BAHIR DAR UNIVERSTIY

ETHIOPIAN INSTITUTE OF TEXTILE AND FASHION TECHNOLOGY

DEPARTMENT- TEXTILE CHEMICAL PROCESS ENGINEERING
Hosting company; ADAMA SPINNING FACTORY

Project title; INCREASING PRODUCTIVITY OF ADAMA SPINNING FACTORY BY

IMPLEMENTING PREVENTIVE MAINTENANCE SYSTEM

Prepared by; Bereket Ababu

Id no; 1107359
Academic advisor; Mr.Tekalegn.M
Company advisor; Mr. Mohammed.
august 2022

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 DECLARATION

I am BEREKET ABABU, fourth year TEXTILE ENGINERRING student, I have taken my

internship experience share in Adama Spinning Factory for three months from june 1to
august 30 , I have declare by my advisor that I had sufficiently and effectively performing
the work task that have been given from the company and also the tasks strongly done by my
own observation and the discipline that I was followed. Here by state that this final internship
report has been submitted to EiTEX Faculty of TED in partial fulfillment of the requirements
of an internship report. And this report is my own work and I properly sited the resource I
used.

I certify that my work is original and compiled according to the internship report writing
guide line given by the Institute-Industry Linkage Office of the Institute.
As the student`s academic advisor, I certify that the internship report written by the student is
his original work and compiled according to the guide line provided by the institute’s IIL
Office as far as my knowledge is concerned.

Mrs. TEKALEGN
Name of Academic Advisor Signature Date
BEREKET ABABU
Name of Student Signature Date

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 ACKNOWLEDGEMENT

First of all I would like to thank God for helping me during those times. For the past three
months our internship and project work we had taken and the help and guidance of some
respected persons, who deserve our greatest gratitude. We would like to show our greatest
gratitude to MR. Mohammed for giving us all the support we need. We also like to expand
our deepest gratitude to all those who have directly or indirectly guided us in writing this
project work. Thanks also to the ADAMA SPINNING FACTORY.

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 EXECUTIVE SUMMARY

This internship report consists of four chapters that give excellent explanation for the
topics given to them. Chapter one of this report deals with back ground of adama spinning
factory and under this topic brief history, main products and customers, raw materials,
supplier of raw material and spare parts, organizational structure and work flow of the
company have expressed. Next to this chapter, Chapter two of this report deals with the
final project that is emphasizes on maintenance system .This chapter is the body of the
report. It gives solution that will minimize the company’s maintenance problem after
collecting and analyzing data. The project was started from observation of the problems
in the production machinery maintenance department of the company. Before
recommending the solutions that will minimize the problem, important data were
collected, analyzed and the effects of the problems were also defined qualitatively as well as
quantitatively.
Finally important solutions were recommended and a preventive maintenance
schedule is prepared, so that the company will shift its run to failure maintenance to
preventive system. Thirdly a newly designed maintenance department structure is developed
in order to crate strong relationship and enhance productivity.

This generally will have the advantage of getting the income around 504,000Birr/year
income including the cost taken out for spares, oils, grease, electric wires, other accessories,
ordering costs, packaging materials (like metal wires, ropes…), transportation materials,
vehicle safeties and accessories, material handlings (like forklifts, hand trollies,……) and
other materials used for processing the products. These means the loss due to poor preventive
maintenance system is the income when they will perform these preventive
maintenance improvement system on belling machine. Chapter three of this report deals
with overall internship experience under this topic terms like reason for selecting the
company, section i have been working with, the work flow of the section and work task i
have been executing. It explains overall Benefit I have gained.

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4
CHAPTER ONE
COMPANY BACKGROUND
COMPANY PROFILE
Adama Spinning Factory is located in Oromia Regional State, Adama/Nazareth city
Dembela sub city, Degaga Kebele(05), about 100km away from the capital- Addis Ababa,
Ethiopia. The Factory was established in August, 2008 with an initial capital of Birr 160
million, 70% bank loan and 30% Equity. Expansion project was implemented in
2011/2012 budget year with an investment of Birr 160 million. Currently, the total capital
of the Factory has reached Birr 405 million.
The Factory is a modern textile factory in Ethiopia equipped with latest technology of
spinning machineries from Reiter and air conditioning unite from Luwa of Switzerland.
The company has starting a medical textile project in the 2018/19 budget year and to be
completed the project in 2020/21 & start production of surgical gauze and other related
products in the fourth quarter of the budget year. The installed spinning technology
produces high quality 100 % cotton carded and combed yarn of different counts for export
and local market.
The Factory has two operating lines, Open-End (OE) spinning and Ring Frame (RF)
spinning line. It has a total capacity of 11 ton per day at an average count of Ne 24 and
Ne 18 of Ring spun and Open End respectively. Out of the total capacity 5 ton (45%) are
ring spun yarn and the remaining 6 ton (54%) are open end spun yarn per day. The yarn
for Open end line ranges from Ne 6 to Ne 24 whereas Ring spun comprises, Ne16 to Ne
40 carded yarn and Ne 20 to Ne 60 combed yarn. Currently, the factory has offered
employment opportunity for 450 employees.
MISSION, VISION, CORE VALUES AND PRINCIPLS
MISSION
Production and supply of 100% cotton yarn, surgical gauze and other textile products for
local & foreign markets with competitive price and thereby ensure profitability and
sustainable growth by establishing efficient and modern management system and practices
that fit the global demand.
VISION
To be the top-quality producer, supply of yarn, surgical gauze and other textile products both
for local and global market at a competitive price in the year 2020/21 G.C.
CORE VALUES AND PRINCIPLES
JUSTICE AND EQUALITY: Adhere to the principles of fairness, impartiality (equal
opportunity) and protection of all employees.
INTEGRITY: Be honest, transparent and accountable to all stakeholders.
INNOVATION: Be oriented towards learning and continual improvement.
EXCELLENCE: Be operationally and professionally excellent.

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SOCIAL RESPONSIBILITY: Build up employee’s community‘s belongingness.

The Raw Material and Accessories Supplier and Raw Material Quality Parameters
The major raw material used in a spinning mill is cotton. In Adama Spinning Factory the
major and the only raw material is cotton, and the company produce 100% cotton products.
The raw material (cotton) of Adama Spinning Factory comes from different ginning factory,
to mix them and to get an acceptable yarn quality and to increase the profitability of the
spinning plant. Some of cotton suppliers of Adama Spinning Factory are mentioned below:
1. Gonder
2. Awash
3. Humera
4. Omo
Accessories and supplier
The major accessories for this company are:
 Greases
 Oils
 Different shape of cans
 Spear parts
 Yarn con
 paper con
The oils and greases like PDP65 OIL and BE31-222 or Nippon grease are imported from:
Germany and India
The other oils are coming from local market like:
i. National Oil Ethiopia PLC
ii. Mobil
iii. Total
iv. Shell

The spear parts of the company are imported from:

 Germany
 India

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The raw material quality parameter
 Spun length
Fiber length is also an important factor influencing spinning as the fiber fineness.
Productivity is influenced via end breakage rate and the quantity of the waste produced at
each stage. This fiber length problem originates from ginning and cleaning process. Adama
Spinning Factory measures the spun length of fiber by using instrument called KVF/V
Classifiber and also as this factory the standard of spun length is ≥ 27mm.
Short fiber content (SFC %)
The negative effect of a high percentage of short fibers is usually associated with:
Extreme drafting difficulties.
Increased number of Neps and Slubs which is detrimental to the yarn appearance.
High wastage in combing and other operations.
Increased yarn irregularity and ends down which reduce quality and increase processing
costs. As such, short fibers are responsible for both quality deterioration as well as
economy of processing. It is very important to measure and control the short fiber content in
spinning operation. In Adama Spinning Factory the standard percentage is <15 and it is
measured by instrument called KCF/V CLASSIFIBER.
Trash content
Cotton stock contains foreign material or trash such as vegetable matter, mineral material
sticky contaminations and other foreign matter (metal fragments, cloth fragments and packing
material the trash not only results in low yarn realization, but also leads to extreme
disturbances during processing. Trash affects yarn and fabric quality. Therefore, it is very
important to know the amount of trash and the type of trash before deciding the mixing.
There for Adama Spinning Factory check the trash by using instrument named Neps and trash
indicator, the standard of the company is <400 and the unit is No./gr
NEPS
Neps are small entanglements or knots of fibers. In general, two types of Neps can be
distinguished. They are:
fiber Neps which are small knots that consist only of fibers, and
Seed-coat Neps which contain foreign particles such as husk, seed or leaf fragments.
Investigations indicate that fiber Neps are predominant, particularly fiber Neps having a core
mainly of unripe and dead fibers. Thus, it is clear that there is a relationship between
Nepinness and maturity index. Nepinness is also dependent, exponentially, on the fiber
fineness because fine fibers have less longitudinal stiffness than coarser fibers.
A large proportion of Neps in raw cotton is produced by the processing method via plucking
and hard ginning, and the NEP count is substantially increased in the blow room. The card is

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the first machine to reduce the NEP count to a usable level, and nep-reduction at the card is
achieved primarily by disentanglement rather than by elimination. Neps not only create
disturbance in themselves as thick places, but also dye differently from the rest of the yarn
and thus become clearly visible in the finished fabric.
Fiber strength
Countless types of fibers, most of which are not usable for textile because of inadequate
strength. Fiber strength will increase in importance in future, since most new spinning
processes exploit the strength of the material less well than older processes.
The strength characteristics can be determined either on individual fibers or on bundle of
fibers. In practical however fibers are not used individually but in groups, such as in yarns or
fabrics. Thus, bundles or groups of fibers come in to play during the tensile break of yarns of
fabrics. In Adama Spinning Factory the standard is >80 PSI and the strength is measured by
instrument called Neps and trash indicator.
Moisture content
As cottons used in the mixing come from different parts of the country, they may contain
different levels of moisture at the time of blending. Differences in moisture content of the
components may lead to inadequate cleaning and individualization of fibers resulting in a
yarn with higher incidence of imperfections and poor appearance. The problem can be
minimized by a proper conditioning of the components to the ambient conditions at the time
of mixing. The measurement of fiber moisture is very important for a spinning factory,
because
It helps to decide on correct invoice weight,
It is important in controlling count variation by maintaining consistency in moisture content
in mixing, and
Since almost all physical properties are affected by moisture, moisture measurement helps to
properly assess other fiber quality parameters.
Color
The color of cotton fibers can be affected by rainfall, freezes, insects and fungi, and by
staining through contact with soil, grass, or the cotton plant's leaf. Color also can be affected
by excessive moisture and temperature levels while cotton is being stored, both before and
after ginning. As the color of cotton deteriorates due to environmental conditions, the
probability for reduced processing efficiency is increased. Color deterioration also affects the
ability of fibers to absorb and hold dyes and finishes.

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OVER ALL WORK FLOW THE COMPANY

As shows in the above chart Adama spinning factory starts their production from temporary
stored of raw material, and ends by forming cotton yarn. Before buying the raw cotton tested
the most common quality parameter by using USTER HVI spectrum machine and they
compare the value of quality parameter with the standard cotton property. If the cotton
qualifies this property then the company accepts the supplier and orders the required amount
of cotton, The raw cotton come from different harvesting area to the company by using truck
and measured its weight by a big digital balance. The bales come from raw material store to
bale store house by using forklift truck and based on amount and necessity, it reaches to blow
room machine.
BLOW ROOM

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Blow room is the first section in the processing sequence which will separate and disentangle
the fibers, mix them, clean foreign matter, remove short fibers in the cleaning process and
supply small, clean and homogeneously blended fiber tufts to carding machine without
increasing fiber rupture, fiber neps, and broken seed particles and without removing more
good fibers.
In Adama spinning factory there are two similar blow room line operations. The first line is
for combed and ring whereas the second line is for open end process. All blow room
machines are Reiter.The following items are clearly distinguished the operating zones of
blow room line.
Basic operations in the blow-room:
1. opening
2. cleaning
3. mixing or blending
4. micro-dust removal
5. Uniform feed to the carding machine.
Blow room installations consist of a sequence of different machines to carry out the above
operations. Moreover, since the tuft size of cotton becomes smaller and smaller, the required
intensities of processing necessitates different machine configuration. These machines are
maintained as follow
Bale lay-down
Received lint cotton bales from various origins from raw material store shall be lay-dawn as
per the blending pattern.
Same lots of bales shall be distributed along the length of lay-dawn to facilitate the blending
(mixing).
UNIFLOC
Extracting lint cotton material evenly from the bale which ordered in two sides and can be
work on two sides by rotating itself after finishing the first side bale. They can order up to 90
bales (maximum) for each side.
Cotton flocks will be plucked from bales along the lay-down to mix from bales of different
lots.
Simi-opening of cotton tuft will be performed during plucking layer of lint cotton from the
bales.
Magnetic separator: Used to remove metallic impurity.
Ventilator fan: Used to suck tuft materials pneumatically for transportation.
Heavy particle separator: Used to clean foreign matter, which is heavier than the tufts by the
pull of gravity like broken seeds.

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Fire extinguisher: TO prevent fire hazards, the spark detector detects and the eliminating
device eliminates fire.
UNICLEAN
Trash and foreign materials in the L/cotton will be eliminated. (Cleaned).
Tuft of cotton will be opened.
Trash cleaned lint cotton will be feed to both OE and Ring Frame lines of mixing machines.
UNIMIX
mixing of fibers lint cotton of different bales or lots will be mixed at three points.
Opening and cleaning of tuft of lint cotton
CARD FEEDING: - Used to deliver the blended and cleaned cotton or bamboo to the carding
machine.

CARDING
Carding is the next machine after blow room in which individualization, Elimination of
impurity, Elimination of dust due to significant Fiber/metal and Fiber/Fiber friction at the
card, Disentangling (opening out) of NEPS , Elimination of short fibers by flats as flat
stripping , Fiber blending, Fiber orientation and Finally sliver are formed. They are 24 in
number, for line one 12 carding machines and the rest 12 for line two. All machines are
REITER. The Sliver formed in a card machine coiled on a large can which have 8000 meters
Sliver holding capacity and transfer to the draw frame machine.
DRAW FRAMES
Draw frames are used after carding in yarn manufacturing process. In the case of combed
yarn manufacturing, draw frame are used before as well as after combing but In the case of
carded yarn manufacturing, draw frames are used at one time. The machine helps to improve
sliver evenness, parallelizing fibers, blending and dust removal
The draw frame operation divided in to two sections; these are:-
FIRST PASS DRAWING
The purposes of the drawing (first pass) machines are:-
 Homogenize and parallelize the fibers and drafting the fiber of the feed stock.
 Producing blended and improved evener sliver by feeding 4-8 slivers.
Producing one evener sliver end by drafting 4 to 8 slivers ends and dust removing. Draw
frame line one contain four draw frame machines, it process the card sliver and deliver its
output for either the UNILAP machine or next section of draw frame
SECOND PASS DRAWING WITH AUTO LEVELER
The purposes of the drawing (second pass) with auto leveler machine are:-

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 Producing blended and improved evener sliver with controlling the feeding speed with
auto leveler controlling system.
 Producing one evener sliver end by drafting 4 to 8 sliver ends.
 Drafting the fiber of the feed stock, dust removing and coiling of sliver in cans.
The second section (Draw frame line two) contains the rest four draw frame machine, it
process by accepting the output of either draw frame line one or comber machine sliver and
finally deliver its output to either open end or roving machine respectively.

The company have 8 RIETER RSB-D 40 & RIETER SB-D 45 draw frame machines. Each of
them uses 6 Sliver as an input and deliver one Sliver on a separate can which has a capacity
of 2600- 8000 meter sliver length.
LAP FORMER OR UNILAP MACHINE
The card sliver are not convenient for combing machine, If we use a card Sliver directly on
to a combing machine ,then the waste extraction would be very high, there would be a high
breakage rate and probably excessive damage so that to avoid thus problem a UNILAP
machine are used . They are 1 RIETER UNILAP machines, which input 24 draw frame sliver
cans and deliver a lap of 220-270 meter length which is compatible for combing machine.
COMBING MACHINE
Combing machine helps to elimination of a precisely pre-determined quantity of short fibers,
elimination of remaining impurities after blow room and carding and elimination of NEPS.
As a result of combing operation, particularly due to elimination of short fibers spin ability of
the fiber increases. Combing machine improves the following properties; yarn evenness,
Visual appearance, Smoothness and strength.
There are five RIETER E66 comber machines and each machine takes 8 lap and the sliver
coiled on a can which have 6000 meter sliver holding capacity. After coiled the can delivered
to the second draw frame for improving quality of the sliver, finally it transfer to the roving
frame machine.
ROVING
Roving is continuous fibrous strand drafted from sliver and given cohesion by either inserting
a small amount of twist
The reasons for the use of roving are;
The required high drafting in ring frame and
Draw frame cans are not convent for transport and presentation of feed material to the ring
frame.
There are three REITER F15 roving machines and the machines have 146 spindles.

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The main functions of these machines are attenuation of the sliver, insertion of protective
twist and winding of the roving in to a package (bobbin), after formed bobbins deliver to ring
frame machine.
RING FRAME
Ring frame is universally applicable and uncomplicated machine in which any material can
be spun to any required fineness and delivers a yarn with optimum characteristics regarding
structure and strength.
Adama spinning factory have totally eight ring machines, Five of them are G33 in each of
them there are 1104 roving bobbin and can be produce 1104 spinning copes & the last three
are G35 RIETER which are latest ring machine in each of them there are 1200 roving bobbin
and can be produce 1200 spinning copes. The main function of the machine is attenuating the
roving until the required fineness is obtained, twisting the fiber strand to impact strength to it
and winding the resulting yarn. The spinning copes are not convenient for the next process;
so that it directly transfer to winding department.
WINDING
Winding is a process of wound together a small sizes of spinning cops to the formation of
suitable package (cone) and checking and clearing the yarn from spinning defects. There are
4 SCHLAFHORST (SAURER GROUP) winding machine. Each of them has a two crosslink
drum and produces 60 winding cones.
OPEN-END SPINNING
Open-end spinning is a technology for creating yarn without using spindle. The main
advantages of open end spinning over ring are:-
Eliminates the roving frame
Eliminates the winding
Higher productivity rate
Less power consumption
The purposes of the rotor (OE) machine are:-
 Opening and drafting sliver and combine single fiber to produce yarn of the desired
fineness.
 Reinforcing yarn by applying twist.
 Winding the produced yarn with paper or yarn cone to have more packages (up to 2.5kgs.)
 Inspecting and cleaning of imperfection yarn by passing the yarn through sensors.

Adama spinning have three RIETER open end machine. They produce 312 cones and every
yarn breakage replaced manually by joint of yarn ends (splice).Finally; the cones enter a big
cylinder machine which called steamer and delivers to the required place.

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 DOUBLING
Doubling is a process of winding two yarn ends together on one cone. This process is
particular case of the winding procedure and is carried out doublers when preparing the yarn
for twisting and the yarns have permanent appearance in terms of strength and equally
tension.
Adama spinning has one AETH (SCHWELZ) doubling machine with a total 60 winding
drum with 2.5 crosslink and 6 twisting machine, each of them are 120 winding drum works
by cam traverse system.
TWISTER
The purposes of the twister operation are:-
Twisting 2-4 plied yarn and wound the produced plied yarn with paper or yarn cone to have
more package.
STEAMER
Steamer is used to steam yarn in the form of copes to increase strength, smoothness, softness
and decrease hairiness of yarn.
THE ORGANIZATION STRUCTURE AND THE RESPONSIBILITY OF FUNCTIONAL
AREAS
Organization structure
Managing director

Advisory Board

Deputy Managing director

Commercial Department Audit and Inspection Service

General Manager

Marketing Procurement
& Sales
Division
Division

Property Administration

HR and Engineering and Production Research and Finance

Technic Department Quality Assurance Department
Administration
Service

HR Division Electrical Spinning General

Maintenance Division Accounts
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General
Fig 1.12 Yarn Management
Mechanical
Services Processing Accounts
Maintenance
Division
RESPONSIBILITY OF SOME FUNCTIONAL AREAS
1.Managing Director: it is responsible for the following activities
 Checking the long term and the short-term plan of a company.
 Checking the sufficient existence of raw materials and accessories in a company.
Generally top manager is responsible for
 checking the correctness of activities done in a company.
2. General Manager: it is responsible for the following activities
 Controls the overall activities of the company
 Plan long term and short-term goals of the company and takes under control
Promotion of production.
 Employs the workers.
 Have responsibility to control production instrument, raw material and other
facilities.
 Sigh the commitment between the company and other organization.
3. Commercial department: it is responsible for the following activities
 Control and check the market quality and customer services.
 Collect the information on public desire or need for development of markets.
 Check and control the market plan for export and import production.
4. Finance: it is responsible for the following activities.
 Direct units and controls the finance work in a company
 Report the finance case team, budget and cost case.
 Check and controls the payments of the company in are corded form.
5. Administration: it is responsible for the following activities.
2 Keeping workers moral, performance and work results with whole freedom of rights.
3 Create safe working environment for employers.
4 Fulfill necessary working materials and instruments for work with the right time.
6. Human resource and administration: this department contains two divisions also this
divisions responsible for the following activities.
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Human resource division: have responsible to:
 Check staffing/Manpower planning
 Designing the Job analysis and job description
 Determining wage and salaries
 Recruit and select the best people for the organization
 Implementing organization policies
 Addressing employees’ grievances
8. General Service division: have responsible to:
- Over all company maintenance (except machineries)
- Check organize transportation facility
- Check the performance of safety and health service
9. Engineering and technical department: it is responsible for the following activities
 It controls electrical and mechanical maintenance of each departments of the
company and upgrade research and development of the company
10. Production department: it is responsible for the following activities
 Check and control the on-time reports on production.
 Control and check the production quality service based on company specification.
 Control and check the production is done at time.
11. Research and quality assurance service: it is responsible for the following activities
A. It tests raw materials qualities that are under the general manager and control the
quality production of the company.
B. Control and check production quality.
C. Check the production of the company fulfills the national and international quality
checkup.
12. Audit and inspection: According to the rules and regulations of a company it is
responsible to control and monitoring the following activities.
A. The management activities.
B. Proper financial usage and documentation.
C. Selling and purchasing activities.
D. Planning and controlling audit services, wok program and preparing the report to the
director’s board.
13. Marketing and sales division: it is responsible for the following activities

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 A. It sales finished products and analysis marketing problem.
B. Workouts and action plan on the detail activities of the department and closely follow
up its proper implementation.
C. It sales finished product and to analysis marketing problem.

THE PRODUCTS OR SERVICE

The factory produces different counts of ring spun and open-end spun yarn and also hank that
are used for:
 Blanket

 Sweater

Fig 1 .13The products of the company

The End Users of the Products

The factory produces and distributes different counts of ring spun and open-end spun yarn for
export and local market. Even though the factory has only three years’ experience in the
production and distribution of yarn, the factory developed good customer relation in
European market. Major European countries in which is exported their products in the last
three years are turkey, china, Italy, Israel, and Germany.
Major foreign customers of the factory
Onimplexs textile Tarimo Turkey
Bimeco Garnhandels Germany
Regmashl Italy
Arad Tetxtile Industries Ltd, Israel
Baoding Tianping Imp china
The company have 56 local customers but the Main customers of the factory in local market
are
Zemen yuhanes general buissness plc

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Elias tesfaye textile and garment  Muluinaged plc.
Debre birhan blanket factory
Almeda textile
Adama garment industry
Getahun aytenfisu hank reeling sink
Dh geda blanket factory
Narga garment factory
Teglu g/medhin
Production Outputs of the Company
The factory has two operation lines: open-end spinning and ring frame spinning, with a total
manufacturing capacity of 10 tons cotton yarn a day which is suitable for weaving and
knitting, in three shifts:
open-end spun yarn of Ne 6 up to Ne 24-7 tons a day
ring frame spun yarn of Ne 20 up to Ne 40-3 tons a day
combed spun yarn of Ne 20 up to Ne 40
This company has 9,120 ring frame spindles and 1,280 roving spindles totally the factory has
10,400 spindles and also 48 socks knitting machines. The daily capacity of the factory is
7 tons of open-end yarn
5.5 tons of ring frame yarn
12.5 tons total capacity
17,000 pairs of socks
Twists fully processed cotton yarn as per customer’s specific need.
Winds 2kg-2.5kg cotton yarn on cones for final delivery

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 CHAPTER TWO
INCREASING PRODUCTIVITY OF ADAMA SPINNING
FACTORY BY IMPLEMENTING PREVENTIVE
MAINTENANCE SYSTEM

4.1. Introductio

To stay competitive, companies are increasingly turning their focus on maintenance of their
production machinery. An effective equipment management system has a great role on
minimizing cost , improvement of quality and timely delivery of products, and
increasing the availability of production machinery and equipment’s. Therefore, it is
critical to keep machinery and equipment’s running at their pick efficiency all the time
(availability is the actual time that machine or a system is capable of operating). Effective
maintenance system examines the roll of maintenance in minimizing the risk of safety and
loss of production. Therefore, for a company to stay competitive, the availability of its
production equipment’s has to be increased by applying an effective maintenance system.

Today, with industry so focused on the bottom line, the cost of downtime has a big impact on
profitability. If equipment starts to wear, it is possible to start producing parts with
unacceptable quality and not know it for a long time. Eventually, machine wear will seriously
affect not only productivity but also product quality. World-class companies already have
taken a game-changing approach, implementing a new service business model to change
maintenance systems into smart service and asset management solutions. They reduce
downtime and provide the ability to look ahead at the quality of products before they ship by
closely watching equipment performance and machine wear.

Causes of machine breakdown: Typically the main causes of equipment break down are
due to:-

 Lack of lubrication system

 Negligence to apply programmed maintenance
 Failure to replace worn out parts
 Negligence to rectify minor faults
 Too high or too low voltage supply
 Un even working parameter

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  Lack of genuine spare parts
 Depreciation of machineries

4.2. Problem S

ASF has no strategy such mentioned above, rather they have followed break down
maintenance. It is the major problem in ASF since the company follows a corrective
maintenance practice. If corrective maintenance is always performed after the occurrence of
machine failure it will results in both high production cost and significant and service down
time caused by process and equipment failure. Due to this problem, the factory incurs
additional cost.

Figure 1. ring frame machine

Let us see the above printing machine, it is out of service because of lack of skill of
maintainer and spare parts, due to ASF used repair of breakdown unless it uses preventive
maintenance.

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Mainly the problem occurred due to:

v. Workers are executing their job carelessly by reflecting the view of

 Gating merely their salary payment.
 Un balanced level of skill allocation of works
 Relative related corruptions
vi. Emergency stops are not operating properly due to improper alignment because of non-
skilled maintainer
vii. Lack of maintainer
viii. Shortage of spare parts
ix. Maintenance without program that is only run to failure maintenance
x. Lack of knowledge of preventive maintenance
xi. Long lead time to receive spare part orders
xii. Unskilled labor force.

ASF only follows simply run to failure maintenance which means it increases idle
time of the machine causes lost profit. Accordingly these project aims to reduce these
production lost by using preventive maintenance system acting the action like lubricating,
cleaning, inspecting, part replacement within a required period of time, maintainer
allocation within reasonable amount of machine and by employing skilled maintainers
with the facilities needed to them.

Generally this project is based on data collected from each area and the result of these data
analysis, to identify and then after to avoid the root cause of the breakdown of different
machine in the process of different products and to improve maintenance program in ASF.

4.3. Objective o

4.3.1. General objective

 Implementing of preventive maintenance to increase productivity of the company.

4.3.2. Specific objectives

 Minimizing the repair time and repair cost.

21
  Minimizing the loss due to production stoppages.
 Efficient use of maintenance personnel and equipment’s.
 Reducing breakdowns and emergency shutdowns

4.4. Significanc

These project will be very helpful in understanding preventive maintenance in all factory
ASF by improving the maintenance system. This will result faster the company productivity
and increase the profit.

4.5. Scope of Pr

The study focuses on the Increasing productivity by implementing preventive maintenance

system in ASF. Regarding to project to improve maintenance system, to study the skill of the
employee, to decrease the repair cost and time, to increase productivity and to recommend the
manager gives special attention and company profitability.

4.6. Limitation

This study focuses on maintenance system. The limitation of the study is prepared respondent for
questionaries’ is limited on maintenance department only. It is not include operators, managers and
other company’s community.

4.7. Literature

4.7.1 Maintenance

British Standard Glossary of terms (3811:1993) defined maintenance as “The combination of

all technical and administrative actions, including supervision actions, intended to retain an
item in, or restore it to, a state in which it can perform a required function”. Maintenance is
the work that is done to keep something such as a building, machine or piece of equipment
required and in good condition (Lie and Chun, 1986). The process of continuing something
or keep it in existence. Maintenance is increase availability of production line, and is equally
important in maintaining environmental systems. Effective maintenance is the paramount
in ASF machine and the release of dangerous emissions low. Maintenance involves
completing machine overhauls and switching out old ports at regular intervals before they
fail, and it reduce the amount of capital spent on storing spare parts (Malik, 1979).

The purpose of a maintenance plan (MP) is to describe the best means to maximize
equipment operational availability, while minimizing equipment downtime. Once
22
developed, the MP will typically identify PM task descriptions and schedules,
troubleshooting, corrective maintenance (repair) task descriptions, and spare parts
identification, stock age (quantity), and any unique storage requirements. This information
will be incorporated in the manual, both as tabular data and text.PM includes adjusting,
lubricating, cleaning, painting, and replacing minor components. Time intensive PM, such as
bearing/seal replacement, would typically be scheduled/planned for regular plant or 'line'
shutdown periods. The definition of maintenance often stated maintenance as an
activity carried out for any equipment to ensure its reliability to perform its functions (Liao
et al., 2010).

Maintenance to most people is any activity carried out on an asset in order to ensure that the
asset continues to perform its intended functions, or to repair any equipment that has
failed, or to keep the equipment running, or to restore to its favorable operating
condition. Over the years, many new strategies have been implemented as maintenance a
strategy which is intended to overcome the problems which is related to equipment
breakdown.( Wu, S. et al., 2010).

Term terotechnology -
.introduced
-Recognition of need to present
equipment failures.
-Models for preventive
maintenance developed.

-Increased
awareness of:
-Environment
Fix the equipment -Safety
when it breaks -Quality
-Need for reliable
equipment.
-Reduction in costs.

Time

Pre-World War II Post-World War II 1980 Onwards

Figure 2, history of maintenance

4.7.1. Purpose of maintenance

The main purpose of regular maintenance is to ensure that all equipment required for
production is operating at 100% efficiency at all times. Through short daily

23
inspections, cleaning, lubricating, and making minor adjustments, minor problems can be
detected and corrected before they become a major problem that can shut down a
production line. A good maintenance program requires company-wide participation and
support by everyone ranging from the top executive to the shop floor personnel.
Breakdowns A machine’s breakdown true cost is sometimes difficult to measure. A recent
survey showed that the cost for a machine breakdown is more than just the maintenance labor
and materials to make the repair, and the actual cost for a breakdown between four to
fifteen times the maintenance costs. , (Basri, et al., 2017).

When the breakdown causes production to stop, the costs are very high because no parts are
being produced. For years, maintenance has been treated as a dirty, boring and often
overlooked job. It is very important to get the best productivity from a company’s equipment
but it is not recognized as a part of the operation that produces revenue. The simple question
is often, "Why do we need to maintain things regularly?" The answer is, "To keep things as
reliable as possible" (Canfield, R.V., 1986.).

4.7.2. Impact of maintenance program

Maintenance operations include all efforts to keep production facilities and equipment’s in an
acceptable operating condition. Failure or ml-functioning of machines and equipment’s in
manufacturing and service industries have a direct impact on the following :( Canto, S.P.,
2008).

Production capacity: Machines idled by breakdowns cannot produce, thus the capacity of
the system is reduced.
Production costs: Labor costs per unit rise because of idle labor due to machine breakdowns.
When machine malfunctions result in scrap, unit labor and material costs increase. Besides,
cost of maintenance which includes such costs as costs of providing repair facilities, repair
crews, preventive maintenance inspections, spare parts and stand by machines will increase
as machines break down frequently. (Fitouhi, M.C. and Nourelfath, M., 2012).
Product and service quality: Poorly maintained equipment’s produce low quality products.
Equipment’s that have not been properly maintained have frequent break downs and cannot
provide adequate service to customers. For example, air craft fleets of the airline, railway and
road transport services not maintained well can result in poor service to customers. (Zhou., et
al, 2009).

24
Employee or customer safety: Worn-out equipment is likely to fail at any moment and these
failures can cause injuries to the workers, working on those equipment’s. Products such as
two wheelers and automobiles, if not serviced periodically, can break down suddenly and
cause injuries to the stress (Ebrahimipour, V.,et al, 2015).

4.8. Materials a

4.8.1. Data collection

Primary and secondary data collection systems are used to collect the data. During the data
collection members of the population be the individuals or organizations are located and
contacted and their participation in the survey is sought.

Primary data collection: The Primary Data are those which are collected afresh and for the
first time, and thus happen to be original in character. There are several methods of collecting
primary data.

 Observation:- The methodology reported for collection of data is primary as well as

secondary data. The biggest source of information is personal observation while working
with staff and having discussion with them with a non-formal interviewees and discussion
also useful. In this regard, trying to observe the manufacturing system, production line,
material flow, storage, utilization of resources etc. in the factory. Moreover, trying to see
products that the factory has manufactured earlier without maintenance problem. Through
direct observation the main problems during operation, the working environment of the
company and working condition of each employees are identified.
Personal interview:- Primarily, information was gathered by conducting personal interview
to the organizations workers, and maintenance department head and members about the
past and present organizational structure.
Questionnaires:- Questionnaires related to maintenance practice in ASF was prepared and
raised for the members of maintenance department in the company.
Secondary data collection: The secondary data have been collected which have already been
passed through the statistical process.

 The collection of data and information of these company with some written
document on the caisson board was done to know the production capacity of different
machines and how many machines have done properly and non-working per day and per
shift.

25
 4.8.2. Data presentation and analysis
No. of respondents (N) =8
120%
100%
100% 90%
80%
80%
60%
40%
20%
20% 10%
0%
0%

yes
no

Figure 3. Percentage of respondents

Based on the questionnaires, 10% of the respondent responds as they do not know about
maintenance, but 90% of the respondent knows about maintenance of machine. This shows
the company has less performance in all section of machine maintenance. Among the
respondents 20% of them have awareness on preventive maintenance, 80% of them respond
as they do not have knowledge preventive As shown in Figure 17, the company totally did
not give training on new machine.

26
 Are you skillfull to maintain different
machine?
20%

yes
some of them not all
50% I am not skillfull only by expe-
rience

30%

Figure 4. Percentage of respondents

As the graph represents, among the respondent all most 50% of them maintain machines by
experience. Also 30% of the respondents respond as they have limited skill on the
maintenance of machine. As a result of this if there is a new machine in the company they
cannot handle perfectly, because of lack of skill how to maintain and how to operate. Due to
this, the company faced problem of machine shutdown which results in losing of profit.
Based on this primary data in the company only 20% of the respondents are skillful, which
means they have proper knowledge about maintenance whatever it is old or new machine.

Did you apply prevantive maintainance ?

10% 10% 30%

no
rarely
sometimes
usually
always

10%
40%

Figure 5. Percentage of respondents

The primary data of this project has shown to the project observed that in maintenance
department 40% of respondents respond as apply preventive maintenance but 30% of them

27
respond as they did not apply preventive maintenance because the awareness about
preventive maintenance is limited. Based on the data present 10% of respondent respond as
the preventive maintenance apply rarely, sometimes and usually, this show as the company
have less attention on the machine preventive maintenance.

4.9. Result and

The suggested solution for the problem can be explained as follows. The solution will
improve the productivity as well as profitability of the company by decreasing unnecessary
losses during production. This will be possible through applying scheduled preventive
maintenance. The maintenance function in ASF should be applied in the following ways to
minimize losses during production:

 By preventing breakdown
 By the repair of breakdown
The term breakdown is used here to indicate any machine condition that is considered to less
than satisfactory according to the seven factors listed bellows. This covers all situations from
the need for minor adjustment to total machine collapse.

The seven factors are:

▪ Performance
▪ Down time
▪ Service time
▪ Efficiency
▪ Safety
▪ Environmental Impact

▪ Cost

28
Although the performance of maintenance function has been separated here into prevention and
repair, the element of prevention is the key to all successful maintenance work including repair.
A well-executed preventive maintenance schedule results in reduced breakdowns and cost
savings. Many organizations hire out preventive maintenance programs and schedule only to file
them away with in a few months like only tool. The tool itself is worth less properly utilized in
the right way.

ASF should follow prevention because it is more useful considering the various ways in which
maintenance arises and to recognize the preventive elements in each. Despite all attempts at
prevention, machine breakdowns of various kinds to occur and often need to be fixed on an
urgent or emergency basis. Although maintenance personnel’s are usually under greater pressure
to return equipment to service in the shortest possible time, there are two important
considerations for the elements of preventive work that should be satisfied.

ASF should apply the following principles;

 Treatment of cause rather than effect.

 Using preventive mechanism rather than corrective mechanisms.
Treatment of cause rather than effect is vital to make sure that the real cause of the break down is
found and remedied and the effect is not rust patched up trouble shooting. Trouble shooting
should be accurate in finding the inherent cause of the problem. If the real cause of the problem
is not known, then further breakdown is likely to occur or to happen.

Planned work

It includes any work that requires an extended equipment shutdown or that needs to be planned
and scheduled in advance. All planned works should be considered as a preventive and
essentially aimed at the avoidance of unscheduled breakdowns.

29
Generally the maintenance activity in ASF is corrective maintenance after broken down of the
machine. Its result is loss of millions of birr so we advise ASF that the maintenance practice
should be shifted to preventive maintenance.

Preventive Vs break down maintenance

Preventive maintenance has been recognized as extremely important in the reduction of the
maintenance costs, improvement of equipment’s, reliability and avoids unwanted scrap. In
practice, it takes many forms. Two major factors that should control the extent of preventive
maintenance program are.

D. The cost of the program compared with the carefully measured reduction in total repair
costs and improved equipment performance.
E. The percent utilization of the equipment maintained.

If the cost preparation for a preventive maintenance inspection is essentially the same as the cost
of repair after failure accompanied by preventive inspection, the justification is small. On the
other hand, reach down could result in server damage to the equipment and for more cost repair.
The scheduled inspection time should be considered. Further more on the verge plant preventive
maintenance should be tailored to fit the function of different items of equipment rather than
applied in the same manner to all equipment’s.
One of the most effective methods of tempering ideal preventive maintenance with practical
consideration of a continuous operation is that of taking advantage of break down in the same
component of the line to perform vital inspections and replacements. This requires recording
deficiencies observed during operation inspections and moving in quick with crafts man and
supervision prepared to work until the job is done.
Generally proposed solutions can be;

E. Preventive maintenance schedule

F. Developing new maintenance department

30
 D. General preventive maintenance schedule

Although preventive maintenance schedule should be followed as opposed to fix-it when-it- fail
approach. This too will lower operating costs by ADAMA SPINNING FACTORY equipment
operating efficiency and reliability high. In addition preventive maintenance increases the useful
life of the equipment. To accomplish thorough preventive maintenance, it is necessary to
establish what will be done and make sure it is done periodically evaluate the effectiveness of the
program. And make change as required to improve it. All these must be done in order to have an
effective program checklists should be development for all mechanical equipment showing each
inspection item and the frequency of performance.

Preventive maintenance is simply a scheduled maintenance making machine adjustments

lubricating moving karts and inspecting for tear and wear. It can occur during use. The machines
can be examined for wear and lubricants can be applied. The machines are less likely to
breakdown when in use.

The manufactures operating and maintenance instruction should use in developing check lists.

Table 1. Preventative maintenance schedule

31
Parts Daily Weekl Monthly Yearly As
y needed

N.B.

32
  Before any adjustments are started precaution ions should be considered or taken into
account.
 All controllers should be replaced in the off position.
 Main emergence switches should be locked in the open position.

E. Developing new maintenance department

In the case of plant with mechanical and electrical equipment which needs continuous
monitoring (for instance plants with high break down costs i.e. ADAMA SPINNING FACTORY
plant), creating heavy workload on the mechanical service(MS) and electrical service (ES),
then it would be wise to group the workshops mechanical workshop service (MWS) and
electrical workshop (EWS) in to a central workshop (CWS).

A third stage in the design of maintenance organization chart applies to a factory with several
production areas working 24hr a day. This is the most complete organization chart for a
maintenance department (see figure below). In considering the various services, we find exactly
the same function as described above. Thus, even though this organization chart can be
considered more or less standard, it has to be adapted in the factory. Therefore, it can only be
used as a guide.

MM
CMPO SECR
MS CWS INS ES SPMS GM
Figure 6. Designed maintenance organization chart for ADAMA SPINNING
FACTORY

33
 4.10. Conclusion an

4.10.1. Conclusion

Whatever the organization has applied preventive and breakdown maintenance strategy,
however, it can’t be said that it is fully effective that is why frequent machine failure is
happened. According to the above analysis and discussion after a new preventive maintenance
plan is scheduled the machine availability increases the productivity and quality of the product.
In terms of the production improvement the amount of production saves after improving the
preventive maintenance plan. But still the organization unavailability is 23.7%. This is a big
number when we compare with standard of availability of a good available machineries. So I can
conclude that the company has in high deficit.

4.10.2. Recommendation

For future maintenance effectiveness and productivity, the organization should: -The
maintenance department must change the preventive maintenance plan for preparation of raw
material from morning 12:00pm to 6:00am night. Apply all the plans which are planned by the
maintenance and planning department. Build a psychological interest to the workers in order to
fill as owner of the company. Plan an effective preventive maintenance according to the manual
of the machine, manufacturer recommendation, past recorded history by determining optimal
inspection number and expert’s voice.

34
 CHAPTER THREE

5. OVERALL INTERNSHIP EXPERIENCE

5.1. Sections in Wh

During my intern ship period, I have gotten so many experiences during the first month
of intern ship period I have studied the overall structure of Adama Spinning Factoryand in other
months left, I have worked my project on specific problem which I have selected from the list of
problem that I have seen during the first month.

5.2. Work Tasks

I have been executing some works during my internship period. Some of them are;

 I try to understand the work flow of the all sections.

 I try to understand the process of the all sections.
 I have been working all sections in all parts (operator, maintainer, on quality test).

5.3. Challenges an

There are numerous challenges I have faced during my internship in ADAMA SPINNING
FACTORY. These problems which impede me from doing or achieving my project with full
potential and intended plan among those problems are the following;

 Lack of office: Is one of the problems which I have faced during my internship program.
Lack of office prevents internets from getting those benefits from discussing as well as to
keep notes organized.
 Shortage of data: As we know data is a back bone of my project or generally to solve
encountered problems. But this is my great problem during my internship program which
is shortage of data even if all the workers found in ADAMA SPINNING FACTORY
helped me by providing necessary data that they know. But I was suffering by luck of
detailed information about the factory starting from long term and short term objective of
the factory since responsible official so are not interested to tell or give detail information
about the factory.

35
  Lack of safety wear: In my opinion in every company every worker should wear safety
wear to perform his/her work. Generally to create a conducive environment for workers
all companies should takes prepare safety clothes or safety wear. Safety wear encourage
workers to do their tasks without any fear and without any accident safety wear reduced
the occurrence of any accident hence preparing safety wear for internees is mandatory
for every company

Measures have taken in order to overcome the challenges:

 I have spent all the shift time in the work area.

 I collect data by asking question for employee and the manager
 I was working by my own clothes.

5.4. The Overall B

In starting period of internship, having practical and theoretical skill, I found out that I have long
way to improve myself to join the real world business activity. This period not only let me know
my level and skill, but also give me opportunity to start stepping forward in improving myself in
many aspects. I have been reading books, watching online tutorial, practicing to apply my
theoretical knowledge and consulting my associates to overcome difficulties and upgrade myself.
In time it was visible for me that I have improved my skill and knowledge. To speed up my
improvement on those skills I have been researching these skills. As a result, I had some points
in from deferent sources to follow them as a guide line;

5.4.1. In terms of upgrading practical skill

In this four month internship I had experienced the difference between theoretical skills. Even
though I already came through practical exercised during my courses at the university, I had a
new environment of practical activity in this internship period.

In this internship program I learn practical knowledge like;

 I have gained practical knowledge of how to make Layout development

 I have gained practical knowledge of how to operate different Machine

36
 5.4.2. In terms of upgrading theoretical skill
Internship program give me the opportunity to apply my theoretical knowledge in real
world environments, In addition to the practical skill. Generally speaking, my theoretical
knowledge got strengthen more by those practical techniques invested on this internship.
It assists me in moving toward my career goals by combining what I had learned from
school, practical and supervised work experience; it thus explained the necessity of every
student to undergo this process.
During my internship program I have got many things from the working members in theoretical
aspect. My improvement in the theoretical knowledge starts from the guards of the
company and goes up to president. I have read a lot of hand books of the machines in
the company. Some of theoretical knowledge’s are:
 How to use each machine,
 How to maintain each machine,
 Machine safety and care and
 How to keep the safety in each machine.

5.4.3. In terms of improving team playing skill

In this internship I got a chance that working in a team increase the work performance, as well as
creates a proper working flow and information distribution between team members which
insured that project is completed in a timely and efficient manner. During my internship, I
improve the following qualities of effective team member leant to speak up and express my
though has and ideas clearly, direction, honestly, and with respect for others and for the work of
the team.
 Good listeners are eventual for team to function effectively. So I understand that teams need
team prayers who can absorb, understand, and consider ideas and point of ravels from center
people without debating and arguing ever point such a team member also can receive criticisms
without reacting defensively.
 Work as an active participant.
 Willingness to share information, knowledge and experience and to take the initiative to
keep other members of team informed.
 Work at a problem together.
 Treating others in a respecting and supportive manner.

37
 5.4.4. In terms of improving leadership skill

Leadership is a process of leading the careers of the company. A person who is in the position of
leadership should be smart enough to manage those individuals whom he/she is leading. Besides
this, he/she must have known the following things:

 Gain trust,
 Solve engineering problems,
 Respect experience and ability of the others,
 Control the learning experience,
 Hold the individuals interest,
 Ability to motivate organization members to their best,
 Giving motivational benefits for organization members,
 Listing the idea and advise of the organization members,
 Understanding problems of the organization members and assist them in solving their
problems,
 The ability to solve problems by focusing on the solutions and
 Respecting organizational members’ difference and interest.

A Leader needs to have a clear and defined goal, mission and vision.

5.4.5. In terms of understanding work ethics, industrial psychology and related

issues

Ethics is a branch of philosophy that defines morality and determines the meaning and rational
justification of the right way to live, correct values as well as correct ways of treating other. As
workers were made to specialize in different fields, specific codes of contact were expected from
each worker. In today’s complex world, ethical conduct of worker is very important for
developing healthy working environment and increasing productivity.

Ethical work conduct enables workers to possess appropriate behaviors and so as to develop
proper relationships with co-worker and help them to create good industrial environment. Two
types of ethics mostly exist. These are;

38
A. Personal Ethics

All human beings as rational creatures are expected to exhibit certain personal principles of
ethics. These principles of personal ethics are values which are expected to be possessed by
all individuals in their life, and contribute a lot for a smooth interaction among individuals
and peaceful coexistence of a society. These principles of personal ethics include:

 Concern for the well-being of other,

 Honesty and integrity,
 Fairness,
 Compliance to the law,
 Benevolence (doing good),
 Refusing to take un-fair advantage and
 Respecting the Autonomy of others.

Understanding customers filling;

 When meeting and discussion in groups listening and respecting other idea,
 Punctuality,
 Not absent (except for special cases),
 Reliability,
 Cooperation with colleagues and
 Open enough to create smooth relation with partners.
B. Professional Skill

Professional ethics refers to the standard or a set of moral principles for regulating behaviour of a
certain defined profession. In order to consider that an activity to be a profession, it should be
carried out by one who has advanced education, knowledge and skill. Thus, for developing
healthy working environment and increase productivity, ethical work conduct is necessary. The
following are some of the common ethical principles which are apply in each company:

 Transparency and openness,

 Integrity,

39
  Avoiding potential or apparent conflict of interests and
 Accountability.

In spite of these I gain a lot of benefits from the factory. Some of them are:

 Performing service only in an area of competence.

 Being punctual at work and leave work by the right time.
 Being responsible in analyzing and interpreting gathering of data.
 Learning career- related skills such as public speaking, dealing with customers etc.
 Being tolerant and patience i.e. when someone is absent, they will cover his
/her work by coordinating.

5.4.6. In terms of entrepreneurship skill

The state of being an entrepreneurship can be realized when on engages in profitable risks and
creates something of valuable. Entrepreneurship is defined by their habit of innovating and
redefines market trends and limits. Regardless of their heredity, their background, their
exposures and what not; entrepreneurs are people who are able to develop new business and
affect the overall condition of the global economy.

There are abilities innate to human beings that can be very helpful when starting out as
entrepreneurs. This ability basically denotes having a sense of one’s self and knowing what one’s
strengths, weaknesses and biases are.

 Self-esteem,
 Self-confidence,
 Integrity and
 Reliability.

The internship program helps for us in order to know the entrepreneurial ways of thinking skills.

 It enables us to understand the business concepts.

 It gives us an idea of business philosophy.
 It helps us to have a long term vision about being entrepreneur.
 It helps us to know the opportunities and resources which we have.
 It helps us to know about the quality team in any industry.

40
  It helps us to know about risk management.

5.4.7. In terms of improving interpersonal communication skill

Individuals often learn different things from colleagues’ through communication. For any
individuals communication is an important way of learning, which can be defined formally as the
act, process, or experience of gaining knowledge or skills. Communication and the subsequent
learning help individual especially engineers more allow them to gain new professional
knowledge and abilities. Good communication is the life hood of the engineering profession.
Even though, it takes many forms, such as speaking, writing and listening, it has the following
usage;

 Improves handling information,

 It brings social interaction to the organization employees,
 Improve to build up self-confidence,
 It improves our speaking and listening skills,
 To exchange new ideas and knowledge’s with the other and
 Improve relationships with the other.

In the company, working with any individual peacefully was gained from your interpersonal
communication. That means asking open-ended questions and listening affectively to the
answers is a great way to show your respect for their experience and ability. Open-ended
question encourage individuals

 To think, to express options and to share ideas.

Interpersonal communication may include one of the following

Communication with many department employees:

 With project planning staff

 With the organization server administrator
 Human resource department

41
Communication with other related organization: Finance and human resource department

Finally, what I have observed was to communicate effectively, it is essential that you choose the
suitable medium.

CHAPTER FOUR
4. GENERAL CONCLUSION AND RECOMMENDATIONS

4.1. Conclusion

Adama Spinning Factory is one of yarn production company in Ethiopian which is become
prosperous within a long period of time by production different types of yarn products. As a
result A.S.F has a greater market share in Ethiopia.

It has six different factories/shops which are responsible for the production of the required
product. However, analysis done on this factory shawls that the performance of the factory is
decreasing from time to time. The sum of the overall existing problem in this factor resulted a
production loss of more than 504,000 birr/year.

Adama Spinning Factory plays a great role by creating job opportunity for the so chatty
including interns. It helps interns to engage in real worked and to get portion knowledge and
effective control and also provides some accessories to support trainers.

4.2. Recommendation

Adama Spinning Factory is a yarn producing factory and profitable through proper coordination
and through hard working. Even if, the factory has made many efforts to effect the production
system, it has a number of problem. Which prohibits it not to use its full potential. Hence, as a
train we will recommend for the factory to avoid these problem.

After analyzing downtime problem and the effect of it on the profitability of the
company I recommended the following major activities

 Since motivation is the one that uses to grad up organizations profitability via employee
satisfaction and giving the care to the materials from shut down, they should have a motivation

42
 program. The company should have to order spare parts to their suppliers within a short lead
time Safety materials have to be given to daily operators and maintainers
 Monthly salary of operators and maintainers should have enough to their satisfaction
 The company should record data’s not only about the downtime but also reasons that cause
downtime. That is failed part and failure frequency of parts must be recorded so that, reliability
and availability of each parts can be calculated.
 Company performs shut down maintenance, assuming that it as preventive maintenance,
but this is not the concept of preventive maintenance they must be clean, inspect, lubricate and
replace parts as per the schedule that I have prepared.
 The company also need to have skilled persons who graduate in the field of industrial or
mechanical engineering to handle and solve such problems in easily and sounded manner.
 There should be a research and development department for the workers to upgrade their
knowledge.
 The company need to have a strong internal supply chain management rather than
focusing on individual department goal. The company should have to employee enough
maintainer

43
 REFERENCES

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system with deterioration. Journal of Intelligent Manufacturing, 21(6), pp.875-884.
2. Lie, C.H. and Chun, Y.H., 1986. An algorithm for preventive maintenance policy. IEEE
Transactions on Reliability, 35(1), pp.71-75.
3. Malik, M.A.K., 1979. Reliable preventive maintenance scheduling. AIIE
transactions, 11(3), pp.221-228.

4, Wu, S. and Zuo, M.J., 2010. Linear and nonlinear preventive maintenance models. IEEE
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Appendix1: Questioner prepared for maintenance department

1. Did you know about maintenance?

Yes No

If yes define maintenance shortly?

2. Did you know about preventive maintenance?

Yes No

If yes define preventive maintenance shortly?

3. Did you apply preventive maintenance in E.P.I?

Yes No

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4. If yes, did you do
Rarely Sometimes Usually Always

5. Are you skillful to maintain different machines?

Yes Some of them not all No, I am not skillful only by experience

6. Did the company train the operators and also the maintainers on new machine?
Yes

4
6