Analysis of Kaizen Implementation in Northern Ethiopia’s Manufacturing Industries

The Kaizen manufacturing processes in Japan have revolutionized the way enterprises deliver products to their customers. Given ambitions to advance, retain market share, and satisfy their domestic market while expanding into the international market, it has become a dream for many manufacturing companies similar to Japanese manufacturing enterprises to build a culture of continuous improvement. In other words, a number of foreign companies are striving to acquire the habit of improvement using kaizen, as well as to focus on a customer-driven strategy to improve productivity and the quality of products and services by continuously amassing marginal improvements over time. Mapping out a survey questionnaire, interviews, direct observation of the personnel who were directly involved with the implementation process, the effects of the newly introduced kaizen techniques at three case factories from the Northern Ethiopia were assessed. Based on key performance indicators that specifically relate to inputs, outputs and process factors of the kaizen management system the three pilot case companies were assessed to determine if 1) top managers and employees have a genuine concern for the short and long-term health of the company, 2) the companies’ work teams have a mindset for action, 3) employees are committed to the companies’ value systems, and 5) the employees’ suggestions are used as leverage for improvement in the production process. The study found that the three pilot companies have reduced the costs of production, improved quality, reduced lead time, improved customers’ satisfaction and have partially achieved three out of five (5S) kaizen steps: sorting, setting, and shining, but they have not yet achieved how to standardize and sustain self-discipline. The study also established that the executives of the three pilot cases don’t seem to be committed to the kaizen teamwork. Though vital for continuous improvement, the front line workers are rarely asked to participate as a team

Effects of acidity, number of hydroxyl group, and carbon chain length of carboxylic acids on starch cross-linking

Corn starch film samples cross-linked using malic, malonic, and succinic acids, and thermoplastic starch were characterized and tested for their water absorption, surface morphology, structural change, and thermomechanical properties. The acids vary in acidity, number of hydroxyl groups, and carbon chain length. The presence of an additional hydroxyl group has helped malic acid form more hydrogen bonding between starch molecules. The relatively higher acidity in malic acid compared to succinic acid is found to be another factor for its better cross-linking potential. The additional carbon chain in succinic acid, which reduces its solubility and acidity; has negatively affected its cross-linking potential. Among the three variables studied, number of hydroxyl group has highly influenced the cross-linking potential, followed by acidity and carbon chain length, respectively. Consequently, the elongation at break and water absorption resistance of thermoplastic starch were improved from 108.63 ​MPa to 175.72 ​MPa and from 140% to 80%, respectively, cross-linking corn starch with malic acid

Briquetting of Charcoal from Sesame Stalk

Due to the easy availability of wood in Ethiopia, wood charcoal has been the main source fuel for cooking. This study has been started on sesame stalk biomass briquetting which can potentially solve the health problems and shortage of energy, which consequently can solve deforestation. The result of the data collection shows that, using 30% conversion efficiency of carbonizer, it was found that more than 150,000 tonnes of charcoal can be produced from the available sesame stalk in Humera, a place in north Ethiopia. The clay binders that are mixed with carbonized sesame stalk were found to have 69 liquid limits; thus, the optimum amount of clay that should be added as a binder is 15%, which results in better burning and heat holding capacity and better heating time. The developed briquetting machine has a capacity of producing 60 Kg/hr but the carbonization kiln can only carbonize 3.1 Kg in 2 : 40 hours; hence, it is a bottle neck for the briquette production. The hydrocarbon laboratory analysis showed that the calorific value of the charcoal produced with 15% clay content is 4647.75 Cal/gm and decreases as clay ratio increases and is found to be sufficient energy content for cooking

Development and Characterization of Sisal Fiber Reinforced Polypropylene Composite Materials

In most of the developing countries, plastic polypropylene is not fully recycled and converted in-to use after it is once used. Sisal fiber is also widely available in different developing countries like Ethiopia. Adding this two materials and developing automotive interior part was taken as a primary motive for it reduces cost and is environmentally friendly. Thus, the main purpose of this research is to develop composite material from natural fibre (sisal fiber) reinforced with recycled plastic waste (polypropylene) for interior automobile accessories specifically for internal door trim panel application. This research examines effect of fiber length, fiber loading and chemical treatment of fiber on the physical and chemical properties of the sisal fiber reinforced polypropylene (SFRPP) composite material. The waste polypropylene and the treated and untreated sisal fiber with variable length and weight ratio (fiber/matrix ratio) were mixed. Flammability of sisal fiber reinforced Polypropylene (SFRPP) composites material was examined by a horizontal burning test according to ASTM D635 and chemical resistance of the sisal fibre reinforced PP composites was studied using ASTM D543 testing method. The result on the flammability test shows that treated fiber has lower burning rate than untreated fiber and decreases with increase in fiber length and fiber loading. The resistance of the composites to water has increased as the fiber length increases and decreased as the fiber loading increase. Generally, SFRPP composite is found to have better resistance to water than NaOH and H2SO4 and treating the fiber has brought considerable improvement on chemical resistance of the composite. Fiber loading and fiber length has positive and negative effect on the flammability of the SFRPP composite respectively