Industrial Engineering

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A Heuristics and Discrete Event Simulation for Optimized Layout Design in Agricultural Machinery Maintenance - A Case Study of Wereta International Business Plc.
(Addis Ababa University, 2024-07) Fitsumberhan Hailemeskel; Ameha Mulugeta (PhD); Ayele Legesse ((Mr.) Co-Advisor
Agricultural machineries play a vital role in agricultural processes and help in the production of food and non-food items. The efficient layout of agricultural machinery maintenance facilities is crucial for minimizing process times and maximizing throughput. This paper deals with the development and optimization of an agricultural machinery maintenance facility using discrete event simulation considering Wereta International Business Plc.’s agricultural machinery maintenance facility layout as a case. The development of the facility layout is done in a way that introduces flexibility of departments and also that combines the different services given in the facility, maintenance, training (customer & staff) and pre-delivery inspection processes. The research tries to construct a new facility layout that decreases the travel distance, considers the relationship between departments using the CORELAP facility layout construction method. The newly constructed facility layout has been optimized using facility layout improvement technique, CRAFT (excel add-in) to further enhance the optimality of the facility layout by enhancing the material flow between departments to minimize the material handling cost. Finally, an improved facility layout, with 15 departments that include main and supporting facilities and also combines the services and training facilities is developed. The proposed facility layout reduces that has been constructed from scratch and then optimized decreases the distance traveled between departments by 2,015.11 meter (a reduction of 33.66%) and the total monthly material handling cost by 531,093.14 Birr per month (a reduction of 86.85%). The entity output of the existing system is 40 units and for the proposed layout, the entity output is 67, an increase by 67.50%. Also, the system output from the existing simulation model is 125.30 units and the proposed layout simulation modeling system output increased by 58.85% to 199.04 units.
Adoption of Additive Manufacturing for Auto Parts Production: Case of Bishoftu Automotive and Manufacturing Industry
(Addis Ababa University, 2023-10) Sultan Asefa; Ameha Mulugeta (PhD)
This study investigates the adoption of additive manufacturing in the Bishoftu Automotive Industry in Ethiopia. The study applies an integrated framework of Diffusion of Innovation (DOI) and Technology-Organization-Environment (TOE). This study also used combined data from primary and secondary sources using quantitative and qualitative methodologies to allow for the exploration of the factors and constraints influencing the decision to adopt additive manufacturing. Additionally, the research undertakes a thorough literature analysis of Adoption theories such as DOI, TOE, and factors affecting additive manufacturing adoption. Five point Likert scale was the method used to collect the useful information for this study. The questionnaire was distributed to managers, engineers, and technicians in the Bishoftu Automotive and Manufacturing Industry. Subsequently, the collected data was subjected to analysis through the application of descriptive statistics and partial least squares structural equation modeling (PLS-SEM) utilizing SPSS version 27 and SmartPLS version 4.0.9.6 software. The study outcomes revealed that several critical determinants significantly impact the adoption of additive manufacturing (AM) in the automotive sector. These determinants encompass relative advantage, compatibility, complexity, trialability, observability, technology-related factors, and organizational as well as environmental factors The results of this study enhance our understanding of the adoption of additive manufacturing and provide valuable practical guidance for decision-makers within the Bishoftu Automotive Industry. Drawing from these findings, recommendations have been formulated to facilitate the effective integration of AM in the automotive sector. Additionally, this study identifies potential areas for future research in this field.
Adoption of Nanotechnology in case of Ethiopian Textile Industry
(Addis Ababa University, 2023) Biruk Wondemneh; Birhanu Beshah (PhD); Gebrewold Teklay (Mr.) Co-Advisor
Nanotechnology provides plenty of efficient tools and techniques to produce desirable fabric attributes, mainly by engineering modifications of the fabric surface. Due to the advancement of Nanotechnology in the manufacturing of fiber or yarns including the development of fabric finishes, the applications and scopes are widespread in the area of textiles for the last few decades. According to this research study the existence and the application of Nano technologies with in Ethiopian textile industries are very minimal or we can say it does not exist. So we listed enablers which will introduce Nanotechnology and used a multi criteria decision making method MCDM to rank which is more effective to implement Nanotechnology among the listed enablers and according to the research result the government is highly capable to introduce and implement Nanotechnology within the Ethiopian textile industries. Government can mobilize market, technical, financial institution and socio economic activities to introduce Nano technology within textile manufacturing industries. The introduction and implementation of Nano technology by the government with in textile manufacturing industries could be easier than the other alternatives. The implementation of Nano technology within textile manufacturing industries enhances the quality of the textile and the development of manufacturing industries.
Alleviating Scheduling Problems in Anbessa City Bus Service Enterprise
(Addis Ababa University, 2009-09) Hailu, Gemechu; Tafesse, Gebresenbet (PhD)
The transport sector is a key element for the development of a country. Almost every item or human being participating in the national economy needs to be transported from one location to another. Thus a problem in the transport sector implies impediment of the development of the socio-economic status of the country. It has become very common that globally emphasis is given to the transport sector. Hence, the modes of transport are diverse, efficient and effective in many countries. City Trains, city Buses, Midi Buses, Taxies, Express Cabs are among the transport means that facilitate city transport services. However, the existences of all these modes of transport dose not guarantee satisfactory transport service. The modes of transport shall address the customers by making themselves available at the time and place they are required. To keep the time and place of destination and departure of means of transport different measures are taken by different countries. Among these are; using different bus lanes on streets, and making appropriate scheduling and time tabling of the different modes of transport. However, the case in our country, specifically, the capital city Addis Ababa, is different in that there is no city train service, the road ways are narrow and not well maintained, they are also un proportional to the number of vehicles available in the city, there is no bus lane, etc. Moreover, the city bus service is the only public transport having a specific route of travel and governed by governmental development agency. The private transport sector is not controlled under a specified route and gives service based on the best advantage of the owner rather than the public. Consequently, the public is suffering from shortage of transport to make its daily activities. These factors have aggravated the problem of city transport in Addis Ababa. The main objective of this thesis is to alleviate the problems of city transport described above through improving the scheduling system of Anbessa City Bus Service Enterprise. The paper gives emphasis on the way that the public gets the required transport service on the time and place which the customer specifies and on the continuity or dependability of the schedule insuring this service. This is done by identifying the core problem of the public transport in relation to the city bus service through delay data collection, questionnaire distributed and interviews conducted to the customers. Finally, appropriate method of data collections and trip time determination for making schedules, timely updating of the existing data for keeping the schedule dependable, consideration of all route disruption factors for sustainability of the feasibility of schedules are recommended. The result of the study can improve the service delivered by the enterprise and shift the customers who are dissatisfied by the private transport sector to Anbessa buses increasing the market share of the enterprise in the city transport service. It will also improve the mobility of resources which is a key factor for improving the socioeconomic status of the city.
Analysis and Optimization of Passenger Waiting Time: In Case Anbessa City Bus
(Addis Ababa University, 2018) Dobosha, Abbelti; Eshetie, Berhan (PhD)
In public transportation providing the fast transport service is the main concern to satisfy the passenger demand. The bus service accessibility in response to the passenger demand is deferent from route to route. This deference resulted in short passengers waiting time for high frequency and long passengers waiting time for the route of low bus service frequency. The long passengers waiting time is one of the measure of poor public transit service quality. In this thesis mathematical modeling was developed based on the dynamic passengers demand and bus service operational constraint to optimize passengers waiting time at bus terminals of Addis Ababa city in case of Anbessa bus transport using the data collected during literature review, interview, field study and secondary data collected from ACBSE. Mixed Integer Non-Linear Programing MINLP and Mixed Integer Linear Programing MILP model were developed for static and dynamic passenger demand. The dynamic passenger demand was solved as Mixed Integer Linear Programing MILP model by discretizing the bus planning horizon into small time (in minutes) to linearize and make the model tractable to solve it using software. LINGO software was used to solve the model. The result was evaluated with bus headway, bus frequency and bus capacity. The evaluation shows that the overall average bus departure time reduction is 39.62% and 37.74% for DAF or rigid Bishoftu bus and articulated bus respectively. The improved average frequency for DAF or rigid and articulate bus is 62.44% and 60.67% of actual bus frequency. The total average passengers waiting time for the DAF and Bishoftu bus was 8.03% more than the passengers waiting time for articulated bus. The overall average passengers waiting time reduction is 39.62% and 37.74% for DAF or rigid Bishoftu bus and articulated bus respectively, through the proposed mathematical optimization models.
Analysis of Supply Chain Performance Measurement System in Addis Ababa: The Case of Selected Shoe Factories
(Addis Ababa University, 2017-06) Sentayehu, Wehibe; Mengist, Hailemariam (PhD)
Supply chain performance measure has a vital role in the improvement of the organization’s overall performance. As a result, different measurement factors were employed and performance frameworks have been changed rapidly due to the effect of today’s competitive global market over a period of time. Although Ethiopia’s manufacturing sector has been developing in a way to fit in a global arena, it is still struggling at an infant stage, this show these factories has problem in their supply chain performance which indicates the presence of problems needs further improvement. This happens due to lack of holistic performance measurement approaches employed for their supply chain performance measurement. The overall objective of this study was to investigate the supply chain performance measurement practices of Ethiopian footwear companies using holistic measurement factors in combination of macro processes and decision making level within performance measurement framework. The study was conducted in three shoe manufacturing companies using a predesigned Likert scale type questionaries’ for purchasing, production and marketing department each companies. Hypothesis was also developed and its significance was tested using SPSS. Additionally, AHP model was employed to check for the desirability of the measurement factors using MATLAB. For checking the internal consistency of the items under study, Cronbach’s alpha was employed and it was learnt that the data were reliable. The results in between groups and within groups are compared using analysis of variances ANOVA. The priority given for each measurement factors were also measured using AHP model. Then, the result of the study shows that the majority of the performance measurement factors differ among the three manufacturing companies at a 5% significant level. Similarly, measuring factors which were given more priority or which are more desirable than other factors to be used for measuring supply chain performance in the case shoe companies were also identified. Moreover areas which need further improvement were also identified, As a result, it was devised that shoe factories should have to give due attention for developing green supplier selection policy, safe and advanced working environment, optimal inventory policy, proper waste management, proper management of obsolete raw material, proper operation of information technology and assessing on degree of bottleneck for managing bottlenecks to achieve best performance in their supply chain and to be competitive in global market.
Analyzing and Optimization of Car Parking Space for Addis Ababa City Case of ADDIS KETEMA sub-city
(AAU, 2018-07) Mengistu, Manaye; Eshetie, Berhan (PhD); Fitsum, Getachew (Mr.) Co- Advisor
Currently in Addis Ababa there are so many problems which are mainly concerned with shortage of parking space such as congestion of roads due to imbalance between on-street parking capacity and number of vehicle, emission of to the environment due to searching of parking space and idle of the drivers by waiting parking spot. The Parking problems have been analyzed with the consideration of both quantitative and qualitative data collection methods. Different data collection methods has been used in this study, such as structured and semi-structured questionnaires, interviews, and observation and survey data collection methods are applied and then the collected data are analyzed and presented by Excel and Minitab. The study has analyzed the current parking system and finding of optimal parking location by considering parking site selection criteria and using AHP method. The space optimization model considers different constraints such as average arrival rate, parking capacity, vehicle size, parking angle and average parking duration and formulate LP model and LINGO17 software has been used to solve the LP model. In addition this study considers two scenarios which are average daily arrival rate of vehicles and parking duration and average daily maximum arrival rate of vehicles and average parking duration in the parking lot are inputs to develop space optimization linear programming model. As a result, it has found that existing parking capacity is increased by 119, 328, 421, and 483 parking spot from 60 parking spot and scenario- one fulfilled with 45, 60, and 90 degree of parking angles. And when considered scenario-two the existing parking capacity is increased by 11.2%, 31%, 40% and 45.4% of parking capacity of vehicles with respective parking angle. Finally comparing the result with actual parking capacity of on-street parking capacity with improved LP model and saved parking area are 6040 meter squares from 90 degree parking angle, 1492.48meters square from 30 degree parking angle, 4102.06meter square from 45 degree parking and 5268.08 meter square from 60 degree parking angle. Therefore, maximum saved parking area is 6040 meter square from 90degree parking angle. But the recommended parking angles for on-street parking are 30, 45, and 60 respectively.
Analyzing Industrial Development, Market Performance, and Competitiveness Case Study on Awash Melkassa Aluminium Sulfate and Sulferic Acid Share Compnay
(Addis Ababa University, 2006-05) Tamerat, Daniel; Gebeyehu, Gashaw (Mr)
The purpose of this thesis is to analysis industrial development relative to the importance of Awash Melkassa Aluminum Sulfate Sulfuric Acid Share Company product to different sub-sector in Ethiopia. It is evaluated integrated development of AMASSASC products like aluminum sulfate and sulfuric acid to other industries, and it is seen the contribution of the company product with other sub-sectors and analysis contribution to the development of industries. AMASSASC market performance and competitiveness is evaluated by considering internal and external factors that affected its market and competitiveness. Some of the factors included on this thesis that affected the company market performance and competitiveness are analyzed based on the current economical, political, social and technological factors. In order to evaluate its market performance and competitiveness of AMASSASC different analytical tools are used, some of them are: PEST analysis, SWOT analysis, cause and effect diagram, Pareto analysis and cost analysis are used. By using PEST analysis the market performance it evaluated by considering the current political, economical, social and technological conditions of the country. Using SWOT analysis the competitiveness of the company is seen based on the strength, weakness, opportunities and threats the company has and faced, and in this thesis it is looked mainly its weakness opportunities and weakness threats. It is also described in the cause and effect diagram the possible causes why the company is not competitive, and by using Parato analysis it is described the vital few and trivial many problems that make the company not competitive. xii The results of the study indicate that the company has low demand in the country, high idle time expense, and has high production costs. The main consumer of the product of aluminum sulfate is A/AWSA should be given much consideration by providing the pre-requisite product hydrated lime, this could be achieved by working in coordination with product of hydrated lime.It is observed that the successful development of the sub-sectors plays a main role for AMASSASC to product at full capacity. It is therefore must focus on strategy in promoting the product and look for market distributing channel, and study the domestic and neighboring country demand and buying price.
Analyzing Supply Chain Integrations and its Performances Metrics to Enhance Productivity Case Company: Five Food Complex Industries around Addis Ababa
(Addis Ababa University, 2021-06) Getu, Abdisa; Gulelat, Gatew (PhD)
To be competitive domestically & across the globe, coordinating various SC functional departments and inter-flows of its activities‟ integrations need to be synchronized. SCPM is activity to quantify efficiency, effectiveness, and resource utilization of SC operations‟ current case industries that resulted from poor SCIs. The major case firms‟ problems were lack of SC coordination, like suppliers, poor inter-flows of resources within SC functional - departments, resources utilization, and poor cost opportunities. To address these problems, case firms need management & resources utilization philosophy to be a success. Pre-dominantly, the objective of this study was to analyze SCI & SCPM to enhance overall SC productivity. In Literature Review, general concepts of SCI, SCPMs & their type, various tools, models, addressed areas by former scholars, and gaps such as the SCOR model used solely, improvement management tools not extensively incorporated in materials. However, the researcher merged it with a tool like MLAC & QMS relevant tool to make the analysis comprehensive. Research framework, data type & method of collection (questionnaires, structured &semi-structured interviews, and discussions, review SC operations‟ reports) have been used. Relevant data analysis tools such as a combination of MS-excel solver & IBM 24 SPSS software, and efficiencies, downtime, and cost opportunity analysis were used. Having these, key SCI such as 10.1%, 57.8%, 30.8% (CIWS), 19.9%, 52.6, 21.4 % (SCIOI) and 16.5%, 51.4%, 26.6% (SCII) as low, medium and high respectively. This weak SC coordination resulted SCPM as 21.4%, 50.0%, 22.9% (response time), 19.7%, 36.6%, 38.1% (quality aspects) as low, medium and high from questioner analysis. Correlation and regression analysis have been examined to define the impacts of one variable on others. And also, cost utilization was 29% (PE),18%(AE), 43%(IFE), and 11%(EFE) respectively while, efficiency as 68.4%, 69.6%,77.3%, 68.9% and 70.4% (Figure 5:18) and SC operations downtime more than 19.5% that can affect overall SC productivity. A possible solution has been proposed via corrective measurements & implementation guideline models through SCOR-model, MLAC & QMS relevant tools to address the aim of the study. So, SC productivity of the case firms and similar companies can be enhanced after the proposed solution is wisely institutionalized.
Assembly Operation Productivity Improvement for Garment Production Industry through the Integration of Lean and Work-Study A Case study in Bahir Dar Textile Share Company, in Garment
(Addis Ababa University, 2021-10) Mequanent, Ewnetu; Ermias, Tesfaye (PhD); Fitsum, Getachew (Mr.) Co-Advisor
Productivity improvement is a very important issue for manufacturing industries to survive in the global competition. A nation’s effort on productivity-improving is mandatory and its achievement of productivity is one of the major weapons to attain cost, time, and quality advantages for competition. Ethiopian garment industries are not competitive in the global market share. The primary reason is low productivity. This study tries to investigate both internal & external productivity factors of the garment industry and proposed genuine solutions using integrated techniques of lean & work-study. So, this paper aims to provide the users are understanding easily the main productivity factors of the garment industry and present the way how to develop a solution using these integrated techniques. The main objective of the research is to enhancing productivity using integrated techniques of lean & work-study for the Ethiopian garment industry, specifically in the case company. To accomplish this objective a literature review has been conducted to get a realistic understanding. The existing productivity status, improvement practices, experience, and productivity factors of the garment industry have been assessed using open interviews and secondary data from the sector. To make this study practical and realistic, a case study has been conducted on the Bahir-dar textile share company in, garment. And the data was collected using interviews, direct observation, recording, measuring, questionnaires, and secondary data. The existing result indicates that the productivity of the Ethiopian garment industry and the case garments is much lower than the government plan and their production targets as well as compared with other best practice garment industries. Due to this, the garment industry has been faced multidimensional productivity factors related to human, method, control, process, and product. To enhancing the overall productivity improvement of the garment industry that has been using the combined techniques & tools of lean and work-study, due to, the nature of garment industry productivity factors are multidimensional as a result a single tool or model hasn’t boosted a significant change. Consequently, to solve the garment industry productivity factors that should be used an integrated techniques & tools for enhancing a significant productivity improvement of the case company and these integrated techniques has been answered the research question.
Assessing Performance of National Quality Infrastructure on Cooking Utensil Products in Ethiopia
(Addis Ababa University, 2019-11) Amaru, Ayansa; Birhanu, Beshah (PhD)
This study is focused on assessing the performance of national quality infrastructure (NQI) on aluminum cooking utensil products in Ethiopia. The quality of cooking utensil products is determined from each production process starting from raw material preparation, which is an aluminum circle sheet until the end product that is cooking utensil products. However, this product which is locally produced shows low-quality products, due to the lack of developing a standard for it. Therefore, to achieve a good quality product of cooking utensils, NQI pillars (standard, conformity assessment, metrology, and accreditation) play a high role. Hence, the objective of this study is to assess the performance of national quality infrastructure on cooking utensil products that are locally produced to improve the quality of the product and competitiveness in local and global markets. To conduct this study both primary and secondary data were collected from twelve manufacturers and different government offices. Primary data was collected by observation and 73 persons were interviewed through discussions. Secondary data was collected from different kinds of literature, articles, journals, and respective offices. From the data collection, the findings of this study suggested the lack of developed standards and these products are categorized under voluntary standard products due to that the way of quality control in this sector is weak. And the researcher evaluated the aluminum circle sheet and cooking utensil products manufacturing process concerning NQI pillar service on each production process for both production process. However, from ENQI pillars service, nothing is practiced or implemented in this sector, which means the relationship between manufacturers and ENQI service is weak. As a result, the low-quality product was achieved that cannot be competent in the local and global markets. Moreover, the health of a society can be affected because of a lack of the tests of the chemical composition of the product. To solve the above problems the researcher developed the NQI model for both the manufacturing process and proposed solution to improve the quality of the product and competitiveness in the local and global markets.
Assessment of Kaizen Implementation and Challenges Toward Sustainability (In case of Hibret Manufacturing and Machine Building Industry)
(AAU, 2017-10) Gelila, Getachew; Daniel, Kitaw (Prof.)
Kaizen is originated from Japan to be applied in the improvement of productivity, quality, efficiency and also it is way of thinking, working (performing), fixing in the attitude and value of organization. As Ethiopian government proclaimed kaizen is a tool of change and focused in some 30 organization beginning to apply. But not much has been done on assessing implementation and challenges toward sustainability of kaizen in HMMBI. The purpose of this paper is to examine current status of kaizen implementation, challenges, and sustainability towards implementation of kaizen. In addition to this, the study focused on identifying the factors affecting, analyzing the achievements, challenges and opportunities of kaizen implementation. To achieve the above objectives descriptive research design was selected and used to gathered primary and secondary data. The selected sample was purposive sampling method; primary data were collected from survey questionnaire, in depth interview and self – observation technique. Secondary data were collected from different published and unpublished documents. The respondent from different department of the factories have been involved for the questionnaires whereas interview were made with kaizen steering committees and observation is done by the help of kaizen promotion officers and the researcher has made deep industrial visit. The data gathered through questionnaires revealed that kaizen implementation in HMMBI is not sustained because of lack of employee and management commitment, lack of training system, lack of management encouragement, less management and employee involvement and lack of active participation. So in order to sustain kaizen implementation, carrying out continuous process practice is necessary for management personals and workers. Therefore, the sustainability of kaizen implementation needs continuous follow up process which includes: strategical planning, performance measurement, and knowledge and change management.
Assessment of Service Quality Improvement Alternative Decision
(Addis Ababa University, 2018-06-15) Endale, Alemayehu; Ameha, Mulugeta (PhD)
Service quality is the ability of the organization to meet or exceed customer expectations. It is the difference between customer expectations of service and perceived service. If the service provider meets or exceeds customer expectation then customer satisfaction occurs. To insure the customer satisfaction, customer service plays vital role. Customer service is the interaction between the customer and service provider. Quality customer service entails providing efficient, quick and friendly service, handling complaints quickly and responding to customers' issues on time. EEU failed to meet its customer expectation, especially in its technical service (operation & maintenance) mainly unplanned service outage, new power connection and customer service. Leaving aside power shortage, technological and financial constraints dissatisfaction occurred due to lack of accountability & responsibility, poor monitoring & controlling mechanism, high bureaucracy, no transparency, and lack of motivation from its employees. EEU has outsourced (contracted out) it bill collection to private sector (Kifeya Lehulu) since two years back. Bill collection service have got a moderate satisfaction level from previous poor satisfaction level. This study shows EEU’s technical service (operation and maintenance) quality of service delivery can be enhanced by outsourcing this scope to the private sector. MCDM AHP & TOPSIS tools used to analyses sector expert’s judgements or opinion (primary and secondary data) & case observation were used to ensure the current service quality. From sector performance indicators (KPI), kept four criteria which are customer service, unplanned outages, safety & employees commitments. Weights of this criteria’s using AHP tools for better service delivery at EEU found unplanned service outages (34.63%), customer service (27.48%), employees commitments (20.64%) & safety (17.24) Result of preference from in-house and outsourcing service delivery by AHP & TOPSIS analysis gives 70% & 86.67% respectively, which indicates that EEU’s technical service (operational & maintenance), service quality level can be enhanced compared from current EEU’s current in-house operation. Finally recommendation is forwarded to deliver standard electricity utility service by contracting out the operation & maintenance in order to place EEU in competitive environment and effectiveness.
Building Construction Occupational health and Safety Assessment: - A case of Condominium Site Projects in Addis Ababa
(Addis Ababa University, 2019-07) Yonatan, Leykun; Eshetie, Berhan (PhD)
Construction industry has been recognized as one of the common hazardous industries in both developed and developing countries. Injuries and work related hazard on building construction sector present a major effect on the workers in the field, and resulting major influences on socio economic consequences. Hence the objective of this research paper is to finding out major safety and health related injuries & hazards in condominium building construction (40/60 and 20/80) schemes to reduce health related injuries and increases safety; so that 139 condominium building construction workers were included in the study with proportional allocation formula sampling techniques. The data has been composed through structured and pre-tested questionnaire and interviews; accordingly analyzed using descriptive statics with Microsoft Excel & SPSS Software. The study result shows major injuries that have been identified from field survey falling from height 70% for 40/60 schemes and 65% for 20/80 schemes, injury due to manual handling 78% for 40/60 schemes and 51% for 20/80 schemes, injuries due to moving equipment 61% for 20/80 schemes and 52% for 40/60 schemes and finally health problem due noise 46% for 20/80 schemes and 48% for 40/60 schemes. The prevalence injuries among workers in condominium building construction were reported to be 48.9%; additionally injuries significantly associated with age, sex, educational level, experience and the type of occupation of the workers. Furthermore the study shows occupational injuries are common among construction workers, thus counter measures are recommended such as organized hierarchy department structure for occupational health and safety to decrease prevalence of injuries.
Capacity utilization improvement for auxiliary machineries: In case of BGI Ethiopia
(Addis Ababa University, 2023-10) Ermiyas Girma; Gulelat Gatew (PhD)
This study aims to improve the capacity utilization of auxiliary machines in brewery factories, focusing on the CO2 plant, boiler plant, cooling plant, and air plant at BGI Ethiopia. These machines are vital for supporting the brewing process, and any breakdown or inefficiency can significantly impact the overall brewery operation. The study identified underutilization of the capacity of auxiliary machines at BGI Ethiopia. Despite its potential to produce 3200 hectoliters per day, the factory is currently operating at 75% capacity, producing only 2400 hectoliters per day. The challenges contributing to this underutilization include auxiliary machine failures, high downtime, breakdowns, and inadequate application of monitoring and control systems. To address these challenges, the study adopts a research methodology that involves collecting quantitative and qualitative data. Quantitative measures such as breakdown and stoppage time, production output, shifts, and workers are used to assess the current state of auxiliary machine capacity utilization. Workplace site observations and expert opinions are also considered, along with secondary data from literature, reports, publications, logbooks, machine displays, and articles related to capacity utilization. The collected data is analyzed using statistical techniques, including mathematical analysis for quantitative data and thematic analysis for qualitative data. This analysis aims to identify root causes and trends to gain insights into the current state of auxiliary machine capacity utilization. The findings are presented through tables, charts, and graphs to support the analysis. Factors that positively or negatively impact auxiliary machine capacity utilization in brewery plants are highlighted. The discussion focuses on the main root causes of breakdowns and inefficiencies, the impacts of downtime on capacity utilization, potential solutions, and best practices to prevent breakdowns. Based on the research findings, recommendations are provided to improve auxiliary machine capacity utilization. These recommendations address factors such as equipment upkeep, operator training, scheduling, and system integration. Applying these recommendations can enhance capacity utilization, improve production efficiency, and increase revenue for BGI Ethiopia.
Circular Business Model for Vehicle Lead-Acid Batteries in Ethiopia
(Addis Ababa University, 2023-10) Samuel Alemu
The automotive battery industry is shifting towards sustainability, driven by the need for circular business models, particularly lead acid batteries (LABs). This transition presents unique challenges and opportunities for circular economy implementation. In developing countries like Ethiopia, the LAB industry faces sustainability issues and undercapacity utilization. This research aims to identify potential circular strategies, pinpoint the most influential factors affecting adopting of circular business model (CBM), and develop a CBM tailored for LABs to address sustainability challenges and promote circular practice in the automotive battery industry. The research employs a multi-faceted methodology including expert opinions, thematic analysis, hybrid Grey and Decision-Making Trial and Evaluation Laboratory (DEMATEL) analysis, and the Business Model Canvas framework. The study identifies and propose three promising circular economy strategies: repair for reuse, repurpose, and recycle which collectively provide substantial environmental and economic benefits by extending battery life, reducing resource consumption, and generating revenue. Further, the study identifies four key factors influencing the adoption of CBM for LABs by analyzing the dynamic interplay of 23 factors: lack of business model with take-back systems, high cost of handling and processing, lack of effective communication and coordination, and lack of supportive government policies. Finally, the study offers a practical roadmap for implementing circular practices by modeling identified circular strategies within the Circular Business Model Canvas framework. This research prioritizes environmental responsibility, resource efficiency, and economic viability, contributing to LAB sustainability and fostering an environmentally responsible automotive sector.
Cluster Development for Metal Work Industries: Case Study on Addis Ababa Micro and Small-Scale Metal Work Industries
(Addis Ababa University, 2011-11) Tariku, Tamiru; Daniel, Kitaw (PhD); Gulelat, Gatew (Mr.) Co-Advisor
The contribution of micro, small and medium Scale industries towards employment generation, alleviation of poverty and inequalities and development of backward areas is recognized worldwide. Although, these industries have great role in economic development of our country, they doesn‟t benefit as their potential due to their problems related to their size. Most of the problems are lack of: market, skilled manpower, working capitals, information and low level of competitiveness. In addition there is lack of cooperation among themselves, which limits sharing of resources between them. Micro and small industries clustering is a group of these industries, producing similar products, located in a geographical proximity, sharing resources (like knowledge, technology etc) among themselves in order to overcome their internal and/or external challenges, and that compete each other but also cooperate with one another. The study is concerned on cluster development of micro and small metal work industries in Addis Ababa city. It covers 32 micro and small scale metal work industries selected from all sub cities with the objectives of developing micro and small metal work industry cluster to create a conducive environment for the development of inter-firm cooperation, improve the competitiveness of the industries, to solve marketing problems of the industries, and to facilitate metal work technology transfer to the country. For the accomplishment of the objectives of the study the selected industries were assessed through questionnaires, interviews and observation. The results obtained from the survey shows that Addis Ababa micro and small metal work industries faced with the following problems. These were:- lack of: market, product displaying area (marketing area), working capital, technical training, trust among the metal working industries; and flexibility of price and quality of raw materials. In order to solve the observed problems with the support of published and unpublished literatures the study proposed the development of micro and small metal work industry cluster and identifies suitable cluster location in the city. Taking into consideration of other countries experiences, for realization of the benefits of developed metal work indus
Cluster Development for Metal Work Industries: Case Study on Addis Ababa Micro and Small-Scale Metal Work Industries
(Addis Ababa University, 2011-11) Tariku Tamiru; Daniel Kitaw (PhD); Gulelat Gatew (Mr.)
The contribution of micro, small and medium Scale industries towards employment generation, alleviation of poverty and inequalities and development of backward areas is recognized worldwide. Although, these industries have great role in economic development of our country, they doesn‟t benefit as their potential due to their problems related to their size. Most of the problems are lack of: market, skilled manpower, working capitals, information and low level of competitiveness. In addition there is lack of cooperation among themselves, which limits sharing of resources between them. Micro and small industries clustering is a group of these industries, producing similar products, located in a geographical proximity, sharing resources (like knowledge, technology etc) among themselves in order to overcome their internal and/or external challenges, and that compete each other but also cooperate with one another. The study is concerned on cluster development of micro and small metal work industries in Addis Ababa city. It covers 32 micro and small scale metal work industries selected from all sub cities with the objectives of developing micro and small metal work industry cluster to create a conducive environment for the development of inter-firm cooperation, improve the competitiveness of the industries, to solve marketing problems of the industries, and to facilitate metal work technology transfer to the country. For the accomplishment of the objectives of the study the selected industries were assessed through questionnaires, interviews and observation. The results obtained from the survey shows that Addis Ababa micro and small metal work industries faced with the following problems. These were:- lack of: market, product displaying area (marketing area), working capital, technical training, trust among the metal working industries; and flexibility of price and quality of raw materials. In order to solve the observed problems with the support of published and unpublished literatures the study proposed the development of micro and small metal work industry cluster and identifies suitable cluster location in the city. Taking into consideration of other countries experiences, for realization of the benefits of developed metal work industry cluster it should be suggested that to properly cooperate all collaborators of the cluster.
Computer Aided Layout Planning for Manufacturing Industries of Ethiopia (Case in Kotebe Metal Tools Factory)
(Addis Ababa University, 2009-12) Ameha, Mulugeta; Daniel, Kitaw (PhD); Birhanu, Beshah (Mr.)
Layout planning has been considered as one of the vital areas for improving performance of any business process. Its main concern is reducing cost by maximizing adjacency of high interaction components of a system or reducing material handling cost or distance between the components. Taking KMTF’s layout as a case, this study considered three approaches of layout design. The first approach utilized the improvement of the existing layout. Section wise exchange and machine wise exchanges are made to the current layout to arrive at a better layout than the currently being used layout. Making the exchange section wise and then using the machine arrangement obtained by this method to be further improved by machine wise exchange is observed to give better layout than improving the current machine arrangements. The exchange has been made according to CRAFT improvement routine. The second approach has been done to construct a new layout for KTMF sections using CORELAP construction routine and then improving the constructed layout using CRAFT improvement routine. But the current layout is observed to be better starting point for improvement using improvement routine than the constructed layout. This shows the current layout is good but can further be improved by using improvement routines. To show the applicability of the approach another study published by Yugoslav Journal of Operations Research has been explained. This approach is suggested to be used in planning a new layout. The third approach introduced is the roll forging machine into the improved layout. The approach assumes the Roll forging machine is used by four products and the dies for the four products are brought together with the machine. Accordingly location of the new Roll forging machine has been obtained using single facility layout problem. Finally, it is concluded that the current layout is a good initial layout for improvement using CRAFT algorithm and a better layout is achieved by improving the current layout. Furthermore, construction routine followed by improvement routine is concluded to be good means of arriving at good layout in initial design of layouts. The improved layout and Roll forging are recommended for KMTF shop floor.
Defect Reduction Using a Lean Six Sigma DMAIC Approach: A Case of 3F Manufacturing PLC
(Addis Ababa University, 2023-06) Legesse Muchew; Gezahegn Tesfaye (PhD)
Companies are forced by competitive pressures to look for ways to reduce defects while enhancing product quality. One of the best methods for corporate transformation is lean Six Sigma. This study seeks to give an empirical case study on the use of lean Six Sigma DMAIC approaches to reduce defects in a wood furniture company. The case company faces issues with the quality of its goods, which are reflected in its quality department and complaints from customers regarding the existence of defect rates of 59% in door product. Therefore, this study's objective is to reduce defects. To evaluate opportunities, present evidence for improvement, and identify possible benefits, the DMAIC technique is used in the study to look into the root causes of problems and suggest mitigation strategies. The result showed a significant decrease in the defect rate for door products. Previously, the defect rate stood at a concerning 59%; after effective interventions, it has dropped substantially to an impressive 22.96%. Through careful examination and rectification of underlying causes, it successfully identified and addressed the issues leading to defects. As a result, the number of defective doors produced has significantly decreased. Not only tackled defects but also made notable strides in improving process efficiency. The cycle time has witnessed a commendable reduction of 51 minutes, decreasing from 2114 minutes to 2063 minutes. To measure the consistency and reliability of our processes, it is important to utilize the sigma level. The sigma level has shown significant progress, improving from 2.6 to 3.2, considering a 1.5 sigma shift. This means that our process now operates within a narrower range of acceptable variations, ensuring greater consistency and reliability in the products. Even without factoring in the 1.5 sigma shift, the sigma level has improved from 1.18 to 1.7. This improvement is in terms of reducing variations and increasing process stability. With these outcomes, it is evident that Lean Six Sigma can indeed be applied for defect reduction in a furniture company, successfully reducing the defect rate, enhancing the overall quality of our products, and strengthening the reliability and consistency of our processes. During the research phase of the DMAIC process, a serious oversight was discovered; a lack of validation relative to the identified root causes. This omission may limit the achievement of intended goals and lead to ongoing processing difficulties.

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