Heat Excanger

Chapter one
1.1 Back ground of Mesfin industrial engineering

Mesfin Industrial Engineering's history goes back to 1982. Its foundation was laid during the
armed struggle -waged by the TPLF against the Dictator Dergue Regime of Ethiopia. The
TPLF had established a workshop, which could support its movements in the bushes The
workshop was established with few professionals in electricity, electronics, metal works,
chemistry, etc., who were educated and trained in colleges and universities in the Diaspora
and inside the country. Few high school students who were interested in working in the
workshop were also trained by those professionals to work in the workshop. The workshop
was helping the armed struggle by maintaining electronic apparatus like wireless
communications radios which were important to the army. Broken down generators and
engine were also being maintained at the workshop. All the machines used at the workshop
were either captured from the Dergue army or (few) bought from outside.
In1991 the Dergue Regime was toppled down. EPRDF, a national front in which the TPLF was
the significant arm, came to power in Ethiopia. During this time situations had changed and
TPLF had to change its activities to fit to the situations. The war time had ended, and
everybody had to think of democracy and development in the country. The TPLF had a
significant capital in cash and in kind collected during the 17 years of armed struggle. It had
two choices, at that time, of what to do with the money and other resources.
One choice was to divide the resources to all its members. This choice was not acceptable at
that time, because it meant completely wasting all the resources collected in 17 years for
nothing, distributing it in hundreds of birr in to the pockets of individual members. The second
choice was to donate it to an endowment fund so that it could be invested in different business
entities and contribute to the development endeavor of the country at large and the Tigray
Region in particular. This second choice was accepted. Therefore, based on the accepted
choice MIE was founded in 1993 as one of the EFFORT owned company with a total initial
investment capital of 7 million Ethiopian birr. And its name Mesfin was derived from a former
fighter technician who graduated from a Poly technique College in Ethiopia and was manager
of the workshop in the bushes during the armed struggle and who died on duty.
MIE is the Leading Engineering Company in Ethiopia has got -ISO 9001:2008 Quality
Management System certificate No, FM 512406 from BSI for the following scope:
MIE currently is mainly engaged in the manufacture of liquid and dry cargo bodies, trailers,
semi-trailers, low beds and in the fabrication of fuel storage tanks and various equipments for the
construction and energy sectors such as cement components, and hydropower elements. It is also
engaged in electromechanical erection and installation works, and includes erection of
machineries.
Introducing one man to many machine strategy in Mesfin industrial engineering machine shop.
Page 1
1.2 Problem statement

In Mesfin industrial engineering machine shop there are around 16 machines, so for each
machine there is at least one operator which means the company is applying one man to
one machine strategy. But one man can operate more than one machine (one man to many
machine strategy) without affecting the quality of the product. Therefore the strategy of the
company has the following main problems.
Unnecessary cost of labor force.
High idle time of workers.
1.3 Scope of the study

In Mesfin industrial engineering there are many workshops. But the scope of this
study is focused only on the machine shop of the company. In addition to this scope,
since the workers are not familiar to operate more than one machine at a time, so this
study is focused on two or three machines.
1.4 Limitation of the study

Some limitations of this study are:
Lack of facility like computer.
Lack full information.
Variety of the machine function.
Page 2
1.5Objective of the study

1.5.1 General objective
To minimize high idle time of labor force in machine shop.
1.5.2 Specific objective
To reduce unnecessary labor cost.
To increase labor utilization.
Page 3
1.6 Research Methodology

1.6.1 Data collection methodology
In order to do this research both primary and secondary data collection methodology
are used.
1.6.1.1 Primary sources from:Direct observation

Informal interview with the concerned body
1.6.1.2 Secondary from:Internet

Reference book
Literature review
1.6.2 Data analysis tools

Work study (using multi activity chart)
Page 4
Chapter two
Literature review
2.1 Optimization
Optimization is Finding an alternative with the most cost effective or highest achievable
performance under the given constraints, by maximizing desired factors and minimizing
undesired ones. In comparison, maximization means trying to attain the highest or maximum
result or outcome without regard to cost or expense. Practice of optimization is restricted by the
lack of full information, and the lack of time to evaluate what information is available. In
computer simulation (modeling) of business problems, optimization is achieved usually by using
linear programming techniques of operations research.
It is also a mathematical discipline that concerns the finding of minima and maxima of
functions, subject to so-called constraints. Optimization originated in the 1940s, when George
Danzig used mathematical techniques for generating "programs" (training timetables and
schedules) for military application. Since then, his "linear programming" techniques and their
descendants were applied to a wide variety of problems, from the scheduling of production
facilities, to yield management in airlines. Today, optimization comprises a wide variety of
techniques from Operations Research, artificial intelligence and computer science, and is used to
improve business processes in practically all industries.
Discrete optimization problems arise, when the variables occurring in the optimization function
can take only a finite number of discrete values. For example, the staff scheduler of a hospital
unit has a finite set of staff members available, and thus staff scheduling consists of taking
discrete decisions, one for each slot of the resulting schedule. Discrete optimization aims at
taking these decisions such that a given function is maximized (for example revenue) or
minimized (for example cost), subject to constraints, which express regulations or rules, such as
required numbers of rest days for the staff in a schedule.
Perhaps surprisingly, discrete optimization is more difficult than its "continuous" counterpart,
where variables are allowed to take fractional values or even "real numbers". In fact, there is no
general solution known for optimization problems that reliably and speedily computes solutions
to discrete optimization problems. A variety of computation techniques compete for the best
solution. In recent years, it has become clear that different application domains lend themselves
to different solution techniques. Linear programming has been applied to discrete optimization
using so-called "branch-and-bound" techniques, for example to solve facility location problems.
Heuristic search aims at finding good but not necessarily optimal solutions quickly. This
technique is successfully used in a wide variety of applications; for example the Lin Kernighan
heuristic for the Traveling Salesman problem finds solutions that are extremely close to the
optimal solution for very large problem instances. Constraint programming is a solution
technique that developed out of programming language research and artificial intelligence. It
employs specialized algorithms in the general framework of tree search, and has been
successfully applied to production scheduling problems.
Page 5
Another recent trend is the combination of optimization techniques for problems that do not lend
themselves easily to one technique alone. Today, these techniques prove to deliver robust
engines that provide very high quality solutions for even very large problem instances.
2.2 Work study
Work study is a body of knowledge designed to increase the productivity of an organization. It has an
objective of elimination of unnecessary work for the objective of finding better and simpler methods of
getting the job done and determining the time required by a qualified and a properly trained person
working at normal place to do the specific task or operation. This is divided to time study and method
study.
2.2.1 Work measurement (time study)
Work measurement is the technique of observing and recording the time required to do
each detailed element of an industrial operation.
Work measurement is used to determine the required time by qualified and well trained
person working at a normal place or temperature to do a specific task.
Objective of time measurement is:-
Comparing alternative methods

Assessing the initial manning
Planning and controlling
Realistic costing
Financial incentive schemes
Delivery date of goods
Cost reduction and cost control
Identifying substandard workers
2.2.2 Techniques of time measurement
Time can measure in different way such as:a. Time study: recording times and rates of a job and analyzing the data to determine the
time for carrying out the job.
b. Synthetic data:- building up the time for a job by totaling element times obtained
previously on other similar jobs or from synthetic data .
c. Work sampling:- recording a number of observations made over a period of time of
machines ,processes of workers as activities, or delay at the instant, and considering the
percentage of activities/delay time occurrence
d. Predetermined motion time study (pmts):- times established for basic human motions are
used to build up the time for a job.
e. Analytical Estimating:- to estimate time partly from knowledge and practical experience
of the elements concerned and partly from synthetic data.
Page 6
2.2.3 Multi activity chart
It is a chart where activities of more than subject (equipment) are each recorded on a
common time scale to show their inter relationship.
It is made to:
Study idle time of the man and machines.
Determine number of machines handled by one operator.
Determine number of operators required in teamwork to perform the given task.
Construction of the chart
A multiple activity chart consists of a series of bars hatched for working and for blank for the
columns) placed against a common time scale. Each subject is allocated with one bar and the
activities related to the subjects are represented in this bar.
0
0.2
.28
.36
1.86
Operator
description
Load job
Switch on;
Switch on
Idle
T(min)
0.20
0.08
0.08
machine
1.91
1.96
Pick up part
Keep in tray
0.05
0.05
subject
Cycle time
Time worked per cycle
%age of utilization
Operator
1.96
.46
23.4
machine
1.96
1.5
76.6
S
.36 min
T(min) S
Idle
Idle
Idle
Machining
of part
auto cycle
1.5
1.5 min
.4 min
Page 7
Chapter three
3.1 Data analysis
Table1. Recorded data
S
Machine
No. name
1
2
3
4
5
6
7
8
9
10
11
12
power
hack saw
Lathe
machine
Lath
machine
Shaper
machine
Shaper
machine
Drilling
machine
Hydraulic
press
machine
Lath
machine
Lath
machine
Lath
machine
Lath
machine
Lath
machine
Function
machine
of Size of Speed
the part (rpm)
Time spend by operator (min)
Record 1
Record 2
Average
time
(25228
1)mm
Turning two From
355
steps
50-30
mm
And 50
to 10
mm
Draw bar pin
20mm 280
2.2
&3
respectively
2 and 3
respectively
1.4&
3respctively
2 and 3
respectively
2
&3
respectively
2 and 3
respectively
Draw bar pin
4.4
5.2
Drilling
of 8 sheet sheet metal
metals
Small hinge 8mm
(bending)
boring
250
5.4
6.2
250
5.3
320
1.3
and3 2. 3 and 3 2and3
respectively respectively respectively
irregular
irregular
irregular
irregular
cutting
100mm -
turning
Boring
Turning
operation
20mm
260mm
2 step
200
2 step
From
50-30
mm
And 50
to 10
mm
_
tread
manufacturing
Tread
_
manufacturing
300
Page 8
13
14
1
Milling
machine
Milling
machine
power
hack saw
Not
functional
Gear
manufacturing
cutting
50mm
irregular
irregular
4.2
3.4
There for using the average time shown above the following analysis
Can be develop.
Page 9
S
No.
Machine
name
code
Function
machine
power
hack saw
50013
cutting
100mm
Lathe
machine
50005
turning
(251)mm
228
Lath
machine
50055
Turning
steps
Shaper
machine
50049
two From
355
50-30
mm
And 50
to 10
mm
Draw bar pin
20mm
280
Shaper
machine
50036
Draw bar pin
Drilling
machine
50017
Drilling
of 8 sheet sheet metal
metals
Hydraulic
press
machine
50009
Small hinge 8mm

(bending)
Lath
machine
5006
boring
260mm
2 step
250
Lath
machine
500012 Boring
200
2 step
250
10
Lath
machine
50015
From
320
50-30
mm
And 50
to 10
mm
Turning
operation
of Size of Speed
the part (rpm)
20mm
300
Time spend
by operator
(min)
4
Time spend
by
machine(min)
65
Activities
done by
operator
Adjusting
&loading
the
machine
2 &3
9
Adjusting
&loading
the
machine
2 and 3 22 and 9 Adjusting
respectively respectively
&loading
the
machine
12
Adjusting
&loading
the
machine.
5
12
Adjusting
&loading
the
machine.
1
4
Adjusting
&loading
the
machine.
1
1
Adjusting
&loading
the
machine
6.2
32
Adjusting
&loading
the
machine
5.3
20
Adjusting
&loading
the
machine
2and3
20 and 9 Adjusting
respectively respectively
&loading
the
machine
Page 10
11
Lath
machine
50011
tread
_
manufacturing
irregular
irregular
12
Lath
machine
50018
Tread
_
manufacturing
irregular
irregular
13
Milling
machine
Milling
machine
50010
Not
functional
Gear
manufacturing
irregular
irregular
14
50056
Adjusting
&loading
the
machine
Adjusting
&loading
the
machine
Adjusting
&loading
the
machine
One power hack saw is occurred in material preparation shop with the following data.
S No.
Machine
name
code
Function of Size of speed

machine
the part
power
hack saw
50024 cutting
50mm
Time
spend by
operator
(min)
4
Time spend Activities

by
done by
machine(min) operator
32
Adjusting
&loading
the
machine
The existing rearrangement of the machines is as follows

One power hack saw is occurred in material preparation shop but for the other
machines it is drawn as shown below. The dimension of the work shop is
Length-60 meter
Wedith-24meter and the average distance between machines is 3 meter.
Page 11
Exit
Welding
area
8m
gap
Machine
14
Machine 7
Machine
13
Machine 6
Machine
12
Machine 5
Machine
11
Machine 4
Machine
10
Machine 3
Machine 9
Machine 2
Machine 8
Machine 1
CNC
machine
Store
CNC
machine
Entrance
Existing rearrangement of machines in Mesfin industrial engineering machine shop
Page 12
The following diagram shows how many machines can handle by one operator at a time and
after how many time is the worker shits from one machine to machine anther machine.
Multi activity chart for two cutting machines (hack saws)

Macine1 is the machine found in material preparation shop
Tt
(min)
0
3.8
4
5
8.8
9
36
36.2
39.2
43
43.2
74
74.2
75.2
75.4
operator
description
Load job
switch on
T time
Load job
switch on
idle
Switch off
Unload
job
Load job
switch on
idle
Switch off
T time
Switch off
Machine
1
T(min)
3.8
.2
1
3.8
.2
27
.2
3
9min
7.2 min
3.8
.2
.2
1
.2
1.4 min
Machine
1
T(min)
idle
idle
cutting
Cutting
cutting
cutting
idle
idle
Idle
idle
cutting
cutting
cutting
finish
1
3.8
.2
27
30.8
.2
1
32 min
32 min
t
idle
idle
idle
Idle
idle
cutting
cutting
cutting
cutting
cutting
cutting
finish
idle
idle
27
.2
3
65
min
3.8
.2
30.8
From the above chart it is possible to determine the utilization of the operator and the machines as
follows.
subject
Cycle time(min)
Time worked
Per
cycle
4
32
%of utilization
Operator
Machine 1
36
36
subject
Cycle time(min)
%of utilization
69
Time worked
Per
cycle
4
Operator
Machine1
69
65
11.1
88.9
5.7
94.2
Page 13
After one worker is assigned to operate two machines

subject
Operator
Machine1
Machine1
Cycle time(min)
146.6
146.6
146.6

17.6
64
65
%of utilization
12.1
43.6
44.3
Multi activity chart for machine 2 &3

Tt
in operator
(min)
0
description
2
Load job
and switch
on
machine
3
Go to M 3
5
Load and
switch on
machine
11
idle
14
Unloading
then
loading
23
idle
26
Unloading
then
loading
24
Go to M3
27
Unloading
then
loading
32
idle
35
Unloading
then
loading
36
Go to M3
39
Unloading
M3
Machine
2(M2)
T(min)
2
Machine
3(M3)
T(min)
idle
T(min)
Idle
5 min
1
2
turning
turning
3 min
1
3
7 min
1
3
9 min
1
2
9 min
turning
6
Finish 1
round
turning
idle
9 min
turning
turning
1
3
9min
turning
idle
idle
idle
Idle
Idle
turning
turning
6
3
turning
turning
9
3
22 min
turning
1
Finished
1 round
turning
turning
5
3
turning
finished
9 min
Page 14
subject
Operator
Machine 2
Cycle time(min)
26
26

8
18
%of utilization
30.7
69.3
subject
Operator
Machine3
Cycle time(min)
39

8
39
31
%of utilization
20.5
79.5

subject
Cycle time(min)
Operator
Machine 2
Machine 3
82
82
82
Time worked
Per
cycle
24
27
31
%of utilization
29.3
32.9
37.8
Multi activity chart for machine 4 &5

Tt
(min)
0
4.8
5
6
10.8
11
17
22
23
23.2
operator
description
Load a job
Switch on
Go to M4
Load job
Switch on
idle
Switch off
& load job
idle
Switch off
Machine
4(M4)
T(min)
4.8
.2
1
4.8
.2
5 min
.2
.2 min
11 min
subject
Cycle time(min)
Operator
Machine 4
17
17
subject
Cycle time(min)
Operator
Machine 5
17
17
Machine
5(M5)
T(min)
idle
idle
operate
operate
operate
operate
Finish
(idle)
operate
operate
1
4.8
.2
6
1
.2
12 min
idle
idle
idle
idle
idle
operate
operate
operate
finished
T(min)
6
5
12 min
Time worked
Per
cycle
5
12
%of utilization
Time worked
Per
cycle
5
12
%of utilization
29.4
70.6
29.4
70.6
Page 15

subject
Operator
Machine 4
Machine 5
Cycle time(min)
40.2

16.2
40.2
40.2
12
12
%of utilization
40.3
29.85
29.85
Machine 7 (Hydraulic press machine) is used for bending of 8mm thickness of plate
metals. So the machine and the operator time is 1 minute for both. Which means the
operator cannot operate more one machine at a time.
Multi activity chart for machine 6 & 8.

Note be: The operator should start with machine 8 rather than with machine 6
Tt
(min)
0
6
7
8
12
13
14
18
19
20
24
25
operator
description
Load job
& switch
on
Go to M6
Load job
& switch
on
idle
Switch of
&
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
Machine
8(M8)
T(min)
6
1
1
8 min
Machine
6(M6)
T(min)
idle
boring
boring
1
1
idle
idle
boring
boring
4
1
drill
idle
boring
idle
boring
boring
4
1
drill
idle
2 min
boring
idle
1 min
boring
boring
4
1
drill
idle
2 min
T(min)
4 min
4 min
4 min
idle
32 min
Page 16
26
30
31
32
38
44
45
46
50
51
52
56
57
58
62
63
64
68
69
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
unloading
M6
idle
Switch of
&
unloading
M8
Load job
& switch
on
Go to M6
Load job
& switch
on
idle
Switch of
&
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
unloading
M6
Loading &
switch on
M6
idle
Switch of
&
1 min
boring
idle
1min
boring
boring
4
1
drill
idle
boring
finish
idle
idle
14 min
1
1
idle
1
1
idle
idle
boring
boring
4
1
drill
idle
boring
idle
boring
boring
4
1
2 min
32 min
drill
idle
2 min
boring
idle
2 min
boring
boring
4
1
drill
idle
boring
idle
boring
boring
4
1
drill
idle
1min
4min
4 min
4 min
4 min
4min
idle
boring
boring
Page 17
unloading
M6
idle
Switch of 6
&
unloading
M8
70
76
6 min
Subject
Cycle time(min)
Operator
Machine 6
subject
Operator
Machine 8
boring
finish
idle
idle
%of utilization
6
6
Time worked Per

cycle
2
4
Cycle time(min)
88

24
88
64
%of utilization
27.2
72.8
33.33
66.67

subject
Operator
Machine 6
Machine 8
Cycle time(min)
138

42
138
138
64
32
%of utilization
30.4
46.3
23.3
Multi activity chart for machine 9&10.

Tt
(min)
0
5
6
8
25
25.2
28
30
operator
description
Load job
& switch
on
Go to M10
Load job
& switch
on
idle
Switch off
M9
idle
Switch off
M10& un
load it.
Machine
9(M9)
T(min)
5
1
2
8 min
.2
Machine10
(M10)
T(min)
idle
T(min)
turning
turning
17
.2
20min
turning
idle
2.8
idle
boring
boring
1
2
boring
finish
17
.2min
2min
idle
idle
20
min
idle
idle
Page 18
Subject
Cycle time(min)
Operator
Machine9
25
25
Subject
Cycle time(min)
Operator
Machine10
22.2
22.2
Time worked
Per
cycle
5
20
%of utilization
Time worked
Per
cycle
2.2
20
%of utilization
20
80
9.9
91.1

subject
Operator
Machine 9
Machine 10
Cycle time(min)
50.2

10.2
50.2
50.2
20
20
%of utilization
19.42
38.84
38.84
Page 19
3.2 Results of the study

As the input data indicates machine 11, 12 and 14 cannot operate by one worker
because their product (gear and tread) needs more accuracy so the operator is not idle
most of his time is spend on operating the machines. Machine 13 is also not
functional at this time. There for each machine 11, 12 & 14 needs one worker. But
Machine 1&1 can operate with one operator.
Machine 3 & 2 can operate with one operator.
Machine 9&10 can operate with one operator
Existing and To-Be utilization of worker becomes as follows:

Operator of
Machine 1&1
Machine 2&3
Machine 4&5
Machine 6&8
Machine 9&10
Existing utilization
11.1&5.5 respectively
20&9.9 respectively
To be utilization
12.1
29.3
40.3
30.4
19.42
Existing and To-Be cost of labor force becomes as follows:

.
In Mesfin industrial engineering machine shop there are 16 machines which have at least one
operator for each machine.
Since there are 3 shift per day 3*16=48 workers
As I have gathered information from the company the average monthly payment of one worker is
2700 birr.
There for the total monthly cost of labor is 48*2700= 129,600birr (existing cost of labor force)
But, according to this study 5 workers per shift can be minimized without affecting the quality
of the product. There for 5*3=15 workers can be minimizing.
(48-15)*2700birr=89,100 birr (To-be cost of labor force)
Then the difference is 129,600-89,100= 40,500 birr per month. This unnecessary cost is only
from one machine shop so if the companies apply this strategy to the other shops it can gain
additional profit.
There for to reduce longest transfer time of labor force, it is better to change the existing
rearrangement of the machines as follows.
Page 20
Exit
Welding
area
Machine 1
Machine
14
Machine 1
Machine
13
Machine 6
Machine
12
Machine 5
Machine
11
Machine 4
Machine
10
Machine 3
Machine 9
Machine 2
Machine 8
Machine 7
CNC
machine
Store
CNC
machine
Entrance
Recommended rearrangement of machines in Mesfin industrial engineering machine shop.
Page 21
Chapter four
4. Conclusion and recommendation
4.1 Conclusion
In Mesfin industrial engineering there many workshops but this study is focused only on
the machine shop of the company. According this study in the machine shop of the
company 40,500 birr cost of labor force can be minimize if the company applies this
study strategy.
According this study the utilization of five workers is increased as follows.
Operator of
Machine 1&1
Machine 2&3
Machine 4&5
Machine 6&8
Machine 9&10
Existing utilization
20&9.9 respectively
To be utilization
12.1
29.3
40.3
30.4
19.42
Page 22
4.2 Recommendation
Using this study as reference the company should apply to other workshops of the
company.
When the company tries to do this it should consider on the load of the workers and
quality of the product.
Since this is new strategy to the company, so rather than fairing the worker it is better to
shift to other shops.
Before applying this, the worker should train how to operate the machines that are
assigned to operate simultaneously.
One power hack saw is found in preparation shop so it must be take to machine shop.
Page 23
References
1.
Work study hand out (un published)

2. http://www.scienceofbetter.org accessed on 26 /05 /2012
3. George kanawaty 3rd ed.introduction to work study, Geneva: ILO, 1979
4. Schroder, R.Goperation management 4th edition New Jersey: pearso educationITD, 2007
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Chapter one

1.1 Back ground of Mesfin industrial engineering

1.2 Problem statement

1.3 Scope of the study

1.4 Limitation of the study

1.5Objective of the study

1.6 Research Methodology

1.6.1.1 Primary sources from:Direct observation

1.6.1.2 Secondary from:Internet

1.6.2 Data analysis tools

Comparing alternative methods

2.2.3 Multi activity chart

Time worked per cycle

Time spend by operator (min)

Draw bar pin

Draw bar pin

Small hinge 8mm

Function of Size of speed

Time spend Activities

The existing rearrangement of the machines is as follows

Multi activity chart for two cutting machines (hack saws)

After one worker is assigned to operate two machines

Time worked per cycle

Multi activity chart for machine 2 &3

Time worked per cycle

Time worked per cycle

After one worker is assigned to operate two machines

Multi activity chart for machine 4 &5

After one worker is assigned to operate two machines

Time worked per cycle

Multi activity chart for machine 6 & 8.

Time worked Per

Time worked per cycle

After one worker is assigned to operate two machines

Time worked per cycle

Multi activity chart for machine 9&10.

After one worker is assigned to operate two machines

Time worked per cycle

3.2 Results of the study

Existing and To-Be utilization of worker becomes as follows:

Existing and To-Be cost of labor force becomes as follows:

Work study hand out (un published)

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