Gazette", Notice No. 510, 18th February,

1964.
7* Wilson, J.B., "The Problems and Significance
of Industrial Standardization in Metalworking
Industries in Developing Countries", paper
presented by United Nations Interregional
Symposium, Moscow, 7th September to 6th October,
1966, U.N. Publication, E.69.11 .B*2., page 115*

8 * Weston, G., "Metrication: Plans and Progress

to Date", same citation as 16 of Chapter II,
but issue of May 1968, page 210*

9* "Metrication At Work", Transcript of Seminar

Proceedings held by Whiteley Lang & Neill
Limited, Speke Hall Road, Liverpool, ILK.
June 1971<>

10. "The Change to the Metric System", same

citation as 5 of Chapter III, but Volume 16,
No* 3 t September 1967* PaSe 82.
 296

CHAPTER VI
1. Manpower Survey, 1967, Statistics Division,•'
Ministry of Finance and Planning, Republic
of Kenya.

2. Jackson, V/., "Education and Training of Tech­

nicians", Commonwealth Education Liaison Com­
mittee, Her Majesty*s Stationery Office, 1966,
page 2 3 .

3* Varley, F . , "Aide-Memoire on Technicians and

Technician Engineers", Journal of the same
citation as 5 of Chapter III, but Volume 19,
No. 4, December 1970, page 106.
I
4. ,Waite, W.W., "Managerial and Technical Per­
sonnel Requirements in Metal-Processing
Industries", same citation as 1 of Chapter I,
but page 2 1 5 .

5. Williams, CM, "Recruitment to Skilled Trades1*,

Routledge and Kegan Paul Limited, London,
1957, page 46.

6. Chandrakant, L.S., "Education and Training of

Technicians", Commonwealth Education Liaison
Committee, Her Majesty’s Stationery Office,
1966, page 31 o

7. Getahi, E.S., "Development of Industrial

Training in Kenya", same citation as 5 of
Chapter III, but Volume J8, No. 2, June 1969,
page 36.

80 Same citation as 14 of Chapter II, but pages

113 and 120 .
9. Edokpayi, S.L., "Industrialisation and Man­
power Development in Africa", paper presented
at a. seminar on Technical Education and
Training for Industrialisation, Berlin, 12th
June, to 3rd July, 1969, (German Foundation
for Developing Countries) proceedings
37/69-1, page 1 „
 *■

?97

10* Wellens, J., "The Training Revolution", Evans

Brothers Limited, London, 1963, page 25*

11* Same citation as 16 of Chapter II, but issue

of October 1972, page 73®

12* Same citation as 5 of Chapter III, but

Volume 15, No* 2, June 1966, page 38®

13® Palmer, W.B.f "The Inclusion of Practical

Work as a Requirement for the Engineering
Degree11, same citation as 5 of Chapter III,
but Volume 18, No* 2, June 1969.

14® Same citation as 25 of Chapter II, but issue

of 14th July, 1972, page 8*

15. Turner, B.T*, “Utilising Highly Qualified

Manpower” , same citation as 16 of Chapter II,
but Volume 19, No. 6, June 1972, page 61*

16* Same citation as 3 of Chapter IV, but page 43®

17* Employment and Earnings, 1963-1967, Statistics

Division, Ministry of Finance and Economic
Planning, November, 1971, page 6*

18. Banjo, A., “The Design Engineer: His Work and

His Role in Development", paper presented at
a seminar on Technical Education and Training
for Industrialisation, Berlin, 12th June to
3rd July, 1969, (German Foundation for Deve­
loping Countries) proceedings, S7/69-11, page 1*

19* Palmer, W.B*, “Engineering Research in East

Africa", same citation as 5 of Chapter III, but
Volume 17, No. 2, June 1960, page 56.

20. “The 1971 Survey of Professional Engineers",

Council of Engineering Institutions, 2, Little
Smith Street, London, page 14.
 CHAPTER V II

16 Same citation as 2 of Chapter III, but page-50.

2. Hempel, E . H . , "Small Plant Management", KcGraw-

Hill Book Company, 1950, page 134.

3. Heinrich, H.VJ*? "Industrial Accident Prevention",

McGraw-Hill Book Company, 1950, page 189*

4o Kuhn, H.S. "Byes and Industry", Henry Kimpton,

London, page 219.

5# Same citation as 5 of Chapter II, but issue of

Wednesday, 5th Hay, 1971, page 5*
 ♦ s.
299

CKAFCSK YIIX

1* Sane citation as 12 qx Chapter II, but

pages 59 and 189.

2* Same' citation as 3 of Chapter IV, but

page ix.

3* Same citation as 29 of Chapter III.