evaluation of farm machinery - University of Khartoum ...

EVALUATION OF FARM MACHINERY

SERVICES MANAGEMENT IN NEW HALFA

AGRICULTURAL SCHEME (SUDAN)

By

Ahmed Khalifa Idris Elbashir

B.Sc. (Agric.)-Honours

University of Khartoum

1984

A thesis submitted to the University of Khartoum in partial fulfillment

for the requirement of the Degree of Master of Science in Agricultural

Engineering.

Supervisor

Dr. Mohammed Hassan Dahab

Department of Agric. Engineering

Faculty of Agriculture

University of Khartoum

November-2003

To the souls of my parent…………………………….

To my beloved children Mohammed, Zienab and Husam….

To my great wife (Amal)……………………………...

With love

First, of all I am grateful to Allah for his great blessings.

My sincere thanks and gratitude to my supervisor Dr.

Mohammed Hassan Dahab for his advice, interest, encouragement and

leadership throughout this study.

I am indebted to my colleagues in Agricultural Engineering

Department in New Halfa Agricultural Scheme for their appreciated

help.

Due thanks are to the staff of Engineering Department,

Faculty of Agriculture, University of Khartoum.

My thanks are also due to Ala Eldeen, Mahmoud and El zaki

for their help in typing of this research.

More thanks to my relatives and friends for their supports and

encouragement.

Finally, the financial support from the New Halfa Agricultural

Production Corporation is highly acknowledged.

Table of Contents

Dedication…………………………………………………………….. i

Acknowledgement……………………………………………………. ii

Table of contents……………………………………………………... iii

List of tables……………………………………………………….…. viii

List of figures………………………………………………………..... ix

Abstract……………………………………………………………….. x

Arabic abstract………………………………………………………... xii

CHAPTER ONE: INTRODUCTION……………………..…………. 1

CHAPTER TWO: LITERATURE REVIEW ………………………... 4

2.1 Agricultural mechanization………………………………………. 4

2.2 Agric. Farm machinery management………………………….…. 5

2.2.1 Importance of machinery management……………..……….…. 5

2.2.2 Organization of machinery services………………..…………... 6

2.2.3 Workshops for shelter and services……………………..……… 7

2.2.3.1 Type of utility buildings (Building designs)………………….. 7

2.2.3.2 Workshop location…………………………………………..... 9

2.2.3.3 Workshop size………………………………………………... 9

2.2.3.4 Workshop components…………………………………….…. 11

2.2.3.5 Workshop construction……………………………………….. 13

2.2.3.6 Workshop objectives ………………………………………… 18

2.2.3.7 Workshop layout……………………………………………… 19

2.2.3.8 Workshop tools and equipment………………………………. 20

2.2.3.9. Spare parts and supplies stores organization………………… 21

2.2.3.9.1 Stores layout and equipment………………………………... 21

2.2.3.9.2 Stock control procedures…………………………………… 22

2.2.3.9.3 Supply of spare parts…………………………………….…. 22

2.2.3.10 Care and maintenance in workshops…………………….….. 23

2.2.4 Farm machinery costing………………………………………... 30

2.2.4.1 Machinery life……………………………………………….... 30

2.2.4.2 Machinery costs…………………………………………......... 30

2.2.4.2.1 Fixed costs………………………………………………….. 31

2.2.4.2.2 Running costs………………………………………………. 34

2.2.5 Field performance of farm machinery……………..………...…. 36

2.2.6 Field operation cost………………………………………….…. 39

CHAPTER THREE: MATERIALS AND METHODS……………… 41

3.1 Materials………………………………………………………….. 41

3.1.1 Location………………………………………………………… 41

3.1.2 Sources of data………………………………………………….. 41

3.1.3 Types of data collected…………………………………………. 41

3.2 Methods…………………………………………………………... 43

3.2.1 Evaluation of workshop location……………………………….. 43

3.2.2 Evaluation of workshop design and construction……………..... 43

3.2.3 Evaluation of workshop tools and equipment………………...... 43

3.2.4 Evaluation of workshop personnel……………………………... 44

3.2.5 Evaluation of workshop spare parts and supplies……………..... 44

3.2.5.1 The main store layout…………………………………...……. 44

3.2.5.2 Stock procurement policy…………………………………..... 44

3.2.5.3 Stock control procedures………………………………….…. 45

3.2.6 Evaluation of workshop organized services…………………..... 45

3.2.6.1 Services given through tractors, combine harvesters and agric.

implements sections…………………………………………………...

45

3.2.6.2 Evaluation of other workshop services……………………….. 46

3.2.7 Estimation of farm machinery services and repair and

maintenance costs……………………………………………………..

46

3.2.7.1 Data analysis procedure for Ford and Cater pillar tractors…… 46

3.2.7.2 Data analysis procedure for combine harvester……………..... 49

3.2.7.3. Data analysis procedure for agric. implements……………… 49

CHAPTER FOUR: RESULTS AND DISCUSSIONS………………. 51

4.1 Workshop location………………………………………………... 51

4.2 Workshop design and construction……………………………….. 51

4.2.1 Improvements in workshop design…………………………….. 63

4.3 Workshop personnel……………………………………………… 65

4.3.1 Project director…………………………………………………. 65

4.3.2 Workshop senior staff…………………………………………... 65

4.3.2.1 Agric. Engineering Department manager…………………….. 68

4.3.2.2 Workshop manager assistant for field operations…………….. 68

4.3.2.3 Workshop and field sections engineers…………………....…. 68

4.3.2.4 Storekeepers…………………………………………………... 69

4.3.2.5 Accountants………………………………………………..…. 69

4.3.2.6 Clerks………………………………………………………..... 69

4.3.3 Operators…………………………………………………….…. 70

4.3.4 Mechanics……………………………………………………..... 70

4.3.5 Improvement to be organized…………………………………... 72

4.4 Workshop tools and equipment…………………………………... 77

4.4.3 Improvements in equipments…………………………………… 78

4.5 Spare parts and supplies store management……………………… 78

4.5.1 Procurement policy……………………………………………... 78

4.5.2 Spare parts store layout………………………………………..... 79

4.5.3 Stock control procedures…………………………………….…. 82

4.5.3.1 Stock control card…………………………………………...... 82

4.5.3.2 Order form……………………………………………………. 82

4.5.3.3 Parts issue………………………………………………….…. 82

4.5.3.4 Receipt order………………………………………………...... 83

4.5.3.5 Audit procedure……………………………………………..... 83

4.5.4 Requirements…………………………………………………… 84

4.6 Care and maintenance in the main workshop…………………….. 84

4.6.1 Services through Ford Tractors section……………………….... 84

4.6.2 Services through Caterpillar tractors section………………….... 88

4.6.3 Services through Combine harvesters section………………….. 92

4.6.4 Services through agric. implements section…………………..... 94

4.6.5 Other workshop services…………………………………….…. 96

4.6.5.1 Battery and electricity unit………………………………...…. 96

4.6.5.2 Sheet metal and welding and blacksmith section………….…. 96

4.6.5.3 Sheltering of farm machinery……………………………..….. 97

4.6.6 Improvements…………………………………………………... 97

4.7 Estimation of repair and maintenance costs………………...….... 99

4.7.1 Repair and maintenance costs of Ford and Caterpillar

tractors………………………………………………………………...

99

4.7.2 Repair and maintenance costs of combine harvesters……….…. 101

4.7.3 Repair and maintenance costs of agric. implements…………..... 102

CHAPTER FIVE: CONCLUSIONS AND RECOMMENDATIONS.. 105

5.1 CONCLUSIONS…………………………………………………. 105

5.2 RECOMMENDATIONS…………………………………………. 106

References……………………………………………………………. 107

Appendices…………………………………………………………… 113

List of Tables

Table 2.1: The annual cost of spares and repairs as percentage of purchase price at various levels of use of farm machinery……………

37

Table 3.1 Specifications of tractors…………………………………... 47 Table 3.2 Specifications of combine harvesters……………………… 50 Table 4.1 Distances of small farm shops (Block workshops) from the main workshop……………………………………………………...

52

Table 4.2 Senior staff qualifications and their salaries per month...…. 67 Table 4.3a Age profile of operators…………………………………... 71 Table 4.3b Educational status of operators…………………………… 71 Total 4.3c. Operational knowledge and training of operators………... 71 Table 4.4a. Educational status of mechanics…..……………………... 73 Table 4.4b. Training of mechanics ………………………………….. 73 Table 4.4c. Experience of mechanics………………………………… 73 Table 4.4d. Skills in repairing and maintaining of mechanics……... 73 Total 4.5 Total No. of the present and suggested operators and their salaries per month……………………………………………………..

75

Table 4.6 Total No. of the present and suggested mechanics and their salaries per month……………………………………………………..

76

Table 4.7 Annual costs of spare parts from (1999 to 2002)………... 80 Table 4.8 Annual lubricants consumption of Ford tractor…………. 86 Table 4.9 Total No. of Ford tractors and their present situation…… 87 Table 4.10 Total No. of caterpillar tractors and their present situation. 89 Table 4.11 Total No. of working Cat. Motor graders and their average annual hours of use per tractor……………………………...

91

Table 4.12 Total No. of combine harvesters, No. of them in work and their annual hours of use ……………………………………………...

93

Table 4.13 Types and No. of agric. implements and their present status…………………………………………………………………..

95

Table 4.14 Average annual hours of use and average R&M costs per hour for Ford and Cater pillar tractors………………………………...

100

Table 4.15 Average annual repair and maintenance cost of combine harvester……………………………………………………………………..

103

Table 4.16 Average annual hours of use of agric. implements and their averages annual R&M costs per hours………………...………...

104

List of Figures

2.1 Types of utility buildings ………………………………………… 10

2.2 Narrow spans and wide spans types of farm built framing ……... 14

2.3 Narrow spans and wide spans types of commercial framing ……. 15

3.1 New Halfa agric. Scheme with the main workshop sited at the

corner of the City…………………...…………………….…………...

42

4.1 Diagram of the main workshop ……………………………….…. 53

4.2 Floor plan of the Ford tractors workshop..……………………….. 55

4.3 A floor plan of the combine harvesters section…………………... 56

4.4 A side view of agric. implements and welding and blacksmith

shops…………………………………………………………………..

58

4.5 A floor plan of the sheet metal, testing and battery shop………. .. 59

4.6 A side view of the sheet metal, testing and battery shop ……...… 60

4.7 A floor plan of the spare parts store……………………………… 62

4.8 A floor plan of the suggested caterpillar tractors section………… 64

4.9 The workshop personnel organization including the suggested

training section ……………………………………..…….…………..

66

4.10 layout of the main spare parts store……………………………... 81

4.11 Improper storing of Ford tractors…………………………….…. 98

ABSTRACT

The study was conducted at New Halfa Agricultural Scheme to

evaluate the machinery services management in the main workshop,

and accordingly to suggest improvements to the present state after

investigating the problems that adversely affect farm machinery

services in the Scheme. A survey was carried out in the main

workshop, other farm shops and in the field to collect data about the

efficiency and performance of machinery and their averages repair and

maintenance costs during the last four years (1999-2002), and also

about the personnel recruited to take care of them, tools and

equipment used, stock control procedures and types of buildings used

in the main workshop sections.

Analysis of data indicated that about 72%of wheeled and

tracked tractors and about 78% of agricultural implements were out of

work due to unavailability of spare parts and improper management

and maintenance of machinery. Also it was observed that operators,

mechanics and engineers were not adequately trained to do their

particular jobs properly, and about 44% of operators and mechanics

were idle, and therefore increasing the operating costs.

Types of buildings, roofing and siding materials used were

sufficient in providing better work conditions for services personnel.

The workshop was well equipped with basic tools and equipment, and

also with specialized power equipment, but hand tools used are not

genuine parts and usually lead to lose of time and improper execution

of work. Stock control procedures used in spare parts and supplies

stores were efficient in keeping stores organization under close

control. Accurate estimation of repair and maintenance costs of farm

machinery was difficult because accurate records over the lifetime of a

machine are usually not readily available. In this study the estimated

repair and maintenance costs were greatly influenced by the age and

annual hours of use of machines.

Suggested measures to improve the present state of farm

machinery services include; improved training programs for the

operators and mechanics, supply of sufficient spare parts to keep

machines always in work, execution of trade-in programs and using

their scrap values in overhauling of broke down machines and gradual

replacement of old machines to guarantee high annual hours of use of

machines and reduce the costs of farm operations and then increase

productivity per unit area and time.

خالصـــة األطروحة

أجريت هذه الدراسة بمشروع حلفا الجديدة الزراعية لتقييم إدارة خدمات اآلالت

بالورشة الرئيسة بالمشروع، ووفقًا لذلك اقتراح التحسينات للوضع الراهن لخدمات تلك

. اآلالت بعد بحث المشاآل التي تؤثر عكسيًا علي خدماتها في المشروع

تمت معاينة الورشة الرئيسة والورش الزراعية األخرى كما تمت معاينة اآلالت الزراعية بالغيط وذلك بغرض جمع المعلومات عن كفاءة وأداء هذه اآلالت ومعرفة

. م 2002م وحتى 1999متوسطات تكاليف اإلصالح والصيانة خالل الفترة من كما تم جمع معلومات عن العاملين الذين تم تعيينهم لرعاية هذه اآلالت ،

واألدوات والمعدات المستعملة داخل الورشة، الطرق المتبعة في إدارة المخزونات، ونوعية المباني والمواد التي استعملت لبناء األسقف والحوائط الجانبية ألقسام الورشة

. الرئيسةمن الجرارات المزودة بلسانك والمجنزرة % 72أظهرت النتائج أن حوالي من اآلالت الزراعية خارج العمل ، وذلك لعدم توفر قطع الغيار وسوء % 78وحوالي

ت والميكانيكية كما أظهرت النتائج أيضا بان سائقي الجرارا. اإلدارة والصيانة لهذه اآلالتوأن , والمهندسين لم يتلقوا التدريب الكافي الذي يؤهلهم ألداء مهامهم بالصورة المطلوبة

. من السائقين والميكانيكية بدون عمل وهذا أدى ألي زيادة تكاليف التشغيل% 44حوالي الحوائط الجانبية كافية لمنح نوعية المباني والمواد المستعملة في األسقف و

تم تزويد الورشة باألدوات والمعدات األساسية كما تم تزويدها . العاملين مناخ صالح للعملبمعدات كهربائية خاصة، ولكن األدوات اليدوية المستعملة ليست أصلية وتؤدي إلضاعة

. الزمن وعدم إنجاز العمل بصورة جيدة بمخازن االسبيرات واإلمدادات جيدة وتساعد المخزونانالطرق المتبعة في إدارة

. في حفظ هذه المخازن تحت سيطرة محكمةهنالك صعوبة في تقدير تكاليف اإلصالح والصيانة لآلالت الزراعية بدقة نسبة

تتأثر تكاليف اإلصالح . بوطة لآللة التي تغطي عمرها لعدم توفر التسجيالت المضوالصيانة المقدرة لآلالت الزراعية في هذه الدراسة تأثيراً كبيراً بعمر وساعات االستعمال

.السنوية لهذه اآلالتتحسين : التدابير المقترحة لتحسين الوضع الراهن للخدمات بالمشروع تشمل

قطع غيار كافية لضمان استمرارية اآلالت في العمل، برامج التدريب للعاملين، توفير إنجاز برامج التخلص من الخردة واستغالل عائدها في إصالح اآلليات المعطلة واستبدال اآلالت القديمة تدريجياً بآالت جديدة لضمان زيادة ساعات العمل السنوية لآلالت وتخفيض

. ية علي وحدة المساحة والزمنتكاليف العمليات الزراعية وبالتالي زيادة اإلنتاج

CHAPTER ONE

INTRODUCTION

Agricultural mechanization plays a vital role in the agricultural

development. This is due to its great efficiency in increasing the

cropped areas, improving soil conditions, controlling of weed, and

increasing yields in quantity and quality by reason of the timeliness,

speed and effectiveness with which field operations are carried out,

(Meij 1960).

In the Sudan large numbers of farm tractors and implements

were imported to increase the crop production, so as to meet the

increasing demand for agricultural products for both human and

animal food. The challenge that faced the managers of farm

machinery and decision makers in the Sudan is how to keep all these

machines efficient and productive along their useful lives?

FAO (1985) reported that in developing countries there are

often conditions which limit the useful life of farm machinery to a

shorter period than in the developed countries; insufficient knowledge

and training, maintenance and servicing for instance, and adverse field

and climatic conditions.

Therefore much care must be taken by the machinery owners

and managers to keep their machines properly and in good condition.

This can be achieved by the availability of adequate facilities,

adherence to preventive maintenance, skilled operators, well trained

mechanics, and availability of spare parts when required.

New Halfa Agricultural Scheme (Sudan) is one of the

government agricultural projects which was provided with a great

number of combine harvesters, wheeled and crawler tractors, together

with different types of agricultural implements, including ridgers, disc

ploughs, disc harrows, wide level discs, ditchers, fertilizer distributors,

herbicide sprayers, ….etc. The main purpose of all these farm

machines is to improve timeliness of field operations and

consequently to increase the productivity of cropped area. The annual

cultivated area was about 160,000 fed., cropped with cotton as a cash

crop, dura, wheat, ground nut and recently introduced sunflower in the

rotation.

A large workshop has been established, provided with essential

tools and equipment and supported by small farm shops distributed

within the Scheme to give continuous services to all working

machines, and to cut down transport and traveling costs. An organized

staff including agricultural engineers, technicians, storekeepers,

operators and mechanics were employed to take care of these

machines. The workshop services given through separate specialized

sections. These sections are; Ford tractors, Caterpillar tractors,

agricultural implements, combine harvesters, sheet metal, welding and

blacksmith and spare parts and supplies sections.

In spite of the availability of all these facilities, most of the

tractors and agricultural implements in the Scheme were out of work

and lost their reliability. Dawelbeit and Ahmed (1987) attributed this

to the lack of maintenance, especially preventive maintenance and

unavailability of replacement parts. Also bad management and loosing

of skilled mechanics and operators affected the services accomplished

by the workshop.

The objectives of this study are:

1. To evaluate the present state of

workshop services for farm

machinery in New Halfa

Agricultural Scheme (Sudan)

through investigation of the

following;

i. Workshop location, design and construction.

ii. Personnel organization.

iii. Tools and equipment available.

iv. Spare parts and supplies stores management.

v. Repairs and maintenance of farm machinery and their

annual costs.

2. To suggest improvements for the

present state of farm machinery and

workshop services by pointing out

the problems that lead to poor

performance of farm machinery in

New Halfa Agricultural Scheme,

and stating solutions for them.

CHAPTER TWO

LITERATURE REVIEW

2.1 Agricultural mechanization:

Liljedhal et al (1979) reported that mechanization of agriculture

has two main objectives.

1. To increase the productivity per

agricultural area.

2. To change the character of farm

works and make it less arduous and

more attractive.

Butterworth and Nix (1983) reported that mechanization has the

following objectives.

1. Reduction in physical efforts.

2. Increasing returns in many ways.

i. Direct increase in yield, by controlling of

weeds and diseases.

ii. Indirect increase in yields, by improving

condition of the soil or tilth.

iii. Increased yields through timeliness.

iv. Increased price through higher quality.

v. Increased price through storage.

3. Reducing costs, by replacing labour.

2.2 Agric. farm machinery management:

2.2.1 Importance of machinery management:

Culpin (1975) reported that as far as mechanization is

concerned, good management involves (1) a choice of enterprises that

blend well together and are right for all the local conditions; (2) choice

of a set of equipment suited to the needs of the farm; (3) the

employment of sound operating techniques for using both individual

machines and matched sets of equipment; (4) attention to detailed

setting and adjustment to suit soil, crop and weather conditions, and

(5) a well planned system of maintenance and overhaul to ensure that

the equipment always in good working order. The last three of these

items depend for their execution on a sound labour management

policy. Stone and Gulvin (1967) mentioned that tractor and machinery

management means (1) Business management; includes important

decisions, plans and methods; such as selecting suitable types and

sizes of machines, determining the cost of using machines, keeping

cost records and planning enough profitable work for your tractor; (2)

Operating management: means efficient operation; such as laying out

fields to reduce lost time, loading the tractor properly and keeping the

tractor and machines well adjusted; (3) Maintenance management:

means taking care of your equipment; keeping it in a good condition,

having it repaired, servicing and lubricating it, keeping it (tuned-up)

and always ready, so you can profit from timely operations.

2.2.2 Organization of machinery services:

Lewis (1980) stated the personnel establishment for a

machinery service organization will be of necessity and vary

according to the nature and extent of the work to be undertaken. He

also reported that it is important to establish a definite chain of

authority and administrative responsibility, and the responsibilities of

all staff be clearly defined.

FAO (1985) reported that it is essential to recruit a well

qualified staff and their terms of employment are sufficiently

attractive to induce them to join the organization and stay with it.

They also reported that the responsibility of selecting the staff

members is in hands of the Project manager who should be a good

organizer and know well the operation, management and repair of

farm machinery and also have a good knowledge of agriculture. They

also reported that the staff who occupy the managerial posts of the

service organization should be considered as permanent and therefore

should be employed on a contract basis. Other key personnel such as

supervisors, mechanics, operators and storekeepers should also be

employed at least on annual basis.

Meij (1960) reported that care and maintenance of machines

needed fully trained mechanics and skilled tractor driver with little

training to carry out simple overhauls on tractor and equipment.

Dawelbeit and Ahmed (1987) reported that one of the factors

contributed to poor performance of the agricultural machinery in the

Sudan was the in adequate training programs for operators, mechanics

and engineers. FAO (1985) reported that the supervisors, foremen,

operators and mechanics should be skilled, well trained, familiar with

the machine and operation of different machines and implements and

before every things they can write and read and well paid.

Bhutta et al (1997) reported that proper operator training in

operation and maintenance of farm machinery is imperative. They also

reported that the less educated or illiterate operators are limited in

their understanding of the idiosyncrasies of a tractor. FAO (1985)

reported that it is important to consider carefully exactly how many

people in the service organization are actually required on full-time

basis, and not to exceed this number, as to do so would merely

increase overhead costs un necessarily. Meij (1960) stated that it is

most economic and effective to employ the operators on a seasonal

basis according to their qualifications.

2.2.3 Workshops for shelter and services:

2.2.3.1 Types of utility buildings (Building designs):

American Association for Agricultural Engineering and

Vocational Agriculture(AAAE & VA.,1969) defined the utility

building as the one that is designed to be used for a variety of

purposes; e.g. machinery storage, livestock shelter, storage of hay and

other farm product, farm shop or service center.

They classified utility buildings into the following types.

1. The shed-type building:

It is characterized by the following;

- It is best adapted for entrance on one side only.

- It has good height on the front side but not on the rear.

- It is simple and easily constructed.

2. Gable-type building:

It is adapted to both end and side entrances. It has good

clearance at the ends. It is a popular type of structure and easy to

build.

3. The curved half-arch type:

Generally constructed of prefabricated steel or glued laminated

beams. It is adapted for side entrance only.

4. The curved full-arch type:

It is adapted for end entrance. It is strong and wind resistant,

adapted to wide spans without center posts.

5. The umbrella-type:

It is simple open-sided shed, which is easy to build. It provides

little protection from driving rain and snow, but withstands high winds

because it has no sides.

Figure (2.1) shows the types of utility buildings as reported by

AAAE&VA (1969).

2.2.3.2 Workshop location:

Whitaker (1979) reported that the workshop is usually located

in the hub of the farm stead traffic pattern. The site should be

adequately drained to prevent water from accumulating in or around

the shop. He also stated that a distance of 45m between the shop and

other major structures provides room to maneuver and park large

machinery nearby and reduces fire hazard, and allow for expansion.

Lewis (1980) reported that the workshop should be located in the

centre of the project, away from the heavily populated area, provided

with essential services, and it should be close to the administrative

head quarters, and on a well-developed road to provide easy access.

2.2.3.3 Workshop size:

Neubauer and Walker (1961) reported that a size of (16ft×24ft)

is usually adequate for farm shop. For large operations a size up to

(32ft×36ft)may be desirable. Some shops grow to double this size on

large farms doing most of their own repairs.

Figure 2.1. Types of utility buildings. Source: AAAE&VA (1969)

Whitaker (1979) reported that the size of the shop will be

determined by the amount of shop equipment, particularly floor power

tools, and the size of the largest farm machines that will be serviced in

the shop.

FAO (1960) reported that workshops are grouped into three

types according to the sizes of equipment required to do the job; small

farm shops, medium workshops and large workshops.

2.2.3.4 Workshop components:

Whitaker (1979) reported that the recommended features for all

shops are;

1. Smooth concrete floor.

2. A large concrete ramp just outside the main

entrance.

3. An easily opened door that is wide and high

enough to accommodate large equipment.

4. Safety equipment should be provided, and dry

powder fire extinguishers should be located

near the door-ways. A first aid kit should be

readily available.

5. A telephone or intercom system for

convenience and safety.

6. Wall fans for general ventilation and a flex tube

to remove the exhaust fumes from an operating

engine through a wall port.

7. Ample artificial lightings.

8. Careful placement of shop equipment.

9. Well organized storage space for materials,

supplies, parts, and manuals.

10. Location of the welder and compressed air

supply near the main entrance.

Lewis (1980) reported that for time saving, the cost and good

supervision, the shop should be established under one roof

accommodating these services; Main overhaul area, welding and

blacking smith work, sheet metal work, battery and tire shop, fuel and

ignition system work, washing and lubricant bays, spare parts storage,

offices for staff and staff services (wash, first aid and locker room).

Whitaker (1979) reported that spare parts section to be closed to the

main overhaul area. Sections from which noise, smoke and dirt can be

expected must be kept as far away from the offices.

2.2.3.5 Workshop construction:

Neubauer and Walker (1961) stated that the roof pattern should

match the remainder of the building. Typical gable, broken gable and

the shed types are used mostly. They also stated that fire proof

materials are recommended. The roof should not require central

supporting pillars to save at least 25% floor space in the work area.

AAAE&VA (1969) classified the roof framing into two main types.

1- Farm-built framing (Fig.2.2).

A- Narrow spans, which include.

i. Common rafters: It has up to

18-ft. span.

ii. Truss: It has up to 24-ft.span.

iii. Truss (high clearance): It has

up to 24-ft.span, but not

recommended.

iv. Umbrella truss: It has up to

28-ft. span.

B- Wide spans; which include

V- Truss (high clearance): It has up to 36-ft. span.

VI- Truss: It has up to 60-ft. span.

VII- Curved-arch rafter: It has up to 40-ft. span.

VIII- Rigid-wood frame: It has up to 40-ft. span.

2- Commercial framing (Fig.2.3):

A- Narrow spans: Which include;

IX- Steel frame: It has up to 25-ft. span.

Figure 2.2 Narrow spans and wide spans types of farm-built framing Source: AAAE&VA (1969)

Figure 2.3. Narrow spans and wide spans types of commercial framing. Source: AAA&VA (1969)

B- Wide span; Which include:

X- Laminated rafters: It has up to 60-ft. span.

X1- Rigid-steel frame: It has up to 70-ft. span.

XII- Frameless steel: It has up to 60-ft. span.

They also reported that the type of roof framing to be used will

determine the amount of post-free you can have, the available height

for tall implement and the possibility to attach a hoist to the roof

framing.

AAAE&VA (1969) reported that roofing material for a farm

shop, machinery storage or other utility building is usually selected

from one of the following:

Galvanizing steel, aluminum, wood shingles, asphalt (roll or

shingle) and asbestos cement (shingle or sheet).

Noton (1982) reported that there are important factors to

consider in selection of roofing materials; probable life expectancy

due to weathering, fire resistance, hail resistance, resistance to heat

from sun, resistance to strong winds, maintenance and weight.

Neubauer and Walker (1961) reported that for siding materials

used wood frame is standard, but concrete blocks, tile, or metal

construction may by favoured for resistance to fire and decay.

The AAAE&VA (1969) reported that the most siding materials

used in buildings are; galvanized steel, aluminum, concrete blocks,

wood siding, exterior plywood and tempered hardboard.

They also stated that the factors to be considered in selecting

the kind that best fits your needs are the following; Life expectancy

due to weathering, fire resistance, resistance to attack by vermin,

maintenance, paintability and type of fastener needed.

Lewis (1980) reported that type of materials used in

construction will contribute to comfort and good working conditions.

He also reported that concrete is the best floor material. It

should be of 5 to 6 inches thick and of good quality. It should be

sloped to the major large door opening. Neubauer and Walker (1961)

stated that in addition to concrete other floor materials sometimes used

are; black top, soil cement, pumice, gravel, sand and clay. They also

stated that in large workshop an approach apron or ramp of concrete is

recommended at the main entrance of the shop, for servicing and

making minor repairs. Neubauer and Walker (1961) and Weller

(1972) agreed that none of these materials are equal to concrete, but

are occasionally used for economy.

The AAAE&VA (1969) stated the following kinds of floors

used for utility strucrtures;

1. A dirt floor: It is least costly, but it is the

least satisfactory. It is difficult to keep

power tools and equipment level, and it is

difficult to anchor them in position.

2. A crushed-rock floor: It is usually

uneven, which makes it harder to roll or

move equipment. It holds dirt and grease

and not satisfactory.

3. Concrete floor: It is easy to keep clean

and forms an excellent base for

equipment and power tools. It is fire

proof, permanent and usually less costly

than a wood floor. It should has a slope

towards one of the access doors.

2.2.3.6 Workshop objectives:

Butterworth and Nix (1983) reported that the job of the

workshop is to support the machinery policy, and to achieve the

optimum balance between minimizing costs and lost time due to

breakdown on one hand, and maximizing utilization and life of

machinery on the other.

Neubauer and walker (1961) stated that the workshop has the

following functions: (1) To keep farm machinery operating, (2) To

keep utilities functioning, (3) To build or construct a limited amount

of machinery and equipment, (4) To prevent costly lost of the time, (5)

To reduce annual depreciation, and (6) Emergency storage of farm

products. Whitaker (1979) stated that farm shop increases the

efficiency of farm operation in several ways; (1) Fast and effective

repairs are often possible in a short span of time, thereby avoiding

expensive, prolonged breakdowns while waiting for a mechanic or

parts. (2) Routine repairs and preventive maintenance of both

equipment and buildings are possible during the off season or

inclement weather. The year-round labour crew is kept busy, and

expensive repairs by machinery dealer and contractors are reduced.

(3). It is possible to build or modify some of the equipment to be used

on the farm.

2.23.7 Workshop layout:

Butterworth and Nix (1983) stated that workshop layout has the

following objectives:

1. Fewer delays by getting machines back into

action once failure has occurred.

2. Reduced handling by minimizing time involved

in fetching tools, equipment and materials to

and from storage.

3. Greater utilization of machinery, manpower and

services.

4. Shorter in-shop time, by good organization and

correct use of tools and stores items, which will

speed up work and reduce down time.

5. Better working conditions.

6. Better management supervision.

7. Reduced clerical work.

8. Saving in floor space.

Good layout for a new workshop is especially important in

order to minimize the demand for space which will cost money to

build.

2.2.3.8 Workshop tools and equipment:

Neubauer and Walker (1961) said that the necessary tools and

equipment should be provided in a suitable location in the shop. Lewis

(1980) reported that equipment as manufactured and used today can

only kept in operating condition by good standard and specialized

tools.

FAO (1960) reported that the basic items of tools and

equipment that must be available to utilize efficiently more

specialized types of shop equipment include; work benches with vices,

lifting tackle, lubrication equipment and a good supply of hand tools.

Specialized power tools, machine shop equipment, testing equipment

and special overhaul tools can be added as required.

Culpin (1976) reported that welding equipment are essential to

be used in farm repair work for two main types of job;

1. To rebuild and hard surface worn parts.

2. To join together broken parts.

Dawelbeit and Ahmed (1987) reported that one of the factors

contributing to poor performance of agricultural machinery in the

Sudan was the in sufficient workshop equipment.

Lewis (1980) stated that it is more economical to invest in a

good quality equipment, this is because these tools last longer and

easier to use and do a better job.

Culpin (1976) reported that for large workshops it is desirable

to have both oxyacetylene and electric welding outfits.

2.2.3.9. Spare parts and supplies stores organization:

2.2.3.9.1 Stores layout and equipment:

Butterworth and Nix (1983) stated that the parts store should be;

i. Well laid out with all parts and bins clearly labeled.

ii. Well lit.

iii. Free from rubbish or junk.

iv. Clean.

v. Fast moving parts readily available.

vi. A stock control system to re-order spent stocks should be

employed and easy to use.

FAO (1960) reported that it is essential to keep costs of spare

parts stocks, equipment and staff to handle them as low as possible.

Lewis (1980) stated that a suitable layout for parts stores should

include the following main features; an issue counter centrally located

at front of the stores, control card files and catalogues at issue-

counter, rows of bins parallel to issue counter, unpacking and bulk

storage area behind the bins and a wide straight aisle from the bulk

storage area to main doors of stores.

FAO (1960) reported that the bins may be of wooden

construction, or entirely made of metal which often purchased at

lower costs than that made of wood.

2.2.3.9.2 Stock control procedures:

FAO (1960) reported that a card system of record and control is

now practically universally used in modern machine parts stores, and

the basic item in this system is the “stock control card” in which the

items; part No., make, machine, model, description, catalogue page

and bin location will be filled. In addition to all details covering

ordering, receiving and issuing of a particular spare part will also be

entered in the card. They also reported that government establishments

may require a periodical inventory check and audit to be carried out

on a definite periodical basis, and also spot checks may be made at

frequent, but irregular intervals to ensure that the whole parts

organization is kept under close control.

2.2.3.9.3 Supply of spare parts:

Dawelbeit and Ahmed (1987) reported that the un availability

of spare parts is a serious problem, and it jeopardizes agricultural

mechanization in the Sudan. They also reported that among the

conditions that impact the supply of spare parts are a shortage of

foreign exchange, unreliable suppliers and lengthy procurement

procedures. FAO (1985) reported that government schemes have been

unsuccessful, because the schemes are obliged to take what ever

machinery is available from aid programmes or government

commercial agreements regardless of its suitability for the specific

jobs to be done, and usually these machines accompanied with their

spare parts. Bukhari (1982) reported that un availability of genuine

parts had been major causes of breakdowns.

Dawelbeit and Ahmed (1987) reported that record keeping

system in the Sudan is unadequate and contains incomplete data.

Therefore, the manufacturers lists of recommended parts are the basis

for choosing the parts to be ordered. These standard lists are not

always appropriate for conditions in the Sudan.

2.2.3.10 Care and maintenance in workshops:

Meij (1960) stated that care and maintenance of machines

needed the following;

1. Time must be allowed for daily maintenance of

machines in use.

2. Adequate facilities must be available to carry out

the daily maintenance.

3. Suitable supply of oils, greases and tools.

4. Manufacturers’ recommendations must be known

and followed.

5. Log sheet or record card must be kept giving

details of the services carried out.

6. Fully trained mechanics.

7. Skilled tractor driver with little training to carry

out simple overhauls on tractor and equipment.

8. Particular care should be given to the cleaning of

spraying machines and fertilizer distributors since

the corrosive action of materials handled can

cause serious damage to a machine in a very short

time.

Butterworth (1984) stated that the purpose of maintenance is to

preserve the operational capability of the tractor and its long- term life

at economic cost. He sub-divided maintenance into types:

A- Routine and preventive maintenance.

B- Replacement bpefore failure.

C- Repairs after failure.

Morris (1988), Ahmed et al (1999) categorized factors

inherence tractors repair and maintenance as following:

i. Tractor accumulated use.

ii. Skill and attitude of tractor operator.

iii. Operational conditions.

iv. Maintenance management. i.e.

maintenance facilities and training

status of personnel, field repairs.

v. Availability of spare parts at

appropriate time and tractor design

feature.

Dahab (2001) stated that maintenance and repairs are essential

in an effort to guarantee a high standard machine performance and

reliability. The longer agricultural machinery is used the more repairs

are needed to maintain its reliability.

Culpin (1976) stated that maintenance in good order of

equipment includes;

i. Adjustment and replacement of parts.

ii. Regular attention to lubrication.

iii. Protection from weather by housing.

iv. Protection from corrosion and decay by painting.

FAO (1995) reported that in developing countries the

difficulties in finding spare parts and competent technicians to repair

machines and shortage, or complete lack of minimum maintenance,

have reduced the services life of the equipment and its economic

profitability. Bukhari et al (1988) reported that in developing

countries, there was much of idle tractors representing a large waste of

mechanical power resources due to shortage and prohibitive costs of

spare parts and untrained operators. Bukhari et al (1987) cited that the

service life of farm tractor greatly depends on timely repair and

maintenance which is the most important aspect of management.

Abdalla (1987) mentioned that factors limiting repair and

maintenance of the farm machinery as follows: financial facilities,

procurement system, diversity of agricultural tractors and training of

technical staff.

Butterworth (1984) reported that all tractors manufacturers have

their own maintenance schedules for each model of tractor. Ford

Motor company (1981) recommended that hydraulic oil for tractor

model 6610 must be changed every 1200 hours be using 54litres.

Ehmke (1986) mentioned that preventive maintenance is the

key for long tractor life. Adekoya (1990) stated that tractors work for

long periods without breakdowns if they are properly maintained.

Hofman and Kucera (1987) stated that farmers could reduce their

machinery repair costs by 25% through improving routine

maintenance procedures. Ward (1990) indicated that by careful

operation and adequate maintenance repair costs can be reduced.

Jones and Aldred (1980) reported that proper lubrication and use of

good quality lubricants are very important in reducing the wear and

repair expense of tractor. Dawelbeit and Ahmed (1987) reported that

in most agricultural schemes in the Sudan, machinery maintenance,

especially preventive maintenance was not given much attention.

About 40% of the machinery in the Gezira scheme are idle because of

the shortage of spare parts and poor management and maintenance.

Butterworth (1984) mentioned that most of drivers are quite good at

oil changing, but many routine adjustments to brake and clutch are not

made until faults occur. He also reported that maintenance before

failure is a key part of efficient operation in the field.

Johnson and Hollenberg (1960) mentioned that the application

of simple maintenance practices to the electrical system will lengthen

tractor life and increase trouble-free services.

Witney (1988) reported that the workshop care of machinery is

of four types;

1. Routine replacement of wearing

parts.

2. Repair of accidental damage.

3. Repair through operator neglect.

4. Routine overhauls.

Ulrich (1991) stated that parts replacement when cease to

function due to the following reasons:

1. They reached the end of their normal life.

2. They worn out and no longer can do their job.

3. They are structurally failed due to an

accidental, faulty operation, or fault in design.

Adam (2000) reported that in the undeveloped countries the

shortage of capital, foreign currency, and low wages and ignorance of

labour who are repairing and maintaining tractors caused many

problems and lowered their efficiency of use.

Culpin (1976) reported that during slack periods, it pays to

carry out any repairs and adjustments necessary to get machines ready

for services. He also mentioned that the availability of specialized

workshops for big repairings and quick repairing of machines in the

field are essential to increase the efficiency of production.

Meij (1960) reported that a card should be kept for each

machine showing what repairs have done and what repairs are needed.

He also stated that management is failing in its duty if a

machine is found to need repairs when it is required for work.

Dawelbeit and Ahmed (1987) reported that in Sudan the supply

of spare parts will not be available for more than one- third of the

machinery’s lifetime. After the initial supply of spare parts is

exhausted, funds are not always available to replenish the stock.

Therefore most machines are idle for lack of spare parts although two-

thirds of their normal lifetime for possible use remains.

Whitaker (1979) reported that the purpose of machinery storage

is to offer protection from weather, theft, vandalism, and to allow easy

maintenance and adjustment of machines.

He also stated that when machines are protected from weather

several economic benefits occur;

i. Lowering of repair cost.

ii. Lowering depreciation cost.

iii. Intangible advantage of timeliness also has a monetary

value.

Culpin (1976) reported that it is uneconomic to put up

implements sheds for ploughs, mounted cultivars and similar

implements which consist almost entirely of painted steel bars of

generous proportions. The best and cheapest form of protection of

such implements is to re-paint the frame-work when necessary. He

also stated that complicated machines and tractors needed to be

properly housed. He also reported that other types of protection are;

1. Painting.

2. Machinery covers.

3. Rust preventives.

Grisso (1996) mentioned that machinery storage is one of the

strategies for extending tractor life.

Betzwar (1987) reported that the following preventive measures

could help to avoid breakdown of parts due to incorrect operation, or

accidents;

1. Operation of equipment only by trained personnel.

2. Scheduled maintenance and service of equipment.

3. Housing equipment in dry, sheltered areas when

not in use.

4. Storage of the equipment with proper protection

and conservation until the next season.

2.2.4 Farm machinery costing:

2.2.4.1 Machinery life:

Hunt (1983) defined the economic life of a machine as the

length of time from purchase of a machine to that point where it is

more economic to replace with a second machine than to continue

with the first. Lonnemark (1967) reported that in developing countries

there are some conditions which tend to prolong useful life of

machinery; Lack of capital and perhaps foreign currency for the

purchase of new machines, and low wages of labour in repairing and

maintaining machines are reasons for continuing to repair and use

machines beyond their economic lives.

Hunt (1983) and Lonnemark (1967) reported that the ASAE

year book gives expected wear-out lives to be as following;

Tractors (wheeled-type) 12000hrs

Tractors (track-type ) 9500hrs

Tillage machines 2500hrs

Harvesters 2000hrs

Seeders 1200hrs

2.2.4.2 Machinery costs:

Bowers (1987) mentioned that accurate cost estimates play an

important role in every machinery management decision. The

operating costs for a machine are divided into two groups, fixed and

running costs.

2.2.4.2.1 Fixed costs:

Fixed costs are dependent on the duration of the ownership of

a machine, and include; depreciation, taxes, insurance, interest, and

shelter.

A- Depreciation:

Hunt (1983) defined depreciation as the amount by which the

value of a machine decreases with the passage of time whether used or

not and attributed to age, wear and tear and obsolescence. He

mentioned the following methods to determine the annual amount of

depreciation.

1. An estimated value method:

It may be the most realistic determination of depreciation. At

the end of each year the value of a machine is compared with its value

at the start of the year. The difference is the amount of depreciation.

2. Straight line method:

It is the simpler method. This method reduces the value of the

machine by an equal amount each year during its useful life. The

annual depreciation charged by this equation.

D = (P S)/L

Where;

D = Annual depreciation

P = Purchase price.

S = Salvage or selling price.

L= Time between buying and purchasing, yr.

3. Declining-balance method:

It is the simplest of all, a constant percentage is applied each

year to the remaining value of the machine at the beginning of the

year. To calculate the amount of depreciation charged each year, the

following formula is used.

D = Vn – Vn+1

Vn = P (1-X/L)n

Vn+1 = P(1 – X/L)n+1.

Where, D = amount of depreciation charged each year.

n = age of the machine in year at the beginning of year

in question.

X = ratio of depreciation used, normally between 1 and

2. for a used machine the maximum rate X = 1.5.

V = Remaining value at any year.

4. Sum- of- the-years-digits method:

This method is accurate but to some extend complicated. The

digits of the estimated number of years of life are added together. This

sum is divided into number of years of life remaining for the machine

including the year in question. This fractional part is multiplied by the

difference between purchase price and the salvage value. The result is

the amount of depreciation charged each year. This can be shown by

this equation.

L – n (P – S) D =

YD

Where;

D = annual depreciation.

L = Economic life of machine in years.

n = Age of the machine at the beginning of the year.

YD = Sum of years digits.

(P – S) = The difference between the purchase price and the

scrap value of the machine.

B- Interest on investment:

Whitney (1988) reported that the yearly charge for interest will

be equal throughout the life of the machine. This can be shown by this

equation;

I = ( P + S) × i 2 Where;

I = Annual interest charge

P = Original cost

S = Salvage value

i = Rate of interest %.

Agricultural bank of the Sudan suggested charge of 15% as an

interest rate for agricultural purpose in the year 2002.

C- Taxes:

Farm machinery is taxed as the same rate as other farm

property. Hunt (1983) stated that the annual cost of taxes would be

1.5% of the purchase price when spread over a 10- year life.

D- Insurance:

Hunt (1983) estimated the annual charge for insurance would be

0.25% of the original price .Bowers(1975) estimated a charge of 0.25-

0.5% as an annual charge for insurance.

E- Shelter:

Hunt (1983) mentioned that a charge must be made against

machine for shelter or paint or other deterioration prevention

practices. He assumed a charge of 1-0.5% as an annual charge for

storage.

2.2.4.2.2 Running costs:

Hunt (1983) stated that variable costs vary with use, and may be

about 64% of all costs for tractors. Variable costs include ; fuel,

lubricants, repair and maintenance and labour costs.

A- Fuel and lubricants costs:

Fuel and lubricants vary with use of the machine. When

accurate records are lacking the costs of fuel and lubricants can be

satisfactory estimated. Witney (1988) reported that diesel fuel

consumption can be expressed by the following equation ;

fc = 2.64 Ru +3.91 – 0.2 (738× Ru + 173)0.5

Where;

fc = Specific fuel consumption.

Ru = The ratio of equivalent P.T.O. power required by an operation to

that maximum available from the P.T.O. in kw.

He also mentioned that the oil consumption can be expressed by

the following equation;

Oc = 0.2189 + 0.00059×Pmax.

Where;

Oc = oil consumption L/h.

Pmax = rated engine power kw. hr.

Another rule of thumb is to assume that the oil and lubricant

costs for tractor are equal to 10% of the fuel cost. Dahab (2001)

reported that fuel and lubricants costs usually about 20-30% of the

total machine annual costs.

B- Repair and maintenance costs:

Repair and maintenance costs include maintenance adjustment

for wear-out parts and daily services as well as the cost of all spare

parts and the labour to install them.

Hunt (1983) stated that repair and maintenance costs are

expected to vary from one part of the country to another because of

differences in soil, weather and crop conditions.

Bukhari (1982) reported that repair and maintenance cost is

necessary to keep machine in serviceable condition and influenced by

the age of the tractor, and tractor cumulative hours of use. He found

that the older tractor had higher repair and maintenance cost per hour

than new ones, because older tractors had frequent breakdowns.

Culpin (1976) estimated the annual cost of spares and repairs as

percentage of purchase price at various levels of use of farm

machinery as shown in Table (2.1). Bukhari (1988) found that repair

and maintenance cost per hour was lower for tractors used for longer

time each year.

C- Labour cost:

Fairbanks et al (1971) found that variable costs for tractors were

about 64% of all costs, with the greatest single cost being for labour.

The cost of labour varies with the geographical location. For owner-

operators, labour cost should be determined from alternative

opportunities for use of time. For hired- operators, constant hourly rate

is appropriate. (ASAE, 1982).

2.2.5 Field performance of farm machinery:

Field capacity of agricultural machine is the rate at which farm

operations are accomplished. It can be expressed in term of area/time

(acre/hr, feddan/hr) or bushels, tones or balers per hour.

Hunt (1983) proposed the following time fractions to be

considered when computing the capacities or costs of machinery.

1. Machine preparation time.

2. Travel time to and from the field.

3. Machine preparation time in the field and

before and after operations.

Table (2.1): The annual cost of spares and repairs as percentage of

purchase price at various levels of use of farm

machinery. Approx. Annual use (hours)

Tractors 500 % 5

750 % 6.7

1000 % 8

1500 % 10.5

Additional use 100 hrs % 0.5

Approx Annual use hours 50 100 150 200 % % % %

Additional use 100 hrs %

Harvesting machinery: combine harvester-self prop. Combine and P.T.O. driven

1.5 2.5 3.5 4.5 2.0

Pick up baler, potato harvesters and sugar cane harvester

30. 5.0 6.0 7.0 2.0

Other implement and machines: group 1. Normal soils ploughs, cultivar, tooth diggers

4.5 8.0 11.0 14.0 6.0

Group 2. rotary cultivars, Mowers, Binders, Pea cutters

4.0 7.0 9.5 12.0 5.0

Group 3. Disc harrows, fertilizers combine drill spreader, sprayers

3.0 5.5 7.5 9.5 4.0

Group 4. Swatch turners, side delivery rakes, forage harvest, semi-automatic planter and transplanters

2.5 4.5 6.5 8.5 4.0

4. Theoretical field time (the time the machine is

operating in the field at an optimum forward

speed and performing over its full width of

action).

5. Turning time.

6. Time to load and unload the machine.

7. Machine adjustment time.

8. Maintenance time.

9. Repair time ( the time spent in the field to

replace or renew parts)

10. Operator’s personal time.

He stated that not all these elements are commonly charged

against machine operations. The operator’s personal time, machine

preparation and travel time to and from the field are highly variable

quantities and are usually un related to the operating efficiency of the

machine.

The theoretical field capacities of farm machinery can be

calculated by this equation;

S×W TFC = C Where; TFC = theoretical field capacity, ha/hr (acr/hr)

S = Speed, km/hr (mi/hr)

W = Rate width of implement, m(ft).

C = Constant, 10(8.25).

Hunt (1983) mentioned the following equation for the effective

field capacity;

SWE EFC = C Where;

EFC = effective field capacity, ha/hr (acr/hr).

S = Speed, km/hr (mi/hr).

W = Rate width of implement, m(ft).

E = Field efficiency as a decimal.

C = constant, 10 (8.25)

Lonnemark (1967) mentioned two main methods by which field

capacity of farm can be obtained; The first method is to collect data by

recording the time taken to cover a given area. The second method is

to calculate the time taken according to the working width of the

machine and its working speed. He stated that the first method can be

used both for obtaining rough averages and for detailed and accurate

studies.

2.2.6 Field operation cost:

Hunt (1983) derived an equation that can be used to calculate

the total cost per year for a field machine.

FC%P CA AC = + {(R&M) P+L+O+F+T} 100 SWE

Where;

AC = annual cost of operating machine $/yr.

FC% = annual fixed costs percentage.

P = Purchase price of machine $.

C = constant, 10(8.25).

A = annual area in ha (acr)

S = Forward speed, km/hr (mi/hr).

W = effective width of action of machine, m(ft).

E = field efficiency, decimal.

R&M = repair and maintenance cost decimal of purchase price per

hour.

L = labour rate $/hr.

O = oil cost $/hr.

F = fuel cost $/hr

T = cost of tractor used by machine $/hr.

T = (zero) if self-propelled.

Dafalla (1990) reported that increase of annual use of both

tractor and implements resulted in low hourly operations costs. He

also mentioned that in New Halfa Scheme disc plowing had the

highest operation cost followed by disc harrowing and dry ridging

respectively, and also there were variations between costs of disc

ploughing, harrowing and dry ridging calculated and costs estimated

for these operations in the Scheme.

CHAPTER THREE

MATERIALS AND METHODS

3.1 Materials:

3.1.1 Location:

New Halfa Agricultural Scheme is located between latitudes

15° 5´ S and 15° 30´ N, in Kassala State, about 350 km east of

Khartoum. The main workshop is located in the centre of the Scheme.

A map of the Scheme showing the location of the main workshop is

shown in Figure 3.1.

3.1.2 Sources of data

The sources included:

i. Records from the main workshop and the small

farm shops.

ii. Personal contacts with managers, agricultural

engineers, civil- engineers , store keepers,

mechanics, operators and machinery dealers.

3.1.3 Types of data collected:

The types of the data collected are;

Work shop design, construction, personnel, workshop tools and

equipment, spare parts and supplies stores, machinery services, farm

machinery and costs of repair and maintenance.

Agricultural Administrative Areas

Debaira section ElSedera section Raira Section 1. F

aras 7. Um Rahou 8. ElSufia ElGdeda

2. Hagir

10. Um Gargour 9. ElSabaat ElUm

K 14 Ghrashi 11. Salama Sarouba 17. ElSabaat Sharg Sasaraib section Demiat section 18. ElSabaat Gharb 4. ElMadina 14. ElShebik Sheikh Omer Section 5. Deghain 15. ElRataga 3. Argin 6. ElLedej 16. ElElew 12. ElButana 13. Abu Nagma Atbara River to Kassala

Khashm ElGirba

To Khartoum

• Main workshop Figure 3.1.New Halfa agric. Scheme with the main workshop sited at the corner of the City.

3.2 Methods:

3.2.1 Evaluation of workshop location:

The location of the main workshop was evaluated according to

the following;

1. Its location in the Scheme.

2. Its distances from other small farm shops.

3. The availability of essential services in the

workshop sections.

3.2.2 Evaluation of workshop design and construction:

1. The dimensions of the workshop were measured,

including length and width.

2. The roof framing, floor, roofing and siding

materials of each section were determined.

3. A floor plan or a side view for each section-

workshop was drawn.

3.2.3 Evaluation of workshop tools and equipment:

1. Essential tools and equipment used in

workshop sections were determined.

2. The quality of hand tools used was evaluated.

3. The specialized power tools, machine shop

equipment, testing equipment used in

electricity unit, fuel pumps unit, and sheet

metal and welding and blacksmith section

were determined.

4. All tools were evaluated in terms of quantity

and quality.

3.2.4 Evaluation of workshop personnel:

1. An organization plan for the workshop personnel

was drawn.

2. Responsibility and authority for each job was

checked.

3. Total numbers, work experience, academic

degree, training, administrative ability and salaries

per month for senior staff were determined.

4. Total numbers, age profile, educational status,

training, and salaries per month for operators were

determined.

5. Total numbers, education status, training, work

experience, skills in repairings and maintainings,

and salaries per month for mechanics were

determined.

3.2.5 Evaluation of workshop spare parts and

supplies:

3.2.5.1 The main store layout:

1. The main store layout including dimensions

measurements, rows of bins, issue area, main

aisle, and storage area were determined.

2. A plate of the main store layout was checked.

3.2.5.2 Stock procurement policy:

1. The policy followed in procuring spare parts stock

was determined.

2. Stock levels were evaluated.

3.2.5.3 Stock control procedures:

The stock control procedures followed were determined

including; stock control card, order forms, receipt of orders and audit

procedure.

3.2.6 Evaluation of workshop organized services:

3.2.6.1 Services given through tractors, combine harvesters and

agricultural implements sections:

1. Types of services given through each section were

determined.

2. Types and numbers of machines in each section

were determined.

3. Plan of work followed in operating machines in

each section was determined.

4. No. of machines in work and that out of work in

each section were obtained.

5. No. of machines kept in door and that out door

were determined.

6. Overhauling and trade-in programmes followed in

each section were determined.

3.2.6.2 Evaluation of other workshop services:

Which include the following:

1. Services through sheet metal unit.

2. Services through welding and black smith unit.

3. Services through batteries and electricity unit.

4. Services through fuel pumps unit.

5. Services through tire unit.

3.2.7 Estimation of farm machinery services and repair and

maintenance costs:

The data were collected about:

1. Type of field operations done by farm

machinery.

2. Annual area executed by farm machinery

in each operation.

3. Machine annual use hours.

4. Machine scrap value.

5. Machine overhauling cost.

6. Annual spare parts cost for each type of

machines used.

7. Annual wages and incentives paid.

8. Annual repair and maintenance costs.

3.2.7.1 Data analysis procedure for Ford and Cater pillar tractors:

1. Ford tractors are treated as one group. Specifications of

Ford tractors were shown in Table (3.1).

2. Caterpillar tractors D5B, D6SA, D7SA, loaders and

motor graders were treated separately. Specifications of

each type were shown in Table (3.1).

Table 3.1 Specifications of tractors.

Types of tractors Machines make Mark and model Power hp

Medium tractors (Wheel-type) U. K Ford 6610 75

D5 (track-type) U.S.A Cat. D5B 175

D6 (track-type) U.S.A Cat. D6SA 225

D7 (track-type) U.S.A Cat. D7G 275

D8 (track-type) U.S.A Cat. D8H 320

D6 Dozer (track-type) U.S.A Cat. D6D 175

Loader (Wheel-type) Japan Furukawa FL150 175

Motor grader U.S.A Cat. 120B 175

3. The annual hours of use, annual spare parts and labour

costs during the studies period (1999-2002) for each

tractors group were determined.

4. The age of each tractors group was determined.

5. The average annual repair and maintenance cost was

calculated by using the annual spare parts and labour

costs.

6. The effects of both age and annual hours of use on the

average repair and maintenance cost for each tractors

group were determined.

3.2.7.2. Data analysis procedure for combine harvester:

1. The annual hours of use, spare parts and labour

costs were calculated during the studied period

(1999- 2002).

2. The averages annual spare parts and labour

costs were used to calculate the average repair and

maintenance cost for combine harvester.

3. The effects of age and annual hours of use on

the average annual repair and maintenance cost

were determined.

4. Specifications of combine harvester were

shown in Table 3.2.

3.2.7.3. Data analysis procedure for agricultural implements:

1. Each type of the implements was treated as a

separate group.

2. Specifications of each type of working

implements were shown in Appendix 1.

3. The average annual working hours for each

type during the studied period (1999-2002)

was obtained.

4. The annual repair and maintenance cost was

calculated by using the annual spare parts

and labour costs.

5. The effects of annual hours of use and age

on the average repair and maintenance cost

per hour for each agric. implement were

determined.

Table 3.2 Specifications of combine harvesters.

Combine harvester Specifications

Machine make Germany

Company Claas

Model Dominator 68S

Power 102hp

Width of cut 4.2m (14ft)

CHAPTER FOUR

RESULTS AND DISCUSSION

4.1 Workshop location:

The main workshop is located at the north-eastern corner of

New Halfa city, closed to the administrative head quarters. It is

centrally located in the Scheme and surrounded by small farm shops

that covered all the field sections. Essential services such as water,

electricity and telephones are provided to all sections of the main

workshop. These facts of locating the workshop in the centre of the

Scheme, closed to the administrative headquarters and provided with

essential services are in agreement with that reported by Lewis (1980).

Distances of small farm shops from the main workshop are shown in

Table 4.1.

4.2 Workshop design and construction:

The main workshop is composed of many sections. Each

section is a typical gable-type of building. Galvanized steel is used as

a roofing material, and also galvanized steel or local bricks are used as

a siding materials. A diagram of the workshop is shown in Figure 4.1.

These sections are; 1. Ford tractors section, 2. Caterpillar tractors

section, 3. Combine harvesters section, 4. Agricultural implements

section, 5. Sheet metal and welding and black smith section, and 6.

Spare parts and supplies stores section.

Table 4-1 Distances of small farm shops (Blocks’ workshops)

from the main workshop.

Distance in km Block Name Block No.21 Faras 1 21 Hagir 2 16 Argin 3 11 Elmadina 4 8 Deghaim 5 22 Alledaj 6 40 Umm Rahau 7 44 Elsufia Elgadida 8 54 Elsabaat Elomm 9 57 Umm Gargour 10 67 Salama sarouba 11 35 Elbutana 12 21 Abu Nagma 13 45 Elshabiek 14 48 Elrataja 15 42 Elelew 16 54 Elsabaat Sharg 17 66 Elsabaat Gharb 18 33 Elghorashi 19

1. Ford tractors section:

The section has two identical shops. Each shop about 64m in

length and 12.3m in width. A single office (4.1m×3.2m) and store

room (8.2m×3.2m) are built. The shop is a typical gable-type of

building. Plenty of window spaces are made along the wall side.

Galvanized steel, concrete and local bricks are used as roofing,

flooring and siding materials respectively. A floor plan of the shop is

shown in Fig. 4.2.

2. Caterpillar tractors section:

The shop is actually a side-entrance type of machinery storage

open on one side. It is about 31m in length and 12.3m in width.

Galvanized steel is used as a roofing and a siding material. The shop is

a typical gable-type of building with roof framing without supporting

pillars, but not rigid enough to attach a hoist to it. Two up-stairs

offices and store room below them are built. Heavy expanded metal is

used on the upper half of the partition walls of the offices, lower half

is made of wood. Concrete is used as a flooring material.

3. Combine harvesters section:

The shop is actually aside-entrance type of machinery storage

open on three sides. Part of it has been used as a workshop. Steel

supporting pillars are used to form the frame of the shop. It is about

96.6m in length and 15.3 in width. Local bricks are used to build the

closed end of the shop. An office and store room are built by using the

scrap sieves of combine harvesters. The lower surface doesn’t has a

hard surface floor. A floor plan of the workshop is shown in

Figure 4.3.

The floor plan of the combine harvesters workshop

4. Agricultural implements section and welding and black smith

unit shops:

These two shops are actually aside-entrance type of machinery

storage open on two sides. They are partitioned by a galvanized steel

wall. It is a typical gable-type of building with roof framing supported

with central pillars, and the ends are closed by galvanized steel walls.

A store room and an office are built in each shop by using the scrap

sieves of groundnut threshers. The lower surface for each shop doesn’t

has a hard surfaced floor. Aside view of the two shops is shown in

Figure 4.4.

5. Sheet metal section, testing and battery shop:

The shop is about 48m in length and 12.3m in width. Two

offices, small room for testing fuel pumps, and a battery shop are built

inside this shop. Local bricks are used to build the shop. The side

walls about 2m high and 1m above them left open for good lighting

inside the shop and ventilation. The shop is typical gable-type of

building and the roof without supporting pillars. Concrete is used as a

flooring material. A floor plan and aside view are shown in Figures

4.5 and 4.6.

6. Spare parts and supplies stores section:

The main spare parts store about 60m in length and 10m width.

Local bricks are used to build ends and side walls. Each side wall

about 3m in height and windows about 1m higher on them. The store

is a typical gable-type of building. Galvanized steel and concrete are

used as roofing and flooring materials respectively. A floor plan of the

store is shown in Fig. 4.7.

Therefore it can be summarized that,

1. All the section-shops are a gable- type of buildings

which is used mostly. This result agrees with that

reported by the AAAE & VA (1969).

2. Most of the section-shops are established with roof

framing without supporting pillars to save more

floor space in the work area of each shop. Local

bricks and galvanized steel are used as a siding and

roofing materials respectively, due to their long life

expectancy, fire resistance, easy maintained and

resistance to attack by vermin. These results agree

with that reported by Neubauer and Walker (1961)

and the AAAE& VA (1969).

3. Concrete is used as a flooring material in most of the sections,

which is the best. This result was confirmed by Neubauer and

Walker (1961) and Weller (1972).

4.2.1 Improvements in workshop design:

1. Caterpillar tractors section:

The design of the caterpillar tractors shop needed to be changed

to suit the sizes of crawler tractors and equipment required to facilitate

the work inside the shop. For time saving and cost, one of the small

farm shops of rigid steel frame can be transported to replace the

present shop. The new shop will be of 12m deep and 40m in length. A

hoist will be easily attached to the roof farming since a rigid steel

frame is used. This was confirmed by AAAE & VA (1969), who

reported that if you are planning on attaching a hoist to the roof

framing, this must be taken into consideration in your planning to

choose the suitable type of the roof framing. Figure 4.8 shows the

floor plan of the suggested workshop.

2. Combine harvesters section:

The west part of the present section-shop must be modified by

using a rigid steel frame that needs no supporting pillars to facilitate

the movability of combines and other equipment, such as fork-lift and

movable jacks in the working area. The shop also needed to be closed

by galvanized inside a closed shop. This was confirmed by Lewis

(1980) who reported that the type of materials used will contribute to

comfort and good working conditions. Concrete must be used to form

a hard surfaced floor of the shop, because it is easy to keep clean and

forms an excellent base for equipment and power tools.

4.3 Workshop personnel:

The Agricultural Engineering Department in the Scheme was

authorized to guide and control all types of works through the

sections of the workshop. Each section is managed by a separate staff.

Each one in the staff has a definite authority and responsibility within

his section. The organization plan of the workshop personnel is shown

in Figure 4.9.

4.3.1 Project director:

He is responsible of directing and coordinating all aspects of the

Project works.

4.3.2 Workshop senior staff:

The staff include, agricultural engineering department

(workshop) manager, workshop manager assistant for field operations,

workshop sections engineers, field sections engineers, store keepers,

accountants and clerks. Table 4.2 shows their qualifications and

salaries per month.

Project director

Workshop manager

(graduate)

Workshop manager- assistant for field

operations (graduate)

Field sections

engineers 2(graduates)

2(technicians)

Ford Tractors sectionSection engineer (graduate) Electrical unit engineer (technician)

Training sectionSection-engineer (graduate) Assistant-engineer (technician)

Caterpillar Tractors sectionSection engineer (graduate)

Assistant-engineer (technician)

Sheet metal and welding & blacksmith section Section engineer (Technician)

Combine harvesters sectionSection engineer (graduate)

Accounting unit2 accountants

Agric. implements section section- engineer (graduate)

Clerking unit3 clerks

Spare parts and supplies stores section 3 storekeepers

Figure 4.9. The works hop personnel organization including the

suggested training section.

Table 4.2 Senior staff qualifications and their total salaries per month

Training Educational status Administrative ability Work experience Total

Salaries per month

dinars

Not trained Higher studies

Short courses

Higher secondary school

Technical school

Graduate poor average Good poor average good Total No.

Senior staff

members

288,607 5 2 1 - - 8 - - 8 - - 8 8 Graduate

engineers 233,713 5 - 1 - 6 - - - 6 - - 6 6 Technical

engineers 107,209 3 - - 3 - - - - 3 - - 3 3 Storekeepers 67,788 1 - 1 1 - 1 - - 2 - - 2 2 Accountants 65,917 3 - - 3 - - - - 3 - - 3 3 Clerks 763,234 17 2 3 7 6 9 - - 22 - - 22 22 Total

4.3.2.1 Agricultural Engineering Department manager:

The manager is authorized by the Project director to direct and control

all types of works in the workshop. He is responsible for supervision

of all works done through the sections. His responsibility also includes

deciding and ordering for spare parts, analysis of annual machinery

reports, and decides whether to keep them in work or to be traded in,

and also daily management and follow up of the work in the sections,

through sections engineers reports.

4.3.2.2 Workshop manager assistant for field operations:

He always represents the department manager. He is

responsible for supervision of all machinery operations in the field

with assistance of filed sections engineers and managing of combine

harvesters’ section.

4.3.2.3 Workshop and field sections engineers:

Twelve engineers are responsible for managing workshop and field

sections works. These works include repairing and maintaining of

machines, keeping of records, ordering of required spare parts and

preparing of periodic reports. Six of them are graduates and the others

are technical engineers. Their particular jobs are shown in Figure 4.9.

As shown in Table 4.2 all of the engineers are of good experience and

administrative ability to control their sections’ works, but only about

29% of the engineers are well trained and the others are in need of

adequate training courses in repair and maintenance and management

of servicing organization. This result of in adequate training was

confirmed by Dawelbeit and Ahmed (1987).

4.3.2.4 Storekeepers:

Three storekeepers are responsible for organizing all stores

including un packing and binning of incoming orders, issuing of parts

and keeping records for each spare part received or issued in stock

control card. Table 4.2 shows that all the store keepers are of good

experience and administrative ability, but they are not trained during

the work.

4.3.2.5 Accountants:

Two accountants are responsible for organizing the wages and

incentives payments to the staff. Their responsibility also includes

recording of field operations done by the machinery and computing

their costs to be paid by the farmers at the end of the season. As

shown in Table 4.2 they are of good experience and administrative

ability and their qualifications are quite enough to perform well and

keeping their unit under good control.

4.3.2.6 Clerks:

Three clerks are responsible for organizing and controlling

office-orders and keeping records concerning workshop personnel and

machinery in special files. As shown in Table 4.2 they are of good

experience and administrative ability. Therefore they can control their

unit works very efficiently.

4.3.3 Operators:

Ninety eight operators are employed to drive Ford and Cater

pillar tractors and to do most of the field operations including

harvesting. Their characteristics including, age, educational status and

operational knowledge and training are shown in Tables 4.3a, b and c.

As shown in Table 4.3a about 42% of the operators are in age of 41 to

50 years, and about 34% of them are over 50 years and this fact will

limit their ability to work hardly. As shown in Table 4.3b about 44%

of the operators are illiterate or less educated (Khalwa). This result

will limit their understanding of idiosyncrasies of a tractor. As shown

in Table 4.3c only 2% of the operators are well trained, about 6% of

them are able to operate all caterpillar tractors and only 4% of them

are able to operate combine harvesters. 77% of the operators are able

to operate only Ford tractors, and about 11% of them are able to

operate only one type of Caterpillar tractors. This is reflected in poor

operation and maintenance of machines. These results were confirmed

by Bhutta et al (1997).

4.3.4 Mechanics:

Ninety seven mechanics are employed to do the repairings and

maintenance inside the workshop sections and in the field.

Table 4.3a Age profile of operators

Percent of total No. Age

24% 24 31 to 40 years

42% 41 41 to 50 years

34% 33 >50years

Table 4.3b Educational status of operators

Percent of total No. Formal schooling

31% 30 Illiterate

13% 13 Khalwa

53% 52 Primary school

03% 03 General secondary school

Total 4.3c. Operational knowledge and training of operators

Percent of totalNo. Particulars

02% 02 Operational training institutional

06% 06 Ability to operate all Cat. Tractors

04% 04 Ability to operate combine harvesters

22% 22 Keeping of records

11% 11 Ability to operate only one type of Cat.

Tractors

77% 75 Ability to operate only Ford tractors

Mechanics profile including educational status, training, work

experience and skills in doing repairings and maintainings are shown

in Tables 4.4a, b, c and d. As shown in Table 4.4a about 26% of the

mechanics are illiterate or less educated (khalwa). About 68% of

them are trained (Table 4.4b) in training section of the Scheme before

have been stopped due to financial problems, or in vocational training

centre of the government. As shown in Table 4.4d about 43% of the

mechanics are of good skills in repairings and maintainings. This

result ensures that most of the mechanics even those who are trained

doesn’t have an adequate training program to be of good skills in

repairings and maintenance. This result agrees with that reported by

Abdalla (1987).

4.3.5 Improvements to be organized:

1- The agricultural and technical engineers are the most effective

members in the personnel organization, and the success or failure of

the workshop depends entirely on them. Therefore intensive training

courses in repair and maintenance and management of servicing

organization are required. The training programme will be initiated by

the workshop manager and to be executed inside or outside the

workshop.

Table 4.4a. Educational status of mechanics

Percent of total No. Educational status

21% 20 Illiterate

05% 05 Khalwa

60% 58 Primary school

09% 09 General secondary school

02% 02 Technical school

03% 03 Higher secondary school

Table 4.4b. Training of mechanics

Percent of total No Particular

68% 66 Trained

32% 31 Not trained

Table 4.4c. Experience of mechanics

Percent of total No. Work experience

06% 6 5 -10 years

20% 19 11-15 years

74% 72 >15 years

Table 4.4d. Skills in repairing and maintaining of

mechanics

Percent of total No. Skills level 43% 42 Good

49% 47 Average

08% 08 Poor

2- Only two storekeepers are required to control the spare parts and

supplies stores. The selected storekeepers must be well trained in

management of stores organization using recent techniques like

computer systems to be able to control the suggested computerized

spare parts stores organization.

3- Only sixty operators and sixty one mechanics are required to be in

the personnel organization and their selection must be based on their

qualifications in operation and maintenance of machines. Table 4.5

shows that about 42% of the present salaries of the operators will be

reduced monthly from the operating costs, and Table 4.6 shows that

about 38% of the present salaries of the mechanics are added

unnecessarily to the operating costs each month. These results support

that reported by FAO (1985).

4- A training section must be established to train both mechanics and

operators. Therefore all the operators and service personnel will be

well trained to do their particular jobs properly. This result was

confirmed by Meij (1960), who reported that care and maintenance of

machines needed fully trained mechanics and skilled tractor drivers

with little training to carry out simple overhauls on tractors and

equipment.

Total 4.5 Total No. of the present and suggested operators and

their salaries per month

Excess in

present salaries

(dinars)

Excess in

present

No.

Suggested

salaries

(dinars)

Suggested

No.

Present

salaries

(dinars)

Present

No.

Job

222,995 7 290,694 10 513,689 17 Cat-

operators

789,004 31 1,106,852 50 1,895,85681 Ford

operators

1,011,999 38 1,397,546 60 2,409,54598 Total

42% 39% 58% 61% % of total

Table 4.6 Total No. of the present and suggested mechanics

and their salaries per month.

Excess in present

salaries (dinars)

Excess in

present

No.

Suggested

salaries

(dinars)

Suggested

No.

Present

salaries

(dinars)

Present

No. Section

47,150 2 385,654 15 435,804 17 Ford Tractors

47,589 2 183,398 08 230,987 10 Cat. Tractors

- - 165,369 06 165,369 06 Agric.

implements

103,804 4 311,412 12 415,216 16 Sheet metal and

welding &

blacksmith

708,990 28 506,422 20 1,215,412 48 Field section

907,533 36 1,552,255 61 2,459,788 97 Total

38% 37% 62% 63% % of total

4.4 Workshop tools and equipment:

The present workshop sections are provided with the basic

items of tools and equipment, which are essential to do all repair

works. Special power tools and equipment are also available in

battery, fuel pumps, sheet metal and welding and black smith units.

These equipment include the following:

1. Battery charger and hydrometer in electric unit.

2. Fuel pumps testing machine and injectors

adjusting machine.

3. A complete oxy-acetylene welding and cutting

unit and two arc welding machines in welding and

blacksmith unit.

4. Two electric saws, two lathe machines, crankshaft

grinding machine, two hydraulic compressors,

two portable electric drills, angle grinder and a

floor model drill press in the sheet metal unit.

For better equipment and tools management in the main

workshop, power equipment are actually required to do repairing of

machines easily, effectively and more economically than to be done in

private shops which are usually not found in the Scheme area. This

result agrees with that reported by FAO (1960) and Culpin (1976).

4.4.3 Improvements in equipment:

1. In additional to the existing equipment in the main

workshop, the Caterpillar tractors section must be

equipped with a hoist attached to the roof framing to save

both time and efforts lost in separating the heavy crawler

tractors parts to be repaired by the service personnel

inside the section shop.

2. Mechanics must be provided with good quality tools that

guarantee quick and better repairings and maintainings of

farm machinery.

4.5 Spare parts and supplies management:

4.5.1 Procurement policy:

Spare parts are usually purchased from the local dealers of

machines manufacturers through the purchasing unit of the Scheme,

according to the purchasing orders made by the workshop manger. In

this procedure genuine parts are usually procured. In case of urgent

orders of spare parts which are not available in the stocks of local

dealers at the required time, their procurement was done from the

local suppliers. These parts are usually not genuine and consequently

more breakdowns of machines are expected. This result was

confirmed by Bukhari (1982).

Management of the Scheme is failed to finance the workshop

with enough funds to procure an adequate stock of spare parts, and

consequently most of the farm machinery are out of work. Table 4.7

shows the percentage of the total costs of spare parts procured during

the studied period (1999-2002) to that estimated in the budget of the

Scheme. Only about 32% of the estimated costs of spare parts are

procured. This is attributed to the shortage of capital. This result

agrees with that reported by Dawelbeit and Ahmed (1987).

4.5.2 Spare parts store layout:

The main workshop spare parts store is well laid out with all

parts and bins clearly labeled. Plate 4.10 shows the layout of the store

including; issue-counter, main aisle, organized rows of bins, clearly

labeled parts bins, ample artificial light and the bulk storage area at

the end of the store. This result supports that reported by Lewis

(1980). Plate 4.10 also shows that bin units are made of metal which is

more economic and of high resistance to attack by vermin and fire

proof.

Table 4.7 Annual costs of spare parts from (1999 to 2002)

% of

total

Costs of spare

parts procured

(dinars)

Costs of spare parts

estimated in the budget

(dinars)

Year

50 23,978,053 48,000,000 1999

32 17,797,249 55,000,000 2000

25 14,000,000 57,000,000 2001

24 14,500,000 60,000,000 2002

70,275,302 220,000,000 Total

32 17,568,825.5 55,000,000 Average

Plate (4.10): Layout of the main spare parts store.

4.5.3 Stock control procedures:

4.5.3.1 Stock control card:

Each spare part has individual stock control card. In New Halfa

Scheme this control card named (stores card No. 51). The items

included in this card are shown in Appendix 2. This card is used to

control the movements of the spare parts and lubricants to and from

the stores. The card is also used by the general accounting section of

the Scheme. This result of using the stock control card agrees with

that reported by FAO (1960) and Butterworth and Nix (1983).

4.5.3.2 Order form:

Orders to suppliers are placed on special forms. A typical form

is shown in Appendix 2. The items required are listed by the section

engineer, then signed by the workshop manager and approved by the

financial manager of the Scheme. The form finally received by the

purchasing unit through which receipt of items will be done from the

suppliers.

4.5.3.3 Parts issue:

A definite parts issue form of four copies named New Halfa

Agricultural Production Corporation (NHAPC) form No. 69, is used

in the main stores. The items recorded in this form are shown in

Appendix 2. One copy will be send to the stores accounting section,

the second copy reserved by the storekeeper, the third copy will be

given to the receiver of parts issued and the final copy received by the

establishments security office.

4.5.3.4 Receipt order:

Spare parts are checked against the quantities on the invoices

received with them. Parts are un packed and binned on their particular

bins noted on the control cards covering them by the storekeeper.

Invoices are signed by the storekeeper and send to the stores and

supplies manager who listed the receipt items in stores form No. 50. A

typical form is shown in Appendix 2. One copy of the form is send to

the storekeeper to add the new items in the receipt side of the control

card.

4.5.3.5 Audit procedure:

The stock control procedures followed in New Halfa Scheme

parts store are very efficient, and to ensure their efficiency in keeping

parts organization under control, auditors checked and audited parts in

stores annually and also frequent irregular spot checks are carried out.

These results are supporting FAO (1960) findings, in which they

reported that a periodical detailed inventory check and audit was

carried out in government establishments, and also spot checks are

carried out at frequent, but irregular intervals to ensure that whole

parts organization is kept under close control.

4.5.4 Requirements:

1. The Scheme must give more attention to procurement

of the required spare parts by making funds available

at the required time to make use of full-lifetime of

machines.

2. Purchasing orders must be made early including all

parts required so as to guarantee their receipt from the

manufacturers through their local dealers in a suitable

time, and to avoid using of un- genuine parts from the

unreliable suppliers.

3. The main spare parts store must be computerized to

save time, minimize paperwork and to ensure easy

and good management of the store.

4.6 Care and maintenance in the main workshop:

New Halfa Agricultural Scheme is provided with a huge

numbers and types of agricultural tractors and implements. All these

farm machinery are in need of care and maintenance to keep them in

work and of good functional performance.

4.6.1 Services through Ford Tractors section:

These services including preventive maintenance and all types

of repairs. In the present workshop the scheduled maintenance is not

given much attention. Some of daily maintenance are not carried out

by the operators, such as checking of oil path cleaner, daily cleaning

of radiator and oil cooler with air compressor. Also some of the

scheduled maintenance are not carried out till failures occur, such as

draining of fuel filters every 50 hours from the accumulated water and

changing of hydraulic oil filter every 300hours. Table 4.8 shows the

average annual amounts of hydraulic oil consumed by Ford tractor

during the studied period (1999-2002), these amounts are 4.8L, 4.8L,

12.2L and 9.4 liters for the years 1999, 2000, 2001 and 2002

respectively. These results contrast that reported by Ford Motor

Company (1981) in which they recommended that hydraulic oil for

Ford tractor 6610 must be changed every 1200 hours of work by

using about 54 liters.

All big repairings of Ford tractors are done inside the section

workshop when the required parts are available. Minor repairings are

done in the field by the mechanics following the tractors. Adjusting of

fuel pumps and repairing of radiators are usually done in specialized

private shops in the area. Table 4.9 shows the total numbers of tractors

and their present situation including numbers in work, numbers

needed to be overhauled and numbers required to be traded-in. Only

about 29% of Ford tractors are kept in work, about 32% of the tractors

are required to be overhauled and about 39% of the tractors are needed

to be traded-in according to the technical decision already taken by the

workshop manager. These results are attributed to the unavailability of

spare parts to overhaul broke down tractors and improper management

in keeping the scraped tractors for many years without being traded-in

and poor maintenance. These results were confirmed by Dawelbeit

and Ahmed (1987).

Table 4.8 Annual lubricants consumption of Ford tractor

Average annual lubricants consumption

GreaseKg

Hydraulic oil (litre)

Engine oil (litre)

Average annual hours of use per tractor

No. of working Tractors

Year

3.7 4.8 69 543 44 1999 3.1 4.8 55 437 35 2000 3.75 12.2 75 612 41 2001 3.3 9.7 59 483 52 2002 3.5 8.0 64.5 517.0 43 Average

Table 4.9 Total No. of Ford tractors and their present situation

Scrap values

in dinars

No. of tractors

to be traded-in

Costs of

overhauling

in dinars

No. of tractors

needed to be

overhauled

No. of

tractors in

work

No. of the

required

tractors

Total No. of

tractors

56,000,000 70 34,800,000 58 52 110 180

39 32 29 % of Total

4.6.2 Services through Caterpillar tractors section:

Caterpillar tractors section is the most effective section in New

Halfa Agricultural Scheme, because no other similar tractors are found

in the area to participate in the execution of their particular jobs.

Caterpillar tractors are expensive and very complicated and required

specialized operators and mechanics who are not available in the area.

These reasons limit their ownership by the private sector. Therefore,

more care are needed to keep these tractors functioning and to do their

jobs efficiently. In the present workshop all Caterpillar tractors are

usually maintained and repaired inside the section when the

replacement parts are available. No regular programmes are followed

to do big repairings and overhaulings due to the shortage of capital

and spare parts to keep tractors in work and of good functional

performance.

Therefore most of repairings are done on a service unit

replacement basis, and consequently more tractors are scraped. All

crawler tractors are driven for long distances to do the required

operations. This practice leads to wear out of tracks which are very

expensive to be repaired. Repairings of fuel pumps, tracks and

crankshafts grinding are done in Caterpillar tractors

dealer workshop due to unavailability of specialized shops in the

Scheme area. Most of caterpillar tractors in the present workshop are

out of work due to improper management and lack of replacement

parts. Table 4.10 shows the total numbers of caterpillar tractors and

their present status including their ages, numbers in work, numbers

waiting to be overhauled and numbers needed to be traded-in.

Table 4.10 Types and total No. of Cat. tractors and

their present status

Scrap values (dinars)

No. of tractors to be traded-in

Costs of aver- hauling (dinars)

No. of tractors needed to be overhauled

No. in work

Total No.

Age (year)

Types of tractors

3,000,000 2 - - - 2 37 Cat. D8H 4,000,000 2 - - 1 3 18 Cat. D7G 3,000,000 2 3,500,000 1 1 4 18 Cat. D6SA 2,400,000 3 4,000,000 1 1 5 13 Cat. D5B 1,000,000 2 4,500,000 1 1 4 18 Cat. Motor grader 1,500,000 1 - - - 1 18 Cat. Dozer D6D 1,700,000 1 4,500,000 1 - 2 16 Loader 16,600,000 13 16,500,000 4 4 21 Total

62 19 19 % of total

Only about 19% of Caterpillar tractors are in work, about 19% of

tractors are in need to be overhauled and about 62% of tractors are

scraped and must be traded in. These results are attributed to lack of

capital and ignorance of labour who are repairing and maintaining

tractors and improper management and maintenance that reduce the

services lives of tractors. These results agree with that reported by

FAO (1995). All the working Caterpillar tractors are of low annual

hours of use due to improper operation and maintenance. Table 4.11

shows the total numbers of working Motor graders during the studied

periods (1999-2002), their ages and average annual hours of use.

Both the numbers of working tractors and their average hours of

used are annually decreased. This is attributed to un availability of

replacement parts and improper operation and maintenance of tractors.

This result was confirmed by Adam (2000).

Table 4.11 Total No. of working Cat. Motor graders and

their average annual hours of use per tractor

Average annual use

hours/tractor Total No. in workAge (years) Year

715.3 3 15 1999

615.5 2 16 2000

520.5 2 17 2001

486.0 1 18 2002

4.6.3 Services through Combine harvesters section:

Harvesting of wheat was the most critical operation carried out

in the field. Therefore, more effort was made by the Scheme

management to facilitate all problems concerning harvesting

operation, including procurement of adequate stock of spare parts and

employing of well-trained operators during the harvesting period. All

combines were repaired and maintained before the starting of

harvesting operation. The mechanics were chosen from other sections

according to their experience and skills in operations and maintenance

of machines. All repairs were done inside the section, except

reconditioning of fuel pumps which was done in specialized private

shops available in the area.

To ensure efficient operation of combines two gangs were

prepared to follow-up them in the field, and each gang was managed

by an agricultural engineering. Table 4.12 shows the total numbers of

combines, numbers in work and the average annual hours of use per

combine during the studied period (1999-2002). About 92.5% of the

total combines are kept in work during the studied period. This is

attributed to the good management in keeping combines well repaired

and maintained. This result agrees with that reported by Bukhari et al

(1987). The average annual hours of use per combine during the

studied period was about 262 hours, which is greater when compared

to that written in literature.

Table 4.12 Total No. of combine harvesters, No. of them in work

and their annual hours of use.

Average annual

hours of use per

combine

Total annual

hours of use

No. of

combines in

work

Total No. of

combines Year

331 3306 10 10 1999

204 1836 9 10 2000

262 2360 9 10 2001

246 2210 9 10 2002

9712 37 40 Total

262 2428 9.25 10 Average

This is attributed to the fact that combines are well repaired and

maintained and all of break downs during the work were properly

controlled to keep combines always productive. This result was

confirmed by Adekoya (1990).

4.6.4 Services through agricultural implements section:

New Halfa Agric. Scheme is provided with a great numbers and

types of agricultural implements. Most of these implements are

received from aid programmes. Adjustments and repairings are done

by the service personnel in the field. Overhaulings are usually done

inside the section. Some of these implements are used for one season

such as automatic levelers and sub-soilers. Implements accompanied

by tires for easy travels such as disc harrows are now used without

these tires which reduce the services lives of bearings, hubs and disks

of these implements. Table 4.13 shows the total numbers of

implements, their types, age, numbers in work, numbers needed to be

overhauled and that required to be traded-in. Only about 22% of the

implements are now in work. This is attributed to the improper

management in purchasing of agric. implement and unavailability of

spare parts and poor operation. Part of these results was confirmed by

FAO (1985) findings, in which they reported that the Schemes are

obliged to take what ever machinery is available from aid programmes

regardless of its suitability for the specific jobs to be done. Other part

was confirmed by Dawelbeit and Ahmed (1987).

Table 4.13 Types and numbers of agric. implements and their present status Scrap values

(dinars) No. of scraped

implements Cast of

overhauling No. to be

overhauled No. in work

Age (year)

Total No.Types of implements

600,000 06 - - - 20 06 Ridger (Massey) 6,000,000 60 3,000,000 60 40 15 160 Ridger (J.S) 1,300,000 26 - - 14 8 40 Disc plough (Baldan)

- - - - 20 1 20 Disc plougn(Mohin) - - - - 06 ½ 06 Disc plough (Giad)

5,025,000 67 2,000,000 20 20 13 107 Disc harrow - - - - 18 13 18 Herb. Sprayer

690,000 69 - - - 13 69 Fert. Distributor

540,000 27 - - 2 13 29 AbuV1 ditcher 1,600,000 08 1,000,000 10 10 8 28 W.L.disc 1,012,000 81 - - - 19 81 Automatic leveler 1,150,000 23 1,350,000 9 10 19 42 Trailer 840,000 8 - - - 19 8 Ground nut thresher

2,200,000 22 - - - 13 22 Ford tractor loader 1,200,000 04 500,000 1 3 18 8 AbuXX ditcher 300,000 01 500,000 1 3 16 5 Disc rome (20) 600,000 02 - - 1 13 3 Disc rome (28) 600,000 03 - - 1 16 4 Disc rome (56)

3,300,000 11 - - - 13 11 Sub soiler 3,000,000 04 - - - 16 4 Cat. Road roller

29,957,500 422 8,350,000 101 148 671 Total 63 15 22 % of total

4.6.5 Other workshop services:

4.6.5.1 Battery and electricity unit:

Electrical parts of tractors and combines including batteries,

starters, motors, head lambs and switches are repaired inside the shop.

Most of repairings done to the electrical parts are mainly due to

negligence of the operators in cleaning the accumulated dust and

lubricants on the electrical parts. This result was confirmed by

Johnson and Hollenberg (1960).The unit is well equipped with

efficient mechanics and equipments to carryout the required services.

4.6.5.2 Sheet metal and welding and blacksmith section:

The section is provided with specialized power tools and

equipment which are used efficiently to give proper services to all

farm machinery. These services are; constructing and rebuilding of

worn parts of implements, joining together broken parts and

manufacturing of lock-nuts and turnbuckles of adjustable chains for

Ford tractors, manufacturing of different sizes of bolts and nuts,

cutting of metal and cleaning of metal services. All these works are

done by the service personnel of good experience in operating

specialized power tools and equipment. These results ensure the good

management in providing the farm machinery with these adequate

facilities to do their jobs easily, efficiently and more economically.

These results agree with that reported by FAO (1960).

4.6.5.3 Sheltering of farm machinery:

Some of the tractors in the main workshop in New Halfa

Scheme are sheltered from the weather factors, others are left outside

subjected to paint faint, rust, bearing cracks and deterioration. All of

the combine harvesters are store inside the section-shop after the

completion of work in the field and prepared for storage. All of the

agricultural implements are left outside without shelter. Plate 4.11

shows the improper management in storing Ford tractors needed to be

overhauled in the yard space of combine harvesters section. This

result contrasts that reported by Culpin (1976) who stated that

complicated combines and tractors needed to be properly housed.

4.6.6 Improvements:

1. Most of tractors in the main workshop are used efficiently for

only one-third of their normal lifetime and the other two-thirds of their

normal lifetime are not utilized due to the unavailability of spare parts.

This result agrees with that reported by Dawelbiet and Ahmed (1987).

Therefore an overhauling programmes needed to be carried out to

make use of these two-thirds of tractor normal lifetime. As shown in

Tables 4.8, 4.9 and 4.12 about 32% of the total numbers of Ford

tractors, 19% of the total numbers of Caterpillar tractors and 15% of

the total numbers of agricultural implements must be overhauled so as

to be of good functional performance and of high annual use hours.

Plate (4.11): Improper storing of Ford tractors

2. Other tractors and agricultural implements which comprised about

39% of the total numbers of Ford tractors, 62% of the total numbers of

caterpillar tractors and 63% of the total numbers of implements must

be traded-in, because it is uneconomic to keep them in the workshop.

Their scrap values are quite enough to execute the overhauling

programmes of other tractors.

3. Caterpillar tractors section must be supplied with a heavy duty low

loading self propelled trailer to safe time and costs spent in repairing

of tracks of crawler tractors.

4.7 Estimation of repair and maintenance costs:

In New Halfa Scheme, it is difficult to estimate repair and

maintenance costs of farm machinery because usually accurate records

over the lifetime of a machine are not readily available.

4.7.1 Repair and maintenance costs of Ford and Caterpillar

tractors:

Costs of repairs and maintenance are closely related to the amount of

annual use of the tractor and include costs of spare parts and labour.

Table 4.14 shows the averages annual hours of use of both Ford and

Caterpillar tractors and their averages repair and maintenance (R&M)

costs per hour during the studied period (1999-2002). The averages

annual hours of use for Ford and Caterpillar tractors were low

compared to that recommended.

Table 4.14 Average annual hours of use and average R&M costs

per hour for Ford and Cater pillar tractors.

Average annual R&M

costs (dinars/hr)

Average annual

hours of use

Types of tractors

884.4 517 Ford tractor

1066.5 1001 Cat. D7 tractor

1066.5 1001 Cat. D6 tractor

5588.2 147.5 Cat. D5 tractor

1719.6 613 Cat. Motor grader

12166.3 67 Cat. loader

This is attributed to the lack of spare parts and improper

operation and maintenance. This result was confirmed by FAO

(1995). The average annual repair and maintenance cost per hour for

Ford tractor was lower than that of Caterpillar tractors. This is

attributed to the fact that Ford tractor was of low power size as

compared to that of Caterpillar tractors which are of more

sophisticated components, and therefore subjected to more

breakdowns. The averages annual repair and maintenance costs per

hour for Caterpillar tractors were decreased with increase in annual

hours of use. Caterpillar loader had the highest repair and maintenance

cost per

hour, followed by Cat. D5tractor, Motor grader and Cat.D6 or D7

tractors respectively. This result was confirmed by Bukhari et al

(1988) who reported that repair and maintenance cost per hour was

lower for tractors used for longer time each year.

4.7.2 Repair and maintenance costs of combine harvesters:

Repair and maintenance cost of combine harvester was usually

the highest single item of operating costs due to the high prices of

spare parts. In New Halfa Scheme more care was taken towards

completion of wheat harvesting operation in its recommended period,

and therefore an adequate stock of spare parts was procured to do the

required repairings and maintainings to guarantee a high standard

combine performance and reliability.

Table 4.15 shows the average annual hours of use of combine

harvester and its average annual repair and maintenance (R&M) cost

per hour during the studied period. The average repair and

maintenance cost per hour for combine harvester was increased with

increase in age of combine. This result was confirmed by Bukhari

(1982) who reported that the cost of repair and maintenance was

necessary to keep machine in serviceable condition and increased as it

becomes older.

4.7.3 Repair and maintenance costs of agricultural implements:

Table 4.16 illustrates the averages repair and maintenance costs

()of different implements. Fertilizer distributor had the highest

average annual repair and maintenance cost per hour among the agric.

implements used in New Halfa Scheme. This is attributed to the fact

that fertilizer distributor had the lowest average annual hours of use

and more casual labour are used to follow- up the operation of

fertilizer distribution in the field. Abu XX ditcher had the lowest

average annual repair and maintenance cost per hour, which may be to

its highest average annual hours of use. The average repair and

maintenance cost of Baldan disc plough was greater than that of

Mohin disc plough. This is attributed to the fact that Baldan disc

plough was old and of low annual hours of use. This result in

agreement with that reported by Bukhari (1982).

In case of tillage implements, disc harrow had the highest

average annual repair and maintenance cost, followed by ridger,

Baldan disc plough, Mohin disc plough and disc rome respectively.

This is attributed to the variation in annual hours of use, prices of

spare parts and labour charges for each operation done by these tillage

implement.

Table 4.15 Average annual repair and maintenance cost of

combine harvester.

Average annual R&M

costs (dinars/hr)

Average annual

hours of use

Year

1808.2 331 1999

1850.4 204 2000

1974.6 262 2001

2414.8 246 2002

Table 4.16 Averages annual hours of use of agric. implements

and their averages annual R&M costs per hour.

Average annual R

&M cost (din./hr)

Average annual

hours of use

Age in

(years)

Types of Implements

448.5 340 13 Disc harrow

390.0 400 15 Ridger

324.7 360 8 Disc plough (Baldam)

248.3 470 1 Disc plough (Mohin)

1220.2 90 13 Fert.distributor

798.6 180 8 W.L.disc

366.3 180 13 Abu VI ditcher

240.0 950 13 Disc rome

165.6 1000 18 AbuXX ditcher

CHAPTER FIVE

CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions

The following conclusions can be drawn from the study:

1. Workshop location, design and construction were suitable and

more convenient for the service personnel to do their jobs

properly.

2. Personnel numbers employed on full- time basis to take care of

farm machinery more than what actually required, therefore

increasing the operating costs unnecessarily and must be

reduced as required.

3. Most of operators and mechanics were not adequately trained in

operation and maintenance of farm machinery.

4. Routine and scheduled maintenance were not followed as

recommended.

5. Most of Ford and Caterpillar tractors were stored out doors

subjected to weather factors that increase their depreciation and

repair costs.

6. Most of tractors and agricultural implements in the Scheme

were out of work due to the lack of spare parts and improper

management and maintenance.

7. Record keeping system followed in the main workshop and

other farm shops was not adequate and contain incomplete data

about services carried out.

5.2 Recommendations:

1. Establishing of training section is of great importance to

train the operators and mechanics for proper operation and

maintenance of machinery.

2. A record card must be kept for each machine in the main

workshop or in other farm shops showing what repairs are

done.

3. All tractors and machinery must be properly housed to

protect them from weather factors.

4. Idle items of spare parts in the main spare parts store must

be replaced by the required ones..

5. The scrap machinery must be sold to make use of their scrap

values in overhauling the idle ones.

6. Decision-makers in the Scheme must find ways that

guaranteed the funds for the workshop management to

replace the old machinery by new ones to increase the

productive hours and reduce the operatin

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Appendix (1)

specifications of Agric. implements.

Types of implements

Machine

make

Model

No. of

bodies

Working

width

(cm)

Maximum

depth (cm)

Width of cut

(cm)

Disc diameter

(cm)

No. of nozzles

Tank size

(litre)

Hopper size

(kg)

Rider U.S.A J.S. 5 400 17.5 - - - - -

Disc ploughs Germany Mohin 3 - 30 25.30 64 - - -

Disc ploughs Sudan Giad 3 - 30 25-30 65.5 - - -

Disc harrow England Tofline 20 238.5 22.5 - 57 - - -

Disc rome U.S.A Rome 20 315 30 - 76.5 - - -

W. L. Disc England Massey 24 400 12.5 - 45 - - -

Herb. sprayer England Allman - 720 - - - 9 600 -

Fert. distributor Brazil Tanzi - 720 - - - - - 300

Appendix (2)

Stores Form No. (51) Minimum Level of Stock Part No. Unit Average Annual Description Consumption

Signature Quantity in

stockNo. of Issue

Receipt form (No. 69)Quantity

Issued No. of additional

Form (No. 50)Quantity Received

Date

Fig.1 Stock control card used in stores.

يمبسم اهللا الرحمن الرح

Appendix (2) (Contd.) New Halfa Agri. Prod. Corp Agric. Engineering Department

Section: Order No.: Date:

To purchasing unit Items to be purchased

Description

Unit Quantity Part No.

Section: Job Agric. Eng. Dep. Manager Signature:

Dep. Manager Financial Dep. Spare Parts & Supplies

Dep.

Approved

Signature

Job

Approved

Signature

Job

Local No.

Signature

Fig. 2 Order form used in New Halfa Scheme.

Appendix (2) (Contd.) NHAPC FORM NO.69 New Halfa Agricultural

Indentters Ref Production Corporation Indent . Pro No. REQISION FOR STORER

ORIGINAL Pro No.... .... .. .. .. .. ..

Acconnting Unit Dept. ………....................…… Consig to ……………..................................…… .

Despatch Details sub accun: No.

Reg. Made out by APPROVED BY ... .. ..... .. ..

Total cost of material

DEMANDS ISSUES FOR USE OF FINCDE DIVISI ON Catalogue Issued Balance Previous Unit Price unt

QUANTITY Unit Section No. Descriptio

n Oty. Unit O/s stock Pro no SD. PT. PT. .......................................

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DATE .. .. .. .. .. DATE .. .. .. .. .. .. Dept . Expenses Total cost

Date __________________Signature______________________ Job: ________________Name: _____________________

Figure 3 Parts issue form used in NHAPC.

Appendix (2) (Contd.)

FROM NO. 50 Description of additional materials to Stock Section No. … .........………………

Previous No. Quantity

in stock Order No. Invoice N o. Total value Part No. Quantity received Received

from PT SD

Description

Quantity Unit

Date .. .. .. .. ...

Store Keeper Signature : .. .. .. .. .. ... .. .. . .. ..

Figure 4 Additional form used in NHAC.

Appendix (3)

Annual R & M costs of tractors and combine harvesters

Annual repair and maintenance costs in (dinars) Average Total

2002 2001 2000 1999

Average NO. of working tractors

Types of Tractors

19,661,901.62 78,647,606.4721,262,185 17,216,091 19,224,290.67 20,945,040.8 43 Ford tractors

5,337,878.52 21,351,514.073,128,100 3,783,496.65 6,965,295.35 7,444,622.07 5 Cat. D7&D6

819,835.2 1,639,670.4 931,950 707,720,4 - - 1 Cat. D5(dozer)

2,108,178.5 843,271.4 1,311,440 1,283,640 2,439,500 3,398,134 2 Cat. Motor grader

815,140.2 1,630,280.4 925,360 704,920,4 - - 1 Cat. Loader 4,842,984.68 19,371,938.7 5,336,637 4,660,000 3,397,249 5,978,052.7 9,25 Combine

harvester

Appendix (3) (Contd.)

Annual R&M costs of agric. implements

Annual repair and maintenance costs in dinars Average Total

2002 2001 2000 1999 Average NO. of

working tractors Types of Tractors

3,900,312.8 15,601,251.2970,000 3,900,000 5,200,00 5,531,251.2 25 Ridgers 1,633,571.0 6,534,285 3,000,000 2,120,000 314,000 1,100,000 14 Disc ploughs 2,132,000 8,540,000 1,880,000 1,880,000 1,880,000 2,900,000 15 Disc harrows 575,000 2,300,000 150,000 950,000 6,00,000 600,000 4 W.L.discs 329,464 1,317,826 - - 1,317,,856 - 3 Fert.

distributors 197,817.3 791,269.18 - 150,000 300,500 341,269,18

3 Abu VI

ditchers

684,000 2,052,000 - 586,500 665,000 800,500 3 Disc romes 331,200 1,324,800 400,000 250,000 324,800 350,000 2 Abu XX

ditchers

evaluation of farm machinery - University of Khartoum ...

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