Introduction

Background of the company

Mesfin industrial engineering (MIE) was established in1992 with a
starting capital of birr 7 million in Tigray regional state, Mekelle
town.
Currently it has close to one thousand employees out of whom 520
are permanent and the remaining are contract & temporary
employees. Currently the net capital of MIE reaches more than birr
250 million.
As an engineering company, MIE can be engaged in manufacturing
various products as well as render engineering services to sectors of
industries. So far MIE has been mainly engaged in the fabrication
and supply of trailer related products that are serving the transport
sector.
About 90% of all types of trailers (dry & fuel trailers, semi-trailers,
low beds etc) required by the local market have been supplied by
MIE during the last 10 years. Other fabricated products required by
other sectors have also been supplied by MIE.
 Problem statement

High failure of pantograph and oxygen plant

Objective of the study

General objective
Introducing the application of RCM to MIE that help to

optimize operation and maintenance on pantograph

machine and oxygen plant with cost effective
maintenance techniques.
 Specific objective
Introducing the company about the reliability concepts on
current system by determining:-
Inspection Optimization model and
Availability and unavailability of machines
Develop accidental budget through
Spare part cost estimation
Labor cost estimation
 Scope of study
The project scope is limited to some selective machines
whose function of operation influence the process of
production most. These machines are pantograph , oxygen
plants and, extend to improve the reliability of Machines
through labor cost and spare cost estimation.
 Significance of the study
The critical significance of the study is to introduce
reliability centered maintenance to MIE and to show how
it can reduce failure and to improve accidental budget to
MIE.
The other importance of the study is to optimize
maintenance operation through reduction of failure rate
and increasing reliability of the machines which affect
most of production process.
Research Methodology
Data collection
The data collection process was conducted in the two
perspectives of data types, which include:-
Primary data
Direct Observation
Informal Interview with concerned body
Secondary data
Different maintenance reference and exercise
books.
Manual data record
Contd

Data analysis
The data analysis is conducted from the recorded data
of maintenance order request voucher and maintenance
works report voucher of both pantograph and oxygen
plant.
Through the analysis of total down time due to
preventive maintenance and breakdown maintenance
result in determining optimal inspection of both
machine and by using this optimal inspection to
determine optimal total down time per month.
Result and Discussion
The result and discussions are obtained by an assumption of:-
The machine operator starts work (operating the machine)

sequentially after the machine has been maintained without

idleness.
The Maintenance personal perform their tasks continuously

without any break unless it is lunch time.

A working hour of 1 shift, 8 hour; 1 hour of the total working

hours for break due to lunch, and twice of 30 minutes each

working day for tea time.-
For the case of machine break down, if the date/time of job

compilation is not written I assume that the job is received by

the customer in the next day, morning.
Equipment constant C is 3.
Contd
Tables contain data of preventive maintenance and
breakdown has similar descriptions for both Pantograph
machine and oxygen plant.
Column 2 shows date and time of job requested by the

customer(production department)
Column 3 shows date and time of job completion by

maintenance department
Column 4 shows date and time of job received by

customer(production department)
Column 5 shows type of man power(E-for Electricians,

M- for Mechanic, F- for Forman)and time it take during

operation
Column 6 shows total machine down time. Tables data
Total up time and Total down time pantograph machine

Data from MIE;

Total availability time per year
= {number of hours per year} {(time lost due to public
holiday)+(Sundays, Saturdays (afternoon)) + (annual, sick and
mortality)}
= 2,920hr- 724hr-200hr
= 1,996hr/year
Total up time and Total down time oxygen plant

Data from MIE;

Total availability time per year
= {number of hours per year} {(time lost due to public
holiday)+(Sundays, Saturdays (afternoon)) + (annual, sick and
mortality)}
= 2,920hr- 724hr-200hr
= 1,996hr/year
Inspection optimization model I for pantograph machine

Existing condition in MIE

The company has monthly one inspection time and total down time
to inspection/preventive maintenance monthly in this year is as
calculated before equal to 4.9153hr/month and total down time due
to breakdown of the pantograph machine is equal to 5.86hr/month.
So the total down time of the machine is calculated by
The improvement using inspection optimization model one
Inspection optimization model one to oxygen
plant
Existing condition in MIE
The company has monthly one inspection time and total down
time to inspection/preventive maintenance monthly in this
year is as calculated before equal to 4.2hr per month and total
down time due to break down of the pantograph machine is
equal to 5.9765hr per month.
The improvement using inspection optimization model one
Spare part cost estimation
Labor cost estimation
Contd

Therefore, at the very beginning, the organization must

allocate 3,993,282.6birr of accidental budget per year in order
to avoid financial problems pertaining to maintenance
department employee salary at the end or at the third quarter
of the year.

 Conclusion
Probability of machine availability (A) and unavailability (U) of
pantograph machine is 96.24% and 3.75% respectively and for oxygen
plant 96.42% and 3.57% respectively.
Accidental budget plan analysis for labor cost & spare cost estimation

was prepared. So , 3,993,282.6birr per year of labor cost is needed in

2012 G.C and the spare part cost needed this year for pantograph
machine and oxygen plant is 155,956.612 birr per year and 236,849.616
birr per year respectively.
The optimum number of inspection is analyzed and results in reduction

of total down time of pantograph machine from 22.4953hr per month to

18.59hr per month and for oxygen plant from 22.1295hr per month to
17.3556hr per month.
 Recommendation

As the study shows that there is a high failure rate of

machines and un optimum inspection so the company should:-
Apply two inspections per month to reduce failure of

pantograph and oxygen plant.

Estimate probability of machine availability and

unavailability.
Apply accidental budget plan spare part and labor cost

Implement reliability centered maintenance to optimize

maintenance operation.
Thank you!