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ADAMA UNIVERSITY School of Engineering and Information Technologies Investigation into Effectiveness of Agricultural Machinery Maintenance Management: The Case of Wonji Shoa Sugar Factory Thesis Submitted to the School of Engineering and Information Technologies in Partial Fulfillment of the Requirements for the Award of the Degree of Masters of Science in Agricultural Machinery Engineering By Amana Wako Advisor: Dr.-Ing Zewdu Abdi Co-Advisor: Dr. Simie Tola Department of Mechanical and Vehicle Engineering June 2010 Adama T > y ` c=+ ADAMAU N I VERSITYid1101687 pdfMachine by Broadgun Software- a great PDF writer!- a great PDF creator! - http://www.pdfmachine.comhttp://www.broadgun.com CANDIDATES DECLARATION I hereby declare that the work which is being presented in this thesis entitled Investigation into EffectivenessofAgriculturalMachineryMaintenanceManagement:TheCaseofWonjiShoa Sugar Factory in partial fulfillment of the requirements for the award of the degree of masters of scienceinAgriculturalMachineryEngineeringisanauthenticrecordofmyownworkcarried outSeptembertoApril2010underthesupervisionofDr.-IngZewduAbdiDepartmentOf Mechanical And Vehicle Engineering, Adama University, Ethiopia. Thematterembodiedinthisthesishasnotbeensubmittedbymefortheawardofanyother degreeordiploma.Allrelevantresourcesofinformationusedinthisthesishavebeenduly acknowledged. Amana wako ____________April 20, 2010 Candidate Signature Date This is to certify that the above declaration made by the candidate is correct to the best of my knowledge and belief. This thesis has been submitted for examination with our approval. Zewdu Abdi (Dr.-Ing) ______________April 20, 2010 1. Advisors SignatureDate Simie Tola (Dr.) ____________April 20, 2010 2.Co-Advisors SignatureDate ADAMA UNIVERSITY School of Engineering and Information Technologies Department Of Mechanical and Vehicle Engineering Investigation into Effectiveness of Agricultural Machinery Maintenance Management: The Case of Wonji Shoa Sugar Factory. By-Amana wako Approved by Board of Examiners: ________________ ________________ ____________ Chairman/ Department SignatureDate ________________ ____________________________ Advisor SignatureDate ________________________________ ____________ Co-AdvisorSignature Date ________________ ________________ ___________ Examiner (Internal) SignatureDate ____________________________________________ Examiner (External) Signature Date T > y` c= + ADAMAU N I V ERSITYi ACKNOWLEDGEMENTS Iwould like to express a sincereand special Thank tomy advisor Dr.-IngZewdu Abdi for his continuoussupport,guidance,creativeideas,thoroughcorrectionandsuggestionsgreatly contributed in doing this thesis. Iwouldliketothankalsomyco-advisorDr.SimieTola.SpecialthankstoprofessorChandraRao for his indispensable help in editing, thorough correction andcontinuous guidance in doing this thesis. I wish also to express my genuine appreciation to Assistant Professor Kasim Kimo for his valuable advice and comment in doing this thesis. Iwouldliketoacknowledgewonjishoasugarfactory(Enterprise)managementandworkers who insisted me to collect necessary data.Especial thanks to Ato Yohannes Tamir (head of field equipmentservicedepartment),AtoHabtamuAwugichew(fieldequipmentservicedepartment planningandinspectionhead),AtoEsayasMadebo(wheeltractorsectionhead),AtoTaddese Bekele(Heavyequipmentsectionhead),AtoHelisoHeramo,andallotherworksofenterprise for their unreserved assistance in accessing data for the study. I would like to thank also Ato Mekonnin Liban co-ordinator of Vehicle Engineering section and Ato Assefa Marga for their encouragement both in moral and material. My gratitude goes to my brothers Ato Muktar Husen and Ato Jemal Kedir for their indispensable helpand encouragement in all aspects of the thesis work. Finallyandmostimportantly,myheartfeltaffectiongoestomywifeFatumaShekaandmy family who are always with me. June 2002 Adama ii TABLE OF CONTENTS Acknowledgements -------------------------------------------------------------------------------------i Contents---------------------------------------------------------------------------------------------------ii List of tables---------------------------------------------------------------------------------------------VI List of figures------------------------------------------------------------------------------------------Viii List of Appendixes-------------------------------------------------------------------------------------i X Acronyms. ----------------------------------------------------------------------------------------------- X Abstract. ------------------------------------------------------------------------------------------------ Xii CHAPTER ONE:INTRODUCTION--------------------------------------------------------------1 1.1. Statement of the problem---------------------------------------------------------------------------2 1.2. Objective of the thesis------------------------------------------------------------------------------2 1.3. Significant of the study-----------------------------------------------------------------------------3 1.4. Research methodology------------------------------------------------------------------------------3 CHAPTER TWO:LITERATURE REVIEW----------------------------------------------------5 2.1. Definition of maintenance--------------------------------------------------------------------------5 2.2. Status of maintenance-------------------------------------------------------------------------------5 2.3. Objective of maintenance management system-------------------------------------------------9 2.4. Importance of maintenance------------------------------------------------------------------------11 2.5. Scope of maintenance-----------------------------------------------------------------------------.-12 2.5.1. Category of Maintenance-------------------------------------------------------------------12 2.5.1.1. Preventive Maintenance (PM) ---------------------------------------------------12 2.5.1.2. Predictive Maintenance (Condition Directed) ---------------------------------14 2.5.1.3. Corrective maintenance (CM) ---------------------------------------------------15 2.6. Down time and availability------------------------------------------------------------------------15 2.7. Maintenance management system----------------------------------------------------------------17 2.7.1. Machinery maintenance standard ---------------------------------------------------------18 2.7.2. Types of standards---------------------------------------------------------------------------18 2.8. Planned maintenance system-----------------------------------------------------------------------18 2.9. Manpower planning---------------------------------------------------------------------------------19 2.10. Planning for machinery /equipment disposal---------------------------------------------------20 2.10.1. Disposal policy------------------------------------------------------------------------------20 2.10.2. Disposal criteria-----------------------------------------------------------------------------21 iii 2.11. Maintenance scheduling --------------------------------------------------------------------------22 2.11.1. Scheduling process--------------------------------------------------------------------------22 2.12. Maintenance record and documentation---------------------------------------------------------23 2.13. Spare part management (SpM) -------------------------------------------------------------------24 2.14. Determination of cost of agricultural machinery-----------------------------------------------24 2.14.1. Fixed cost-----------------------------------------------------------------------------------25 2. 14.1.1. Depreciation---------------------------------------------------------------------25 2.14.1.1.1. Method of determining depreciation----------------------------26 2.14.1.2. Interest----------------------------------------------------------------------------29 2.14.1.3. Tax--------------------------------------------------------------------------------30 2.14.1.4. Insurance-------------------------------------------------------------------------30 2.14.1.5. Shelter /housing-----------------------------------------------------------------31 2.14.1.6. Capital Recovery of Agricultural Machinery-------------------------------31 2.14.1.7. Inflation --------------------------------------------------------------------------32 2.14.2. Variable Cost-------------------------------------------------------------------------------32 2.14.2.1. Repair and maintenance cost--------------------------------------------------32 2.14.2.2. Fuel Cost-------------------------------------------------------------------------35 2.14.2.3. Lubrication (Oil) Cost----------------------------------------------------------36 CHAPTER THREE: CASE STUDY OF WONJI SHOA SUGAR FACTORY------------38 3.1. Historical Background of the WSSF-------------------------------------------------------38 3.1.1. Objectives of the Enterprise-----------------------------------------------------------------38 3.1.2. Mission-----------------------------------------------------------------------------------------39 3.1.3. WSSF Production Capacity-----------------------------------------------------------------39 3.1.4. WSSF Organizational Structure and Set up-----------------------------------------------39 3.2. Status of Agricultural Machinery------------------------------------------------------------------41 3.3. Machinery replacement-----------------------------------------------------------------------------41 3.4. Origin and Makes of Field Equipments (Machinery of WSSF) ------------------------------46 3.5. Down Time and Availability-----------------------------------------------------------------------48 3.6. Capacity of Man Power-------------------