Final Report of internship.pdf

Dashen Brewery s. c Internship report

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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

[email protected]

Mentor’s Name

Ass. Tessema Blia

Report date: Feb. 22/02/12

mailto:[email protected]


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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 Work flow of the company .......................................................................................................... 12

1. Raw material store room .............................................................................................................. 13

2. Pre-cleaning room ...................................................................................................................... 13

3. Brew house...................................................................................................................................... 13

3.1 Mill Star ............................................................................................................................ 14

3.2 Mash Tun Kettle (MTK) ........................................................................................................ 15

3. 3 Lauter Tun Tank (Mash separating vessel) .............................................................................. 16

3.4 Pre Run Tun ................................................................................................................................ 16

3.5. Wort Kettle.............................................................................................................................. 16

3.6 Whirlpool ................................................................................................................................ 16

3.7 Heat Exchanger (wort cooling) ................................................................................................. 17

4. Beer processing ................................................................................................................................ 17

4 Bottling ........................................................................................................................................... 19

Process Description:.............................................................................................................................. 19

4.1 Crate washer............................................................................................................................. 19

4.2 Un caser (un packer) & caser (packer) ..................................................................................... 19

4.3 Bottle Washer.......................................................................................................................... 20

4.4 Empty bottle inspection (EBI) .................................................................................................. 21

4.5 Filler Machine (Bottle Filling) .................................................................................................. 21

4.6 Pasteurizer Machine .................................................................................................................... 23

4.7 Labeler .................................................................................................................................... 23

4.8 Full bottle inspector (FBI) ...................................................................................................... 24


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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 Objective of the project:.............................................................................................................. 34

2.4 Problem statement:...................................................................................................................... 34

2.5 Possible causes: ............................................................................................................................. 34

2.6 Effects: ......................................................................................................................................... 34

2.7 Problem description ...................................................................................................................... 34

2.8 Proposed solution ........................................................................................................................ 36

2.8.1 Maintenance planning & scheduling .................................................................................... 36

2.8.2 Total productive maintenance (TPM) ................................................................................. 38

2.8.3 Reliability Engineering .......................................................................................................... 40

2.9 Challenges I Have Been Facing During My ................................................................................. 44

Project Work: ........................................................................................................................................ 44


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2.10 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 In terms of improving practical skills: ........................................................................................ 45

3.3 In terms of upgrading theoretical knowledge:............................................................................. 46

3.4 In terms of improving interpersonal communication skills: ........................................................ 46

3.5 In terms of improving team playing skills: ................................................................................. 46

3.6 In terms of improving leadership skills: ....................................................................................... 47

3.7 In terms of understanding about work ethic ................................................................................ 47

Related issues: ....................................................................................................................................... 47

3.8 In terms of entrepreneurship skills: .............................................................................................. 48

Conclusion: .............................................................................................................................................. 49

Recommendation: ................................................................................................................................... 50

Reference: ................................................................................................................................................ 51

Appendices:............................................................................................................................................... 52

List of table & Figure

Page No

Fig—l organizational structure………………………………………………………11

Fig-2 Beer production process flow……………………………………….................12

Fig-3 Process flow of brew house……………………………………………………14

Fig-4 Beer filling & packing process…………………………………………………18

Fig-5Beer filling & packing of Drought ……………………………………………25

Fig-6Work flow of maintenance Department…………………………………… 31

Fig-7Maintenace Analysis Process……………………………………………… .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 comparison………………………………………………………28

Table-5 Raw material………………………………………………………………….41


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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.


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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.


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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.


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Southern Sudan.

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.


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Employee profile

Table 1

Permanent and contractual Employees.

Term of employment Total

Permanent Contract

169 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

Educational background Sex

Less

than

grade

10

12 and 12 +

certification

10+3

Technical

&

Academic

diploma

College

diploma

12+

3

First

degree

2nd

Degree Male Female

55 99 15 19 1 31 4 181 43

Total 224


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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

Fig.1 organizational structure

Border of Director

General Manager

Deputy General Manager

, Marketing

DGM, Technical

Customer service &

promotion division

Sales & distribution

Division

Market

research

& dev’t

division

Marketing Region 1

Marketing Region 2

Marketing Region 4

Finance

Dep’t

Supply

dep’t

Human

resource

Magtdep’

t

Production

Dept, Maint.Dept

.

Quality

assurance

dept.

Processing

Division

Filling &

packing

Division

Marketing Region 3

Worksho

p&

Garage

Division

Production

machinery

division

Electric &

instruments

division

Utilities

Machinery

division

Physicochemical

Team

Microbiological

Team

Procurement

division

Warehouse

division

Finishe

d

Produc

ts &

empty

contain

er

store(A

.A)

Input

Material

Store

General

Store

Spare

parts

store

Finished products store

Empty

containe

r store

General accounts

division

Cost & Budget

division

General

Service

division

Personnel

Administration

Division


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1.3 Work flow of the company

Beer production Process Flow

All malt rejects used for cattle feeding

Figure-2 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)

Conditioned wet milling

The husk will be used

for wort clarification

Brewing

water

Mashing

Break Down of high molecular

starch to glucose & maltose

Lauter Tun

Wort separation as

using husk as cake

medium

Spent grain for cattle

feeding

Wort Pre run Tank

Wort collection

Wort Kettle

Wort sterilization & concentration

Alpha-acid isomerisation

Hops

Bitter

Arom

a

Whirl pool

Hop trub separation

Separation of colloidal

Wort cooling & yeast

addition

Wort cooling &

Yeast pitched

Fermentation Tank

Fermentation

& maturation

Laagering &

conditioning

Filtration plant

Cellar filtration

Clarity control

by online haze

meter

Filtered beer

transferred to

bright beer

tank (BBT)

Figure


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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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1

2 3

4

5 7

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.

Figure


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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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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 103ͦ 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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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 obtained.

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.


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BEER FILLING AND PACKING PROCESS OF BOTTLED BEER

Figure-4 Beer filling & packing process

Empty bottles in crate from marked

Un packer

Bottle separated from

crate & send to bottle

washer

Bottle Washer Bottle cleaning & label

removal

Visual Inspectors

Inspection of

cleaned bottle

FBI Machine (Full

Bottle Inspector)

Proper labeling,

filling & proper

corking

EBI Machine Micro crack

any dirt

inspection by

wave of

cleaned

bottles

Bottle Filler Machine

Bottle evacuation

& beer filling

Corking of bottles

BBT (Bright Beer Tank)

Filtered beer transferred to bottle

filler or draught filler

Online meter

Beer oxygen

measurement

Bottle Labeler Machine

Body & Neck

labeling

Dating coding

Pasteurization of filled

bottles

Killing any microbes

if found

Packer

Packing of filled

bottles to washed

empty crates

Palletizes

Palliating full

crates to

pallets

Full product store

Distribution of

product to their dear

customers

Empty

crate

washer

Figure


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4 Bottling

Process Description:

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


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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

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,

Pre warming, presoak 35-40 °c

2nd

soak 55-60

Caustic bath 75-85

Intermediate rinsing 45-50

Warm water 35-40

Cold water 20-25

Fresh water 10-15


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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,


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Evacuation of the bottle,

Counter pressurizing with co2,

Slow initial filling- rapid phase,

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 producer’s

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.


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Steam sterilizes. s

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

Beer Filling & packing Process of Drought

Figure-5 Beer filling & Packing 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

Weight sensor

Checking proper

filling labeling at

production data

Empty drought container

From market

Dashed(container

only

Product store

sales


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Table 3 the basic difference of draft and bottled beer

Draft Bottled beer

Pasteurization temperature 73oC for 30 seconds 27

o C - 66

o C for one hour

Number of Machinery and space

requirement

Small Large

Length of time for expiration About one month About 6 month

End product container Short cylinder 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-

Carbon filter

Sand filter

HCl

PH reader

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.


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3. CO2 balloon (storage).

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-37

oC. 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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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 o

C). 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 Energy supplied

Steam power plant Heat Mechanical energy

Compression refrigeration

plant

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:


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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.


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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 it’s 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,

z)

Inform

Job order order

Issue

Distributer

check Fig.6 work flow of maintenance department

Maintenance

Department

Preventive

maintenance

Break down

Maintenance

Maintenance

plan Expert

Division Manager

Forman

Review Forman &

worker

Maintenance

plan Expert

Operators

Division Manager Forman Worker


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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


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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


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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)


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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


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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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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 day’s 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


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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.

TPM-combines concepts of,

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


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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.

PLANT

MANAGER

Production

Manager

Maintenance

Manager

Production

ass.Manager

Maintenance

planner Maintenance

supervisor Coordination

Coordination


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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


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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

3145.00 15,814.000 16 1,292,500 20,207,733

Carmel

colorant

3145 10,859 16 891 8,719

Hop extract

alpha acid

3145 4,629 16 378 4,623

Phosphoric

acid

3145 3,145 16 2,056 30,426

Calcium

chloride

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 d=15,814.000 Required= EOQ & R

LT=16 Pc=20,207,733

Co=1,292,500

Solution: Q= √2DCo/Pc

=√2*3145*1292500/20207733

=√402

Q = 20 brew

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 Co=891 Required= EOQ & R

d=10,859 Pc=8,719

LT=16

SOLUTION: Q= √2DCo/Pc

=√2*3145*891/8719

=√642

Q =25 brew

R= L*d =16*10859 =1, 73744 kg

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


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R= 1, 73744 Kg

3 . Hop extract Alpha acid

Given:

D=3,145 Pc=4,623 Required= EOQ & R

d=4,629

L=16

Co= 378

SOLUTION:

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 company’s 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.


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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


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Problem solving

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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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, it’s 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

doesn’t 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 worn-

out. 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 Empty Bottle Inspector

FBI Full Bottle Inspector

ICS Inventory Control System

CIP Cleaning in Place

S.C Share Company

BOD5 Biochemical Oxygen Demand for 5 days.

COD Chemical Oxygen Demand

TPM Total Productive Maintenance

RIME Ranking Index for Maintenance Expenditure

EOQ Economic Order Quantity

R Re-order level

Final Report of internship.pdf

Documents

ied eng 120201

improving

bright beer

improving

full bottle

raw water

make close

upgrading