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Research Article
Reliability and Maintenance Performance Analysis of a 1600-ton Press Machine Using MTBF, MTTR, KPI, and Downtime Indicators
Issue:
Volume 9, Issue 2, December 2025
Pages:
36-41
Received:
17 August 2025
Accepted:
3 September 2025
Published:
23 September 2025
Abstract: This study presents a comprehensive analysis of the reliability and maintenance performance of a 1600-ton press machine in refractory production using an innovative inverse KPI model. Key metrics—including Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), a specially formulated Key Performance Indicator (KPI), and total downtime—were systematically evaluated over a 24-month observation period (June 2023-May 2025). The methodology involved the meticulous collection of monthly operational data, failure events, and repair logs. Time-series analysis was employed to identify trends and correlations between the implemented proactive maintenance strategies and equipment performance metrics. The inverse KPI, defined as KPI = (MTTR / MTBF) × 100, proved to be a highly effective tool for performance tracking. The results demonstrate a remarkable 75% reduction in total downtime by mid-2024, correlating directly with a significant increase in MTBF and a decrease in the KPI value. A temporary performance anomaly in early 2025 was investigated and linked to an unforeseen component failure, highlighting the importance of continuous monitoring. The findings conclusively demonstrate the efficacy of a data-driven, proactive maintenance approach, providing a practical and transferable framework for enhancing industrial asset management. This study underscores the substantial benefits of applying systematic reliability engineering principles to optimize performance in traditional industrial settings.
Abstract: This study presents a comprehensive analysis of the reliability and maintenance performance of a 1600-ton press machine in refractory production using an innovative inverse KPI model. Key metrics—including Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), a specially formulated Key Performance Indicator (KPI), and total downtime—were s...
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Research Article
Modification of Rope and Washer Pump to Engine Operated for Irrigation in South Western Oromia, Ethiopia
Roba Adugna,
Adem Tibesso*
,
Abu Dedo
Issue:
Volume 9, Issue 2, December 2025
Pages:
42-47
Received:
19 August 2025
Accepted:
30 August 2025
Published:
23 September 2025
Abstract: Suitable methods of water lifting and distribution are the most important aspects that determine the efficiency and success of an irrigation system. The rope and washer pump, a water-lifting device made with appropriate technology, has been effectively used in a number of developing nations all over the world. Engine operated rope pumps are one application of the “rope and washer” pumping principle, driven or powered by an electrical, petrol or small diesel motor. The aim of this study was to modify the rope and washer pump to engine operated for small-scale irrigation applications in southwestern Oromia, Ethiopia. The modification of the rope and washer water pump was undertaken with the intention of solving the suction head problem that rural people are facing during the dry season for crops and vegetable farming at the group or household level. Engine-operated rope and washer pump efficiency is mainly affected by engine horsepower for the used head and pipe diameter. The performance of the modified rope and washer pump was conducted using two different diameters of PVC pipe (2" and 4 “), as well as two discharge heads (6 m and 8 m). Using a 5 hp engine, the maximum head and pipe diameters achieved for this study were 8 m and 4 inches, respectively. The maximum efficiency of the pump was 2.532 l/sec and 12.178 l/sec using 2 and 4 inch pipe diameters, respectively, at an 8 m head.
Abstract: Suitable methods of water lifting and distribution are the most important aspects that determine the efficiency and success of an irrigation system. The rope and washer pump, a water-lifting device made with appropriate technology, has been effectively used in a number of developing nations all over the world. Engine operated rope pumps are one app...
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Research Article
Development and Performance Evaluation of an Engine Driven Air Assisted Teff Planter
Merga Workesa*,
Solomon Lammessa
Issue:
Volume 9, Issue 2, December 2025
Pages:
48-59
Received:
2 September 2025
Accepted:
13 September 2025
Published:
17 October 2025
Abstract: Teff is a staple of Ethiopian culture and national identity and is very nutrient-dense. Ethiopia and its farmers now have more economic opportunities as a result. The process of planting involves putting seeds in the ground for optimal germination. It is among the most significant cultural customs related to the production of crops. At present it has little development in teff row seeder in Ethiopia. However, their field evaluations showed that, none of the developed planters has been functioned effectively, in way of the desired functional requirement, especially in all soil types as well as weather conditions of the country. So many research institutes and private sectors have been developed different types of teff row planting device which seed from single to many rows, animal drawn and operated manually. This work focused on the creation and performance evaluation of an inexpensive self-propelled five rows air seeder teff row planter in order to overcome the need for human labor for sowing, which leads to delayed operation, low yield, and high production costs. The developed machine consists of different major component parts like seed and fertilizer hoppers, driving wheel, air diffuser, controlling mechanism, seed and fertilizer delivery chute and the like. The planting machine's effective field capacity, theoretical field capacity, and field efficiency were determined to be 0.25 ha/hr, 0.31 ha/hr, and 0.81 ha/hr, respectively, during the performance evaluation. The largest plant population was observed replication 5 and the smallest observation was recorded at replication 3 which was 141.3 and 103.5 respectively.
Abstract: Teff is a staple of Ethiopian culture and national identity and is very nutrient-dense. Ethiopia and its farmers now have more economic opportunities as a result. The process of planting involves putting seeds in the ground for optimal germination. It is among the most significant cultural customs related to the production of crops. At present it h...
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Research Article
Optimizing Vehicle Assembly Line Achievement via Lean Manufacturing: An Evaluation of the Bishoftu Automotive Manufacturing Industry
Semere Ayele Mengistu*
Issue:
Volume 9, Issue 2, December 2025
Pages:
60-69
Received:
9 September 2025
Accepted:
17 October 2025
Published:
3 December 2025
DOI:
10.11648/j.ie.20250902.14
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Abstract: Vehicle manufacturers nowadays must contend with rising consumer demand and fierce competition for timely delivery of high-quality goods at affordable costs. But the assembly line was not productive at the required rate and capacity due to assembly line delay constraints. However, some workstations in the production line would be delayed. In the assembly line process, from the first to the last workstation, it became starving and blocking at some workstations in the assembly line due to unbalanced assembly workstation. The study aims to Optimizing Vehicle Assembly Line Achievement via Lean Manufacturing: An Evaluation of The Bishoftu Automotive Manufacturing Industry. The study was employed both qualitative and quantitative research approaches. By using those data, the current assembly line was developed with the help of lean manufacturing principles and technique among them methods, value stream map was the most important and the researcher used VSM. The most important wastes were found when the current assembly process then output was examined. Finally, optimized workstation and splitting suggested to the example company after a variety of alternative scenarios, including the current one, were performed to increase the company's production. The findings demonstrated that the first and second scenario increased the case company's bus assembly line output rate. There has been increased line efficiency by 44.65% from 19.25% to 63.9% and also production rate also increased by 0.125 unites.
Abstract: Vehicle manufacturers nowadays must contend with rising consumer demand and fierce competition for timely delivery of high-quality goods at affordable costs. But the assembly line was not productive at the required rate and capacity due to assembly line delay constraints. However, some workstations in the production line would be delayed. In the as...
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