Dashen Brewery s.

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Internship report IED ENG 1202/01

BAHIR DAR UNIVERSITY
INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL & INDUSTRIAL ENGINEERING DEPARTMENT OF INDUSTRIAL ENGINEERING

FINAL INTERNSHIP REPORT HOSTING COMPANY: DASHEN BREWERY S.C

Start Date for Internship- Oct, 24/10/2011 End Date for Internship- Feb, 10/02/2012

Name: Solomon Ferede ID: 1202/01 complicatedsol@gmail.com Mentor’s Name Ass. Tessema Blia Report date: Feb. 22/02/12 I

Dashen Brewery s. c

Internship report IED ENG 1202/01

Preface:
This report documents the work done during the internship better time at Image understanding the overall process of the Dashen brewery & the rank of technology the company used, under the supervision of our advisor Mulalem ,mechanical engineer & general manager of the maintenance department, Ato Gashaw . The report first shall give an overview of the tasks completed during the period of internship with details, then project work on specific area with detail solution & Analysis .The Report shall also elaborate on the the future works which can be persuaded as an advancement of the current work. I have tried my best to keep report simple to understand. I hope I succeed in my attempt.

Solomon Ferede

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Dashen Brewery s. c

Internship report IED ENG 1202/01

Acknowledgments:
I would like to acknowledge the following people for their support and assistance with this internship. First I would like to say thanks to God who makes me powerful & patient during my project work. From Dashen brewery, I would specially like to thank Ato Gashaw Tekel, General Manager of Maintenance Department , for making me confident & initiative to do something by myselves & push me to create something in the day to day problem of the factory & for his good behavior to listen me & satisfying my needs whatever we want as much as he can . I am also highly indebted to our assistant Ato Dilom Girmay, Maintenance Plan Expert who is an industrial graduate, for making me active in my project work starting from selecting project title by giving me his time to advice & follow my progress to make it good & pushed me to succeed to make best solution for my selected problems .I would like to thank my advisor Mulalem Mekonen, division Manager, for his great ideas to initiate me to know on which area can be the problem exist & his interest to show me something which is very important for me without tired. I would also to thank Ato Mokonen, store Manager, for his appreciation to do more by my selves &giving me some needed information & quantitative data. And I wouid like to thank to the operators (mechanics) of my department for their interest & support to show me practical works. Finally I would like to thank to my department mentor Ass, Professor Tessema Belie, for his great deal with our company advisor to insert us on the basic area of our next department course.

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& yeast propagation. Project work on specific area ‘inventory control’ (using Re-order level system problem) 3. The overall benefit from the internship program . Utility is the back bone of the company.C which are listed below: 1.Beer processing. effects. in CO2 recovery plant (CO2 purified). beer filling & labeling starting from KEG plant. maintenance planning & scheduling. The overall work flow of the company focus on the main structure of the company & process flow of each room. Total Productive plan (TPM) & Reliability engineering. & proposed solution with detail description are settled in this report .L. Inventory control (re-order level problem) objectives. wort from brew house through the process of. The overall benefits that I gained from the internship program & the whole experience are also set at the end of the chapter clearly IV . The raw water heated. Maintenance activities are preventive. NH3 plant for cooling purpose and boiler for production of steam and there is waste water treatment that makes the environment safe. Bottling . then to the pre-cleaning room . The quality department ensures the quality in each step of the process starting from raw material.Dashen Brewery s.Brew house room. It consists of Raw material room . The overall work flow of the company 2. separation of bottled beer & draft beer through different bottle & creat washing processes to the finished product store room. fermentation.& overhaul. corrective. malt feed to infeed hopper.proposed solutions to solve the problem are. wort production through different process . filtration. causes. c Internship report IED ENG 1202/01 Executive summery The report presents the three tasks completed during internship at Dashen Brewery P.

............ 16 3...................................... 13 Mill Star ................................................. Brew house............ 15 1.....................................................2 The main products & service ................ 21 4.....7 Heat Exchanger (wort cooling) .............................................................................7 4............................................... 4 Mission................................... 17 4.................................................................................. IV CHAPTER –ONE ............................ Beer processing ......................................................2 Un caser (un packer) & caser (packer) .................................................................................................................................................................................................................................................... 17 4 Bottling ..............................................................................................................................1 4....... 19 4......................................................................................................................................................................................................... 23 4.................................................................. 12 Pre-cleaning room .................................................................................................................................6 Wort Kettle.................. 14 Mash Tun Kettle (MTK) ..4 Pre Run Tun ....................... 23 Full bottle inspector (FBI) ............................................................................................................................5 Filler Machine (Bottle Filling) ............... III Executive summery...........................................................................3 2...... 20 Process Description:.................6 Pasteurizer Machine ........Dashen Brewery s............................................................................................1 3............................................................................................... 3 Lauter Tun Tank (Mash separating vessel) ... 3 Vision .............................................................................................................................................. 19 4............................... 1 1...................... 16 3..............................................................................................................................5.............................................................................................................................................................8 Labeler ................................................... 3...3 Crate washer............................................................................ 3...... 4 1.4 Empty bottle inspection (EBI) .......................................................................... II Acknowledgments: ........................................................1 Brief history of the company ........................................................................................................................... 1 1.............................................................................................................................. 21 4............................................................ 19 4............................................................................................................... 13 3.............................................................. 13 3................................................................................................................................................................................................................................................................2 Work flow of the company .......................................................................... 16 Whirlpool ................................................. 24 V .......................................................................... 16 3............................ c Internship report IED ENG 1202/01 Table of Contents Preface: .......................................................................................................................................................................................................... 1 BACKGROUND OF THE COMPANY . Raw material store room ......... 19 Bottle Washer.................................

.............................................................................................................. 29 BOD5....................7 Problem description ..... 30 Chapter Two ..................2 2................... 26 c......................................................... Preventive maintenance ...................... 34 Proposed solution .......... Quality assurances ............................................................................................................................................................................................ 32 2................ 29 A ...................................................................................................................................................................................................................................................................................................... 36 Total productive maintenance (TPM) .................................8......................................................................................................8 Objective of the project:...................................... 40 2...................................................................................................3 Reliability Engineering ........................................................................................................................................ 27 D....................................................... 30 B... 36 2.............................. 24 4............................................................................................. Raw water treatment ................ 29 7............................................................................ 31 Methodology: ...................................................... Corrective maintenance ............................ 29 COD.......... 44 VI ................................................................................................... Utility...................................................................................................... 24 5............................................................................................................................................................................... 34 2.................................................................................................................................................................................................................................................................. 30 8................................................................ 32 Introduction: ...................................... 34 Problem statement:............................................................................................. 31 Maintenance Department ............................9 Challenges I Have Been Facing During My .................. 26 A.........Dashen Brewery s............ 30 C...................................................................................... 31 Project work on ...... 32 2...................................................................................................................................................1 Procedures I have been using while performing my..................... 38 2.......................4 2...............................................5 Possible causes: ..10 Keg draft plant ................................................ Waste water treatment..................................................................... NH3 plant ................................................................................... 34 Effects: ....................... 44 Project Work: .........................3 2.............................. 26 B........ Maintenance activities ....................................................................................................................... 27 6.................................................... Overhaul maintenance ........................................................................................................................................... 31 Inventory Control (re-order level problem) ...................................................................... 32 Project work .......................................................9 Caser .......................................................................................................8.......................................................................................................................................... 34 2.............. CO2 plant ..........................................................................1 Maintenance planning & scheduling ........ c Internship report IED ENG 1202/01 4..........8............................................................................................................................................................................................................6 2... Boiler ..................................................................................

..........3 In terms of upgrading theoretical knowledge:............................................ 51 Appendices:..............................2 3..................................................... 50 Reference: .................... 45 3......................... 46 In terms of improving team playing skills: ............................................................................................................................................................................................... 44 CHAPTER..................... 46 In terms of understanding about work ethic ... c 2......1 Goals /Objectives: .............. 49 Recommendation: ...........12 Fig-3 Process flow of brew house……………………………………………………14 Fig-4 Beer filling & packing process…………………………………………………18 Fig-5Beer filling & packing of Drought ……………………………………………25 Fig-6Work flow of maintenance Department…………………………………… 31 Fig-7Maintenace Analysis Process……………………………………………… ........................................... 44 Challenges: ............................ 45 3................................................................... 47 In terms of entrepreneurship skills:. 46 3...............................................................................................................................................................................................................5 3............. 45 In terms of improving interpersonal communication skills: .............................................................................................................................................................................. 48 3........................................................................................................................ 52 List of table & Figure Page No Fig—l organizational structure………………………………………………………11 Fig-2 Beer production process flow………………………………………..................................................................... 45 THE OVERALL BENEFITS I GAINED FROM THE ............39 VII .......................................................................Dashen Brewery s...................................................................................................................... 47 Related issues: ..........................3 ............................................................................................................................................................7 3.....................................8 In terms of improving practical skills: .4 3............................................................................................................. 45 Internship......................................................................6 In terms of improving leadership skills: ............................. 47 Conclusion: ...........................10 Internship report IED ENG 1202/01 Measures I have taken to overcome these....................................................................................................................................................................................

21 Table-3 Basic difference of drought &bottled beer…………………………………..26 Table-4 Energy flow comparison………………………………………………………28 Table-5 Raw material………………………………………………………………….Dashen Brewery s. c Internship report IED ENG 1202/01 Table-1 Employee profile……………………………………………………………………..41 VIII .5 Table-2 Temperature during bottle washing……………………………………………...

and a home to rare endemic fauna and flora and renewed for its breath taking scenery.5 hectors . It's named after Mount Dashen .occupying an area of 8. The Brewery is located in the historical town Gondar which is annually visited by more than 95.000 tourists.Thus. Dashen Brewery has an initial annual total capacity of 500.1 Brief history of the company Dashen's modern plant . waste managment and satisfying customer need and expectations.000 hectoliters (151 million bottles ) current production output stand at 300.Dashen Brewery s. 1 .was completed with an initial capital investment of over 340 million Birr. The principal aim of Dashen Brewery is meeting the customer requirements for quality beer and to offer customers more choice in the market wirth out affecting the environment . recognized certifications. Dashen brewery has already been a beer tycoon and a pioneer in customer satisfaction. the brewery is highly committed to waste reduction. c Internship report IED ENG 1202/01 CHAPTER –ONE BACKGROUND OF THE COMPANY 1. Despite its young age.000 hectoliters (91 million bottles ). ISO 9001 and ISO 14001. which is confirmed by being awarded two internationally. Dashen brewery utilizes state of the arts technology and has a hightly qualified professional work force that will enable it to complete on the export market with the leading international beer producing and marketing companies.Ethiopia's highest mountain elivation4523 meters).

creating self-help job opportunities etc.225. c Internship report IED ENG 1202/01 As a result of relentless effort of its professionals. the brewery is now in a position where its supply could not meet the demand created for its products . its high-tech technology and appropriate strategy designed to penetrate the seemingly congested local market. carefully selected yeast and hops only. assumed to be finalized in the coming August. will put the brewery at number one position with respect to both quantity and quality.The Brewery has been working with youth associations and clubs in the fight against HIV/AIDS . As to the raw materials the brewery uses the most suitable water. The new capacity after expansion. a figure anticipated to increase within the next 6 months as the company steadly expands its market share and plant capacity to 750. two raw spring barley malt. the work to expand the Brewery to three fold of its actual current capacity has already begun. The project aims to benefit the farmers of the area by integrating them as suppliers of the Barely for the factory Dashen Brewery is taking in various activities as part of its social responsibility to the society .In line with this. The brewery has 600 employees. The Brewery is currently undertaking projects of malt factory to supply the Brewery and other Brewery's with a sustainable supply of quality malt produced in the unique two-raw barely grown in the high lands of the region.Dashen Brewery s.000 hectoliters (or 225. Hence. modern technology diffusion and vigorous human resource capacity development work is under taken at all levels.225 Bottles). 2 .Helping street children.This has therefore put the brewery in the forefront of the local market even at its infant stage.

 Australia. barley. The end users/customers are every person aged above 18 years old. Chicago in America. The brewer has modern technology diffusion vigorous human resource capacity development work is under taken at all levels. Region 2: this covers the whole Tigray region.2 The main products & service The main products of Dashen brewery are Dashen beer. The brewery uses the most suitable water for brewing quality beer. malt. yeast and hops nothing else added. Benishangul and Afar region. The Brewery's ISO 9001 Quality Management system has won customer confidence that the brewery is supplying products of desired quality with its internationally recognized system . c Internship report IED ENG 1202/01 Dashen brewery is the only and first ISO 9001 and ISO 14001 certified company in Ethiopia which are passports for the global market. There is no any limit or boundary in order to be a customer for Dashen beer.  Israel. Dashen's ISO 14001 Environmental Management System will enable the company to formulate a policy and objectives by taking in to account regulatory requirements and information on activities with significant environmental impacts. Woldia and Addis Ababa. Region 4: east and south parts of Ethiopia. The regions are: Region 1: covers Amhara.Dashen Brewery s. Dashen brewery utilizes state of the arts technology and highly qualified experts that will enable it into compete on the export market with the leading international beer producing and marketing companies. Region 3: covers central and western part of Ethiopia. two row springs. 1. 3 . Dashen brewery exports its products to the following foreign countries:  California. draught beer (locally called draft beer) and cellar. royal beer. There are three warehouses: thus are Gondar. The products are distributed across the country in four regions and three warehouses.

their commitment is increasing. 4 .  Employees of the Brewery: Employees of the Brewery has a fair commitment and owner ship feeling (specially the technical team).  To be the best Ethiopia beer lead drinks company with sustained revenue growth and consistently improving returns on invested capital.Dashen Brewery s. Generally employees in production. Quality and Maintenance departments are highly committed and energetic and with a fair composition. Internship report IED ENG 1202/01 Agents distribute 90% of the product and 10% distribution done by direct distribution to retailers. Vision -To make Dashen the central venue for quality beer celebrities -Building the brands that people love/prefer to drink Mission  It is an endowment fund established to contribute for the development of Amhara region by producing & selling customer proffered quality beer at competitive price & generate reasonable price. c  Southern Sudan.

Term of employment Total Permanent 169    Contract 55 224 Expected work force = 265 The actual current total work force = 224 Accomplishment to date = 224/265*100 = 84. c Employee profile Table 1 Less than 12 and 12 + Internship report IED ENG 1202/01 Educational background 10+3 Technical & Academic diploma 99 15 19 1 31 4 181 College 12+ First diploma 3 2nd Sex grade certification 10 55 Total degree Degree Male Female 43 224 Permanent and contractual Employees.Dashen Brewery s.5% The number of contractual employees will depend on the situation encountered 5 .

c Internship report IED ENG 1202/01 6 .Dashen Brewery s.

c Internship report IED ENG 1202/01 7 .Dashen Brewery s.

Dashen Brewery s. c Internship report IED ENG 1202/01 8 .

Dashen Brewery s. c

Internship report IED ENG 1202/01

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Dashen Brewery s. c

Internship report IED ENG 1202/01

Purpose
 By generating profit it aims to improve the socio-economic well-being of the Amhara region

Commercial Rational To produce & sell quality beer at reasonable profit Value Rational  To support the socio-economical development of the Amhara region in particular & the overall development well-being of the country in general.              Dashen brewery has customer focused orientation Dashen brewery has prevalence of accountability Dashen brewery has well trained & committed work force It gives value for the eco-environment friendly manner. Economic use of resources To involve in export market. To reduce productions loss. To reduce breakage. Determination of safety stock and recording level and implementation. To reduce water consumption. To reduce power consumption. To ensure product consistency at the required level. To train all employees of the brewery is to the end of the next

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Dashen Brewery s. c

Internship report IED ENG 1202/01

ORGANIZATIONAL STRUCTURE OF THE COMPANY

Border of Director

General Manager

Deputy General Manager , Marketing

DGM, Technical

Finance Dep’t

Supply dep’t

Human resource Magtdep’ t

Production Dept, Market research & dev’t division Customer service & promotion division Processing Division Filling & packing Division Marketing Region 1 Marketing Region 2 Marketing Region 3 Marketing Region 4

Maint.Dept .

Quality assurance dept.

Sales & distribution Division

Physicochemical Team Production machinery division

Microbiological Team Utilities Machinery division Electric & instruments division

Worksho p& Garage Division Procurement division Warehouse division

General accounts division Cost & Budget division

Finishe d Produc ts & empty contain er store(A .A)

Input Material Store

General Store

Spare parts store

Empty containe r store

Finished products store Fig.1 organizational structure 11

General Service division

Personnel Administration Division

poor quality malt rejection. Hops.3 Work flow of the company Beer production Process Flow  Barley Malt. c Internship report IED ENG 1202/01 1.& brewing yeast-quality of basic inputs will be insured to be used by QAD(Quality assurance department)  Treating malt(stone. Brew water.Dashen Brewery s. dust & iron removal) All malt rejects used for cattle feeding Conditioned wet milling  The husk will be used for wort clarification Brewing water  Mashing Break Down of high molecular starch to glucose & maltose Wort Pre run Tank  Wort collection Lauter Tun  Wort separation as using husk as cake medium Spent grain for cattle feeding Hops Bitter Arom a Wort Kettle  Wort sterilization & concentration  Alpha-acid isomerisation Whirl pool  Hop trub separation  Separation of colloidal Filtration plant  Cellar filtration  Clarity control by online haze meter  Filtered beer transferred to bright beer tank (BBT) Fermentation Tank  Fermentation & maturation  Laagering & conditioning Figure-2 Wort cooling & yeast addition  Wort cooling &  Yeast pitched Beer production process flow 12 .

Mash tun kettle 3. Lauter tun tank 5. Mash kettle 4. Mill star 2. Pre-cleaning room Malt is pass through the bucket elevator which is from intake hopper& collected into screening box in order to remove big objects. Pre Run Tank 6. then discharged to destoner which separates stones & other heavy particles from the malt. CaCl2and caramel. 1. H3PO4.from pipe magnet malt is discharged into weighed which records weight of malt before it releases malt into bucket elevator.2.Dashen Brewery s. The intake hopper which is grounded is one side vertical for ease of inserting the malt.1 Process description in the first raw material store room The raw materials are discharged through a galvanized body into the intake hopper in order to make it free from the first unnecessary particles& ready for the next section. Wort kettle 7. c Internship report IED ENG 1202/01 1. Brew house Process flow in brew house: 1. 2. Whirlpool Process Flow in Brew House: 13 . 3. Raw material store room The main raw materials those Dashen brewery uses to produce beer are:  Malt  Yeast  Hops  Water & some other chemicals such as CaSO4. malt is discharged into bucket elevator to feed it into pipe magnet which separates metal parts in the malt .

Valves are there to perform their intended function such as manual. Two corrugated press-roller carry out the rough grinding process.water regulation (the mashed in a grist is collected by a conveyor & delivered to mash pump). 14 .grinding process while carefully treating the malt grain . the steeped malt passed over the feed roller.Dashen Brewery s. automatic.Malt is pre-steeped with warm water when passing through the attached steep conditioning unit. c Internship report IED ENG 1202/01 1 2 3 4 5 6 7 Figure -3 process flow of brew house Process description of each step: 3.then to the crushing roller pair . The malt is steeped before milling.1 Mill Star Malt is transferred from a malt storage hopper into the grist-mill in which it is ground to a suitable size. Ensures an optimal rough.next to the mush mixing chamber with spray nozzles . butterfly valve & pneumatic.

These are: Infusion process: the entire mash is heated up with appropriate rests to the final mashing temperature &no part of the mash is removed to be boiled separately. mashing involves increasing temperature of the machine to the optimum temperature for enzymes to act & maintaining a rest (i. the extract (soluble part) obtained. The purpose is to give as much as soluble extract as possible. starch simple sugar Mashing: grist (grounded malt) & water are mixed together & contents of malts are thereby brought into solution & with help of enzymes.Dashen Brewery s. Energy consuming Here in Dashen brewery the most used process is infusion process.2 Mash Tun Kettle (MTK) Used to digest the wort with continuous stirring before going to lauter tun tank. 15 . Maximizing yield Decoction process: the temperature is increased by removing part of the mash & boiled by ``pumping it back to the remainder of the mash the temperature of the total mash is increased to the next higher temperature. c Internship report IED ENG 1202/01 Mixing valve: regulate hot &cold water which is needed for steeping &mashing purpose to insert through tube to each part. is holding for a period of time).e. Convert . 3. with help of two process.

again these parts feed to the lauter tun when there is new process or sparging (extracting). The wort obtained here is boiled for 1-2 hours about 103ͦ C.6 Whirlpool It is an enclosed cylindrical vessel with a flat base & a 2% inclination towards the outlet . the wort is pumped into the whirlpool.Dashen Brewery s. 16 . Here in this tank wort which is for beer purpose is produced as a main output. wort above 358 hl might be extracted into other unnecessary particles so that parts over the expected amount transferred to the weak wort tank. The main function that is performed by this tank is storing wort which is from lauter tun .5. in pre run tank Carmel that gives golden color of beer is added here. then the trub stored & transferred to outside as a waste. Differentiate strong wort from weak wort & sends the weak one to the weak wort tank which is near to lauter.It is an optimum vessel for separating the wort from the hot trub.The wort stay here for some time before it enters to the wort kettle. a filtration process in which spaint grains (insoluble part) play role of filter material. c Internship report IED ENG 1202/01 3. 3. finally boil them together. After extracting enough amount of wort up to 358 hecto liter. Once the wort boiling process completed. 3. Wort Kettle Wort kettle is an optimum tank for boiling wort.In this tank hops are added with their bitterness chemical to make it bitter taste. 3 Lauter Tun Tank (Mash separating vessel) Separating the soluble extract in the wort from the insoluble material (spaint grains). In addition. with a simple design & a variety of combination options. The hops are added according to the brewery specification. the other part which is the unnecessary one extracted as trub to the trub tank near to whirlpool. 3.4 Pre Run Tun Here in this tank wort from lauter tun is transferred into pre run .

this is performed using plate heat exchanger which is ready for this purpose inside the brew house . . the cold CIP is for fermentor. Filtration Extended laagering period and addition of different acids both greatly reduce yeast loadings and suspended particles. Casting wort is used for yeast propagation because the hop bittering compounds it contains exert an inhibiting effect on growth of contamination. HOT and COLD CIP. A final filtration is needed to remove residual yeast and other turbidity causing materials and microorganisms in order to achieve biological stability.here heat exchanger minimized the hot wort temperature from 95 ͦ c to 11 ͦ c. 3% caustic and intermediate water. disinfectant and HOT water. Beer processing There are three distinct stages in pure yeast propagation: 1. c Internship report IED ENG 1202/01 3. There are two CIPs (Cleaning Internal Place) in beer processing. filter line whereas. In filtration the hiez meter check whether the beer clarified properly or not. Isolation of suitable yeast cells. caustic (3%).e. 17 obtained. this needs to be minimized to the lower temperature as it is needed. disinfectant and cold water. Yeast multiplication in the plant until an amount sufficient for pitching is Important points about yeast propagation:   Operations must be performed under sterilized conditions. It uses 100% acid. 4. HOT CIP uses acid. i. The cold CIP uses acid. yeast line.5%). Cleaning and disinfecting using a CIP system CIP (cleaning in place) is essential to clean and sterilize special huge tanks automatically. bright beer tank and unfiltered beer tank. The hot CIP used for cleaning yeast storage tank. 3. caustic (1. 2. Multiplication of the yeast in laboratory.7 Heat Exchanger (wort cooling) Wort which can be produced in the whirlpool is very hot with high temperature.Dashen Brewery s.

c Internship report IED ENG 1202/01 BEER FILLING AND PACKING PROCESS OF BOTTLED BEER Empty bottles in crate from marked BBT (Bright Beer Tank)  Filtered beer transferred to bottle filler or draught filler Empty crate washer Un packer  Bottle separated from crate & send to bottle washer Online meter  Beer oxygen measurement Bottle Washer  Bottle cleaning & label removal EBI Machine Bottle Filler Machine  Bottle evacuation & beer filling  Corking of bottles  Micro crack any dirt inspection by wave of cleaned bottles Visual Inspectors  Inspection of cleaned bottle Pasteurization of filled bottles  Killing any microbes if found Bottle Labeler Machine  Body & Neck labeling  Dating coding FBI Machine (Full Bottle Inspector)  Proper labeling.Dashen Brewery s. filling & proper corking Full product store  Distribution of product to their dear customers Palletizes  Palliating full crates to pallets Packer  Packing of filled bottles to washed empty crates Figure-4 Beer filling & packing process 18 .

4.1 Crate washer The bottle crates must be easily conveyed from the depalletizer. Conveyors for crates & collapsible boxes are also important. after emptying they pass through a crate washer & turner & are stacked in a crate store until used after filling. There is however very great difference in the way in which the bottle gripper heads is moved.Dashen Brewery s. The essential elements of a packing machine are:     The machine frame. & the process is begun again. grips the bottles & sets them down on the belt Whilst the bottles are being set down the emptied crate is replaced by the next one. via the un packer & packer. c Internship report IED ENG 1202/01 4 Process Description: Bottling 4. to the palletize. The gripper heads. moved forward on rollers. The gripper heads drive The bottle arranging system Operating principle of caser & un caser(Batch operation)    The crates for unloading are positioned behind one another A gripper cross-bar with up to 7 gripper heads is lowered.2 Un caser (un packer) & caser (packer) The unpacking of bottle from crates & the subsequent repacking of them into the crates is performed by unpacking & packing machines which work on the same principle & are therefore considered together. 19 . Here the type of conveyor used for bottle crate transport is roller conveyor which is driven by roller chain or belt drive which can be brought into operation by pressure rollers. Because the crates can become dirty during transport and in stores.

All the bottles for a bottle carrier are pushed in synchronously. Here in Dashen brewery washer has a capacity to washes around 60.the is done by bottle inspecting machine.  The bottle conveyor . It is considered to have been achieved if the bottles are covered by a continuous film of water. 10-70 bottle cells in a row.to remove the residues of drink from the interior of the bottle. The bottle. The mechanical or optical cleaning effect is regarded as achieved when no visible soiling can be detected in or on the bottle .  The immersion steep. depending on the size of washer. which 20 . The drink residues present a heavy waste water load & can be treated separately (presoaking). c Internship report IED ENG 1202/01 4. Basic Principle of Bottle Washing:  The bottle must be cleaned mechanically &  All beer spoilage microorganisms must be removed & killed. For reuse the bottles must be cleaned & the label & tin foil wrapping must both be removed. The emptied bottles are immersed in bath of caustic & are conveyed in one or more loops through this loops. monitored by microbiological control department. Essential component assemblies of bottle washer:  The bottle loading & discharge units.  The presoak stations. which inspect the bottles at a much faster rate than can be done by human eye.  The rinsing stations. to start the cleaning process. to prewarm the bottle.comprising bottle cell compartments.3 Bottle Washer Returnable bottles come back from the customer dirty & still labeled.Dashen Brewery s. Every bottle carrier comprises. The bottles to be cleaned are delivered to the bottle washer by slat conveyor chains. Moreover many bottles still have remains of aluminum foil capping wrappers on the bottle neck. The aim of bottle cleaning is to remove all visible dirt from the inside & outside of the bottle & to ensure that the bottle has been sterilized. Biological cleaning is achieved when all microorganisms are killed & removed. &  The caustic & water container.  The label remover. easily soluble external dirt.000 bottles in one hours.

c Internship report IED ENG 1202/01 are now in the upper part of washer with the bottle mouth facing downwards are then jet rinsed several times inside & out. Table 2 Temperature during Bottle Washing 35-40 °c 55-60 75-85 45-50 35-40 20-25 10-15 Pre warming. For this the following are particularly important The avoidance of contaminations.Dashen Brewery s. The nominal fill of every bottle must be ensured. For this to apply. Finally heat insulated container installed beneath the rinsing zones are used to store the liquids flowing back from the rinsing zones.During this. the caustic or water passes over a sieving device to a pump which recirculates the caustic. presoak 2 soak Caustic bath Intermediate rinsing Warm water Cold water Fresh water nd 4. must be separated & removed before filling. 21 . The cleaning caustic is pumped round inside the bottle washing machine & maintained at the predetermined temperature by additional heating. This includes. the bottles which are not fit to use. used hot water is led back to the presoaking section.5 Filler Machine (Bottle Filling) Filling the cleaned bottles is the most important task . during this the soaked off labels in caustic stream are conveyed to the suction & retained there by a sieving device.    Bottle containing foreign bodies Bottles with defects in the mouth region Bottles containing residual caustic from the washer 4.& The quality of the beer must be maintained. all bottles should be clean & fit to use after cleaning. for various reasons.4 Empty bottle inspection (EBI) Basically.     Loss of beer must be avoided.

the pressure is released & the bottles are lowered again & moved away Component element of the filling machine. 22 .  the filling elements.  the beverage container. separated to a predetermined spacing by an separating device.  the lifting elements . The filling process is also electronically controlled as follows. Filled . c   Internship report IED ENG 1202/01 The prevention of air entry & consequent oxidation.  the machine frame. & The avoidance of co2 loss from the beer.  the machine drive. The most important & longest process is the filling of bottles which needs about half of the total time. a higher throughput can only be obtained by employing more filling heads & therefore using a larger filler diameter. During rotation of the filler the bottles are :       Pressed against the filling element. & positioned on a lifting platform under the filling elements by a star wheel loading device.Dashen Brewery s. The filling height in them is corrected. Because it is not possible to simply limit the time for filling. The bottles are delivered on a conveyor belt. Principles of bottle filling Machine Design Bottle filling machines are always built as rotating machines with up to 200 filling valves. Purging the bottle with co2.   Pre-evacuation of the bottle or purging with steam. Evacuated & counter pressurized once or twice. & of course.

Dashen Brewery s. subjected to the pasteurization temperature for a fixed time.   The actual temperatures in the bottles. Counter pressurizing with co2. Here bottles are closed with a crown cork . & The pasteurization units supplied Heating & cooling of the bottles or cans is performed using various water circulation paths in order to utilize recovered heat. & then cooled again. Internship report IED ENG 1202/01 End of filling with initial pressure venting. For this. the appearance of the bottles is very important. the closing machine is built into the the same bloc as the filler & they are equipped with a common drive to ensure synchronous operation. The number and size of labels.a slide conveying device into the storage hopper of the bottle closer & is there brought into the correct orientation by a sorting device.6 Pasteurizer Machine In the pasteurizer the filled cans are heated in stage. the crown cork passes on a magnetic conveyor band . The temperature is monitored by a recorder. 4. In the unending struggle for market share. 23 . c      Evacuation of the bottle.7 Labeler The main function of labeler is labeling on neck and body of the beer bottle. 4. Slow initial filling. their arrangement and the overall effect should show a customer that a producer’s beer is not only the best but also the most attractive. These records:  The spray temperatures in the individual zones. Final pressure venting.rapid phase. Basic principle of labeling The label should be stuck firmly and completely straight at the predetermined position on the bottle. design. In this way heat usage by the tunnel pasteurizer can be reduced to minimum. Closing the bottles After filling the bottles are closed as soon as possible. it takes about an hour to pass through. their color.

4.  Cold water rinse/spray. 4.9 Caser The caser holds and put the final product (labeled) bottled beer to the crate. 4. that the label is cut out or pressed out very cleanly. It inspects the under fill. Gripper cylinder.Dashen Brewery s. In second rotation. Label supply. 3. Station 3:  Caustic blow out. Bottle. 4.10 Keg draft plant There are four stations in keg plant: Station 1: the keg container is ready for registration. In a first rotation. 6.  Caustic washes internal of the container. Station 2:  Pressure blow out the dirty components. Label. c Internship report IED ENG 1202/01 Operating steps when labeling a bottle 1. the now glued labels are caught by a holding device (gripper) and held with the printed side inwards against a sponge. Adhesive or removal segment. neck label and body label. The labeled bottles are then moved past brushes and rubber rollers and the labels are there by firmly stuck on. the rotating gluing or picking up segments are coated with adhesive by the adhesive-applying roller and then pass to the label magazine. Adhesive roller.8 Full bottle inspector (FBI) Full bottle inspector is located next to labeler.  Hot water rinse. overfill. In third rotation. otherwise two or more labels could be removed together and this would lead to stoppage. As a result of the great adhesive strength of the glue a label is picked up. the labels are rolled with their glued side against the bottle whilst the gripper opens and thus releases the label. 5. 2. 24 . in this connection. It is important.

Dashen Brewery s. Beer Filling & packing Process of Drought BBT (Bright beer tank)  Filtered transferred to drought filler Pasteurization & cooling  Beer is pasteurized & cooled before filling Drought filler machine  Empty drought container Empty drought container From market  Dashed(container only Weight sensor  Checking proper filling labeling at production data Product store  sales Figure-5 Beer filling & Packing of drought 25 . c  Steam sterilizes. s  Internship report IED ENG 1202/01 The cycle time for all stations (start and finish at the same time) is 70 seconds.

Dashen Brewery s. 26 Carbon filter Sand filter HCl PH reader . 5. It uses    B. process water glycol and purified carbon dioxide those have significant impact on production.66 o C for one hour Large Number of Machinery and space Small requirement Length of time for expiration End product container About one month Short cylinder About 6 month Bottle Note: both the bottled beer in crate and draft container is transported to end product storage by fork lift. CO2 plant CO2 recovery Components of CO2 recovery plant: 1. CO2 compressor The compressor is piston type. Utility It is the backbone the company.carbon free which is needed for beer and service water for other purpose in the company. First stage saction side air enters and compressed at approximately two bars at wide diameter and at second saction compressed air again enters and compressed at 15 bar (low diameter side). Raw water treatment The raw water treated and classified as process water: . it is the sources of steam. Heat exchanger This is a shell type heat exchanger. c Internship report IED ENG 1202/01 Table 3 the basic difference of draft and bottled beer Draft Pasteurization temperature 73oC for 30 seconds Bottled beer 27 o C . 2. A. Because.

c 3. Boiler Three pass boilers This term is used because the flame and exhausted gases pass through these boilers in three flow paths. 5. c. Ammonia is condensed from outside and condensed by water. The unpurified CO2 from fermentor has been showered by water scrabber. CO2 condenser is a shell and tube type heat exchanger in which CO2 on tube side and ammonia on the shell side. Internship report IED ENG 1202/01 4. NH3 plant It is one of the cooling elements because its boiling point is-37oC. CO2 balloon (storage). NH3 is recycled only in NH3 p D. Ammonia cools glycol which is used to chill the beer at the fermentor so the hot glycol is piped to cooling plant and heat exchanged with ammonia. 27 . 6. At pressure of approximately 18 bars and at temperature of -240c the CO2 condensed. The condensed CO2 is flowing by gravity to storage tank. Ammonia compressor. Carbon filter-it removes odor and impurities. well insulated sheet steel cylinder. Before the CO2 gas enters in CO2 balloon. CO2 stored in liquid state and spent to fermentor and filler in gas form after evaporation. 9. There is heat exchanger to reduce the temperature. CO2 condenser-CO2 cooled by ammonia. By means of this the gas/air or oil/air mixture is burnet in a large flame in the fire-tube. Dehydrator (silicon absorbs the moisture). the moisture removed by water lock and dehydrator. Scrabber-CO2 from fermentor showered by water. 8. The ammonia compressor is screw type. 7. The boiler consists of a horizontal. At one side of the boiler is the fire-tube at the front end of which the burner is installed.Dashen Brewery s.

The energy flow of a compression refrigeration plant is compared with a steam power plant as follows. the softener prevents scale created when the minerals entered with water. For this purpose    The feed water is preheated in an economizer by cooling the exhaust gas. The heated water from feed water tank sends to boiler to be supper heated steam (180 oC). chemicals (NaCl) for treatments. and The waste heat is used to heat up the condensate. expansion valve (metric valve) lower the pressure approximately one or two bar and heat energy. Energy recovery It is advantageous to use the energy released from the fuel as completely as possible with in the brewery. The boiler uses fuel. The steam is superheated to make it transportable. Compression refrigeration plants The Compression refrigeration units are: evaporator. compressor. The servo motor balances fuel and air.Dashen Brewery s. condenser (liquefier). It uses softeners. furnace and air. Table 4 Energy flow comparison Energy source Steam power plant Compression refrigeration plant Heat Mechanical energy Energy supplied Mechanical energy Cooling energy Energy flow comparison between compression refrigeration and steam power plant Condensers (liquefiers) Condensers are heat exchangers in which the heat removed is taken up by a cooling medium (air or water). The water enters to feed water tank and heated at 105 oC. The condensation process proceeds in three stages: 28 . c Internship report IED ENG 1202/01 The boiler has its own water treatment system.

c    Internship report IED ENG 1202/01 Removal of the super heating heat until the evaporation temperature is reached.  Avoiding catastrophic damage properties and loss of human life. COD The chemical oxygen demand (COD) is determined from the reaction of a strong oxidizing agent with the oxidizable organic and inorganic substances in the waste water. The foreign bacteria need O2 for reproduction and the O2 sensor controls the amount of O2 needed.e. First the wastewater neutralized by H2SO4. the slag results from sedimentation used for fertilized and the water is free environmental pollution.  Minimizing the loss of productive time and cost because of maintenance effect. Removal of the heat for evaporation. Objectives of Maintenance management  Minimizing the loss of productive time and cost because of malfunctioning of the equipment. 29 . the amount consumed in a period of 5 days at a temperature of 200c by bacteria. Cooling down of the liquid. Maintenance activities Maintenance management It is the direction and organization of resources in order to control the availability and performance of an industrial plant to specified level. 7. Then the foreign bacteria eat the bad bacteria. Waste water treatment BOD5 The BOD5 is a biochemical oxygen demand of the waste water. i.Dashen Brewery s. Finally. It uses a solution of potassium di-chromate (K2Cr2O7) with this method the organic compounds are completely oxidized according to their theoretical oxygen requirement. 6.  Efficient use of maintenance techniques and equipments.

pure hop. Duration of fermentation.    2. In dashen brewery Share Company it is performed in 1998 and 2008 that took a long period of time. Overhaul maintenance It is examining thoroughly so as to make any repairs and changes that are needed.0% alcoholic concentration and approximately 94% water. Micro-biological-It focuses on the presence and absence of microorganisms. performance and safety.pure malt. In addition the fermentation temperature and time have to be controlled. There are two sections in quality assurance departments: 1.It analyses the physical and chemical properties. Process default. Overhauling in dashen brewery is performed by specialists from foreign countries. Corrective maintenance It is carried out when the equipments fails below the acceptable condition while in operation. Physico-chemical. The life of equipments Preventive maintenance helps in prolonging and ensures the accuracy of equipments. Preventive maintenance It is the technique of minimizing ultimately equipments breakdown and /or equipments condition falling below a required level of acceptability. The fermentation duration for Dashen beer is 17 up to 21 days. It is also planned in 2011. 30 .Dashen Brewery s.in bottled beer 120 p (Plato) is food and 4. C. Hang over: high weak feeling. 8. the PH value.e. I. It is also off-schedule and emergency maintenance which is carried out after break down. Type of maintenance A . Quality assurances In Dashen brewery quality is assured at any stages of production starting from malt to bottled beer and keg draft.5 to 5. It is a scheduled maintenance that is performed at regular intervals for the purpose of keeping the system in a condition consistence with built a level of reliability. alcoholic content etc. water and etc. Quality is expressed by:  Raw materials. B. Food content. c Internship report IED ENG 1202/01  Preserving the companies’ investments and prolonging the life of assets.

An internship will provide relevant experience in a field to include in a resume as well as providing you with professional references and networking contacts I get this internship chance by the good relation of the industry linkage of the university with the company & by direct contact to the company using an application form & telephone. Maintenance Department Preventive maintenance z) Break down Maintenance Maintenance plan Expert Job order Issue Division Manager Operators Inform order Division Manager Forman Worker Forman & worker Distributer Review Forman check Fig.Dashen Brewery s.  The work flow in my section looks like. c Internship report IED ENG 1202/01 Chapter Two Maintenance Department Project work on Inventory Control (re-order level problem)  The overall experience that I gained from this program described below as follows: Internships offer experience and a way to see what it’s actually like working in the field or industry.6 work flow of maintenance department Maintenance plan Expert 31 .

consumables. Give proposed solution to the given problem. Show title of the project to my company advisor & deal with him on the title name.  Finally set all the necessary data & comment that I collected in a written docume Introduction: Inventory control-is the activity which organizes the availability of items to the customers. obsolescent items and all other supplies. interview different people using prepared quetionaries 2. Take the comment & correct myself as I told me. spare parts. Show my day to day activities to my advisor to get basic comments to correct my self. methods I have been using to gather data are simply    Interviewing types of data acquisition .1 Procedures I have been using while performing my Project work        Identify the problem. This role includes the supply of current sales items. Collect data to solve the problem using full information. Inventory enables a company to support its customer service. logistic or manufacturing activities in situations where purchase or manufacture of the items is not able to satisfy 32 . manufacturing and distribution functions to meet marketing needs.Dashen Brewery s. direct contact to the related body Qualitative data Questionnaires. c Internship report IED ENG 1202/01 Methodology: During my project work. new products. Coined the problem area name. It coordinates the purchasing.

Stock control is definitely a balancing act between the conflicting requirements of the company. A fixed-order inventory (FOI) model can be used to determine the quantity to order at this point in time. quality assurance contracts and general administration. When the inventory level has reduced to a certain amount. or because the appropriate quantities cannot be provided without stocks Stock control1 exists at a crossroads in the activities of a company. The quantity to order at this point in time may be calculated using the economic order quantity (EOQ) model. c Internship report IED ENG 1202/01 demand.and return-time reduction • Improving the kitting and delivery process • Reducing inventory and associated carrying costs • Reducing expedite freight costs • Improving profitability • Increasing inventory accuracy 33 . finance. but the definition of the term 'correct level' varies depending upon which activity is defining the stock. an order for further inventory is made. In some cases there will also be manufacturing. but the time between orders varies according to the rate of use of the inventory item. The reorder point can be calculated by the use of a computer system which can also automate the ordering system. purchasing. termed the ‘reorder point’. In a fixed-order period inventory system. Fixed-order quantity inventory systems In this system the order quantity is the same each time the order is placed. Lack of satisfaction could arise either because the speed of purchasing or manufacturing is too protracted. Each of these has a particular view of the role of stock control. distribution or support services or a variety of industry specific activities. and the prime reason for the development of inventory management is to resolve this conflict in the best interest of the business.Dashen Brewery s. OBJECTIVES OF INVENTORY Control The main objectives of inventory management include the following: • Reducing cycle-time by • Lead-time improvement • Transportation-time reduction • Repair. A conventional supply organization will have many departments including sales. inventory is ordered at a fixed point in time (say once a month). Many of the activities depend on the correct level of stock being held.

c Internship report IED ENG 1202/01 2. Ordering problem (when a responsible person order) Causes  poor item code searching method(for each spare part) 34 .4 Problem statement:  Ordering problem. To make close relationship between the maintenance department & management system.  Lack of spare part plan. Budget based order.  Ordering schedule (once a year).  . Spare part planner (not set clearly as a schedule). Everyone looks only on his/ or her burden.Dashen Brewery s. Increase lead time.5 Possible causes:       Poor item code searching method(manual based order). To minimize down time. Lost of material. 2. Work load to a single person.6    Effects: High down time.7 Problem description 1. Order once a year. 2. 2. 2.3    Objective of the project: To set consistent plan( on spare part).

etc) 3. there is no simplified method)  work load to a single person Effects  receive unnecessary part  high down time  lead time increase 2. Lack of spare part plan Causes     Budget based order Order once a year Effects Worn out part Lost of material( bottle.oil.Dashen Brewery s. decoration paper. c Internship report IED ENG 1202/01 (Manual based order. Ordering schedule ( once a year Causes  Spare part planner ( not set clearly the duration when to order)  Equal opportunity to all spare part once a year Effects 35 . Less interaction between the maintenance department & the management system Causes  Everyone looks only on his\her burden  Effects  Non.water.effectiveness  Limited to creativity  Less In continuous improvement 4.

  customers supported.8. Total production maintenance (TPM) 3.8. Minimization of labor delay & idle time through effective co-ordination of participating function.1. Reliability engineering Detail description: 2. in a safe & efficient manner. Maintenance planning & scheduling 2.     36 .1 Maintenance planning & scheduling Things to be discussed:      Objectives Maintenance planning Maintenance scheduling Responsibilities Criticality & prioritization 2. Optimized utilization of maintenance labor & material through effectively planned & balanced schedules. c Internship report IED ENG 1202/01  Less emphasis to critical spare part  Down time  Lost of material 2.Dashen Brewery s. Completion of maintenance work when it is needed.8 Proposed solution The proposed solution those we have selected to be the best alternative to solve the problem that we discussed before are: 1. Minimization of lost production time due to maintenance.1 Objectives of maintenance planning: Optimal support of the operational production plan by improving maintenance in broadest sense.

equipment criticality. The coded information includes:    Work type Work category Work classification & perhaps others The primary interest of planner is focused on the priority that has been indicated for the work (priority: something given or meriting attention before completing alternatives.2 Responsibilities of maintenance planning & scheduling Specific responsibilities include:  Customer liaison(co-ordination)for non-emergency work  Job plans & estimates  Full day’s work each day for each man 2.The priority is based on equipment criticality & on the type of work to be performed. 2.8. c Internship report IED ENG 1202/01 Planning (how to do job)-is the advanced preparation of selected jobs.3 Criticality & prioritization The maintenance planner initiates job planning based on work orders received & code information on the work order.1. It is the process of detail analysis to determine & describe the work to be performed:  Task sequence & methodology  Identification of required resources  Including skills  Crew size  Labor hours  Spare parts & materials  Special tools & equipment Scheduling (when to do the job)-the process by which required resources are allocated to specific jobs at a time interval customer can make the associated equipment or job site accessible.) Job priority is the determinant for sequencing work planning . The first of this.8. The second work type is determined by:  Work class  Work category 37 .1. ranks each piece of equipment in relation to its impact on the production process.Dashen Brewery s.

Dashen Brewery s. Use computerized technology-enabling operators to calibrate selected instrumentation. It includes:    Maintenance prevention(PM) Maintainability improvement(MI) Good-old fashioned PM. Equipment criticality.  A comparison of job RIME numbers will indicate which jobs are essential & which ones can wait. TPM is a company-wide equipment maintenance system involving all employees.  Employee involvement. from top level management to production line works & the building custodians. Combining these two RIME elements provides a better determination of which maintenance jobs should be scheduled for completion first.  Relating to equipment capacity & reliability  Estimated repair costs & impact on the process B. Work class. & labor.  Continual Improvement. a maintenance plan for equipment entire life span. A ranking index for maintenance expenditure (RIME)-has been developed to help maintenance departments do a more equitable & logical job of controlling maintenance expenditures. The RIME index consists of: A. operating costs. c Internship report IED ENG 1202/01 Work class-is a dynamic attributes such as breakdown repair of a potential failure. 2.8.  Total quality. . Work category-is a fixed attributes such as preventive maintenance (PM) or equipment alteration.2 Total productive maintenance (TPM) Application of RIME index results in better maintenance decision & leads to better planning. TPM works towards elimination of obstacle to equipment effectiveness.  Down time  Speed loss  Defects 38 TPM-combines concepts of. which takes into consideration safety hazards.

Dashen Brewery s. to do so the structure must be arranged in such away to improve the oldest one again. then the company can minimize the work load on each of manager. 39 .Manager Maintenance planner Coordination Maintenance supervisor Fig. 7 Maintenance analysis process I suggest that best analysis to be done to correct the company poor or unrevised structure. c Internship report IED ENG 1202/01 PLANT MANAGER Production Manager Maintenance Manager Coordination Production ass.

It is important that the reliability engineering staff work closely with planners & schedulers to define skill classification level & category.3 Reliability Engineering Reliability engineering is the element of maintenance operation that functions to:    Guide efforts to ensure reliability & maintainability of equipment . utilities . & other maintenance problems 2.8.process. administer & refine the preventive / predictive maintenance program. failures.facilities .1 Reliability engineering functional effectiveness results in:  Fewer failures             Less down time Lower material cost Improved equipment reliability Improved equipment operation Increase plant outputs Extended equipment life Fewer emergency More planned work Better resource utilization Reduced overtime Reduced contract expenditures Reduce maintenance cost 40 . The reliability engineering has two principal responsibilities.control loops & safety(security system) Define .3. Development of engineering solution to repetitive equipments. Reduce & improve (optimize) maintenance work wherever feasible.develop.   Development & refinement of the preventive maintenance program. c Internship report IED ENG 1202/01 2.8.Dashen Brewery s.

145 16 2.207.160 16 3.236 Let us calculate Economic order Quantity (EOQ) & re-order level(R) of the above selected data of the company: 41 .426 3145 25.00 15.500 20.814.056 30.719 3145 4.733 3145 10. c Internship report IED ENG 1202/01 Raw Material from production Department Table-5 Raw material Material needed Demand (Kg) Daily demand Lead Time(LT) Ordering cost(Co) Quality to be purchased (Pc) Imported Malt Carmel colorant Hop extract alpha acid Phosphoric acid Calcium chloride 3145.292.859 16 891 8.000 16 1.371 48.623 3145 3.629 16 378 4.Dashen Brewery s.

859 LT=16 SOLUTION: Q= √2DCo/Pc =√2*3145*891/8719 =√642 Q =25 brew R= L*d =16*10859 =1.733 Required= EOQ & R  R= L*d=16* 15184 =25.145 LT=16 Co=1. c Internship report IED ENG 1202/01 Given1. malt Q= 20 brew.719 Required= EOQ & R The company must order Q= 25 brew.500 Solution: Q= √2DCo/Pc =√2*3145*1292500/20207733 =√402 Q = 20 brew d=15.207.292.000 Pc=20. Imported Malt D= 3. when the level reach at R= 25. Carmel colorant Given: D=3.145 d=10. 3024 kg 2. 3024 kg The company order.814. 73744 kg Co=891 Pc=8. when the level reach at 42 .Dashen Brewery s.

623 Required= EOQ & R Q= √2DCo/Pc =√2*3145*378/4623 =√514 Q= 22 brew  R =L*d =16*4629=74064 kg The company must order. 73744 Kg 3 . I can say that.145 d=4.629 L=16 Co= 378 SOLUTION: Hop extract Alpha acid Pc=4. Given: D=3. as interns finds out weak areas that require improvements for long. I was good while performing my project work.Dashen Brewery s. This can be measured by the final output of the project that is trying to find proposed solutions to solve the basic problem of the company as much as I can. c Internship report IED ENG 1202/01 R= 1.term benefit of the organization which are directly affected on efficiency & performance of the company. 43 . hop extract alpha acid Q=22 brew when the level reach at R= 74064 kg Finally.

2. Some measures that I have taken are:      Make close relationship with each of worker & operator of the company.       The company government system. 44 . some of these are. Over work of the manager in each department.10 Measures I have taken to overcome these Challenges: To make my project succeful or to lead it to the completion. By following the company’s official rule to ask something. Less willingness of worker to show something what I want to ask.Dashen Brewery s. guards who those keep the inside & outside entrance gate of the company. Being patient to get something what I want Asking them repeatedly without saying it is boring. Non voluntary body(department managers)to give data & make an interview. Lack of library access to read manuals & some reference about the operation machines. I tried my best as much as possible.9 Challenges I Have Been Facing During My Project Work: During my project work there was different challenges exist to decline my readiness & moral to minimum point. By telling the problem to my advisor & to the general manager of maintenance department . c Internship report IED ENG 1202/01 2.

Repair-after inspection if there is wear part repair it & make it ready to function. seal. Among them: Machine maintenance: there are activities which are maintain daily. The type of maintenance I used to practices is:  Inspection-daily before process is started. weekly monthly. such as transfer plate which is on the bottle chain conveyor. checked & inspected.1 Goals /Objectives: 1. To relate the interns with the common obstacles who those must straggle 3. wear bolt & others Replacement-parts which are highly damaged are replaced using new spare part to make it ready for use again.3 THE OVERALL BENEFITS I GAINED FROM THE Internship 3. 4. 2.Dashen Brewery s. 45 . water tubes are checked weather they can lubricate correctly. I have got a good chance to improve my practical skill highly.2 In terms of improving practical skills: From this internship program. To relate theoretical knowledge with the practical one . Chain conveyors are checked if there is problem shortened it. & yearly according to the maintenance plan. To identify the major benefit that can be gained from an internship program.    Lubrication-daily before process is started. on each part of water tube. To show to the interns what interface is there when they conduct in such area after graduation. I can develop my skill by participating myself into different part as I had learned theoretically in my department course. parts such as. such as plastic conveyor. c Internship report IED ENG 1202/01 CHAPTER. 3.

Dashen Brewery s.5     In terms of improving team playing skills: I can develop very interesting behavior that is never happened before.4 In terms of improving interpersonal communication skills:  Problem solving  Motivation  Negotiation & conflict control-to reach an agreement  Politeness  Being openness  Self –confidence  Honesty  Personal right & obligation 3.3 In terms of upgrading theoretical knowledge: In terms of upgrading my theoretical knowledge I gained detail & clear way of scheduling maintenance plan for machine spare part on which day can be each machine maintain . 3.& in what duration gap can we apply the scheduled plan for each of them by classifying them in to daily. And also how can order spare part list using their item code by referring manual & using inventory list on the computer for each part according to maintenance plan. monthly. c Internship report IED ENG 1202/01 3.what type of maintenance can be they used . weekly. I can improve How can be patient Giving respect for other How can Make Close relation with the community of my environment Develop listening skill 46 . & yearly.

47 . A work ethic include being reliable.Being open to change & improvements to complete work in more efficient.   Dependable & responsible-come on time. respect for fellow workers. having initiative. c   Problem solving Internship report IED ENG 1202/01 3.These all are teaches me a lot for the future work life of myself. or pursuing new skills. Characteristics that I gained generally includes being:  Strong work ethics-learning the most efficient way to complete tasks &finding ways to save time while completing daily assignments. .workers & supervisors . and showing initiative. attendance. It is also a belief in the moral benefit of work and its ability to enhance character. Adaptability-adapting to the personality & work habits of co. more responsibility & ultimately promotion (placed in positions of a greater responsibility). honesty.6 In terms of improving leadership skills:  How can establishing direction as a leader of a team  Aligning people  Motivating & inspiring  Focus on team & overall goals  Communication with each people under my control 3. responsible for the actions. And also I gained a good work ethics for better positions. From this program I can develop how to improve work related issues before I meet such an organization or when I contact myself in such social network environment .Dashen Brewery s. conducting quality work.7 In terms of understanding about work ethic Related issues: Work ethics is a set of values based on hard work and diligence.some of them includes punctuality.

& expecting rewards for undertaking.8 In terms of entrepreneurship skills: As Entrepreneurship is the process of creating something new with value by devoting the necessary time & effort. from this internship program I gained different ideas to:    Make myself free from the limit of standardized pay for standardized work(profit) Freedom from supervision & rules of bureaucratic organizations(independence) Freedom from routine. boring & unchallenging jobs(satisfying way ) And it makes me interested in:      High need for achievement Willingness to take risks A need to exercise leadership Self-confidence Creativity 48 . motivates others to do the same within challenges.Honesty & Integrity. c  Internship report IED ENG 1202/01 Possessing a positive attitude. assuming the necessary risks.  .to get the job done in a reasonable period of time.Dashen Brewery s.is the responsibility of each person to use their own individual sense of moral & ethical behavior when working within the scope of their job 3.

My staying In Dashen make me to practice so many things out of academic area . Beside commication way (mechanism) to smooth very hard deal with related person was very nice thing during my staying. I hope my work on the specific area ‘inventory control’ helps the company meet its goals if they give a higher emphasis for it. great minds and very high quality of work. c Internship report IED ENG 1202/01 Conclusion: The whole experience of working at Dashen brewery P. I learned a lot of very related things about maintenance in broad and I can connect myself with higher technology of the world besides to my theoretical knowledge..C was great. 49 . I have tried to develop as many as possible for the company by converting my theoretical knowledge and even got very encouraging results as much as I can with help of my team. This organization has a super work culture.L.it helps me to understand & analyze what should I take when I conduct myself within the environment or looking myself into a responsible person place.Dashen Brewery s. The work I could complete here was very satisfactory.

this gives solution to the problem happened frequently. this team work on the exact time of ordering level and the part which is first ordered by studying the day to day process of each machine. The company should trained all operators to minimized down time by knowing worn-out parts . c Internship report IED ENG 1202/01 Recommendation: Here in my recommendation part I want to recommend different things to the company besides its good strength. The maintenance plan should also revised by the skilled person carefully.Dashen Brewery s. 50 . so that analysis should be the important thing to problem .The operator should take an action when breakdown is reach to higher point before parts are wornout. by taking sample problems on the damage part of the machine a responsible person should study the consistent way to make the part doesn’t exist again or take an action to revise the plan to minimized the problem to be happened again. it’s better to use computer based management to control the overall workers & process of the whole company. means that the company must give a higher emphasis on the overall maintenance plan.The other thing is that the company should prepare one team to control the overall problem on the order of the spare part. The company should implement different mechanism to control or minimized high downtime. The company should implement fully computerized system to minimize the wastage & lost of material during the operation.

by Bruce Hawkins. 51 .Dashen Brewery s.D. Kister 3. revised edition of Technology Brauer und malzer 2nd revised edition. ‘Guidelines for writing an internship report’ 5. Ram Naresh Roy Ph. for different machine in the company.1999. 2. Dr. A Modern Approach To Operation Management. Timothy C. Maintenance Planning and Scheduling. Internet links. 4. c Internship report IED ENG 1202/01 Reference: 1. Text book of the factory ‘Wolfgang Kunze Technology brewing & malting English translation of the 7th. Machine Manual of the company.

C BOD5 COD TPM RIME EOQ R Empty Bottle Inspector Full Bottle Inspector Inventory Control System Cleaning in Place Share Company Biochemical Oxygen Demand for 5 days. c Internship report IED ENG 1202/01 Appendices: EBI FBI ICS CIP S.Dashen Brewery s. Chemical Oxygen Demand Total Productive Maintenance Ranking Index for Maintenance Expenditure Economic Order Quantity Re-order level 52 .

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