• EIT-M

SCHOOL OF MECHANNICAL AND INDUSTRIAL

ENGINEERING

DEPARTMET OF INDUSTRIAL ENGINEERING

PROJECT TITLE:OPTIMIZING OPERATION OF HDPE 02
MACHINE BY APPLYING PREVENTIVE MAINTENANCE AT
BRUH TESFA IRRIGATION AND WATER TECHNOLOGY
HOSTING COMPANY: Bruh tesfsa Irrigation and Water Technology plc.

DURATION OF PROJICT: Three Month

PREPARED BY: KIBROM TADELE

ID: EIT-M/UR/129575/10

ADVISOR NAME: GEREMEDHN .

COMPANY SUPERVISOR: MULU
.

SUBMISSION DATE:
 ACKNOLODEGEMENT

I would like to express my deepest gratitude thanks to biruh tesfa irrigation

and water technology manager who gives me the chance to intern in that
company for three months and for their much contribution in gathering data
and also for their collaborations in whatever I wanted during the three month
internship period in the company. Next, I want to thank my advisor
geremedhn and my supervisor mulu ,for their guidance and advice while
doing this project.

ABSTRACT

This study is conducted to identify the major factors that affect the operation of
HDPE 02 machine at biruh tesfa airrigation and water technology and to find out
the improvements so as to decease machine failure of HDPE 02.

Data was collected and analyzed the analyzed data is shown in tables and cause
&effect diagram. Finally the analyzed data is presented to draw conclusions and
recommendations.
On the basis the finding factors minimizing operation of HDPE 02 machine are:

• The absence of effective maintenance scheduling

• Less understanding of reliability and availability concepts of the machines

• Lack of continuous preventive maintenance

• Less number of inspection time

Therefore, in order to minimize the major affecting the operation of the

machine are:

• Improve the exiting PM schedule

• Apply reliability and availability analysis of the machine

• Using optimal inspection time

• Operators should use correct procedures and specifications carefully

during operation

LIST OF ABRIVATION

-preventive maintenance

-number of failures

-total down time of the failure.

µ-mean repair rate

λ -mean failure rate

MTBF- Mean time between failures

MDT-mean down time

A-availability of machine

U-unavailability of machines

Y- Optimum number of inspection

C- Constant related to the machine

Tb- time of breakdown

Ti- inspection time

CHAPTER ONE

1.INTRODUCTION

1.1 Background Of The Company

Bruh Tesfa Irrigation & Water Technology PLC was fouded in September 2004 with the vision
of being competed and the leading technological pioneer company in the modern irrigation and
water supply technology development, by offering best quality products and Services (i.e. study,
design and installation) at competitive price in east Africa. The factory is situated in Mekelle, the
capital city of Ti gray National Regional State and has a branch office in Addis Ababa. In order
to accomplish its vision and objectives the company is currently in gagged in producing quality
and complete set of modern irrigation system

1.1.1 Brief history of the company

s: Drip irrigation plastic pipes, HDPE pipes, fittings, to individual farmers, commercial farms,
governmental & nongovernmental organizations for efficient use of water scarce resource &
minimize energy consumption of the country. Since Bruh Tesfa Plc is ISO9001:2008 Quality
Management System Certified, the processing system and the quality of the input and finished
products status are as per the international standards of ISO and DIN. For this purpose the
company has introduced different computerized laboratory requirements for the quality and
grade of the raw material and finished products. Br uh-Tesfa Plastic Products PLC is an
Ethiopian Company established under the Dejenna Endowment (Government Endowment) in
accordance with the commercial laws of Ethiopia. The main objective was:

• To actively participate in the irrigation strategy of the Government of Ethiopia,

• To improve agriculture technology and to shift from rain-fed agriculture
As other industries Bruh tesfa irrigation and water technology has its own vision,
mission, and objectives. These include the following

1.1.1 Vision
The company vision to be competent and the leading technologies pioneer company in the
modern irrigation and water supply technological development.by offering best quality products
and services (i.e. Study, design and installation) at competitive price in East Africa.

1.1.2 Mission
To generate profit and maximize wealth of the owner by satisfying the customer and introducing
new modern irrigation and water supply technology contributing its share in agricultural transformation,
creating assive job opportunity and professional man power in the field and in reducing poverty in the
country.

1.1.3 Objective of the company

• To promote the optimal uses of agriculture and other natural resources in the region.

• To increase the share of the manufacturing sector through value adding and more
income generates schemes.

• To create job opportunities.

• To encourage the establishment of medium and large industries, which call for the most
and create the conditions for the settings up of other industries or the emergence of
other sectors.

• Build and development entrepreneurial, technological and managerial capabilities in the

region.

• Ensure environmental and protection.

1.1.4 Company strategy

The factory has the following plans:

• Develop one step shop marketing

• Give priority to understand customer’s needs and their specific requirements

• Develop team spirit and sense of ownership

• Focus on both local and export market

• Develop a strong customer relationship

1.1.5 Major raw material of Bruh tesfa irrigation and water technology:

• The company uses virgin raw materials in the production of standard products;
while recycled inputs are used to produce flexible conduits.at any rate, it makes sure that
the quality of product at every stage meet the customer requirements. The major raw
materials include:

• HDPE(high density polyethylene )

• LDPE (low density polyethylene)

• LLDPE(linear ontinuous product development endeavors

1.2Company product and services

Bruh tesfa HDPE pipe and fitting are verified and registered regarding potable water
suitability. HDPE can meet the requirement of the ISO4427. The company is currently
manufacturing wide range diameter of PE pipes.

• LDPE PIPE 16ḋ-32ḋ

• HDPE PIPE 50ḋ-315ḋ

• Pressure rating (4, 6, 10, 16 bar, standards and 20 bar on demand

1.2.1 Main Products and Service
• Modern irrigation technology

• Water supply systems

• Other plastic users

• . services

• Modern irrigation technology

• Complete pressurized irrigation system

• Complete gravitational irrigation system
• Other irrigation related accessories and equipment
2. Water supply system
• HDPE (High density polyethylene pipes) made up of polyethylene that
can substitute any type of pipe for water transport and gas distribution
networks.

• PE (polyethylene) fittings, water meters, filters and other accessories

• Welding machine as a special order

3. Other plastic users

• \e tubes/ Tubular films

• polyethylene

• Rigid and flexible conduits

• . Polly bags and sheets

4. Service

• Installation and maintenance

• Study

• Distributed high quality of pipe

• Maintenance services on both modern irrigation as well as water

supply systems

• Butt welding & electro fusion welding services

• top map preparation for large scale irrigation& water supply

projects

• Installation of all kinds of irrigation system (drip sprinkler,

irrigation machinery (pivot, traveling guns &booms)
 • Installation of pipe supported furrow irrigation systems for
different crops

Row material type and quality to be used

• Row material inspection(package list HE3490,HE3405)

• Packaging criteria set according to customer requirement
• Production startup
• Detail Specification or requirement specify
• Job order is dissipated to concern department
• Customer name defined
Dimensional checkup and feed back to the operator

• Diameter of the pipe

• Thickness
• Appearance
• Length
• Spacing number of holes(regarding to drip pipe)
• Continuous checkup (according to the sample size)and immediate
feedback is given for line operator
Management principles
The management should be able to understand the basic problem and aspirations that could hinder a
worker to attain the production targets, the management should always strive to keep the equilibrium
company and employee’s interest. Because the following and other needed principles are necessary.
• Senior managers need to spend most of their time at the production floor.
• Communication from top—bottom and vice versa need to be fast and
effective
• Quality controlling is every-body’s responsibility’s
• Every-body starting from the top management up to the operative staff
needs to be time, quality and cost conscious
• Besides to maintaining quality standards, ensuring on time delivery is
crucial for building along lasting busines

1.2.2Applicable of the products

Modern irrigation technology:

• To irrigate plant

• Use for raw crop by drip and sprinkler to irrigate vegetable, fruits treesetc

• Applicable in modern mechanized irrigation system

 Bruh
tesfa HDPE pipe and fitting are verified and registered regarding potable water suitability. HDPE
can meet the requirement of the ISO4427. The company is currently manufacturing wide range
diameter of PE pipes.

• LDPE PIPE 16ḋ-32ḋ

• HDPE PIPE 50ḋ-31P

1.3 The Company Main Customers Or End Users

• Agricultural bureaus & water resource enterprise

• Rest

• ORDA

• USAID & kobo Girana

• Investors

• water resource & sewerage supply office

• Textile industries

• Laundries

• Tannery companies

• housing agencies

• construction companies and whole sellers of conduit

• private farms

• flower industries & green houses

essure rating(4,6,10,16 bar
1.4 Over all work of the campany
Bruh tesfa irrigation and water technology factory all the required type and amount of
production is contoured (planned) by the planning department (planers).the planners are ordered
to each area of production how amount and what are they produce according their capacity and
plane. The production process is starting from the input or raw material is changing to pipes.
From this product some of the product is marketing directly and other product is goes to the next
processes. The next processes sacker. Then after the raw material is changed to pipes. From this
output also some of the product is marketing directly and the other product is goes to the next
process.

 Quality of the production is checked at every process or at each area of production

 Marketing also takes place at any time and area of production according the customer
demand.

General Manager

Planning Quality assurance

&monitoring, service
service
Internal auditor Executive secretary
service

Study design and isn Addis Ababa branch head Human resource Supply
department department &process
Marketing department
Production Senior Supply
Marketing and promotion section
division secretary

Production and Procureme

tech department
division
Personnel General
&training Service
Maintenance division section Inv.Plannin
division
Sales &dist division
Installation and
maintenance
Cost &bu
division
Finance & logistics section Design & isnsection Marketing & promotion
division
 1.4.1 prodaction flow of the pipe

Very flexible and brand new state of the technology, consisting of the following equipment’s:

• Raw material: are imported from internationally renowned sources as SABIC and
BORAUGE .it contains carbon black 2.5 or 0.03.the raw materials are PE100, PE80 and
PE 40.

• Drier: a machine which used to dry the plastic tube. We don’t use drier if the product is
in humid condition.

• Extruder: this part is they include three zones those zones are; feed zone, transition zone
and melting zone. Therefore the extruder is transforming the raw material from the
hopper to the heating zone.

• Feed zone: in this zone, the resin is inserted from hopper in to the barrel, and
the channel depth is constant.
• Melting zone: The plastics material is melted and the channel depth gets
progressively smaller.it is also called the transition or compression zone.
• Metering zone: The molten plastic is mixed at uniform temperature and
pressure and forward through the die. The resin is inserted from hopper in to
the barrel, and the channel depth is constant.
• Die head: is used to adjust the external size of the pipes. The extrusion head is heated in
malty heating zone with PID electronic temperature regulation for precise temperature
profile over the extrusion die.

• Calibration: is used to adjust the diameter of the size of the HDPE.it performs for sizing
of the outer diameter of the pipe with initial cooling on the extrude pipe coming out
from the extrusion die head.

• Vacuum tank: it is soft and non-air. Is used to protect the product quality and the pipe. If
it is more or less air and temperature in the vacuum it has the following defects: -

By air

• Ovality : if it is shortage of water in the vacuum and if thickness variation is

created.

• Line: if it is more distance between die head and calibration.

• No appearance .
 By temperature

• Dot: when the circulation pump closed with such defects chips and salts.

• Oblique: when the operator has not familiar with that machine.

• Cooling: is used to increase the strength of the pipe. the cooling water exiting from
chambers are collected in lower collection tanks, where it is mixed with re-cooled water
from re-cooled system to attain constant temperature cooling water (15-20).

• Take-off: is provided by three chain-pad caterpillar units driven by AC motors running in

synchronization by programmable electronic AC motors driven controlling the motor.

• Extrusion: this design is targeted specially for higher quality production of HDPE pipes.

• Cutter: is equipped with protection cage to prevent possible operator injuries.

• Roller conveyor: is used to translate the pipe to the end place, if necessary to the winder.

• Winder: it is a pneumatic system it driving of the coilers archived by AC gear motors

5.5kw-8rpm driven by digital AC inverter with high performance torque control for
controlling pipe tension.

Fig 1.2 production flow chart of the HDPE

1.1.2 Pipes inspection

The types of inspection in Bruh Tesfa are the following

Pre-production: this is done before production stars; it is done to cross check according to the
production stated PE materials, manufacturing details and work product of the pre-production
sample as per the customer requirement.

• Inline production inspection: this inspection is done at the start of production

when first production output of particular style of Bruh tesfa inspected to
 distinguish possible discrepancies or vacation and to do necessary corrections to
be made pipe production.

• Offline production inspection: is done during production to ensure initial

discrepancies have been corrected and rectified. This inspection is a follow up of
the first in line production and is generally carried out after first line inspection
when discrepancies have been detected at that time.

• Random inspection: is carried out when the production of the total quantity of an
order or partial delivery is completed. Sample lot will be selected from the order
and percentage of the pipe will be inspected, the percentage usually being
stipulated by the customer.

1.4.3 Pipe defect classification

Defects in pipes are classified with the following categories:

• Critical defect: serious defect that can cause harm or injury to the user result in
hazardous condition.

• Major defects: a defect that falls to meet the mandatory regulations directly
affecting the usability, salability, safety and value of the merchandize or as
specified by customer buyer are considered as major defects and generally non
repairable.

• Minor defects: defect that does not adversely affect the usability of the product
but does consists of a deviation from the organizational sample and may affect the
sale of the product. Some of the defects are due to electrical power, thickness of
diameter, pressure of the pipe.

THE PROCESS OF MANUFACTURING PLASTIC PIPE

 Fig1.3: the process of manufacturing plastic pipes

1.4.4 Procedure of the pipes factory

The pipes are composed of the following procedures

• Raw material type and quality to be used

• Dimension checkup and feedback to line operator

• Physical appearance of the pipe(dots, crake, ovality)

• Sampling method size

• Product tagging and printing

• Assuring the type and amount of the product that has been produced

• Assuring the type and amount of the product that has been

1 Raw material type and quantity to be used:

• Raw material inspecting

• Production start up

• Packaging criteria set according to customer requirement

• Detail specification or requirement specify

• Job order is dissipated to concern department

• Customer name defined

2. Dimensional checkup and feed back to line operator:

 • Diameter of the pipe, Thickness, Appearance, Length, Spacing number of holes,
Continuous checkup.

• Measuring tools are employees for dimensional check up

3. Physical appearance of the pipe:

• Presence of defects

• Measuring for suspected product is conducted using measuring tool

• On line decision is given for defected product

• Defected pipe will be segregated by tagging

4. Sampling method (size):

• Actual parameter value is recorded

• Feedback is given for immediate supervisor with the help of formats

• Carry out necessary parameters checking according to the production stated

sampling method

• Red=rejected product

• Yellow=suspected product

• Green=for approved product and the approved product will be printed

6 .Assuring the type and amount of product that has been produced:

• Amount of product is rechecked with production and department

1.9 Maintenance system of the company

Biruh tesfa water irrigation and Technology Company uses two types of maintenance system.
Those are

1. Corrective maintenance
2. Preventive maintenance

1. Corrective maintenance: a maintenance action which takes place after occurrence of failure.
And difficult to forecast when they are going to happen. Perhaps it is known that corrective
maintenance will happen some times, but nobody knows when.
 Flow of corrective maintenance
Internal work flow of format
Maintenance
Repair or maintaining

Preventive maintenance: a maintenance action which takes place before occurrence failure. And
it is programed maintenance.

Flow of preventive maintenance

Preventive maintenance checklist format
Maintenance report format
Maintenance planning

2 Over all internship experienced

Bruh tesfa irrigation and water technology factory is a big factory which is consists of all
activities of making complete pipes. In bruh tesfa irrigation and water technology there are about
10 departements. these are :
• production and techniqe department
• study, design , installation and maintenance department
• HRD
• Finance department
• Supply and procurement department
• Quality assurance service
• Planning and MIS
• Internal audit service
• Branch offices
2.1 Work flow and operational organization
First the production and technique section accepted the order with specification of customer
product specification to the operator of machine, after that directly start the operation to produce
the product.

Manufacturing process of HDPE pipe

Fig production flow chart of HDPE pipe

Process description of the flow chart

The sacker transmits the raw material to the hopper& the hopper receives the raw material and
sends to the screw according to their proportion. Then in the screw the raw materials are going to
melt at about 115oc but this temperature according to the diameter of the HDPE pipes. After the
raw material is melt it is going then to the Die head. This Die head is used to adjust the external
size of the pipe. Having adjusting the size of the pipe we insert this pipe into the calibration. This
calibration is used to adjust the diameter of the pipe. Then after adjusting the size and diameter
of the HDPE pipe the pipe is going to the cooling tanks. These cooling tanks may be eight or
more than. These cooling tanks are used to increase the strength of the pipe and prepare the pipe
suitably for cutting and the takeoff passes the pipe to the cutter. The cutter is used to cut the final
product (HDPE) pip] according to its appropriate size. Finally there is a wider that is used for
coiling the pipe.

Basic technologies found in Bruh tesfa irrigation and water technology

Very flexible and brand new state of HDPE production pipe technology, consisting of the
following major equipment’s.
Die head: the extrusion head is heated in malty heating zones with electronic temp regulation
for precise temp profile over the extrusion die. This die head is used to adjust the the diameter of
the HDPE pipes.

Calibration: it is a whole metal that creates the required diameters of the pipe

Take- off: is provided by threechain-pad caterpillar units driven by AC motors running in

synchronization by programmable electronic AC motor driven controlling the motor. This Take-
off machine is used to transfer the HDPE pipes to the cutter.
Extrusion (heating): this design is targeted for the higher quality production of HDPE pipes.
This is used to melt the raw material which is coming from the hopper.
Cutter: it cuts the pipe according to the specified length of the pipe.
Cooling Tank: The cooling tank protect cage to prevent possible operator injuries. And also
equipped with sizing of the outer diameter of the pipe with initial cooling on the extrude pipe
coming out from the extrusion die head.
Winder: which is a pneumatic system of part of the machine & it is a final part of the machine
to the production process
2.4 The Work Tasks That Executing:

I start my project to reduce the problems due to maintenance in bruh tesfa

irrigation and water technology by applying the theoretical knowledge in to
practical.

2.5 The Procedures That I Have Been Used For This Task:

 I was tried to understand about machine availability & reliability and also
preventive maintenance.
 I was tried to understand how they prepare maintenance plan.
 Identify the current maintenance schedule and how they perform.
 Identify the limitation of the maintenance schedule.
 Finding the proper solution

2.6 The Challenges That I Have Been Faced:

 They have no internet access.

  They have shortage of data.
 Lack of available resource.
2.7 The measure that I have been taken:

 Taking the data relative to the current situation.

 Create a smooth relationship with my mentor.
 Make close relationship with the worker and operator.
 Being wise to get something what I want.