Internship report on EABSC Bahir Dar plant/2010 E.

BAHIR DAR UNIVERSITY

BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF MECHANICAL AND INDUSTRIAL

ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
Final Internship report

HOSTING COMPANY: EAST AFRICA BOTTLING SHARE COMPANY

BAHIR DAR PLANT (EABSC)

Compiled by:
Name ID
1. Yalelet Tadesse-----------------0702465
2. Mulugieta Tesfie-----------0702152

Duration of internship:

Submission date:
Internship report on EABSC Bahir Dar plant/2010 E.C
Declaration

We want to assured that this report exactly belongs to us. We have done a project during the
internship program and is included as part of this report. We were fully engaged to write this
report and also to perform our project. Except we have taken from reference materials all the
descriptions, recommendations are our own. Finally, we are intended to tell you this document is
a good indicator of how much effort we made to go steps forward in the practical world by
integrating it with the theoretical knowledge.

Intern name: Signature: Date:

Yalelet Tadesse ----------------------------------------------------

Mulugieta Tesfie ----------------------------------------------------

Approval of advisors Signature: Date:

Mr.Meseret ----------------------------------------------------

Approval of company supervisor Signature: Date:

Ezana Amakelew----------------------------------------------------

1
Acknowledgment
There are many people around that have supported us all the way through and to make things
easier. First of all, we would like to thank Bahir Dar institute of technology for giving of this
chance which helps us to integrate our theoretical knowledge with practical knowledge in the
factory. And also, thanks for all managers and employees of coca cola company specially Mr.
Tadesse who is mechanical specialist, Mr. Allelign, Mr. Habtamu, Mr. Eiba and our company
supervisor Mr. Ezana for their admired patient and genuine intention to teach us under great
motivation. Our advisors Mr. Messeret for her visiting and advising in doing of our project.

2
Executive summary
This document consists of the internship report that we have performed in the internship program
from E.C. It includes the background and overall organization of our internship hosting
company. The report includes our overall internship experience, benefits and the challenges that
we have been faced and the measures we have taken to overcome those challenges and
recommendations.

The report also contains our project in productivity improvement through effective material
handling, minimizing working hazard and through minimizing stoppage of the bottleneck coca
cola plant.

3
Lists of figures and Tables
Figure 1: Organizational structure of EABSC Bahir Dar Plant..................................................11
Figure 2Work flow diagram of EABSC Bahir Dar plant............................................................13

Table 1:work flow in production department........................................................................12

List of acronyms

AC----------------------------------------------Activated Carbon

CIP----------------------------------------------Cleaning In Place

CW ---------------------------------------------Cold Water

Dr------------------------------------------------Doctor

EABSC------------------------------------------East Africa Bottling Share Company

EBI-----------------------------------------------Empty Bottle Inspection

FBI-----------------------------------------------Full Bottle Inspection

GC-----------------------------------------------Gregorian calendar

Hx------------------------------------------------Heat exchanger

INS-----------------------------------------------instructor

NOM---------------------------------------------Natural Organic Matter

PLC-----------------------------------------------Programmable Logical Control

RWT----------------------------------------------Raw Water Treatment

WWT---------------------------------------------Waste Water Treatment

4
WW-----------------------------------------------Warm Water

Table of Contents
Declaration..............................................................................................................................1
Acknowledgment....................................................................................................................2
Executive summary.................................................................................................................3
Lists of figures and Tables........................................................................................................4
List of acronyms......................................................................................................................4
CHAPTER ONE..........................................................................................................................7
COMPANY BARGROUND...............................................................................................7
1.1 Brief History...............................................................................................................7
1.2 Vision............................................................................................................................8
1.3 Mission/Purpose............................................................................................................8
1.4 Values...........................................................................................................................9
1.5 Main products or services.............................................................................................9
1.6 Main customers or end users of its products or services..............................................9
1.7 Organizational Structure of the Company.................................................................10
1.8 Work Flow of the Company........................................................................................11
1.10 Section of the Company............................................................................................13
CHAPTER TWO.......................................................................................................................42

5
2. Internship experience........................................................................................................42
2.1 The Section of the Company We Had Been Working In............................................42
2.2. The work tasks that we have been executing:............................................................42
2.3 The Engineering methods, tools and techniques we have been using.........................43
2.4The major Challenges and problems we have faced during the internship program:.43
2.5 Measures we have used to overcome challenges.........................................................44
2.6 Overall benefits we gained from the internship..........................................................44
2.7 CONCLUSION...........................................................................................................48
2.8 Recommendation........................................................................................................49
CHAPTER THREE.....................................................................................................................50
3. Project work:.....................................................................................................................50
3.1Summary of the project...............................................................................................50
3.2 problem statement and justification...........................................................................51
3.3 Objectivity of the project............................................................................................55
3.4 Methodology...............................................................................................................56
3.5LITERACHER REVIEW............................................................................................56
DATA COLLECTION AND ANALYSIS.........................................................................................59
Proposed solution..................................................................................................................66

CHAPTER ONE
COMPANY BARGROUND

6
1.1 Brief History

Coca-Cola is the most popular and biggest-selling soft drink in history, as well as the best-
known product in the world. Created in Atlanta, Georgia, by Dr. John S. Pemberton, Coca-
Cola was first offered as a fountain beverage by mixing Coca-Cola syrup with carbonated
water. In 1899, The Coca-Cola Company began franchised bottling operations in the United
States. Coca-Cola might owe its origins to the United States, but its popularity has made it
truly universal. Today, you can find Coca-Cola in virtually every part of the world. The first
Coca-Cola bottler in Ethiopia was established in 1959 G.C by five Ethiopians with its initial
capital 750,000 Birr as the Ethiopian Bottling Share Company. As the business expanded a
branch was established in Dire Dawa in 1965 G.C again with the capital of 750,000 Birr. In
February 1975 G.C the two factories were nationalized, re-named as Addis Ababa Soft
Drinks and Dire Dawa Soft Drinks and operated under separate management. In March 22,
1996 G.C the two plants were re privatized again by five young local entrepreneurs with a
registered capital of Birr 67 million and who formed Ethiopian Bottling Share Company. In
May 1999 G.C, a joint venture agreement was signed between Ethiopian Bottling Share
Company & Coca-Cola SABCO to bring the professionalism, knowledge and experience that
was lacking in the operation. The name of the company was changed to East Africa Bottling
Share Company (EABSC). This integration has proven to be a perfect match which has
brought about many positive changes, such as people development, which is mandatory to
grow the business. In line with this, a fully equipped training center was established as soon
as the joint venture was signed. Bahir Dar coca cola plant was established in (November
2016) in Bahir Dar town with the capital of 420milion dollar. The plant takes 300 hectare
from Bahir Dar city administration. The plant located 4kmat south –west of the city or in
front of Dibanke medhanialem monastery. It becomes the most successful plant in Africa
with in this short period of time. It ranks first of the whole coca cola bottling companies of
Africa. Currently the company has 170 permanent employees. An average plant production
capacity is 36000 bottles per an hour.

This is part of the 500-million-dollar investment, which the company launched in April
2012, to be carried out by 2020. This plan includes three new plants, including one in
Hawassa and another one in western Ethiopia, whose construction depends on the
performance of the company’s other lines. After all in mid- December 2016 the new
plant in Bahir Dar city starts production. The new plant in Bahir Dar with a capacity of
producing 15 million cases per annum is expected to be inaugurated within 18 months.
East Africa Bottling Share Company is committed to developing and maintaining an
integrated Occupational Health &Safety, Environment and Quality Management System
based on ISO 9001:2000, ISO14001:2004 and ISO 2008. Ethiopians enjoy a range of
beverages from EABSC, including those from the Fanta group, Coca-Cola, Sprite,
Schweppes, Coke Light and Dasani Bottled Water.

Available in the following territories

7
South Africa, Mozambique, Namibia, Ethiopia, Kenya, Uganda, Tanzania

1.2 Vision
 To be the best Coca-Cola bottler in the world and Africa’s most valuable food
and beverage company.

1.3 Mission/Purpose
 OUR CUSTOMERS are at the center of all our actions
 OUR CUSTOMERS “love” for our brands grows as they purchase ice-cold,
quality products for every occasion at “arm length of desire”
 OUR EMPLOYEES are inspired, highly engaged and proud to work for Coca-
Cola Beverages Africa
 OUR COMMUNITIES welcome us as a valuable partner and an integral part of
their lives
 OUR SHAREHOLDERS well rewarded over the long term.

1.4 Values
 We have a passion for the Coca-Cola business and for the brand
 We think and act like “owners” at all time
 We work and win in teams across the business
 Accountability is clear and persona
 We are humble but confident in all we do
 Sustainability are integral to our working lives

1.5 Main products or services

EABSC Bahir Dar plant produces most of the Coca-Cola Company Products such as:
 Coca-Cola
 Sprite
 Fanta orange
 Fanta ananas/pineapple
1.6 Main customers or end users of its products or services
 Major Distribution center (MDC)
 Secondary users:
 Hotels

8
  Restaurants
 Institutions
 Supermarkets
1.7 Organizational Structure of the Company

OPERATIONAL MANAGMENT

PRODUCTIO QUALITY ENGINEERIN SALES LOGESTIC

N MANAGER MANAGER G MANAGER MANAGER MANAGER

MAINTENANC
PRODUCTION QUALITY E PLANNER REGIONAL WARE HOUSE
TEAMLEADER CONTROLLER SALES SUPERVISOR
MANAGER
MAINTENANCE
CONTROLLER
DESTRICT
TECNICIAL SALES
TECHNICIAL TRAINER MANAGER STORE FORK WARE
KEEPER LIFT HOUSE
ELECTRICAL OPER FACILITY
OPERATOR SALE ATOR
SPECIALIST REPRESENTA
TIVE
OPERATOR
MECHANICAL

TECHNICIAL
L DISTRUBITION
CONTROLLER
DISTRUBITION

DISTRUBITION
ANALYSET

9
Figure 1: Organizational structure of EABSC Bahir Dar Plant

10
1.8 Work Flow of the Company

Work flow of EABSC Bahir Dar plant is a loop from production to end users.

Figure 2 Work flow diagram of EABSC Bahir Dar plant

11
1.9 Work Flow of the production area
The work flows of the production area of company are as follow in a table below.

Table 1: work flow in production department

N Process description Operatio Transpo Dela Inspectio Storag

o n rt y n e

1 Empty bottle warehouse

2 Palletize
3 Depalletize
4 To create washer
5 Create washer
6 To un packer
7 Unpacker machine from
crate to washer in feed
conveyor
8 To bottle washer
9 Remove any dirty inside
the bottles and remove the
pervious date code
10 To stations
11 Visual inspection
12 To EBI
13 check knack breaks and un
cleaned bottle
14 To filler
15 File the mixed beverage
16 To FBI
17 Check under and over file
18 To Date code
19 Print expired date and
mfg. date
20 To Packer
21 Packed the full bottle
22 To de palletize and un
palletize

12
23 full bottle warehouse

1.10 Section of the Company

There are different sections in Bahir Dar coca cola plant which have various functions in the
production of soft drinks

There are three main sections in this company. These are:

A, Service and utility

 Raw water treatment plant

 Waste water treatment plant
 Boiler
 Compressor
 Refrigeration (chiller)
 Generator
 CIP (Cleaning internal parts)

B, Manufacturing

 Sugar dissolving (simple syrup preparation room)

 Final syrup preparation room
 Bottle Washer
 Blinder /mixer
 Filler
 Packer and un packer

C, Quality

 Laboratory

13
A, Service and utility

I. Waste water treatment plant

Waste water treatment consists of a combination of physical, chemical, and biological processes
and operations to remove solids, organic matter and sometimes nutrients from wastewater. The
aim of waste water treatment is complying legislations, acts, standards and approval conditions
of discharge and disposal of both Ethiopian government and coca cola standard. We use
biological, physical and chemical methods of removing wastes.

1. Biological method: - This can remove organic wastes by using growing bacteria, and then
these bacteria decompose organic matter in order to get energy. As they eat organic matter they
start to grow and then die. The died body of bacteria is then settle as sludge. Urea is added as
energy source for microorganisms. The source of oxygen for bacteria is from dissolved oxygen.
This is measured using BOD meter due to pressure difference in bottle.

2. Chemical method: -chemicals are used to remove inorganic matter using chemical like
phosphorus using coagulant ferric chloride. It reacts and settles as sludge. Also adjusts PH of
water.

3. Physical method: -used to remove large particles by simple physical separation

mechanisms like sieve/screening.

In the process of waste water treatment of coca cola the following process are involved:

1. Screening/preliminary treatment/:- Screening is the first separation technique in waste

water treatment system. It uses physical barriers (screens) as a removal mechanism. Primary
objective of screening is to remove coarse (large) solids such as rages, sticks, plastics, etc. It
helps to protect pumps and other mechanical damage and enhances the quality of sludge.

14
2. Oil skimmer: - using oil skimmer device oil, grease and floating matters are removed using
plastic Conduit. The cond1uit is porous and can absorb floating matters and reject those matters
as it passes through narrower space.

3. Pump pit: - most of incoming waste water is in basic media, sulfuric acid (75%) is added to
neutralize by using solenoid valve automatically depend on the PH value of the incoming waste
water. Submerged blower used to aerate water to increase dissolved oxygen and facilitate
mixing. Two slurry pumps then transfer water to equalization pond (next process).

4. Equalization pond: -the main objective is to minimize or control fluctuation in treatment

process characteristics in order to provide optimal condition for subsequent treatment process.

Four chemicals are added:

 Ferric chloride as coagulant in order to precipitate phosphorous.

 urea as nutrient for bacteria
 sulfuric acid as pH adjustment (6.5-8.5)
 sodium hydroxide as pH adjustment

Submerged blower used as aerator. In this pond initiation of microorganism will start.

5. SBR/Sequential Batch Reactor/

The heart of treatment plant because microorganisms are developed and decompose pollutants
and produce low BOD and COD. No chemical is added in this pond. Surface aerator and internal
mixer are installed and flexible hose used to remove sludge.

15
Figure 4 pond structur of SBR

6. Fishpond: -this pond is used to store final treated water after completing the treatment
process. The pond has surface aerator to increase the amount of dissolved oxygen. As the name
indicates treated water in this pond can be a habitat for fishes. It has no effect for fishes and
organisms living in water. Water from this pond is discharged to atmosphere by over flow.

Table 1 Effluent waste water standard in Bahir Dar coca plant

COD PH Oxygen Nitrogen Phosphorus TDS TSS BOD
<67mg/ 6.5-8 >4mg/L <5mg/L <2mg/L <2000mg/L <50mg/ <50mg/L
L L

7. Sludge pond: -This pond is design to store sludge from each pond. There are also blowers to
supply sufficient oxygen in to sludge. Sludge is used for fertilizer production. Polymer is added
to remove water or dewatering for filter press unit operation.

II. Raw water treatment plant

16
Raw water treatment is critical process in coca cola factory in order to treat raw water and uses
as process water through a serious of treatment mechanisms. Coca cola factory use raw water
from underground. The objective is to increase the pH value at lower turbidity to neutralize
acidity of concentrate. Also ground water is used to produce soft water. Chemicals used are:
hydrated lime as pH adjustment, iron salts as coagulant, chlorine as disinfectant.

Processes in Raw water treatment

1. Settling tank
Ground water stored in concrete reservoir is pumped in to settling tank in order to increase the
PH value and to reduce turbidity after chemicals are added. In chemical mixing tank lime (12kg)
stirred alone for 10min, ferrous sulfate (0.32kg)and chlorine (0.8kg) added after 10min then set
to settling tank which have 100000L capacity with recirculation pump (100,000L/Hr.) capacity it
re circulate about 50 min and allowed to settle.

2. Multi Media/Sand filter

Water from the bottom of the settling tank is pumped in to the sand filter on the top and treated
water is removed at the bottom. It is equipment filled with sand based on size increasing order
from top to bottom. In which physical process such as sand, lime, suspended particles filtration
takes place and stored in semi treated water storage tank. Back wash is done using semi treated
water.

17
Figure 5 Arrangements of sand size in sand filter

3. Activated carbon filter

These called activated means have the capacity to absorb odorous or colored substance from gas
or liquid phase due to large surface area of activated charcoal giving countless bonding sites.

The treated water from semi treated tank at the bottom is transferred in to the carbon filter in
which chlorine is trapped by carbon. It performed part of the water purification process by
removing chlorine and matters that gives color, odor and taste to the water. Steam (80 0C-850C) is
used to regenerate activated carbon in every 3 month.

18
Figure 6 Activated carbon (AC) filter

4. Polish filter
Water that is treated in carbon filter is pumped in to the polisher. Polishing is a step of water
treatment where by very fine suspended particles are removed from the water. This is done by
passing water through a polishing unit containing special filter membranes which having 20
micrometers in diameter. This treated water is sent to filling, blending, CIP, syrup preparation
room. Polishing is the final stage in water treatment where by any minute suspended particles are
removed from water.

This is done by passing water through a polishing unit containing either special filter papers or
cotton cartridge, which are the polishing media the polisher body should be either stainless steel
or nickel plated brass.

The polisher should be located after the carbon purifier and before any takeoff piping to process
areas. A number of factors will affect the polisher’s ability to do the required job.

Which include:-

 Water turbidity
 Water flow rate
 Medium porosity
 Available filtering areas

Under normal condition the water entering the polisher should not contain large amounts of
suspended material. If the water flow rate exceeds the rated capacity of the polisher, its ability to
do the right job is greatly reduced. Porosity or opening of the medium determines the size of the
particles removed from the water. Particles larger than the porosity openings will be removed
from the treated water however, the porosity of the medium will affect the water flow rate
through the medium A polisher with an extremely small porosity will have a lower flow rate
capacity than one with a larger porosity.

For adequate polishing, the medium should have a porosity of 10 – 15 microns. This will remove
particle larger than 1/2000 inch, and still provide practical water flow rates.

19
The surface available for practical remove also is important for polishing efficiency. Spool type
cartridge and flat filter paper.

A filter paper is essentially a surface filter. That is, particles are filtered out, they from a layer on
the relatively thin paper. And could ultimately be forced through the paper

Because of this paper filter have to be replaced very frequently. For a single filter paper polisher,
the paper has to be replaced daily. With a multiple filter paper polisher, the paper generally have
to be replaced weekly.

A cartridge spool is a depth filter. The cotton fiber are wound in a pattern, so that the opening are
like minute tunnels, in which the suspended particle become trapped in this manner a progressive
filtration takes place In depth rather than just on the surface.

20
Figure 7 Flow direction in polisher

When these minute “tunnels” become filled particles could be forced through however, before
this stage is reached. The cartridge should be rejected.

The useful life of cartridge is directly is directly related to the quantity and quality of treated
water which has passed through it for example. If the treated water has little or no suspended
particles in it, the cartridge will do its job for a much longer period of time than if the treated
water contains a lot of suspended particles.

However, there is possibility of bacteria buildup occurring in the cartridges, and if no in – pairs
bacteriological testing is done, the cartilages should not be used for longer than 1 month. Weekly
the cartridge should be inspected to observe their condition.

GROUND SETTLING TANK

CONCRET CHEMICAL
WATER
TANK MIXING
TANK

ACTIVATED
SAND
SEMI TREATED CARBON
FILTER
TANK FILTER

POLISH FILTER

21
 FILLER SYRUP Laboratory
CIP MIXER PREPARATION
ROOM

Figure 8 process water treatment flow diagram

Water softener
In almost every raw water supply, hardness is present as calcium and magnesium bicarbonate,
often referred to as carbonate hardness.

From the storage tanker water is pumped in to the softeners in which hard water is converted in
to soft water. The main function of the softeners is to soften hard water by eliminating Mg 2+ and
Ca2+ ions existing in their carbonate form.

These reactions are continuous until the active site of sodium in zeolite complex compound is all
occupied by Mg and Ca. The structure contains a relatively large central open area which allows
large ions or other molecules to move through or reside within its frame. As a result, sodium
zeolite can function as a chemical sieve. During the reactions since alkali metals are more active
than alkaline earth metals; Mg and Ca are displaced from their carbonate compound by Na to
form Na2CO3. Na2CO3 does not have an effect on the hardness of water.

In the second softener:

In this softener sodium zeolite is regenerated by adding 50kg/250L NaCl. 70 percent NaCl by 30
percent water is entered in to the softener.

Softened water obtained from the softener is temporary stored in 1000L break tank then
transferred in to different rooms; such as boiler room, washer room and cooling room, chiller
room.

Pump Zeolite tank

Underground water house

22
 Concert
reservoir

Soft water tank

Brine
solution

Washer Boiler Cooling

Chiller
tower
Figure 9Water softening flow chart

Auto and Manual CIP Processes

CIP is the process of cleaning internal part of machine. The main objectives of CIP are:

 To clean (sanitize) the filler machine against product deposits, organic and inorganic
salts, oils and other materials which are difficult to clean by mechanical cleaning
means.
 To disinfect the filler machine and its component against microbial contamination
EABSC Bahir Dar plant uses caustic (NaOH) at a concentration of 2% as a sanitizing
agent and hot water at a temperature of 850c as disinfectant agent.

In the plant, there are two types of CIP procedures

1. Five step CIP

23
2. Three step CIP

Five step CIP performs every 72 hours and when there is a product change from Fanta to other
product.

Three steps CIP performs when there is any product change from other coke products to coke.

Three step CIP

Step 1: - Rinsing with cold treated water to flash previous product.

Step 2: - Disinfection with hot water by circulation.

Step 3: - Rinsing and Empty the cold water.

Five step CIP

Step 1: - Rinsing with cold treated water to flash previous product.

Step 2: - Cleaning (sanitizing) with hot caustic solution.

Step 3: - Rinsing the caustic with cold treated water.

Step 4:- Disinfection with hot water.

Step 5:- Rinsing and Empty the cold water.

24
Figure 11Supply and return in CIP room PLC control
Boiler

Boiler is pressure vessel at which water is heated in order to produce steam. There are three types
of boilers namely, fire tube, water tube and electrical tube boiler. The plant uses fire tube boiler
to produce steam Fire tube boiler flame is move inside the tube and water is on the outside of the
tube meaning on the shell side, while water tube boiler water moves inside the tube and flame on
the outside of tube. Bahir Dar Coca cola factory’s fire tube boiler has the following
characteristics:

 85% efficiency and operating pressure 800 k pa

 4000L water holding capacity and operating temperature 1860c.
 Designed pressure is 110 k pa and designed temperature is 2500c.

Two chemicals are added anti-scale (Nex guard 22300scale inhabitation) and anti-corrosion
(NALCO 77211 oxygen scavenger).

Soft water is used in boiler because scale formation happens and reduce heat transfer rate this
results tubes become damaged.

25
Fire tube boiler has the following advantage over water tube boiler.

 Compact constriction
 Lower total cost of ownership
 Simple operation
 Easier access and maintenance

Bair Dar coca cola plant boiler is afire tube type boiler simple working principle is soft water is
send to boiler using multi impeller pump. Fuel burns on the grate on the fire box and pass
through bundle of tubes and water from the shell side starts to boil. The resulting hot fuel gases
are allowed to pass through the tube which is three passes as flame pass water become heated by
convection and steam is produced up to operating pressure 8kpa.The steam is sent to different
parts and cold water returns to boiler. Waste gas is removed using chimney. The boiler consists
of a pressure gage, level indicator, safety valve.

The steam generated is used in: -

 Sugar dissolving.
 CIP room.
 Bottle washer.
 Activated carbon regeneration.

26
Figure12 EABSC Bahir Dar plant boiler
Air Compressor

Ambient air is sucked and filtered by dust filter so as to avoid undesired particles. Then the
filtered gas is then transferred to vacuum suction to form pressure difference which enables to
transfer the sucked air to the desired location. Then this air is transferred to the compressor in
order to develop pressure in parallel with temperature and then cooled in two stages in both
cases. After air is stored in storage tank and used for the needed application. E.g. to operate
pneumatic valves.

27
 Atmospheric air

Suction unit
Air filter

Oil filter Double screw

Radiator Air Cooler compressor

Storage
tank

Figure 13Flowdiagram of air compressor.

Refrigeration /Water chilling unit/

A chiller is a machine that removes heat from a liquid via a vapor compression or refrigeration
cycle. The refrigerant is circulating through a heat exchanger to cool the process water. The basic
principle of refrigeration is by addition of external energy because it is impossible to transfer
heat from low to high temperature without using external energy.

28
Figure 14EABSC Bahir Dar plant chillier unit

EABSC plant chooses to use R143a as a refrigerant gas. The chiller consists of four main parts.
These are:

 Evaporator
 Compressor
 Condenser
 Expansion valve

Evaporator
The chilling system begins in the evaporator where the liquid refrigerant flows over the
evaporator tube bundle and evaporates, absorbing heat from the water that we want to chill
(cooled) which therefore becomes cooled. Then the refrigerant vapor is drawn out of the
evaporator by the compressor.

29
 Compressor
Then the refrigerant vapor is drawn out of the evaporator by the compressor. The task of the
compressor is to compress the refrigerant to high pressure as a result the temperature of the gas
becomes high as its volume decreases. To achieve this task the system uses screw type
compressor. The refrigerant enters the compressor as vapor and is compressed. The compressor
then “pumps” the refrigerant vapor to the condenser raising its pressure and temperature.

Condenser
That refrigerant condenser is a shell and tube heat exchanger where the refrigerant gas under
high pressure and temperature pass through shall and its condensing water from cooling tower
pass through tubes. The heat from the refrigerant gas is transferred through the tube walls to
water which is passing through the tubes.

That warm water spray is then cooled in the tower as some of it evaporates into the air also
passing through the cooling tower. A cooling tower is a heat rejection device, which extracts
waste heat to the atmosphere though the cooling of a water stream to a lower temperature. In
order to cool the loop of cooling water, it is brought in to a cooling tower. In the cooling tower,
the water mixes and evaporates in the introduced airflow by a fan. Airflow escapes the top of the
tower at a more humid condition than when it entered. By evaporating the water, the remaining
water is cooled, and then mixed with a smaller flow of make-up water to maintain the mass flow
rate. The cooled water by the cooling tower is pumped back to the condenser by two pumps. The
water that is lost to that evaporation and also to mist carry-over will be replaced with fresh water.

Expansion valve
The high pressure liquid refrigerant from the condenser then passes through the expansion device
that reduces the refrigerant pressure and temperature when it expands. The refrigerant again
flows through evaporator coils to absorb more heat from the fluid to be cooled and completing
the cycle.

30
 Working principle of vapor compression chiller

Heat addition to refrigerant in evaporator

Refrigerant moves inside the tube whereas water on the shell. The reverse of condenser.
Refrigerant gets vaporized by taking heat from chilled water in evaporator thus serving its prime
purpose. Refrigerant comes out of evaporator as vapors but on other side chilled water is
produced. Heat transfer takes place from water to refrigerant. Chemical treatment in cooling
tower is done using biocide (ST40) and anti-scale.

Compression of vapor in compressor

Refrigerant (R134a) vapors compressed using single screw compressor to high pressure and
temperature. Compressor requires energy input to its working and hence electric energy is
supplied to it.

Heat rejection by refrigerant in condenser

Refrigerant reject its heat to outside cooling water which is passes through cooling tower and
recycled again in to condenser. In this area the refrigerant vapor is on the shell side whereas
cooling water in the tube side.

Expansion of refrigerant in expansion valve

Refrigerant coming out of condenser is expanded in expansion valve and its pressure and
temperature is reduced and ready to remove heat from the fluid to be cooled in the evaporator.
B, Manufacturing

Syrup preparation

Syrup is a condiment that is thick, viscous liquid consisting primarily of a solution of sugar in
water containing large amount of dissolved sugar. Syrup preparation starts from simple sugar
dissolving tank and ends in final syrup tank.

Simple process description of syrup preparation: -

1. Water stored in simple sugar dissolving tank (3920L) circulates through shell and tube heat
exchanger to attain 820c using steam.

31
2. Sugar (6400kg) on Hooper immersed into flowing hot water through venture tube. When the
mixture of sugar and hot water passes through venture tube, sugar start to dissolve because of the
pressure difference created by venture tube which results turbulence of the flowing fluid. And
send to sugar dissolving thank.

3. Sugar and hot water mixture from sugar dissolving tank circulates again through heater using
pump. This compromise the temperature drops due to the addition of sugar.

4. Balancing tank adjust pressure developed from dissolving tank and send to bag filter then to
plate and frame heat exchanger to lower the temperature of dissolved sugar. First using water
from cooling tower, it reduces from 82 0c to 400c, chilled water reduces from 400c to 250c. Then
temporary stored in simple syrup storage tank.

5. The brix value is checked and it must be 62then send to final syrup room. Concentrate of each
type is added part by part to avoid foam formation with their proportion in to concentrate
dumping tank then transfer into final syrup tank and mix with simple syrup using circulating
pump. By check brix value of the final syrup and add water to the final syrup up to its brix
becomes 65 after this we send to mixer/blender section.

32
 Sugar
dissolve
Shell & tube H.x
tank
Hopper

Bag filter
Balancing tank Plate and
frame H.x

Concentrate Final syrup

damping tank Simple
tank
syrup tank

To
Mixing
unit

Figure 10Syrup preparation flow diagram

.

33
 Filler Machine

Bottle filling is the heart of any fluid producing company. Bahir Dar plant uses krones filling
machine which have the capacity to fill 3600 bottle per hour.

Filling operation has many advantages. Those are:

 Avoid product loss.

 Fill the bottle to the desired content consistently.
 Minimize loss of carbon dioxide gain of oxygen
 Prevent microbial, chemical or physical contamination.

The filling machine has the following distributor: - product, air or pressure and electric.

1). Product is transferred from static to moving ring ball using bearing.

2). Pressurized air is moves using hole alignment.

3). Electric using slip ring.

Stages in filling process:

1) Pressurization of bottle: - The main aim of pressurization is to avoid foaming of beverage
during filling. Depend on beverage type the bottle will be pressurized until bottle pressure equal
to pressure in ring ball.

2) Filling: - After pressurization, beverage in ring ball starts to flow over vent tube in to bottle
internal surface using gravitational force over spreader.

3) Settling: - A short period of time the filled bottle becomes stable on rotating ring ball.

4) Sniffing: - Removing remaining air above beverage level in the bottle in order to balance
bottle pressure to atmospheric pressure to control foaming.

Status of bottles is detected by EBI and FBI before and after filling respectively.

Working principle of filler

The bottles after a washer machine are fed to bottle filler by conveyor. The bottle is made to feed
on to individually by in feed star wheel. Hydraulic piston will rise and fall making it to meet the

34
filler valve positioned above. The mouth of the bottle is pushed against the rubber seal of filling
device thus making it air tight. Bottle sensor send signal to the PLC.Then the battle
pressurization starts using vent tube. After pressurization, filling is start spring in vent tube
opened using the pneumatic valves. Due to gravity beverage starts to fill in to the bottle. At this
time density of beverage greater than gas the gas move up and the level of beverage increase
then gas move inside of vent tube and turn back to ring ball. The filled bottle is then allowed to
stabilize itself. The remaining air above beverage level inside the bottle is removed out. After
this Central star wheel receive filled bottle and send to crowner. Crowner cups bottle and send to
discharge star wheel then conveyor receive the caned bottle.

Blender/mixer

Mixer/blender is a unit operation used to mix final syrup, water and carbon dioxide all together.
Bahir Dar plant use Conti flow type mixer which have degassing unit and carbonation unit.

Degassing unit: - it is a horizontal tank which having sprayer at both ends. The aim of degassing
is to remove oxygen or air in the incoming water by increasing surface area, because more
air/oxygen consumes more carbon dioxide. Vacuum pump is installed to remove this gas inside
the tank.

Carbonation: -The process by which carbon dioxide gas dissolves in to beverage is called
carbonization. This involves injecting of carbon dioxide into the beverage at high pressure
(12bar). Since the solubility of carbon dioxide is less in at lower pressure and lower temperature.
We use plate and frame type heat exchanger to cool the beverage before carbon dioxide addition.

Table 2.1Value of brix and carbon dioxide in each beverage

Types of soft drink Beverage brix CO2 (%v)

Coca Cola 10.37 3.92

Sprite 9.2 3.85
Fanta orange 13 2.2
Fanta ananas/pineapple 13 2.2

Working principle of mixer

35
1). Treated water from tank is set to degassing unit in order to remove oxygen using vacuum
pump.

2). Carbon dioxide in gaseous form is send to mixer.

3). Final syrup passes through simple storage tank and driven using two stage pump in order to
mix with water (e.g. Coke 1:5) final syrup to water ratio.

4). Water and final syrup mix in line and sucked using booster pump. Then the solution sent to
plate type heat exchanger to be cool up to 10-120C using chilled water. Recirculation pump
receive this cold solution and mix with carbon dioxide at 12bar in venture tube. Water, final
syrup and carbon dioxide are mixed in line and stored in buffer tank. In this section beverage
analyzer is installed to measure the brix content of beverage. Finally beverage is send to filler.

Figure 15EABSC Bahir Dar plant blending unit

36
 Syrup, water and CO2

Blinder (Mixer)

Sampling and testing

Is the brix ok? NO Adjustment

YES
Transfer the product to the filler

Filling and crowning

Sampling and testing

NO

Is CO2 OK?
Adjustment

YES
f
Continue production and monitor the process

Finished beverage

Figure 16 flow diagram mixer to final beverage

37
Washer Machine

Bottles have to be washed in order to remove extra and internal dirt and also in order to kill
microorganism. Bahir Dar bottle washer have an ability to wash about 17000-49000 bottles per
hour and optimal operating point is 39600 bottles per hour. Two parts of carrier active and
inactive carrier. Active means carrier which have bottle where inactive means returnable carrier
without bottle. One carrier has 34 holding pocket. There are 480 active carriers and 150 in active
carrier.

Bottle washer has 4 parts based on function. These are: in feed dirt bottle, clean bottle discharge,
carrier chain drives system, pumps side.

Based on cleaning effect we can divide in to:

1). Mechanical cleaning effect: - using jet water to remove dirties.

2). Chemical cleaning effect: - using hot caustic, stabilon, chlorine, ferrisol, horolith.

3). Time cleaning effect: - for optimal washing capacity one bottle takes about 25 min. If we
increase retention time bottle will not resist heat or if we decrease retention time dirt will not
remove properly.

Factors affecting bottle washing

To get effective cleaning of bottles several influential factors are used in combination.

Effect of cleaning agent: The cleaning effect of water on its own is small: The cleaning effect
can be up graded by addition of other cleaning agent, which is caustic soda: cleaning agents are
alkaline and it also acts as disinfectant particularly at high temperature. It has an ability to release
dirt. The concentration of caustic in washer is 2-3 % or 101 ms. Other chemical additives like
stabilon, ferrisol, horolith.

Effect of higher treatment temperatures: higher temperatures have an ability to accelerate the
dissolution of dirt. In order to obtain a good cleaning effect, cleaning temperature of 65 0c – 800c
for glass bottles is used. We use hot caustic at 650c.

Exposure time: the longer the hot cleaning liquid acts the higher cleaning effect. The average
contact time of caustic is 6-7 min.
38
Mechanical effect of jetting: this applies for the removal of labels, glue and foiling using jet
and flash at different angel.

Function of chemicals in bottle washer

1). Horolith: - is used for pH adjustment after post caustic treatment, to give bottle bright color.

2). Ferrisol: - used to remove date code.

3). stabilon: - used to protect corrosion, scale, and rust formation on the machine.

4). Chlorine: - use as disinfection.

5). caustic: - as a cleaning agent.

Heat and caustic soda flow system in washer

Heat is transferred from steam to caustic using shell and tube heat exchanger by convection and
conduction. Water flow in pre–cleaning is from soft water treatment and warm water -1. In post
treatment water is flow due to over flow from cold water, warm water -2 then warm water -1.

Working principle of washer

1). Unpacker put dirt bottle on the conveyor to feed into carrier using feed finger.

2). finger shaft transfer bottle in to carrier. There are 34 pockets on one carrier.

3). Pre-cleaning section: it has two parts.

A). High pressure pre-jetting: -has 3mm diameter hole

b). Pressure pre-jetting: - has 1.5 mm diameter hole

Both of them remove large dirt matters.

4). Main cleaning part:

Most dirt is cleaned in this section. Because we use hot caustic as a cleaning agent. It has two
parts caustics -1 (28900L) and caustic – 2(28600L). Both of them have the same concentration

39
(2-3%) and conductivity (101ms). If this is lower in set point caustic is added automatically. The
carrier is socked in two baths in order to having maximum dirt removal. Two tanks have flashing
and jet water.

5). Post treatment area: This section is occurring after caustic -2. The main objective is to remove
alkalinity by adding horolith, to reduce temperature and rinse. Post treatment has the following
sections.

a). Post caustic cleaning is the final treatment using only fresh water to remove caustic

b). Cold water

c). Warm water -2

d). Warm water -1

Chlorine is added as disinfection. Finally, bottles are rinsed using fresh water.

Packer and Unpacked

Packer is used to carry and put filled bottle in to the crate. And unpacked separate dirt bottles
from crate. The working principle of packer and unpacked is similar. Vertical and cross transfer
are two motions in this unit. Vertical motion is performed using forward reverse motor which is
used to move up and down the gripper. Grippers are a plastic that hold bottle neck using pressure
applied on it. It can hold about 144 bottles at a time. Cross travel motion is used to move to and
for the gripper from leading frame to bottle. The push rod is used to move the cross transfer
forward and backward. Limit switch sensor used to stop the motor when it rotates 180 degrees.
Incoming bottle in packer is detected using ultrasonic sensor and shaker aligned battle in to
gripper. Photo cell used to indicate the filling of bottle in gripper feed.

C, Quality

Laboratory

40
 CHAPTER TWO

2. Internship experience
2.1 The Section of the Company We Had Been Working In
We have been working every section of the company by rotating weekly. But mostly in
maintenance section, and production section. We have spent halve of our internship period in
maintenance section and production section. The reason is since our subject is more related to
those sections we have been assigned there.

2.2. The work tasks that we have been executing:

The working task that we have been executing during the internship period

 We observe every section of the company is functioning

 We have been preparing preventive maintenance schedule for operator, mechanical
technician and electrical technician with in syrup room and waste water treatment plant.
 We have been preparing tags for boiler crowner valve, and linkage of steam in washer
machine at gasket.

41
 We are also participated during maintenance activities

42
 

Lubrication, cleaning, inspection, spare part replacement and assemble components

43
44
 We have been measuring the net content and gas volume of final beverage and We have
able to take 5 bottles every 30 minutes for quality controllers.

 We are also able to analyze the performance of the process by calculating the mean, CPK
and PPK value

45
 

 We are able to draw the existing layout of the company and we are to try to recommend
the problem related to layout
 Arranging the bottle when there is over load happen on the conveyor
 We work as Washer, filler and boiler machine operator

2.3 The Engineering methods, tools and techniques we have been using
o Preventive maintenance
o Statistical quality tools such as control chart, pareto diagram, cause and effect analysis
o Facility layout
o Work shop
o Engineering economics
o Machine design
o Safety and ergonomics
o Production planning and control

46
 o Method and value engineering

2.4 The major Challenges and problems we have faced during the internship program:
 All most all of the worker doesn’t have any idea about industrial engineering
and what industrial engineering do. Most of employer confused with industrial
control and industrial chemistry.
 We have no got any additional information from last forth year industrial
engineering student for the company. Since, we are the first industrial
engineering internship student in coca cola Bahir Dar plant.
 Some of workers have wrong attitudes about the internship student
 The company is well organized and work by standardize system with in the
world produce the same brand to it. We have challenged working project on
such company.
 It was difficult to get reliable data and full information about our project
because touching the display board and take camera is not allowed
 We have to be adapt working condition due to high noise on filler machine
during bottle burst and high temperature in syrup room during CIP time
 There is only one chair for operator in each work station. so, we are forced to
observe with standing throughout the day
 We have a challenge to find the price of each spare part and other data related to
production planning and control. Since, every raw material and spare parts are
govern by Addis Ababa plant

2.5 Measures we have used to overcome challenges

 At work, we try to approach each worker positively to make them open to share
their knowledge and skill.
 We were eager to know and this makes our self not pay attention for each
challenge. But we always try to get solution for each problem
 Asking different workers for the same type of equation
 referring on website and referring book

47
2.6 Overall benefits we gained from the internship
2.6.1Improving our Practical Skills

The main aim of this internship program is to improve student practical skill by Appling his/her
theoretical knowledge. The practical skill makes us ready to realize, understand and grasp
theoretical knowledge. This is due to visible and practically done activities are unforgettable in
nature. Generally, we have understood that every practical works has to be done carefully.
During our internship program, we got the following practical skill.

48
o How to goes safety as a culture

49
o

o
o We understood the effect of safety, layout, quality, maintenance on productivity
o We able to understood how to minimize the risk in a work place with different
controlling method like; personal protective equipment, administration control and
engineeringcontrol

50
51
o The effect of ergonomically risk on workers performance
o Ways of satisfaction employees working moral
o How to plan maintenance and implement it
o Minimizing risks with good machine installation and machine safe guarding
o What decision is needed to plan the annual production capacity of the company

52
o How to make a business plan
o How to control the inventory
o

o The use of safety stock

o How to standardize the working method
o We able to understand how to check the quality from raw material to the finished product
and quality standard of the company. Although, how to check quality in laboratory

53
 o How to select the location when we need invest an investment

o What decision is needed when constructing layout of different department

o We are understood the effect of layout with maintenance, safety and ergonomics and etc.
o How to make optimal transportation cost
o

2.6.2 Upgrading Our Theoretical Knowledge

54
We were in the company which is technologically developed, we improved the theoretical
knowledge on every courses starting from fresh year 2nd semester to the 7th semester that
are related and helped us. We have also understood that having such an experience may
influence our future career. Usually theoretically, it is difficult the methodologies to execute
some task but the practical work upgrades the knowledge of metrologies executing different task.

Sometimes theoretical knowledge seems “imaginary “it is because not known practically

2.6.3 Improving Team Playing Skills

Team playing skills are crucial requirement for the proper working of a good company
regardless of work level, sex and heredity. During this four month internship program, we have
developed a good playing skill with operators, specialists, quality controllers, maintenance
planners, production managers and with other intern students. We have learned a lot how to
improve interactions with our team members. When activities are done in group the reasonability
and accuracy found to be always better than those done individually. Therefore we really
understood team work is important to strengthen the effort to accomplish the task. Ideas that are
raised in team work help us to see one thing in different angles and to be a multi directional
thinker for elaborating our knowledge regarding the given issue .Here being patient ability
to listen carefully are the mandatory task.

2.6.4 Improving leadership skills

We have got the opportunity to compare our leadership principles with the leaders/managers in
the company. Our leadership principles are: firstly thinking globally not personally then respect,
listen and work with all concerned bodies of the company. Those managers lead honestly as per
rules and regulations of the company. We also got practical skills of that leadership can
influence others to work towards the achievement of the desired service and it is one of the
functions of management which includes planning, organizing, staffing, leading, and
controlling. We have learned about how we are going to be a good leader, who has strong
principles courage’s to a clear vision , mission, building a strong team and success full
institution.

2.6.5 Work Ethics and Related Issues

55
Everyone should have ethics in any aspects not only in work places .in order to have work ethics
in each member of the company, the companies rule and regulation, the managers leading
system, fair salary and level distribution for every worker is critical. In addition to this, workers
must be employed in terms of their educational level and their concerned places. These
statements of intended conduct are expected of every member (permanent members, associate
members, contract members, and student members) of the EABSC Bahir Dar plant.

General moral imperatives:

 Contribute to society and human well-being.
 Avoid harm to others.
 Be fair and take action not to discriminate.
 Respect property rights (copyrights and patents; give proper credit; not steal, damage, or
copy without permission).
 Respect the privacy of others.

Work ethics would really help us in pushing our career quickly. Discipline, punctuality
Deliverance of work in time, and respect to our higher officials make us a favorite and devoted
intern/trainer in the eyes of employer. Work discipline or desired work behavior can be achieved
only by obeying and respecting the moral or ethical standards of profession. Ethical standards
enable workers to distinguish the right or desired way of conduct from the wrong ones. This
helps workers to develop good working environment and enables them to sustain good
communication skills and behavior with each other and with customers.

A worker with a right conduct or good ethical standard:

 Shall not be absent from work unless for sufficient reason.

 Not to be late.
 Shall not involve in corruption.
 Shall have good relations with the factory administration and the employees.
 Shall be competent.

2.6.6 Entrepreneurship skills

56
It is the way of creating business oriented value which is not present before by spending the
valuable time and effort and taking commitment on risks and also expecting rewards for
undertaking new job opportunity. We have understood that, being entrepreneur make some body
free from supervision and rules of bureaucratic organizations.

Entrepreneurship makes entrepreneur:

 Self-confident
 Creativity
 Leadership ability
 Willing to take risks
 High need for achievement
 Make our self-free from the limit standardized pay for standardize work
 Need of exercising leadership

2.6.7 Improving our interpersonal communication skills

It is essential that every member of a team understands and shares relevant information related to
the project. It is also important that they have a clear picture of their roles and responsibilities
with respect to the project and deliver accordingly. Thus, in order to ensure a successful project
execution, it is important that the team members share a healthy relationship based on trust,
confidence and mutual understanding. All this is possible only when a team develops and
practices effective communication skills

This internship program also develops my interpersonal communication starting from daily labor
to the respected project manager and with other internship student to have a successful
accomplishment of task and to get answer for my question. On the beginning of the internship
program my interpersonal communication with worker of the company and with another
internship student is not good as than after end of internship program. In order to accomplish the
task given in the office we had to talk on it so this communication lead me to develop my
interpersonal communication. And also, while we asking question on site it develop the

57
interpersonal communication with workers of the company. After we have a good interpersonal
communication if we ask something that is new for me they are explain it in detail.

2.7 CONCLUSION
As we try to explain above internship program helps to see practically what we have learned
theoretically starting from fresh year 2ndsemester to the 7thsemester. EABSC teaches a lot of
things how to solve different problem happening in a work please, how to manage our working
environment and how to communicate with other. In addition to that it helps to see things in
different direction. We can generally conclude that the internship program helps to improve and
develop our:

 Leadership ability skill

 Team work ability skill
 Work ethics related issues
 Industrial problem-solving capability and
 Practical and theoretical knowledge

2.8 Recommendation
EABSC Bahir Dar plant is highly profitable company through good leader ship, good team play
and through hard working. Even if the company highly profitable it has some problem. Based on
the internship experience we have some recommendation for the company.EABSC Bahir Dar
plant must improve the following problem in order to competitive more:

1. Take care for used working equipment

Since the company is profitable they do not care about little thing that can cost them high
amount of money. For example, the operators have no much care for the empty bottle
when it falls. But one bottle has a cost of 10birr
2. The leaders must keep daily labor and operator’s moral

58
 In the work, please there are hazards like; physical, biological, chemical and
psychological. Among those hazards we are try to look psychological hazard in EABSC
on operators.
3. The company must prepare documented file for each chemical
4. The company assigns the operator with their qualification level

CHAPTER THREE

3. Project work:

Improving productivity of a bottleneck process in production area

3.1 Summary of the project

This project deals with improving productivity of a bottleneck process in production area. When
we start from the problem statement there are different problem in the company but we select the
frequent stoppage of filler machine problem. To analyze this problem, statistical quality control
tools such as Pareto diagram cause and effect diagram, planned and actual production for
frequently stoppage of the filler machine have been used.

59
3.2 problem statement and justification

Ergonomic risk problems

Even though EABSC have clean and comfort working condition inside and surrounding of the
production area, there are some uncomfortable working condition that exist in the production
area according to our observation and asking the workers in the production area, they are
frustrated with these crucial effects of problems. Those problems are:

o Effect of light on operator at visual empty bottle inspection: -high light intensity on
operator at the visual inspection is one of the contributors for this problem. Even if the
company take administration control like, shifting the operator every 20 minutes and
personal protective equipment at visual inspection it is not enough to arrest the problem.
Since, due to high speed, repetition and excessive in brightness difference between the
working area and the closest surrounding those leads the problem make more severe and
minimize the performance of the workers
o Hot working area: - Even if in the company have good thermal condition inside every
offices and most working area, there is some problem (discomfort) inside the final syrup
room due to hot thermal condition. Since, hot water and hot caustics used for CIP are
produced inside the final syrup room by heat exchanging those caustic and water with a
steam having a temperature of 350 degrees centigrade. Hence, there is no ventilation and
widow inside the room these problem leads for common cold, very stressful to the heart and
lungs as we try to observe during our intern ship period.
o High noise during bottle burst on filler machine: - this is one of the most discomfort
working condition inside the production. Due to the life cycle of the bottles and temperature
difference, some bottle is burst at filler machine during pressurizing step with 4.5 bar
pressure. So, because the production area is highly confined space and the operator operates
closer to the machine these contributes the sounds makes high. This high noise leads
impaired hearing and cumulative disorder after a certain year if it is continued in such away.

o Twisting movement at Palletizer and depalitaizer of crates/cases: -

Empty bottle crates lift from the ground to the conveyors and full bottle crates from
conveyors to ground. At that time workers induce back pain due twisting repetitively
more than 3 hours.

60
61
o Improperly designed Ladders: -All Ladders in production area especially in crown feed
system container almost all ladders in production area are perpendicularly joined with
ground. The workers will get injured when they move up and down when there is crown

62
 stack and deformed crown.

Machine stoppage less than 5 minutes and greater than 5 minutes

In filler machine

A, Machine stoppage less than Five Minutes

 empty bottle inspector

 gap detection sensor
 bottle present sensor
 backup container sensor
The above listed sensors are stop the machine when the bottles are fallen over container,
then the sensors read no bottle is presented sensors are not clean in that time not
transmitted signal.
 Roller stack due to bottle burst
at the time of filling stage when the bottle is pressurization step to check its crack/
breakage, life cycle and easier for filling process, so at this time the bottle is burst due to
the above cases in that time roller move up and down to carrying bottles, so at the time of
bottle burst roller stop working.

63
  lack of crown
Due to empty of crown the filler machine is stop for packaging purpose/capping
 packer machine stops
When the packer machine is stop working in different reasons e.g. insects / flies are
cover the sensor specially safeguard (capacitor) sensors, so the machine is synchronized
system as soon as the filler machine is stop.

B, machine stoppage greater than five minutes

 lack of product water (treated water)

To prepared product water the time elapsation is 4:00-8:00, due to this lack of water is
happen
 faulty of conveyors1
When lubrication type is not comfort to conveyors in this time happen friction and stop
conveyors as well as fallen over container is stop conveyors to rotate

In washer machine

A, machine stoppage less than five minutes

 Over load of bottles in discharge conveyors

When at the time of bottle washing in washer machine to gain washed bottles from 25-30
minutes in this time bottles soaking by caustics and by hot water due to this bottle break
down i.e.by life cycle, crack in this time happen stack at discharge time
 Safeguard sensor (capacitor sensor) due to Plastics/other materials
come together with bottles
When bottles came from external customers in that time different dirty particles came
with in bottles in that time plastics or other materials seen above the bottles the safeguard
sensors stop the washer machine.

B, machine stoppage greater than five minutes

 Lack of caustics in die tank

Caustic is the key raw material among bottle washing used materials, so lack caustic is
stop the washer machine
 Unpacker machines stoppage
When unpacker machine stops by the below cases so the system is synchronized at that
time washer machine is stop by lack of bottles
 Lack of steam at start up time due to boiler machine
Steam is very essential for washer machine to soaking bottles by hot water for the
purpose of to get clean bottles easier and faster by this case washer stop working.
In unpacker machine

64
A, Machine stoppage less than five minutes

 shrinkage crates/cases
Empty crates came from customers, so the customers by different problems crate
shrinkage happen due to this unpacker machine is not easily gripped the bottles.
 Crate stopper sensor
Due to lack of cleaning the sensors are not transmitted signal in this case the sensor stops
the machine
 Lack of crates in un palletizer area
When insufficient crates in depalitaizer area the unpacker machine stop working.

In packer machine

A, machine stoppage less than five minutes

 Faulty in crate washer

Crate washer is not washed the crate and properly discharge to the packer machine so the
packer is stop working
 Crate stopper sensor
The sensors are not clean so it has not transmitted signal in that time stop the machine
 Fallen over container/bottle
When the bottles fallen over conveyors then flappers stop the machine, i.e. flapper is
count the bottle came in to packer machines for proper gripper purpose

B, Machine stoppage greater than five minutes

 Filler machine stoppage due to different

problem
All machine is synchronized system each other, so filler machine is discharge full bottles
to packer machine that means filler stops as soon as packer machine
 Date code machine
When the date code is not properly write the required time and place, so the operator
stops the machine in that time the machine is synchronized system as soon as the packer
machine is stop.

Maintenance problem

In waste water treatment plant

 Split /breaking of Oil skimmer

65
 Using oil skimmer device oil, grease and floating matters are removed using plastic
Conduit. The conduit is porous and can absorb floating matters and reject those matters
as it passes through narrower space, so the oil skimmer split / break not perform those
tasks and affected treated waste.
 Un working of Filter press machine
At the time of over filling of sludge tank, Filter press machine is used to filter sludge
change into water form and very compacted particles, then the water form is return to
sequential batch reactor tanker and compacted particles remove to the environment.

In boiler room

 Linkage of steam at chrone valve

At this valve steam linkage is happen steam transfer from the boiler to the washer / sugar
dissolving room at this time steam tripped out to the environment in this case steam
efficiency is decreased.

 Linkage steam in the blow down stage/drain

When total dissolved solute (TDS) is greater than 3500 check by chemists, so the boiler
is required fresh water to generate steam in that time blow down occurs i.e. Steam is
extracted to environment by this case boiler steam efficiency is lower than the required
one.

In washer machine

 There is also linkage of steam come from boiler room at gasket

This problem is due to boiler startup time as well as not to get efficient steam due to
different linkages.

o Dry wastage disposal of break down bottles problems: -EABSC have not bottle crusher
machine, so the break down bottles giving to others taker to require this break down bottles
without payment due to this the company pay cost.

66
3.3 Objectivity of the project
 Main objectivity

The main objective of this project is improving productivity of a bottleneck process through
minimizing frequent stoppage of the bottleneck process in production area.

Specific Objectivity
 To identify the bottleneck process in the production area
 To identify the cause for bottleneck
 To estimate the difference between planned and actual capacity of bottleneck process
 To analyze loss of production due to bottleneck process
 To make propose solution

3.4 Methodology
They have used both primary data collection and secondary data collection mechanisms.

 Primary data collection

 Direct observation

The first method we have used by direct observation; we observe every raw material,
every machine to reduce the efficiency of machines, seen which machine lowest
throughput rate and seen overall area of the company specially related with our
department. This helps to understand the problem and the cause of the problem.

 Informal interview with the operators, supervisors, technicians, human resource manager
as well as specialists, the last but not the least they have asked the production manager;
how this problem have occurred and how to tackle those problems.
 Secondary data collection

67
  Written materials in the organization
We have seen manuals and other written materials prepared by the organization. Those
materials help to know actual design working of the machines, different profile of
machine design and related data’s.
 Referring to some book
We have read some reference books about productivity improvement techniques.
 Using internet
we have searched about productivity improvement techniques as well as WWW.
EABSC.COM

3.5LITERACHER REVIEW
3.5.1 productivity improvement

Productivity improvement is to do the right things better and make it a part of continuous
process. Therefore, it is important to adopt efficient productivity improvement technique so
as to ensure individuals and organizations growth in productivity

Productivity is nothing but reduction in wastage of resources like men, material, machine,
time, space, capital etc. It can be expressed as human efforts to produce more and more with
less and less inputs of resources so that there will be maximum distribution of benefits
among maximum number of people. Productivity denotes relationship between output and
one or all associated inputs.

3.5.2Linking product design and process selection

A basic process performance metrics is throughput time. A lower throughput time means that
more products can move through the system.

One goal of process improvement is to reduce throughput time.

What is a bottleneck?

Bottleneck is the process stage with the smallest throughput rate [Longest cycle time]

How do measure throughput time

Throughput time: Average time that a unit takes to go through the entire process [including
waiting time]

Work in process [WIP]: Average number of units in the system over a time interval.

How do we analyze a complex process?

68
 1, Look at the process step by step

2, Determine throughput rate (i.e. capacity) of each step

3, Identify the process bottleneck (smallest processing rate, or largest cycle time)

4, The capacity of the process equal to the capacity of the bottleneck

3.5.2 CAUSE-AND-EFFECT DIAGRAM

A Cause-and-Effect Diagram is a tool that helps identify, sort, and display possible causes of
a specific problem or quality characteristic. It graphically illustrates the relationship between
a given outcome and all the factors that influence the outcome.

 Why should we use a Cause-and-Effect Diagram?

A Cause-and-Effect Diagram is a tool that is useful for identifying and organizing the known
or possible causes of quality, or the lack of it. The structure provided by the diagram helps
team members think in a very systematic way.

 Some of the benefits of constructing a Cause-and-Effect Diagram are that

 It helps determine the root causes of a problem or quality characteristic using a structured
approach.
 Encourages group participation and utilizes group knowledge of the process.
 Uses an orderly, easy-to-read format to diagram cause-and-effect relationship.
 Indicates possible causes of variation in a process.
 Increases knowledge of the process by helping everyone to learn more about the factors
at work and how they relate.
 Identifies areas where data should be collected for further study.

3.5.3 PARETO CHART

A Pareto diagram is a simple bar chart that ranks related measures in decreasing order of
occurrence. The principle is based on the unequal distribution of things in the universe. It is the
law of the "significant few versus the trivial many." The significant few things will generally
make up 80% of the whole, while the trivial many will make up about 20%.

The purpose of a Pareto diagram is to separate the significant aspects of a problem from the
trivial ones. By graphically separating the aspects of a problem, a team will know where to direct
its improvement efforts. Reducing the largest bars identified in the diagram will do more for
overall improvement than reducing the smaller ones.

69
How Pareto helps group work

Pareto’s Principle is really a trick to save time. Here are some of its uses:
* If you can identify the 20% of activity that will produce 80% of your assignment, you can plan
accordingly and save a lot of time.
* In any situation where there are a number of factors, separate the vital few from the minor
many
* Don’t give equal weight to all factors.
* Most of your answers will come from a small amount of information (so a huge amount of data
is no guarantee of quality information).
* If you have too much to do in the time available, identify the critical 20% and do that

DATA COLLECTION AND ANALYSIS

We have to collect these data by using observation and recording in each machine part
for five days during the internship period.

NO Machines Days Performance of machines

Performance
of machine
within one
hour
1 crates in one day (24 Crates per
hour) hour
1 33000 1375
Packer 2 30261 1261
3 30000 1250
4 30120 1255
5 30228 1259
2 Unpacker 1 45027 1876
2 45060 1878
3 45144 1881
4 47019 1959
5 46272 1922
3 Washer 1 45021 1876
2 45054 1877

70
 3 45135 1881
4 56013 2334
5 46266 1928
4 Empty bottle Good Rejectio Total 1876
inspector(EB n
I) 1 41024 3992 4501
6
2 40276 4910 4518 1883
6
3 40027 4940 4496 1874
7
4 43156 5615 4377 1824
1
5 40252 5333 4558 1899
5
5 filler 1 33024 1376
2 30276 1262
3 30027 1251
4 30156 1257
5 30252 1261

 In Empty bottle inspector (EBI) machine rejection consists of in the above table:
 Base dirt
 Neck finish break
 Hf caustic
 IR oil
 IR residual liquid
 Infeed monitoring too high
 Infeed monitoring under height
 Neck finish cap
 Fallen over container

71
 From the above data to calculate the bottleneck process

 Bottleneck is the process stage with the smallest throughput rate (longest cycle time)

Machines Actual capacity Planned capacity Design capacity

(i.e. Crates per (i.e. crates per hour) (i.e. crates per hour)
hour)

Packer 1280 1400 1880

Unpacker 1905 1980 2200
Washer 1904 2000 2154
EBI 1901 1990 1925
From the
Filler 1281 1500 1750
above data
collected
the bottleneck machine is filler machine, but Packer machine and full bottle inspector (FBI) is
starving (stoppage of activity because of lack of full bottles) by filler machine.

 Cause and effects diagrams for filler machine

This diagram elaborates or justifies what problems/ causes are filler machine stop and what is the
effect of this problem in EABSC seen during the internship periods.

Sensors
METHODS
MATERIALS
MACHINE
S Lack of proactive
Lack of Lack of maintenance
Washer
Packer machine stop in product crown
stop
different problems water
Sequence of repair
Lack of
Lack of bottles
FBI stops by final syrup Filler machine proble
differentproblems

72

Poor attitude
Amount of brix
and carbonation
training Amount of
pressure
Omissions Power
interruption
PEOPLES
MEASURMENTS
ENVIRONMENTS

PARETO CHART

This Pareto diagram shows about the frequency of filler machine stoppage less than five minutes
and greater than five minutes from the collected sample data for five days during the internship
period.

N Causes of machine Frequency Cumulative Percentage Cumulative

O stoppage frequency percent
1 Crown stack on 64 64
chute
2 Centering bell 39 103
tripped
3 Lack of bottle from 19 122
bottle washer
4 Water pressure low 18 140
5 Brix value low 11 151
6 power interaction 10 161
7 CO2 value low 8 169
8 Discharge rejection 8 177
monitoring (EBI)
9 Infeed gap detection 7 184
sensor
10 Back up at filler 7 191
discharge
11 Checkmate elible 5 196
inspection
12 Glide line 5 201
malfunction
13 Empty bottle 5 206
inspection
14 Syrup tank change 3 209

73
15 Deformed crown 3 212
16 Block arrangement 3 215

 The filler machine is stop working by the above problem, so by this stoppage the
EABSC Bahir Dar plant lost the following production from the collected sample data
for one month during the internship period.

Day Type Actual production Planned production

within three shift(24 within three shift (24
hours) in case hours) in cases
1 Coca-Cola

74
 36000
Sprite 32698
Sprite
2 Sprite
Fanta 17478 36000
Coca-Cola
3 Coca-Cola
Coca-Cola 23502 36000
Sprite
4 No production by - -
planned maintenance
5 Sprite
Sprite 12703 36000
Fanta
6 Fanta
Coca cola 21546 36000
Coca cola
7 No production - -
schedule
8 Coca cola 36000
Coca cola 33931
Coca cola
9 Sprite
Sprite 14067 36000
Fanta
10 Coca cola
Fanta 20268 36000
Coca cola
11 No production by - -
planned maintenance
12 Coca cola
Coca cola 21525 36000
Coca cola
13 Sprite
Sprite 31752 36000
Sprite
14 No production - -
schedule
15 Fanta
Coca cola 21455 36000
Coca cola
16 Coca cola
Sprite 27070 36000
Coca cola
17 Coca cola

75
 Sprite 22506 36000
Sprite
18 No production by - -
planned maintenance
19 Sprite
Fanta 15648 36000
Coca cola
20 Fanta
Coca cola 21513 36000
coca cola
21 No production - -
schedule
22 Sprite
Sprite 20043 36000
Sprite
23 Fanta
Fanta 20170 36000
Coca cola
24 Coca cola
Coca cola 25928 36000
Coca cola
25 No production by - -
planned maintenance
26 Sprite
Sprite 22459 36000
Sprite
27 Coca cola
Coca cola 25992 36000
Coca cola
28 No production - -
schedule
29 Sprite
Sprite 25287 36000
Sprite
30 Fanta
Fanta 18506 36000
Coca cola

From the above sample data to calculate total actual production and planned production of filler
machine monthly working, so from the above sample data total actual production=496,047 cases
and total planned production =792,000 cases from this data to calculate monthly loss of
production in EABSC, so we can calculate loss of production in monthly.

76
 Monthly loss of production in EABSC= planned production – actual production

Monthly loss of production in EABSC =792,000 cases -496,047 =295,953 cases

The cases for this loss of production is above listed problems in filler machine.

Cost analysis
EABSC lost in one month 295,953 cases, the company selling one cases by 174 birr (one
bottles for 7.25 birr), so the company pays cost by different problems of machine stoppage
less than five minutes and greater than five minutes.

So, the EABSC pay the total cost in monthly = loss of production in monthly * price of one
cases EABSC selling.

EABSC pay the total cost in monthly=295,953 cases*174 birr/cases

EABSC pay the total cost in monthly =51,495,822 birr

Proposed solution
How to improve the filler machine.

To improve the filler machine, reduce/minimize stoppage of machine less than five minutes and
greater than five minutes by controlling stoppage activities to be stop the machine by using
preventive maintenance as well as to adjust start up time of other machines because the machine
is synchronized system one machine stoppage to the others stoppage.

PREVENTIVE MAINTENANCE SCHDULES IN EABSC TO MINIMIZE MACHINE

STOPPAGE ACTIVITIES IN FILLER MACHINE

Safety: ensured that you are wearing the required personal protective equipment such as safety
shoes, protective closing, and ear protection and wear glove. Isolation: before caring out any
work on any of the equipment listed below, ensured that you obtain a job card and if the machine
is non-running. Frequency: daily at start up time. Check/ work by: filler operators.

NO Machi sensors ID freque Ca3uses Preventive Optima Meth tool Tim Action if
ne to ncy to maintenanc l od e not ok
be prevent e task conditi (min
stop description on )
need
ed
1 Filler Infeed operat Daily Not Check The hand eye 1 Involve to
gap or transmitt sensor to sensor the
detection ed signal transmit is respective
77
 signal or transmi controller
not and t signal
clean the
sensor
2 Filler Side wall operat Daily Not Check The Hand eye 1 Involve to
inspectio or transmitt sensor to sensor the
n at front ed signal transmit is respective
signal or transmi controller
not and t signal
clean the
sensor
3 Filler Side wall operat Daily Not Check The Hand eye 1 Involve to
inspectio or transmitt sensor to sensor the
n at ed signal transmit is respective
discharge signal or transmi controller
not and t signal
clean the
sensor
4 Filler Discharg Operat Daily Not Check The Hand eye 1 Involve to
e or transmitt sensor to sensor the
rejection ed signal transmit is respective
monitorin signal or transmi controller
g not and t signal
clean the
sensor
5 Filler Back up Operat Daily Not Check the The Hand eye 1 Involve to
container or transmitt sensor to sensor the
ed signal transmit is respective
signal or transmi controller
not and t signal
clean the
sensor

CHAPTER FOUR
GENERAL CONCLUSION AND RECOMMENDATION

CONCLUSTION
Productivity improvement in EABSC was demonstrated by fish bone diagram, Pareto diagram
and by collected sample data for one month.

78
Productivity improvement in EABSC especially in production area the machine is synchronized
system, so from this seen how to minimize loss of production in overall production area to
minimize/reduce the cause of machine stoppage less than five minutes and greater than five
minutes by using industrial engineering tools.

The productivity analysis of fish bone diagram was demonstrated by listing all major and sub-
causes of the problem and by listing corresponding answer for the problem. This results
increase in productivity in production area by minimizing overall waste in EABSC.

RECOMMENDATION
The following recommendation is important for future works of the company

We can recommend EABSC give monthly induction for operators, technicians, and
specialists and all workers how to affect minimum problems (simple problems) in
production line and shows how much loss of production by this simple problems (i.e.
less than five minutes and greater than five minutes) and how to reduce/minimize
these problems.
We can recommend EABSC give induction especially for operators and technicians
about condition monitoring maintenance (predictive maintenance) to reduce machine
failures and involve the respective controller maintenance to seen/hearing unusual
sound or working habits of the machine.
We can recommend EABSC to prepare spare parts for different parts of machine e.g.
warm gear in filler machine and chrone valve of boiler machine are not spare parts.
We can recommend EABSC use treated waste water by recycling at least for plants
and washing for cars as well as use the filler press-machine by giving proper
maintenance for the machine.
We can recommend EABSC the team leaders understand with each other, remove
confliction and resolve difference, clear roles and responsibility, improve collaboration

and develop all workers in EABSC “I” became “WE”.

79
80