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Dashen Brewery s.

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 Mentors 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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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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Executive summery

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

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Table of Contents
Preface: ....................................................................................................................................................... II Acknowledgments: ................................................................................................................................... III Executive summery................................................................................................................................... IV CHAPTER ONE ....................................................................................................................................... 1 BACKGROUND OF THE COMPANY .................................................................................................... 1 1.1 Brief history of the company ....................................................................................................... 1 1.2 The main products & service .......................................................................................................... 3 Vision .......................................................................................................................................................... 4 Mission........................................................................................................................................................ 4 1.3 2. 3.1 3.2 Work flow of the company .......................................................................................................... 12 Pre-cleaning room ...................................................................................................................... 13 Mill Star ............................................................................................................................ 14 Mash Tun Kettle (MTK) ........................................................................................................ 15 1. Raw material store room .............................................................................................................. 13 3. Brew house...................................................................................................................................... 13

3. 3 Lauter Tun Tank (Mash separating vessel) .............................................................................. 16 3.4 Pre Run Tun ................................................................................................................................ 16 3.5. 3.6 Wort Kettle.............................................................................................................................. 16 Whirlpool ................................................................................................................................ 16

3.7 Heat Exchanger (wort cooling) ................................................................................................. 17 4. Beer processing ................................................................................................................................ 17 4 Bottling ........................................................................................................................................... 19 4.1 4.3 Crate washer............................................................................................................................. 19 Bottle Washer.......................................................................................................................... 20 Process Description:.............................................................................................................................. 19 4.2 Un caser (un packer) & caser (packer) ..................................................................................... 19 4.4 Empty bottle inspection (EBI) .................................................................................................. 21 4.5 Filler Machine (Bottle Filling) .................................................................................................. 21 4.6 Pasteurizer Machine .................................................................................................................... 23 4.7 4.8 Labeler .................................................................................................................................... 23 Full bottle inspector (FBI) ...................................................................................................... 24 V

Dashen Brewery s. c

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IED ENG 1202/01 4.9 Caser ......................................................................................................................................... 24 4.10 Keg draft plant ........................................................................................................................ 24 5. Utility............................................................................................................................................... 26 A. Raw water treatment ................................................................................................................. 26 B. CO2 plant ................................................................................................................................... 26 c. NH3 plant .................................................................................................................................... 27 D. Boiler ......................................................................................................................................... 27 6. Waste water treatment....................................................................................................................... 29 BOD5..................................................................................................................................................... 29 COD...................................................................................................................................................... 29 7. Maintenance activities ..................................................................................................................... 29 A . Preventive maintenance ............................................................................................................. 30 B. Corrective maintenance ................................................................................................................ 30 C. Overhaul maintenance .................................................................................................................. 30 8. Quality assurances .......................................................................................................................... 30 Chapter Two ............................................................................................................................................ 31 Maintenance Department ....................................................................................................................... 31 Project work on ....................................................................................................................................... 31 Inventory Control (re-order level problem) ......................................................................................... 31 Methodology: ............................................................................................................................................ 32 2.1 Procedures I have been using while performing my.................................................................... 32 Project work .......................................................................................................................................... 32 Introduction: .......................................................................................................................................... 32 2.3 2.4 2.6 2.8 Objective of the project:.............................................................................................................. 34 Problem statement:...................................................................................................................... 34 Effects: ......................................................................................................................................... 34 Proposed solution ........................................................................................................................ 36 Total productive maintenance (TPM) ................................................................................. 38

2.5 Possible causes: ............................................................................................................................. 34 2.7 Problem description ...................................................................................................................... 34 2.8.1 Maintenance planning & scheduling .................................................................................... 36 2.8.2 2.8.3 Reliability Engineering .......................................................................................................... 40 2.9 Challenges I Have Been Facing During My ................................................................................. 44 Project Work: ........................................................................................................................................ 44 VI

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IED ENG 1202/01 Measures I have taken to overcome these................................................................................. 44

Challenges: ............................................................................................................................................ 44 CHAPTER- 3 ........................................................................................................................................... 45 THE OVERALL BENEFITS I GAINED FROM THE ...................................................................... 45 Internship................................................................................................................................................. 45 3.1 Goals /Objectives: ........................................................................................................................... 45 3.2 3.4 3.5 3.7 3.8 In terms of improving practical skills: ........................................................................................ 45 In terms of improving interpersonal communication skills: ........................................................ 46 In terms of improving team playing skills: ................................................................................. 46 In terms of understanding about work ethic ................................................................................ 47 In terms of entrepreneurship skills:.............................................................................................. 48 3.3 In terms of upgrading theoretical knowledge:............................................................................. 46

3.6 In terms of improving leadership skills: ....................................................................................... 47 Related issues: ....................................................................................................................................... 47 Conclusion: .............................................................................................................................................. 49 Recommendation: ................................................................................................................................... 50 Reference: ................................................................................................................................................ 51 Appendices:............................................................................................................................................... 52

List of table & Figure Page No


Figl organizational structure11 Fig-2 Beer production process flow.................12 Fig-3 Process flow of brew house14 Fig-4 Beer filling & packing process18 Fig-5Beer filling & packing of Drought 25 Fig-6Work flow of maintenance Department 31 Fig-7Maintenace Analysis Process .39

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Table-1 Employee profile.5 Table-2 Temperature during bottle washing. 21 Table-3 Basic difference of drought &bottled beer.....26 Table-4 Energy flow comparison28 Table-5 Raw material.41

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Dashen Brewery s. c

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CHAPTER ONE BACKGROUND OF THE COMPANY

1.1

Brief history of the company

Dashen's modern plant ,occupying an area of 8.5 hectors ,was completed with an initial capital investment of over 340 million Birr. The Brewery is located in the historical town Gondar which is annually visited by more than 95,000 tourists. It's named after Mount Dashen ,Ethiopia's highest mountain elivation4523 meters),and a home to rare endemic fauna and flora and renewed for its breath taking scenery. 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 .Thus, the brewery is highly committed to waste reduction, waste managment and satisfying customer need and expectations. 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. Dashen Brewery has an initial annual total capacity of 500,000 hectoliters (151 million bottles ) current production output stand at 300,000 hectoliters (91 million bottles ). Despite its young age, Dashen brewery has already been a beer tycoon and a pioneer in customer satisfaction, which is confirmed by being awarded two internationally, recognized certifications, ISO 9001 and ISO 14001.

Dashen Brewery s. c

Internship report IED ENG 1202/01

As a result of relentless effort of its professionals, its high-tech technology and appropriate strategy designed to penetrate the seemingly congested local market, the brewery is now in a position where its supply could not meet the demand created for its products .This has therefore put the brewery in the forefront of the local market even at its infant stage. Hence, the work to expand the Brewery to three fold of its actual current capacity has already begun. The new capacity after expansion, 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 600 employees; a figure anticipated to increase within the next 6 months as the company steadly expands its market share and plant capacity to 750,000 hectoliters (or 225,225,225 Bottles).In line with this, modern technology diffusion and vigorous human resource capacity development work is under taken at all levels. As to the raw materials the brewery uses the most suitable water; two raw spring barley malt, carefully selected yeast and hops only. 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. 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 .The Brewery has been working with youth associations and clubs in the fight against HIV/AIDS .Helping street children, creating self-help job opportunities etc. 2

Dashen Brewery s. c

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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. 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 . 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. 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. The brewer has modern technology diffusion vigorous human resource capacity development work is under taken at all levels. The brewery uses the most suitable water for brewing quality beer; two row springs, barley, malt, yeast and hops nothing else added.

1.2 The main products & service


The main products of Dashen brewery are Dashen beer, royal beer, draught beer (locally called draft beer) and cellar. The end users/customers are every person aged above 18 years old. There is no any limit or boundary in order to be a customer for Dashen beer. The products are distributed across the country in four regions and three warehouses. The regions are: Region 1: covers Amhara, Benishangul and Afar region. Region 2: this covers the whole Tigray region. Region 3: covers central and western part of Ethiopia. Region 4: east and south parts of Ethiopia. There are three warehouses: thus are Gondar, Woldia and Addis Ababa.

Dashen brewery exports its products to the following foreign countries:

California, Chicago in America. Australia. Israel. 3

Dashen Brewery s. c Southern Sudan.

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. To be the best Ethiopia beer lead drinks company with sustained revenue growth and consistently improving returns on invested capital. Employees of the Brewery: Employees of the Brewery has a fair commitment and owner ship feeling (specially the technical team), their commitment is increasing. Generally employees in production, Quality and Maintenance departments are highly committed and energetic and with a fair composition.

Dashen Brewery s. 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. 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 = 84.5%

The number of contractual employees will depend on the situation encountered

Dashen Brewery s. c

Internship report IED ENG 1202/01

Dashen Brewery s. c

Internship report IED ENG 1202/01

Dashen Brewery s. c

Internship report IED ENG 1202/01

Dashen Brewery s. c

Internship report IED ENG 1202/01

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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ORGANIZATIONAL STRUCTURE OF THE COMPANY

Border of Director

General Manager

Deputy General Manager , Marketing

DGM, Technical

Finance Dept

Supply dept

Human resource Magtdep t

Production Dept, Market research & devt 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

Dashen Brewery s. c

Internship report IED ENG 1202/01

1.3 Work flow of the company


Beer production Process Flow
Barley Malt, Brew water, Hops,& brewing yeast-quality of basic inputs will be insured to be used by QAD(Quality assurance department)

Treating malt(stone, poor quality malt rejection, 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

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1. 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, H3PO4, CaCl2and caramel.

1.2.1 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. The intake hopper which is grounded is one side vertical for ease of inserting the malt. 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, then discharged to destoner which separates stones & other heavy particles from the malt, malt is discharged into bucket elevator to feed it into pipe magnet which separates metal parts in the malt ,from pipe magnet malt is discharged into weighed which records weight of malt before it releases malt into bucket elevator.

3. Brew house
Process flow in brew house: 1. Mill star 2. Mash tun kettle 3. Mash kettle 4. Lauter tun tank 5. Pre Run Tank 6. Wort kettle 7. Whirlpool

Process Flow in Brew House:


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Dashen Brewery s. c

Internship report IED ENG 1202/01

3 4

5 6

Figure -3 process flow of brew house

Process description of each step:

3.1

Mill Star

Malt is transferred from a malt storage hopper into the grist-mill in which it is ground to a suitable size. The malt is steeped before milling, the steeped malt passed over the feed roller,then to the crushing roller pair ,next to the mush mixing chamber with spray nozzles ,water regulation (the mashed in a grist is collected by a conveyor & delivered to mash pump). Ensures an optimal rough- grinding process while carefully treating the malt grain .Malt is pre-steeped with warm water when passing through the attached steep conditioning unit. Two corrugated press-roller carry out the rough grinding process. Valves are there to perform their intended function such as manual, automatic, butterfly valve & pneumatic. 14

Dashen Brewery s. c

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IED ENG 1202/01 Mixing valve: regulate hot &cold water which is needed for steeping &mashing purpose to insert through tube to each part. 3.2 Mash Tun Kettle (MTK)

Used to digest the wort with continuous stirring before going to lauter tun tank. The purpose is to give as much as soluble extract as possible.

Convert ,

starch

simple sugar

Mashing: grist (grounded malt) & water are mixed together & contents of malts are thereby brought into solution & with help of enzymes, the extract (soluble part) obtained, with help of two process, mashing involves increasing temperature of the machine to the optimum temperature for enzymes to act & maintaining a rest (i.e. is holding for a period of time).

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.

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.

Energy consuming

Here in Dashen brewery the most used process is infusion process.

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Dashen Brewery s. c

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3. 3 Lauter Tun Tank (Mash separating vessel) Separating the soluble extract in the wort from the insoluble material (spaint grains). Differentiate strong wort from weak wort & sends the weak one to the weak wort tank which is near to lauter, a filtration process in which spaint grains (insoluble part) play role of filter material. After extracting enough amount of wort up to 358 hecto liter, wort above 358 hl might be extracted into other unnecessary particles so that parts over the expected amount transferred to the weak wort tank, again these parts feed to the lauter tun when there is new process or sparging (extracting). 3.4 Pre Run Tun Here in this tank wort from lauter tun is transferred into pre run .The wort stay here

for

some time before it enters to the wort kettle. In addition, in pre run tank Carmel that gives golden color of beer is added here. The main function that is performed by this tank is storing wort which is from lauter tun . 3.5. Wort Kettle Wort kettle is an optimum tank for boiling wort, with a simple design & a variety of combination options. The hops are added according to the brewery specification. Once the wort boiling process completed, the wort is pumped into the whirlpool. The wort obtained here is boiled for 1-2 hours about 103 C.In this tank hops are added with their bitterness chemical to make it bitter taste, finally boil them together. 3.6 Whirlpool

It is an enclosed cylindrical vessel with a flat base & a 2% inclination towards the outlet .It is an optimum vessel for separating the wort from the hot trub. Here in this tank wort which is for beer purpose is produced as a main output, the other part which is the unnecessary one extracted as trub to the trub tank near to whirlpool, then the trub stored & transferred to outside as a waste.

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Dashen Brewery s. c

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3.7 Heat Exchanger (wort cooling) Wort which can be produced in the whirlpool is very hot with high temperature, this needs to be minimized to the lower temperature as it is needed, this is performed using plate heat exchanger which is ready for this purpose inside the brew house ,here heat exchanger minimized the hot wort temperature from 95 c to 11 c.

4. Beer processing
There are three distinct stages in pure yeast propagation: 1. Isolation of suitable yeast cells. 2. Multiplication of the yeast in laboratory. 3. Yeast multiplication in the plant until an amount sufficient for pitching is Important points about yeast propagation: Operations must be performed under sterilized conditions. Casting wort is used for yeast propagation because the hop bittering compounds it contains exert an inhibiting effect on growth of contamination. Filtration Extended laagering period and addition of different acids both greatly reduce yeast loadings and suspended particles. A final filtration is needed to remove residual yeast and other turbidity causing materials and microorganisms in order to achieve biological stability. In filtration the hiez meter check whether the beer clarified properly or not. Cleaning and disinfecting using a CIP system CIP (cleaning in place) is essential to clean and sterilize special huge tanks automatically. It uses 100% acid, 3% caustic and intermediate water. There are two CIPs (Cleaning Internal Place) in beer processing, i.e. HOT and COLD CIP. HOT CIP uses acid, caustic (3%), disinfectant and HOT water. The cold CIP uses acid, caustic (1.5%), disinfectant and cold water. The hot CIP used for cleaning yeast storage tank, yeast line, filter line whereas, the cold CIP is for fermentor, bright beer tank and unfiltered beer tank. 17 obtained.

Dashen Brewery s. c

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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, 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

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4
Process Description:

Bottling

4.1 Crate washer The bottle crates must be easily conveyed from the depalletizer, via the un packer & packer, to the palletize. Because the crates can become dirty during transport and in stores, after emptying they pass through a crate washer & turner & are stacked in a crate store until used after filling. 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. 4.2 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. There is however very great difference in the way in which the bottle gripper heads is moved. Conveyors for crates & collapsible boxes are also important.

The essential elements of a packing machine are: The machine frame, The gripper heads, 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, 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, moved forward on rollers, & the process is begun again.

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4.3 Bottle Washer Returnable bottles come back from the customer dirty & still labeled. Moreover many bottles still have remains of aluminum foil capping wrappers on the bottle neck. For reuse the bottles must be cleaned & the label & tin foil wrapping must both be removed. 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.

Basic Principle of Bottle Washing: The bottle must be cleaned mechanically & All beer spoilage microorganisms must be removed & killed. The mechanical or optical cleaning effect is regarded as achieved when no visible soiling can be detected in or on the bottle ,the is done by bottle inspecting machine, which inspect the bottles at a much faster rate than can be done by human eye. It is considered to have been achieved if the bottles are covered by a continuous film of water. Here in Dashen brewery washer has a capacity to washes around 60.000 bottles in one hours. Biological cleaning is achieved when all microorganisms are killed & removed, monitored by microbiological control department. Essential component assemblies of bottle washer: The bottle loading & discharge units, The bottle conveyor ,comprising bottle cell compartments, The presoak stations, The immersion steep, The rinsing stations, The label remover, & The caustic & water container, The bottles to be cleaned are delivered to the bottle washer by slat conveyor chains. All the bottles for a bottle carrier are pushed in synchronously. Every bottle carrier comprises, depending on the size of washer, 10-70 bottle cells in a row. The drink residues present a heavy waste water load & can be treated separately (presoaking),to remove the residues of drink from the interior of the bottle, easily soluble external dirt, to prewarm the bottle, to start the cleaning process. The emptied bottles are immersed in bath of caustic & are conveyed in one or more loops through this loops. The bottle, which 20

Dashen Brewery s. 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. The cleaning caustic is pumped round inside the bottle washing machine & maintained at the predetermined temperature by additional heating, during this the soaked off labels in caustic stream are conveyed to the suction & retained there by a sieving device. Finally heat insulated container installed beneath the rinsing zones are used to store the liquids flowing back from the rinsing zones, the caustic or water passes over a sieving device to a pump which recirculates the caustic, used hot water is led back to the presoaking section.

Table 2

Temperature during Bottle Washing


35-40 c 55-60 75-85 45-50 35-40 20-25 10-15

Pre warming, presoak 2 soak Caustic bath Intermediate rinsing Warm water Cold water Fresh water
nd

4.4 Empty bottle inspection (EBI) Basically, all bottles should be clean & fit to use after cleaning. For this to apply, the bottles which are not fit to use, for various reasons, must be separated & removed before filling. This includes, Bottle containing foreign bodies Bottles with defects in the mouth region Bottles containing residual caustic from the washer 4.5 Filler Machine (Bottle Filling) Filling the cleaned bottles is the most important task .During this, Loss of beer must be avoided, The nominal fill of every bottle must be ensured,& The quality of the beer must be maintained.

For this the following are particularly important The avoidance of contaminations, 21

Dashen Brewery s. c

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The prevention of air entry & consequent oxidation, & The avoidance of co2 loss from the beer.

Principles of bottle filling Machine Design

Bottle filling machines are always built as rotating machines with up to 200 filling valves. The bottles are delivered on a conveyor belt, separated to a predetermined spacing by an separating device, & positioned on a lifting platform under the filling elements by a star wheel loading device. The most important & longest process is the filling of bottles which needs about half of the total time. Because it is not possible to simply limit the time for filling, 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, Evacuated & counter pressurized once or twice, Filled , The filling height in them is corrected, the pressure is released & the bottles are lowered again & moved away Component element of the filling machine, the machine frame, the machine drive, the beverage container, the lifting elements , & of course, the filling elements,

The filling process is also electronically controlled as follows,

Pre-evacuation of the bottle or purging with steam, Purging the bottle with co2, 22

Dashen Brewery s. c Evacuation of the bottle, Counter pressurizing with co2, Slow initial filling- rapid phase,

Internship report IED ENG 1202/01

End of filling with initial pressure venting, Final pressure venting. Closing the bottles

After filling the bottles are closed as soon as possible. For this, the closing machine is built into the the same bloc as the filler & they are equipped with a common drive to ensure synchronous operation. Here bottles are closed with a crown cork , the crown cork passes on a magnetic conveyor band ,a slide conveying device into the storage hopper of the bottle closer & is there brought into the correct orientation by a sorting device. 4.6 Pasteurizer Machine In the pasteurizer the filled cans are heated in stage, subjected to the pasteurization temperature for a fixed time, & then cooled again. The temperature is monitored by a recorder. These records:

The spray temperatures in the individual zones,


The actual temperatures in the bottles, & The pasteurization units supplied

Heating & cooling of the bottles or cans is performed using various water circulation paths in order to utilize recovered heat. In this way heat usage by the tunnel pasteurizer can be reduced to minimum, it takes about an hour to pass through.

4.7

Labeler

The main function of labeler is labeling on neck and body of the beer bottle. In the unending struggle for market share, the appearance of the bottles is very important. The number and size of labels, their color, design, their arrangement and the overall effect should show a customer that a producers beer is not only the best but also the most attractive.

Basic principle of labeling The label should be stuck firmly and completely straight at the predetermined position on the bottle.

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Operating steps when labeling a bottle 1. Label supply, 2. Adhesive roller, 3. Adhesive or removal segment, 4. Gripper cylinder, 5. Bottle, 6. Label. In a first rotation, the rotating gluing or picking up segments are coated with adhesive by the adhesive-applying roller and then pass to the label magazine. As a result of the great adhesive strength of the glue a label is picked up. It is important, in this connection, that the label is cut out or pressed out very cleanly, otherwise two or more labels could be removed together and this would lead to stoppage. In second rotation, the now glued labels are caught by a holding device (gripper) and held with the printed side inwards against a sponge. In third rotation, the labels are rolled with their glued side against the bottle whilst the gripper opens and thus releases the label. The labeled bottles are then moved past brushes and rubber rollers and the labels are there by firmly stuck on. 4.8 Full bottle inspector (FBI) Full bottle inspector is located next to labeler. It inspects the under fill, overfill, neck label and body label. 4.9 Caser The caser holds and put the final product (labeled) bottled beer to the crate. 4.10 Keg draft plant There are four stations in keg plant: Station 1: the keg container is ready for registration. Station 2: Pressure blow out the dirty components. Cold water rinse/spray. Caustic washes internal of the container. Station 3: Caustic blow out. Hot water rinse. 24

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The cycle time for all stations (start and finish at the same time) is 70 seconds.

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

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Table 3 the basic difference of draft and bottled beer

Draft Pasteurization temperature 73oC for 30 seconds

Bottled beer 27 o C - 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.

5. Utility
It is the backbone the company. Because, it is the sources of steam, process water glycol and purified carbon dioxide those have significant impact on production. A. Raw water treatment The raw water treated and classified as process water: - carbon free which is needed for beer and service water for other purpose in the company. It uses B. CO2 plant CO2 recovery Components of CO2 recovery plant: 1. CO2 compressor The compressor is piston type. 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). 2. Heat exchanger This is a shell type heat exchanger. 26 Carbon filter Sand filter HCl PH reader

Dashen Brewery s. c 3. CO2 balloon (storage).

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

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IED ENG 1202/01 The boiler has its own water treatment system. It uses softeners, chemicals (NaCl) for treatments; the softener prevents scale created when the minerals entered with water. The water enters to feed water tank and heated at 105 oC. The heated water from feed water tank sends to boiler to be supper heated steam (180 oC). The boiler uses fuel, furnace and air. The servo motor balances fuel and air.

Energy recovery It is advantageous to use the energy released from the fuel as completely as possible with in the brewery. For this purpose The feed water is preheated in an economizer by cooling the exhaust gas, The steam is superheated to make it transportable, and The waste heat is used to heat up the condensate. Compression refrigeration plants The Compression refrigeration units are: evaporator, compressor, condenser (liquefier), expansion valve (metric valve) lower the pressure approximately one or two bar and heat energy. The energy flow of a compression refrigeration plant is compared with a steam power plant as follows. 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 condensation process proceeds in three stages: 28

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IED ENG 1202/01 Removal of the super heating heat until the evaporation temperature is reached, Removal of the heat for evaporation, Cooling down of the liquid.

6. Waste water treatment


BOD5
The BOD5 is a biochemical oxygen demand of the waste water, i.e. the amount consumed in a period of 5 days at a temperature of 200c by bacteria.

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. It uses a solution of potassium di-chromate (K2Cr2O7) with this method the organic compounds are completely oxidized according to their theoretical oxygen requirement. First the wastewater neutralized by H2SO4. Then the foreign bacteria eat the bad bacteria. The foreign bacteria need O2 for reproduction and the O2 sensor controls the amount of O2 needed. Finally, the slag results from sedimentation used for fertilized and the water is free environmental pollution.

7. 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. Objectives of Maintenance management Minimizing the loss of productive time and cost because of malfunctioning of the equipment. Minimizing the loss of productive time and cost because of maintenance effect. Avoiding catastrophic damage properties and loss of human life. Efficient use of maintenance techniques and equipments. 29

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IED ENG 1202/01 Preserving the companies investments and prolonging the life of assets. Type of maintenance A . Preventive maintenance It is the technique of minimizing ultimately equipments breakdown and /or equipments condition falling below a required level of acceptability. 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, performance and safety. The life of equipments Preventive maintenance helps in prolonging and ensures the accuracy of equipments. B. Corrective maintenance It is carried out when the equipments fails below the acceptable condition while in operation. It is also off-schedule and emergency maintenance which is carried out after break down. C. Overhaul maintenance It is examining thoroughly so as to make any repairs and changes that are needed. In dashen brewery Share Company it is performed in 1998 and 2008 that took a long period of time. It is also planned in 2011. Overhauling in dashen brewery is performed by specialists from foreign countries.

8. Quality assurances
In Dashen brewery quality is assured at any stages of production starting from malt to bottled beer and keg draft. Quality is expressed by: Raw materials- pure malt, pure hop, water and etc. Food content- in bottled beer 120 p (Plato) is food and 4.5 to 5.0% alcoholic concentration and approximately 94% water. Duration of fermentation. The fermentation duration for Dashen beer is 17 up to 21 days. In addition the fermentation temperature and time have to be controlled. Hang over: high weak feeling. Process default. There are two sections in quality assurance departments: 1. Physico-chemical- It analyses the physical and chemical properties. I.e. the PH value, alcoholic content etc.

2. Micro-biological-It focuses on the presence and absence of microorganisms.

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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 its actually like working in the field or industry. 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. The work flow in my section looks like, 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.6 work flow of maintenance department

Maintenance plan Expert 31

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Methodology:
During my project work, methods I have been using to gather data are simply Interviewing types of data acquisition , direct contact to the related body Qualitative data Questionnaires, interview different people using prepared quetionaries

2.1

Procedures I have been using while performing my Project work

Identify the problem, Coined the problem area name, Show title of the project to my company advisor & deal with him on the title name, Collect data to solve the problem using full information, Show my day to day activities to my advisor to get basic comments to correct my self, Take the comment & correct myself as I told me, Give proposed solution to the given problem,

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. It coordinates the purchasing, manufacturing and distribution functions to meet marketing needs. This role includes the supply of current sales items, new products, consumables, spare parts, obsolescent items and all other supplies. 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

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IED ENG 1202/01 demand. Lack of satisfaction could arise either because the speed of purchasing or manufacturing is too protracted, or because the appropriate quantities cannot be provided without stocks Stock control1 exists at a crossroads in the activities of a company. Many of the activities depend on the correct level of stock being held, but the definition of the term 'correct level' varies depending upon which activity is defining the stock. Stock control is definitely a balancing act between the conflicting requirements of the company, and the prime reason for the development of inventory management is to resolve this conflict in the best interest of the business. A conventional supply organization will have many departments including sales, purchasing, finance, quality assurance contracts and general administration. In some cases there will also be manufacturing, distribution or support services or a variety of industry specific activities. Each of these has a particular view of the role of stock control.

Fixed-order quantity inventory systems In this system the order quantity is the same each time the order is placed, but the time between orders varies according to the rate of use of the inventory item. When the inventory level has reduced to a certain amount, termed the reorder point, an order for further inventory is made. The reorder point can be calculated by the use of a computer system which can also automate the ordering system. The quantity to order at this point in time may be calculated using the economic order quantity (EOQ) model. In a fixed-order period inventory system, inventory is ordered at a fixed point in time (say once a month). A fixed-order inventory (FOI) model can be used to determine the quantity to order at this point in time. OBJECTIVES OF INVENTORY Control The main objectives of inventory management include the following: Reducing cycle-time by Lead-time improvement Transportation-time reduction Repair- 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

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2.3

Objective of the project:


To set consistent plan( on spare part), To minimize down time, To make close relationship between the maintenance department & management system.

2.4

Problem statement:

Ordering problem, Lack of spare part plan, , Ordering schedule (once a year).

2.5 Possible causes:


Poor item code searching method(manual based order), Work load to a single person, Budget based order, Order once a year, Everyone looks only on his/ or her burden, Spare part planner (not set clearly as a schedule).

2.6

Effects:

High down time, Lost of material, Increase lead time,

2.7 Problem description


1. Ordering problem (when a responsible person order) Causes poor item code searching method(for each spare part) 34

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(Manual based order, 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, decoration paper,water,oil,etc)

3. Less interaction between the maintenance department & the management system

Causes Everyone looks only on his\her burden Effects Non- effectiveness Limited to creativity Less In continuous improvement 4. 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

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Less emphasis to critical spare part Down time Lost of material

2.8

Proposed solution

The proposed solution those we have selected to be the best alternative to solve the problem that we discussed before are: 1. Maintenance planning & scheduling 2. Total production maintenance (TPM) 3. Reliability engineering

Detail description: 2.8.1 Maintenance planning & scheduling Things to be discussed: Objectives Maintenance planning Maintenance scheduling Responsibilities Criticality & prioritization 2.8.1.1 Objectives of maintenance planning: Optimal support of the operational production plan by improving maintenance in broadest sense, Completion of maintenance work when it is needed, in a safe & efficient manner, Minimization of lost production time due to maintenance, Optimized utilization of maintenance labor & material through effectively planned & balanced schedules, customers supported, Minimization of labor delay & idle time through effective co-ordination of participating function.

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IED ENG 1202/01 Planning (how to do job)-is the advanced preparation of selected jobs. 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. 2.8.1.2 Responsibilities of maintenance planning & scheduling Specific responsibilities include: Customer liaison(co-ordination)for non-emergency work Job plans & estimates Full days work each day for each man 2.8.1.3 Criticality & prioritization The maintenance planner initiates job planning based on work orders received & code information on the work order. 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.) Job priority is the determinant for sequencing work planning .The priority is based on equipment criticality & on the type of work to be performed. The first of this, equipment criticality, ranks each piece of equipment in relation to its impact on the production process. The second work type is determined by: Work class Work category 37

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Work class-is a dynamic attributes such as breakdown repair of a potential failure. Work category-is a fixed attributes such as preventive maintenance (PM) or equipment alteration. 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. Equipment criticality, Relating to equipment capacity & reliability Estimated repair costs & impact on the process B. Work class, which takes into consideration safety hazards, operating costs, & labor. Combining these two RIME elements provides a better determination of which maintenance jobs should be scheduled for completion first. A comparison of job RIME numbers will indicate which jobs are essential & which ones can wait. 2.8.2 Total productive maintenance (TPM) Application of RIME index results in better maintenance decision & leads to better planning. TPM is a company-wide equipment maintenance system involving all employees, from top level management to production line works & the building custodians. It includes: Maintenance prevention(PM) Maintainability improvement(MI) Good-old fashioned PM, a maintenance plan for equipment entire life span. Continual Improvement, Total quality, Employee involvement. Use computerized technology-enabling operators to calibrate selected instrumentation. TPM works towards elimination of obstacle to equipment effectiveness. Down time Speed loss Defects 38

TPM-combines concepts of,

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PLANT MANAGER

Production Manager

Maintenance Manager Coordination

Production ass.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, 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.

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2.8.3 Reliability Engineering Reliability engineering is the element of maintenance operation that functions to: Guide efforts to ensure reliability & maintainability of equipment ,process, utilities ,facilities ,control loops & safety(security system) Define ,develop, administer & refine the preventive / predictive maintenance program, Reduce & improve (optimize) maintenance work wherever feasible.

It is important that the reliability engineering staff work closely with planners & schedulers to define skill classification level & category. The reliability engineering has two principal responsibilities. Development & refinement of the preventive maintenance program. Development of engineering solution to repetitive equipments, failures, & other maintenance problems 2.8.3.1 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

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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

3145.00

15,814.000

16

1,292,500

20,207,733

3145

10,859

16

891

8,719

3145

4,629

16

378

4,623

3145

3,145

16

2,056

30,426

3145

25,160

16

3,371

48,236

Let us calculate Economic order Quantity (EOQ) & re-order level(R) of the above selected data of the company:

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Given1. Imported Malt D= 3,145 LT=16 Co=1,292,500 Solution: Q= 2DCo/Pc =2*3145*1292500/20207733 =402 Q = 20 brew d=15,814.000 Pc=20,207,733 Required= EOQ & R

R= L*d=16* 15184 =25, 3024 kg

The company order, malt Q= 20 brew, when the level reach at R= 25, 3024 kg 2. Carmel colorant Given: D=3,145 d=10,859 LT=16 SOLUTION: Q= 2DCo/Pc =2*3145*891/8719 =642 Q =25 brew R= L*d =16*10859 =1, 73744 kg Co=891 Pc=8,719 Required= EOQ & R

The company must order Q= 25 brew, when the level reach at 42

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3 . Given: D=3,145 d=4,629 L=16 Co= 378 SOLUTION:

Hop extract Alpha acid

Pc=4,623

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, hop extract alpha acid Q=22 brew when the level reach at R= 74064 kg

Finally, as interns finds out weak areas that require improvements for long- term benefit of the organization which are directly affected on efficiency & performance of the company, I can say that, I was good while performing my project work. 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.

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2.9 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, some of these are; The company government system, Less willingness of worker to show something what I want to ask, Over work of the manager in each department, guards who those keep the inside & outside entrance gate of the company, Non voluntary body(department managers)to give data & make an interview, Lack of library access to read manuals & some reference about the operation machines.

2.10

Measures I have taken to overcome these Challenges:

To make my project succeful or to lead it to the completion, I tried my best as much as possible. Some measures that I have taken are:

Make close relationship with each of worker & operator of the company, Being patient to get something what I want Asking them repeatedly without saying it is boring, By telling the problem to my advisor & to the general manager of maintenance department , By following the companys official rule to ask something.

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CHAPTER- 3 THE OVERALL BENEFITS I GAINED FROM THE Internship

3.1 Goals /Objectives:


1. To identify the major benefit that can be gained from an internship program, 2. To relate theoretical knowledge with the practical one , 3. To show to the interns what interface is there when they conduct in such area after graduation, 4. To relate the interns with the common obstacles who those must straggle

3.2

In terms of improving practical skills:

From this internship program, I have got a good chance to improve my practical skill highly. I can develop my skill by participating myself into different part as I had learned theoretically in my department course. Among them: Machine maintenance: there are activities which are maintain daily, weekly monthly, & yearly according to the maintenance plan. The type of maintenance I used to practices is: Inspection-daily before process is started, such as transfer plate which is on the bottle chain conveyor, on each part of water tube, checked & inspected. Chain conveyors are checked if there is problem shortened it. Lubrication-daily before process is started, parts such as, water tubes are checked weather they can lubricate correctly. Repair-after inspection if there is wear part repair it & make it ready to function, such as plastic conveyor, seal, wear bolt & others Replacement-parts which are highly damaged are replaced using new spare part to make it ready for use again. 45

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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 ,what type of maintenance can be they used ,& in what duration gap can we apply the scheduled plan for each of them by classifying them in to daily, weekly, monthly, & yearly. 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.

3.4

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

3.5

In terms of improving team playing skills:

I can develop very interesting behavior that is never happened before. 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

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3.6 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

3.7

In terms of understanding about work ethic

Related issues:
Work ethics is a set of values based on hard work and diligence. It is also a belief in the moral benefit of work and its ability to enhance character. 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 ,some of them includes punctuality, attendance, conducting quality work, respect for fellow workers, honesty, and showing initiative. A work ethic include being reliable, having initiative, or pursuing new skills. And also I gained a good work ethics for better positions, more responsibility & ultimately promotion (placed in positions of a greater responsibility).These all are teaches me a lot for the future work life of myself. 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. Dependable & responsible-come on time, responsible for the actions. .

Adaptability-adapting to the personality & work habits of co- workers & supervisors .Being open to change & improvements to complete work in more efficient.

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IED ENG 1202/01 Possessing a positive attitude- to get the job done in a reasonable period of time, motivates others to do the same within challenges.

.Honesty & Integrity- is the responsibility of each person to use their own individual sense of moral & ethical behavior when working within the scope of their job

3.8

In terms of entrepreneurship skills:

As Entrepreneurship is the process of creating something new with value by devoting the necessary time & effort, assuming the necessary risks, & expecting rewards for undertaking, 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

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Conclusion:
The whole experience of working at Dashen brewery P.L.C was great. This organization has a super work culture, great minds and very high quality of work. 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. The work I could complete here was very satisfactory. 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.. I hope my work on the specific area inventory control helps the company meet its goals if they give a higher emphasis for it. My staying In Dashen make me to practice so many things out of academic area ,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. Beside commication way (mechanism) to smooth very hard deal with related person was very nice thing during my staying.

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Recommendation:
Here in my recommendation part I want to recommend different things to the company besides its good strength. The company should implement different mechanism to control or minimized high downtime, its better to use computer based management to control the overall workers & process of the whole company. The maintenance plan should also revised by the skilled person carefully, means that the company must give a higher emphasis on the overall maintenance plan, by taking sample problems on the damage part of the machine a responsible person should study the consistent way to make the part doesnt exist again or take an action to revise the plan to minimized the problem to be happened again, so that analysis should be the important thing to problem .The other thing is that the company should prepare one team to control the overall problem on the order of the spare part, 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 .The operator should take an action when breakdown is reach to higher point before parts are wornout. The company should implement fully computerized system to minimize the wastage & lost of material during the operation, this gives solution to the problem happened frequently.

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Reference:
1. Text book of the factory Wolfgang Kunze Technology brewing & malting English translation of the 7th, revised edition of Technology Brauer und malzer 2nd revised
edition,1999.

2. Maintenance Planning and Scheduling, by Bruce Hawkins, Timothy C. Kister 3. A Modern Approach To Operation Management, Dr. Ram Naresh Roy Ph.D. 4. Internet links, Guidelines for writing an internship report 5. Machine Manual of the company, for different machine in the company.

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Appendices:
EBI FBI ICS CIP S.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. Chemical Oxygen Demand Total Productive Maintenance Ranking Index for Maintenance Expenditure Economic Order Quantity Re-order level

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