PROCESS CAPACITY IMPROVEMENT BY EQUIPMENT AND OPERATIONS CONTROL RATIOS IN DE-HUSKING LINES OF SMALL-SCALE RICE PROCESSING FACTORIES

Celestine Nnaemeka Achebe; Stephen Chijioke Nwanya; Samuel O. Enibe

doi:10.4314/njt.v43i2.8

Authors

C. N. Achebe Department of Mechanical Engineering, University of Nigeria, Nsukka
S. C. Nwanya Department of Mechanical Engineering, University of Nigeria, Nsukka
S. O. Enibe Department of Mechanical Engineering, University of Nigeria, Nsukka

DOI:

https://doi.org/10.4314/njt.v43i2.8

Keywords:

Control Ratios, Process Capacity, Small-scale, Rice processing, Operations effectiveness, Equipment availability, Process improvement

Abstract

Inadequate knowledge of equipment and operations control ratios which contribute largely to low process capacity in the de-husking lines of small-scale rice processing factories is one of the critical challenges to improving rice processing in Sub-Saharan African countries, particularly Nigeria where capacity deficit leads to rice importation. This study seeks to empirically investigate equipment and operations control ratios in de-husking lines of small-scale factories in order to explore their potential and improve process capacity. The objectives are to determine the equipment and operations effectiveness, identify the root causes of inefficiency, and prioritize improvement efforts in the de-husking lines. The study was carried out in 10 selected factories of a milling cluster where production data for 2017-2022 was collected to complement data obtained through direct observation during processing hours and structured interviews. Microsoft Excel and Scilab software were used for data analysis based on existing models and other mathematical models developed for this study. Fluctuations observed in the process capacities of the de-husking lines from 2017-2022 indicated variabilities in equipment availability and performance. The overall equipment effectiveness (OEE) was generally below 50% which indicates production losses caused by frequent downtime and reduced speed of the machines. The overall operations effectiveness (OOE) were below 40%, and that implies the de-husking lines do not respond well to unscheduled downtime or unexpected tasks to reduce downtime for process capacity improvement. Tracing other potential to be unlocked to improve process capacity with the existing machines in the de-husking lines; the total effective equipment performance (TEEP) values were found below 25%, leaving 75% potential to be unlocked. Reliability modelling before machine installation, preventive maintenance, extended work scheduling, continuous training of workforce to reduce delays in equipment repairs are some of the measures to increase machine availability and improve process capacity in de-husking lines of small-scale rice processing factories.

Author Biographies

S. C. Nwanya, Department of Mechanical Engineering, University of Nigeria, Nsukka

Professor of Industrial Engineering and Management,

Department of Mechanical Engineering,

University of Nigeria, Nsukka.
S. O. Enibe, Department of Mechanical Engineering, University of Nigeria, Nsukka

Professor of Energy and Power Technology,

Department of Mechanical Engineering,

University of Nigeria, Nsukka.

References

Abbas, A. M., Agada, I. G., and Kolade, O. “Impacts of Rice Importation on Nigeria’s Economy”, J. Sci. Agric., 2018; vol. 2, pp. 71-75; doi: 10.25081/jsa.2018.v2.901.

KPMG, “Rice Industry Review,” 2019; pp. 40, [Online]. Available: https://assets.kpmg/conten t/dam/kpmg/ng/pdf/audit/rice-industry-review. pdf. Retrieved: 17th April, 2022.

Rose, F., Aliou, D., and Vincent, F. “Comparative analysis of rice milling strategies: Evidence from rice millers in Benin”, African J. Agric. Res., 2014; 9(36), pp. 2765–2774; doi: 10.5897/ajar2014.8782.

Ibrahim, Y. T., Iya, S. A., Aliyu, B., and Kabri, H. U. “Modeling Rice Brain Cleaning Process in a Stationary Destoner”, Journal Agric. Eng. Technol., 2019, 24(1), pp.29–34.

Federal Ministry of Agriculture and Rural Development, “National rice development strategy II (2020-2030) Report”, 2020, [Online]. Available: https://riceforafrica.net/w p- content/uploads/2022/02/nigeria_nrds2.pdf. Retrieved:25th July, 2023.

Nzeka, U., Taylor, J., and Trego, R. “Nigeria Grain and Feed Annual Report”, 2019, [Online]. Available:https://apps.fas.usda.gov/n ewgainapi/api/report/downloadreportbyfilename?filename=Grain%20and%20Feed%20Annual_Lagos_Nigeria_5-6-2019.pdf. Retrieved: 1st January, 2023.

Saniso, E., Prachayawarakorn, S., Swasdisevi, T., and Soponronnarit, S. “Parboiled rice production without steaming by microwave-assisted hot air fluidized bed drying”, Food Bioprod. Process., 2020, vol. 120, pp. 8–20; doi: 10.1016/j.fbp.2019.12.005.

Chakrovorty, R. S., Roy, R., Forhad, H. M., Alam, R., Zinnah, M. A., Moniruzzaman, M., and Saha, B. “Modification of conventional rice parboiling boiler to enhance efficiency and achieve sustainability in the rice parboiling industries of Bangladesh”, Process Saf. Environ. Prot., 2020, vol. 139, pp. 114–123; doi: 10.1016/j.psep.2020.04.024.

Wincy, W. B., and Edwin, M. “Techno ‐ economic assessment on the implementation of biomass gasifier in conventional parboiling rice mills”, 2019, pp. 1–15; doi: 10.1002/er.4991.

Wincy, W. B., Edwin, M., and Sekhar, S. J. “Energy and exergy evaluation of rice processing mills working with biomass gasifier in parboiling process,” Fuel, 2020, vol. 259, pp.1-510; doi: 10.1016/j.fuel.2019.116255.

Kwo, E. M., Ngadi, M., and Mainoo, A. “Energy for Sustainable Development Local rice parboiling and its energy dynamics in Ghana”, Energy Sustain. Dev.,2016, vol. 34, pp. 10–19; doi: 10.1016/j.esd.2016.06.007.

Nguyen-Van-Hung, Tran-Van-Tuan, Meas, P., Tado, C. J. M., Kyaw, M. A., and Gummert, M. “Best practices for paddy drying: case studies in Vietnam, Cambodia, Philippines, and Myanmar”, Plant Prod. Sci., 2019, 22(1), pp. 107–118; doi: 10.1080/1343943X.2018.15435 47.

Mondal, M. H. T., Shiplu, K. S. P., Sen, K. P., Roy, J., and Sarker, M. S. H. “Performance evaluation of small scale energy efficient mixed flow dryer for drying of high moisture paddy”, Dry. Technol.,2019, 37 (12), pp. 1541–1550; doi: 10.1080/07373937.2018.1518914.

Taghinezhad, E., Szumny, A., Kaveh, M., Sharabiani, V. R., Kumar, A., and Shimizu, N. “Parboiled paddy drying with different dryers: Thermodynamic and quality properties, mathematical modeling using ANNs assessment”, Foods, 2020, 9 (1), pp. 1–17; doi: 10.3390/foods9010086.

Orge, R. F., Sawey, D. A., Leal, L. V., and Gagelonia, E. C. “Re-engineering the paddy rice drying system in the Philippines for climate change adaptation”, Dry. Technol.,2020, 38 (11), pp. 1462–1473; doi: 10.1080/07373937.2 019.1648289.

Van Hung, N., Martinez, R., Van Tuan, T., and Gummert, M. “Development and verification of a simulation model for paddy drying with different flatbed dryers”, Plant Prod. Sci., 2019, 22 (1), pp. 119–130; 2019, doi: 10.1080/1343943X.2018.1518723.

Olatunde, G. A., Atungulu, G. G., and Smith, D. L. “One-pass drying of rough rice with an industrial 915 MHz microwave dryer : Quality and energy use consideration.”, Biosyst. Eng., 2016 vol. 155, pp. 33–43; doi: 10.1016/j.biosys temseng.2016.12.001.

Folami, A., Chinweike, K., Ayobami, A., and Olasunkanmi, S. “Effectiveness of industrial rubber as roller material for rice processing machine”, Agric. Nat. Resour.,2020, vol. 54, pp. 98–104; doi: https://doi.org/10.34004/j.anre s.2020.52.1.14.

Das, A. K., Saha, C. K., and Alam, M. M. “Evaluation of traditional rice husking mill Evaluation of a Traditional Rice Husking Mill”, J. Agric. Machanization Bioresour. Eng., 2016, 7(1), pp. 41–46.

Firouzi, S., Alizadeh, M. R., and Minaei, S. “Effect of rollers differential speed and paddy moisture content on performance of rubber roll husker”, World Acad. Sci. Eng. Technol., 2016, vol. 47, pp. 687–690.

Dhankhar, P. “Rice Milling”, IOSR J. Eng.,2014, 4(5), pp. 34–42; doi: 10.9790/3021-04543442.

Gana Yisa, M., Fadeyibi, A., Kayode Katibi, K., and Ucheoma, O. C. “Performance Evaluation and Modification of an Existing Rice Destoner”, Int. J. Eng. Technol. IJET, 2017, 3(3), pp. 169–175; doi: 10.19072/ijet.329 078.

Olusegun, J., Emeka, O. C., and Afolabi, O. A. “Development of a motorized rice de-stoning machine”, Agric Eng. Int. CIGR Open Access, 2018, 20(4), pp. 202–209.

Wolniak, R. “Main functions of operation management,” Prod. Eng. Arch., 2020, 26(1), pp. 11–14; doi: 10.30657/pea.2020.26.03.

Sushil, G., and Starr, M. "Production and operations management systems", Prod. and Op. Mgt. Sys, 2014; pp. 1-475; doi: 10.1201/b1 6470.

Jagadeesh, R. “Optimizing the Capacity Addition in a Component Manufacturing Industry – an Empirical Investigation”, Contemp. Res. Manag., 2016, vol. 5, pp. 334–366.

Singh, M., Rathi, R., and Singh Kaswan, M. “Capacity utilization in industrial sector: a structured review and implications for future research”, World J. Eng.,2022,19(3), pp. 310–328; doi: 10.1108/WJE-09-2020-0447.

Raguram, R. “Implementation of Overall Equipment Effectiveness (OEE)”, Middle -East J. Sci. Res., 2014, 20(5), pp. 567–576; doi: 10.5829/idosi.mejsr.2014.20.05.11336.

Winatie, A., Maharani, B. P., and Rimawan, E. “Productivity Analysis to Increase Overall Equipment Effectiveness (OEE) by Implemen-ting Total Productive Maintenance”, Int. J. Innov. Sci. Res. Technol., 2018, 3(12), pp. 433–439, 2018.

Palanisamy, V., and Vino, J. A. “Implementing Overall Equipment Effectiveness in a Process Industry”, Indian J. Sci. Technol., 2013, 6(6), pp. 2–6.

Clements, E. J., Sonwaney, V., and Singh, R. K. “Measurement of Overall Equipment Effectiveness to Improve Operational Efficien-cy”, Int. J. Process Manag. Benchmarking, 2018, 8(2), pp. 246-261; doi: 10.1504/ijpmb.20 18.10010267 .

Prayogo, A. “Analysis of Total Effective Equipment Performance SD5 Machine on Krosok Production Line, Primary Manufacturing Department. (Case Study: PT NT)”, J. of Indust. Eng. and Technol., 2020, 1(1), pp. 1-10.

Joseph, A., and Jayamohan, M. S. “Evaluation of Overall Equipment Effectiveness and Total Effective Equipment Performance”, Int.J. of Adv. Eng. and Res., 2017, 4(5), pp. 343-346.