Professional Documents
Culture Documents
ID: EIT-M/UR/162494/2006
This study is conducted to identify the major factors that affect the operation of
HDPE 02 machine at biruhtesf 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:
N F-number of failures
A-availability of machine
U-unavailability of machines
1.INTRODUCTION
4. Then after a lot of water is added into the longest horizontally placed container
which allows gradual cooling of molten polythene and paves the way to
solidification
5. The operation before cutting, the solidified polyhtene with the required
diameter and length is taking off. The cooled and solidified polythene moves
into the cutting area.
7. Immediately after cutting the conveyer takes the high density polythene tubes,
that substitute any types of pipe for water transport and gas distribution to the
winder and the winder wrap up it in a circular way and release it to the
ground.
sucker
Cooling wind
excluder Die head Take off conveyer
system er
CHAPTER TWO
BLOW TO
RAEW MASTER EXPAND,CO PACK TO BE
DIE HEAD TACTION
MATERIAL EXTRRUDER OLING AND SORED
FORMING
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
CHAPTER THREE
3. BENEFITS FROM THE INTERNSHIP
I realize that actively participate in team work has make some body
know more and increase personal confidence.
Always be honest and give appreciation to other help someone to
have good relationship with them.
I tried to make good working atmosphere and create good will to
make others share their experience.
Ideal disputes were solved through peaceful communication.
I know that criticizing the other person about his mistake not make
him right full for the next time rather trying to admit his wrong
doing smoothly make him effective not doing it gain and
encouraging worker for their doing make them to work harder.
CHAPTER FOUR
4. INTRODUCTION:
Maintenance is a combination of actions intended to retain an item or
equipment in or restore it to, a state in which it can perform the function that is
required for the item to provide a given service.
The scope of maintenance has grown to include not only system repair but also;
System safety
Economic viability
Quality
Appropriate use of environmental resources
Requirements for increased product quality
Reduced throughput time.
This chapter deals with theoretical frame of the study of maintenance. Some
believes that objective of maintenance is to repair damaged machines. This
approach is very costly and creates a lot of problems to maintain. In modern
maintenance management, it is not recommendable to construct too much on
breakdown equipment when they are broken. Modern maintenance management is
to act in the way that by planning time to keep the machine in operation and
produce quality products.
4.8.2 Reliability:
Reliability (R) is the probability that an item will perform its stated
mission satisfactory for given time of period when under them specified
conditions. It is an important factor in equipment maintenance because lower
equipment reliability means higher need for maintenance.
The unreliability of the product can be defined as the probability that
product fails to meet the specification, over given time of period subjected to
given environmental conditions.
Failure can occur due to many factors:-
For example incorrect use of procedures, over stressed parts, chemical
corrosion, wear etc….
In reliability analysis of a system is often assumed that the time dependent
failure rate of items follows the shape of a bath tub curve.
Since at any time t, the product either survived or failed failed. This means R (t)
+F (t) =1
into normal operation. The total down time for N F Failure is therefore ∑ T DJ and
j=1
total up time= N T - ∑ T DJ
j=1
The mean up time or the mean time between failures (MTBF) is therefore given
by:
Total up time
Mean time between failures= Number of failures
i.e.
MTBF=
N T−¿ N FMDT
¿
NF
i.e.
i=N
for N failures is therefore ∑ T i and the mean time failure is given by:-
,
i=1
Total up time
Mean time to fail= Number of failures
i=N
i.e. 1
MTTF=
N
∑ Ti ,
i=1
The failure rate of a system usually depends on time, with the rate varying over the
life cycle of the system. For example, an automobile's failure rate in its fifth year of
service may be many times greater than its failure rate during its first year of
service. One does not expect to replace an exhaust pipe, overhaul the brakes, or
have major transmission problems in a new vehicle.
i=1
4.8.5 Availability:
When a repairable product is up, i.e., working satisfactorily, it is available for use.
When the product is down, i.e., being repaired, it is unavailable for use. It is
important to have an average measure of the degree to which the product is either
available or unavailable.
The availability of the product is the fraction of the total test interval that it is
performing within specification, i.e. up; thus we have:
Total up time
Availability= Test interval
Total up time
= Total up time+Total downtime
NF
= N ∗MTBF + N ∗MTBF
F F ∗MDT
i.e.
………………………eqn (I)
A=
MTBF
MTBF+ MDT
Unavailability U is similarly defined as the fraction of the total test interval that it
is not performing to specification, i.e., failed or down, thus we have:
Giving;
MDT ……………………eqn (II)
U= MTBF+ MDT
……………………………………eqn(III)
A+U=1
we see from eqn (I) & eqn (II) that A and U depend on MTBF, i.e. availability
depends by increasing on reliability. Availability can therefore be increased by
increasing MTBF, i.e., reducing mean failure rate. We see also that A and U
depend on mean down time, MDT; availability can be increased by reducing MDT.
Thus availability also depends on maintainability, i.e. how quickly the product can
be repaired and put back into service.
√
By differentiation we get Y = CTb
Ti
4.9 Methodologies:
Data can be collected in two ways;
1. Primary data.
2. Secondary data.
Observation.
Hand out
Internet
Recorded data
Some books
Table.
MTBF.
MTTR.
Downtime.
4.11 Result And Discussion:
The recorded data that have gained from bruhtesfa irrigation and water
technology of the four month data is given below the following table.
Table 4.1 daily downtime for February
February:
TDt :11:40+5:00
= 16:40 hrs.
MDT =TDt/NF
=16:40/2
=8:20 hrs.
µ = 1/8:20
= 0.122
March:
TDt =
15:80+10:60+11:60+1:40+4:60+6:45+18:65+21:00+5:40+9:50+17:80+12:2
5+9:15+1:25+2:00
=148:05 hrs.
MDT = TDT/NF
=148:05/15
= 9:87 hrs.
µ = 1/MDT
=1/9:87
=0.101
April:
TDt
=10:15+5:55+5:35+9:00+18:90+9:45+17:40+9:70+1:85+8:05+20:00+10:75
+4:80+0:40+6:80+6:70+12:70+16:00+17:30
=190:85 hrs.
MDT = TDt/NF
=190:85/19
=10:04 hrs.
µ = 1/MDT
=1/10:04
=0.099
May:
TDt =
16:10+21:00+11:60+5:60+15:60+14:20+21:00+4:30+1:80+1:80+2:40+10:9
0+12:30+4:95+16:30+2:30+11:80+9:80+14:10+4:20+1:30+12:40+2:60
= 218:35hrs.
MDT = TDt/NF
= 218:35/23
=9:49hrs.
µ = 1/MDT
= 1/9:49
=0.105
Working date from Bruh tesfa irrigation and water Technology Company:
Total up time
MTTF 8.18
A = MTTF+ MDT = 8.18+9.4 = 0.4653=46.53%
U =100-46.53%=53.47%
This unavailability means the machine need for preventive maintenance to reduce
the MDt to increase the availability of the machine.
Tb (TDt) = 59hr/month
Ti=2hrs/month
12hours
i.e. 4
=3hr/week (every Monday the concerned person should inspect the
CTb
The total optimal down time per month is TDt =YTi + Y
2∗143.41
=12*2 + 12
=47:9hr/month
By applying the above calculation the down time of the machine reduce from
143:41hrs./month to 47:9hrs./month.
Therefore,
MTBF = 578.1/59
= 9.798
= 0.5104
= 51.04%
U = 100% - 51.04%
= 48.96%
CHAPTER FIVE
5. Conclusion and recommendation
5.1 conclusions:
In the Biruh Tesfa irrigation and water technology there is continuous machine
failure, this shows that in the unit there is a lack of effective preventive
maintenance.
5.2 Recommendations:
I recommend to the company in order to be effective and efficient productivity
apply effective preventive maintenance to increase the reliability and availability
of machines and have get the following benefits:
Bibliography/References
2. Handout