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
DOI:
10.11648/j.ie.20250902.11
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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
DOI:
10.11648/j.ie.20250902.12
Downloads:
Views:
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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