al_najah national university faculty of engineering industrial engineering department

Al_Najah national universityFaculty of Engineering

Industrial Engineering Department

Haneen Abu Rasis Rabia Tahboosh Sajeda Sarsoor Yasmeen Aqoobeh

Dr . Ayham Jaaron

AL-Arz Company

From our humble begging in1950 , producing ice in order to cool water and store food

at the time when electricity didn’t exist , Al Arz company has evolved to be the leader

of frozen treats market in Palestine . Since its establishment by the late Mohammad

Anabtawi in Nablus – Palestine , AL- Arz grew in to a successful producer of high

quality extruded ice-cream products.

In 2007 , the company started its first step towards exporting, where Jordan was its first

station. That was after it acquired the Palestinian quality certificate .

Tow years later, the company acquired the global food safety certificate HACCP. This

achievement was a Palestinian industrial pride, since AL ARZ was the first company

that acquires this certificate among the ice cream and dairy manufactures in Palestine

and Jordan.

History of Al -Arz Company

Maintenance Any activity, such as tests, measurements, replacements, adjustments and

repairs, intended to restore or retain a functional in a specified state in

which the unit can perform its required function

Types of Maintenance

Preventive maintenance

Corrective maintenance

Maintenance Management System in AL-Arz Company

 Sources of Data Collection 

Data information was taken from Al-Arz company by this ways: By making frequent visits to the factory and observe the

process of maintenance. By the manager of Research and Development Department

(R&D).By help from maintenance manager (Mechanical engineer).

Flow Chart

Turning point for maintenance management system in AL-Arz Company

 The turning point that occurred due to this project is to shift maintenance

management system in the factory from manually system to an integrated

computerized system using the program " Microsoft office Access " , which led to

saving time, effort and increase accuracy in the process of information storage and

retrieval speed . Plant need for Computerized Maintenance to demonstrates the

flow chart from start to finish or from the time of the failures until the system

return to work again, explaining the steps and tools and spare parts used and the

engineer in charge of maintenance process.

The turning point is to convert (MMS) to (CMMS)

Performance Analysis

Types of failures analysis:This part talks about the types of failures (Mechanical, Electrical, general

maintenance services, and Structural).

Type of failure with frequency: This section shows the relation between each type of failure (Electrical,

Mechanical, Structural, and general maintenance services) and their

frequencies in general, and the relation between each type of failure with its

frequency.

4 12107 3.3 9.887.0

100.0 96.7 87.0

100

50

0

100

80

60

40

20

0

DefectCount

PercentCum %

Perce

nt

freq

uenc

ythe type of failure with their frequency

نوع العطل التكرارية

ميكانيكي 107

كهربائي 12

إنشائي 3

خدمات عامه 1

Mechanical failures:

الزمنيه الفتره التكراريه

1\1\10-28\2\10 20

1\3\10-30\4\10 34

1\5\10-30\6\10 16

1\7\10-31\8\10 16

1616203418.618.623.339.5

100.0 81.4 62.8 39.5

90

80

70

60

50

40

30

20

10

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

Cou

nt

mechanical maintenance

Electrical failure

1236 8.316.725.050.0

100.0 91.7 75.0 50.0

10

5

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

electrical maintenanceالزمنيه الفتره لتكراريها

1\1\10-28\2\10 3

1\3\10-30\4\10 6

1\5\10-30\6\10 2

1\7\10-31\8\10 1

Structural failure: 

1233.366.7

100.0 66.7

3

2

1

0

100

80

60

40

20

0

DefectCount

PercentCum %

Perce

nt

freq

uenc

y

structural maintenance

الزمنية الفترة التكرارية

1\2\10-30\3\10 2

1\4\10-30\5\10 1

 Type of failure in machine with

frequency

3 1 1 2 3 3 5 81723 4.5 1.5 1.5 3.0 4.5 4.5 7.612.125.834.8

100.0 95.5 93.9 92.4 89.4 84.8 80.3 72.7 60.6 34.8

60

50

40

30

20

10

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

machine name with frequencyالماكنه اسم التكراريةالشفاط 3

العيدان ماكنه 2التغ*ليف ماكنه 17

البركه 8

الشراب مضخه 1نفاش 23

الشوكالته ماكنه 3الديليه ماكنه

هوير 1الزيت مضخه 1

الكاسات ماكنه 5مضخه الشوكالته 1

الماء مضخه 1

Mechanical failure (machine name with frequency).

Electrical failure (machine name with frequency).

11112212.512.512.512.525.025.0

100.0 87.5 75.0 62.5 50.0 25.0

8

7

6

5

4

3

2

1

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

machine name with frequencyالماكنه اسم التكرارية

النفاشه 1

التغليف ماكنه 1

خزان 2

البركه 1

الشوكالته ماكنه 2

الشوكالته مضخه 1

Machine failure:

All machines, all kinds of failure and time of failure occurrence for each kind of failure

kind of failure for each machine with frequency:

This section shows the relation between all kind of failure for each machines and its frequency.

الشفاط

1233.366.7

100.0 66.7

3

2

1

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

alshfat

العطل التكرارية

طبيعي غير صوت 2

بستون كسر 1

ماكنه التغليف

11112358 4.5 4.5 4.5 4.5 9.113.622.736.4

100.0 95.5 90.9 86.4 81.8 72.7 59.1 36.4

20

10

0

100

80

60

40

20

0

DefectCount

PercentCum %

Perce

nt

freq

uenc

y

packaging machine السكاكين تغير 8

بمجموعه خللالورق سحب 2

بيل تغير 3

جنزير تغير 2

عين تغير 1

العجالت خلل 1

قشط قطع 1

معايره في خلل 1

النفاشة

1 1 2 812 4.2 4.2 8.333.350.0

100.0 95.8 91.7 83.3 50.0

25

20

15

10

5

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

alnfash machineالعطل التكراريهتسيل 8

تبريد مشكله 1

اسفل صوتالنفاش 2

واللبدات بيل 12

القشط عطل 1

مضخه عطل 1

بالحامل عطلالسكين 1

Period of failure time with frequency

1233.366.7

100.0 66.7

3

2

1

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

alshfat

زمنيه فتراتالعطل فيها يحدث التكرارية

1\1\10-28\2\10 2

1\3\10-30\4\10 1

الشفاط

التغليف ماكنة

334816.716.722.244.4

100.0 83.3 66.7 44.4

15

10

5

0

100

80

60

40

20

0

DefectCount

PercentCum %

Perce

nt

ferque

ncy

packaging machine يحدث زمنيه فتراتالعطل فيها التكرارية

1\1\10-28\2\10 4

1\3\10-30\4\10 8

1\5\10-30\6\10 3

1\7\10-31\8\10 3

النفاشات

5 51025.025.050.0

100.0 75.0 50.0

20

10

0

100

80

60

40

20

0

DefectCount

PercentCum %

Per

cent

freq

uenc

y

alnafashat

يحدث زمنيه فتراتالعطل فيها التكرارية

1\1\2010-30\4\2010 10

1\5\2010-30\9\2010 5

1\10\2010-28\2\2010 5

Results of analysis:1-More failures in most time occur on Saturday because in Fridays there is no maintenance for the machines.

2-There are high differences of frequency from period to other because neglecting the documentation of all maintenance reports. 3-More failures are occur in packaging machine andالنفاشه""machine, because this two machine have the highest use in this company. 4-The highest frequency is in the period from (1\1\2010-30\4\2010) because this period are the beginning season (high production), and the machines work for long time in this period

 Recommendation:

1 .Al -Arz company is highly advised the new model (CMMS) that can be easily managed by their managers and operators.

2 .To Convert manual system of maintenance to computerized system.3 .It must be good documentations of maintenance report.

4 .It must be a good contact between Managers and employees.