COMPANY’S NAME - mustafa Cigal€¦ · Web viewNow as Çukurova in production of forklift hydrostatic system is being implemented as accepted the greatest technological and

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COMPANY’S NAME

ÇUKUROVA MAKİNA İMALAT ve TİCARETİ A.Ş

COMPANY’S LOCATION

Adana Yolu Üzeri P.K. 61 33470 TARSUS / İÇEL TURKEY

Phone: 90 (324) 613 86 40-41-42(Pbx) Fax : 90 (324) 624 28 94

COMPANY’S PROFILE

Business enterprise in Çukurova Holding established with the name of Çukurova Makina İmalat ve Ticaret A.Ş. at 1970. Combine with John Deere license, begin to produce tractor in 1981. Considering the chancing economical condition and the condition of market since 1986.It has been producing industrial and working machines. After the years while the production of agricultural machines was degreasing, the industrial and working machines product increased. The production of the tractor was stopped in 1988 and the production of combine was stopped in 1992. The factory established on 109.710 (14.444 closed area) range. The products produced on modern counters are worked in Turkey and difference countries of earth today. It is continuing to produce products such as 7 different model diesel forklifts which have various lifting between 1.5 and 8 tones, the leader having rubber wheel and breaking on back has 2,5 ladle and backhoe loader breaking on back has 1 capacity. In addition to this business enterprise which has all of the industrial and working machine potential produce different product in the past (way road, cylinder, excavator broom etc.) If factories are working perfectly, 1750 machines will be produced in every year. It accepted the production of 1000 machines in this year. Now as Çukurova in production of forklift hydrostatic system is being implemented as accepted the greatest technological and has the maintain less than its rivals with this technology not only in Turkey which is produced but also it has demands outside of Turkey. In addition to these, all machine type’s properties and pictures are given in machines catalogues appendix section in my training report.

Signature of Controller

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ORGANIZATION FIGUREOF ÇUMİTAŞ FACTORY

In addition to these, I will explain factory organization in next pages. And, I want to give planning of factory.


GENERAL DIRECTOR

REPRESENTATIVE OF ADMINISTER

SECRETARY OF GENERAL DIRECTOR

ASISTANT OF GENERAL DIRECTOR

IMPORTING

ASISTANT OF GENERAL

DIRECTOR TECHNICAL

DIRECTOR OF BUSINESS

ENTERPRISE

DIRECTOR OF

QUALITY CONTROL

DIRECTOR OF DEVOLEPING

THE PARTS AND DESIGN

CHIEF OF METHOD

DIRECTOR OF PRODUCTION AND

TRADING

INFORMATION PROCESSING

DIRECTOR OF

FINANCING

CHIEF OF PERSONALS

CHIEF OF ACCOUNTING

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TECHNIQUE MAN POWER

Çukurova Makina İmalat veTicaret A.Ş have 17 mechanical engineers (1 general headmaster, 2 assistant of general headmaster, 6 trading and production headmaster, 6 business enterprise, 1 quality control, 1 designer), 3 industrial engineers (2 trading and production planning, 1 quality control), 1 agricultural engineer at trading and production planning .In addition to expert members interested financial managerial works, accounting exporting of the Çukurova Makina İmalat ve Ticaret A.Ş.

PRODUCTION PLANING AND CONTROL’S TECHNIQUE

Production planning department is found in ÇUMITAŞ. I think this department is working very well. 2 mechanical engineers and 1 industry engineer are working here.

Production planning program is prepared on every year. They are working according to this program. But orders, which are taken in year, change this program.

According to their works, this department is divided on 3 sections.

Plate production Production with milling, turning, CNC, etc. Side Industry

These three sections have product tree for all machine types. This tree shows number of parts, which are used in one machine from bolt to engine. These product trees have been loaded in computer, if they are necessary, they will be used. Trees are different in al sections

I want to give some knowledge about workflow, Firstly, technical drawing is drawn at design department and it is send to

production planning. According to coming drawing, material is controlled. If material is not enough for production, it will be demanded to buy department. If material is enough; Work commend document is prepared. It has 3 copies, firs copy is sent to production and planning department second is sent to accountancy, last one is sent to inside of factory with store material order document. These documents are given at production planning appendix section in my training report too.


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Plate production:

Parts is drawn with AutoCAD program and loaded in disk. This disk will be loaded to CNC Cutter machines. Then plates are ordered to store. Store workers are sending plates according to order to plate production section in factory. Plates are cut with oxygen, plasma or laser cutting machine. In addition to, if welding operations are necessary for plates, again they will be sent to plate production section in factory.

Production with milling, turning, CNC, drilling, etc.:

Engineer that works in this section, are working similar plate production. But they interest different parts. He interests solid parts, pipes, rods, profiles, and lamas. All parts are controlled and ordered with work commend to store and at last send to interested production department. During I am studying store section, I will give more knowledge about work commend.

Side industry:

Sometimes ÇUMİTAŞ works with side industry firms. If materials need to heat works, chrome covering or galvanize covering, they will be sent to side industry firms. For example; Hydraulic rods need to heat works. But this operation is not made in ÇUMİTAŞ, so that company works with ISISAN.

After the all these works, number of materials that are used in 3 sections, are decreased from stock. If materials are come to end or it is not enough for a new production, these conditions will be told to buy section. At the last of the year, meeting is made for new year. Row materials will be bought according to this meeting.


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ACCUANTANCY DEPARTMENT

Store entering cards are written in store section according to coming materials to store. This card has 3 copies (again I will explain in store section). One copy is come to here. MAHSUP document is prepared according to these cards by accountancy personals. It is given at accountancy appendix.

Interested production departments prepare work commend and it is sent to production and planning department. After the necessary investigations, this work commend is come to here. It is given at appendix, too.

Material exit price, material workmanship price and general production expense are calculated here. I want to give some information about these prices.

*Material exit price:

It is only a row material price. This price is given from store to accountancy department.

*Material workmanship price:

It is calculated according to worker’s work hours. It is followed with workbench following card. It is given at accountancy appendix, too. One worker is how long work in one workbench according to only one work commend is found in this document. All workers’ hours are added to each other. According to these hours, workmanship price is calculated for one work commend.

I want to give one example for only one work commend.

Workers Working Times in 1 day Salaries in 1 month First worker………………..120min………………………….310millions Second worker……………..100min…………………………400millions Third worker………………110min………………………….250millions Fourth worker……………..115min………………………….515millions Total………………………..445min………………………...1475millions

This calculation is made with only 4 workers and one work order.

*General production expense:

It is outside the material price and workmanship price. There are transports, electricity, water, foods and official workmanship expenses etc. I have given one example document about the calculation of the material price in accountancy appendix. After the all productions, parts are come to assembly section for. Work commend is prepared for assembly operations, too. Again necessary calculation is made similar in productions. As I said at quality control, machines are tested at


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their maximum capacities. If machines have not problems, quality control exit card will be prepared, and this card will be sent to here. Then new production work commend is come to here. But it is different from first commend. It has production finishing date and interested engineer’s signature.

Assembly and productions prices are added to each other. Lastly KDV and profit are added to them. According to these calculations, selling price is determined.

In addition to these works, workers salaries documents are prepared here, too. After the worker performance card is prepared in personnel’s department, it will be come to here. Worker’s working hours, days and extra days are found in this card. It is given in accountancy appendix. Worker’s salaries are determined according to them.


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BUYING AND MARKETTING DEPARTMENTS

This department is working tied to Trade and Production Planning Director. 2 mechanical engineers and 1 helper worker are working here. Mainly 2 main groups divide it; 1- Helper products

2- Systematically Products a-Row Materials

b-Home Materials(Which are produced in Turkey)c-Plate Materials

Helper Products:

There are papers, pencils, computer pieces and something is used in office, not used on produced machines. If these goods are finished in one office, interested person arranges helper materials request form. Prices are fixed the price of them at market by buying engineers. When the suitable firm is found, consumption material request form will be prepared. General manager has signed all forms. Then given materials are put in store with store receipt or firm receipt form. Systematically Products:

According to coming request from all departments, absent materials list are wrote in store, and it is come to buying department. This list is called work order absent materials report. Then absent materials are ordered to interested firms. Generally ÇUMİTAŞ has been worked with these firms too long years ago. When the materials are ordered, old price and new price will be compared with euro or dollar. If new price is more than old price, conversations will be started with other interested firms. If they are equal to each other, or old price is more than new, Order Consignments programs will be prepared and one copy will be sent to interested firm. If interested firm is given okay, order will be finished, and they will be given to factory as a short time.

Row materials, home materials, plate materials are interested in subgroups of the systematically products.

*Row Materials:

According to request, which is come from design section, store will be checked. If row materials are needed, row materials list will be prepared. Similar ordering works are made for them. But in addition to them, coming materials are sent to KOSGEB for some tests. Their chemical properties are tested in KOSGEB. These tests have to make, because some materials will be sent to heat works. Heat works are made different to all materials.


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*Home Materials:

When the works have been very well, 3 months home materials lists were prepared. Absent materials were known before one month. So orders had been made according to this list. But now, there is little production in factory. So, they are order materials day to day.

*Plate Materials:

Iron plates are taken from Ereğli Demir Çelik A.Ş. according to them; their iron plates are high quality. So, money is not important for them. Generally, four orders are given to them at one year. Customer order form is prepared for plate materials.

In addition to them,

*Transmitting form is prepared on marketing department for changing materials with guaranty. It is coming to buying department. If necessary materials are found in stock, they will be sent to customer. If it is not found, it will be ordered to interested firm with guaranty document.

*During the production, when absent materials are found, interested department will be prepared transmitting note form. And it will be sent to buying section. According to this document, materials are ordered to interested firm.

*If buying department is working with a new firm, firstly one sample is wanted. Necessary all test are made on it. When this sample is given okay, orders will be given to this firm. But it is not given okay (sample has some problems), after the improving on materials, again orders will be given to this firm.

All documents that are explained are given in buying and marketing appendix.

Last one, marketing works are not made in ÇUMİTAŞ very well. Other firms that dependent on ÇUKUROVA HOLDİNG are making marketing works in everywhere in Turkey and world.


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ORGANIZATION OF FACTORY

As I explained before, General Manager is found at factory head. Unities managers are working tied to him. Then chiefs, superior and foremen are coming in ÇUMİTAŞ. If there is a problem in factory, firstly it is said to foreman, if he does not found solution for it, he inform to superior then inform to chief, lastly if this problem still is not removed, it is informed to unities manager. They work on this problem with general manager.

According to workstation, if one department need a new machines or workers, they will inform to personnel manager. Personnel manager makes necessary investigations interested with these subjects.

If new workers are obtained to factory, unities manager must be take okay. Salaries and personnel rights are prepared and followed by personnel manager. If there is economical crisis in factory, workers may be gone out. In these positions general manager informs to personnel manager. He makes necessary investigations. If he needs, he will talk with unities manager about worker performances. After the several formalities workers will be gone out of the factory. Personnel’s cards are found in personnel manager office. These cards are documented at essence files. Personnel manager controls personnel’s performance, behaviour in factory, work efficiency, relation with their chiefs and workers friends, etc. According to them, personnel manager make all appointment works salaries and evaluate are.

In addition to these, personnel directorate interests lunch, workers transporting service, workers healthy and safety. Necessary orders and following works are made here, too.

FACTORS FOR CHOOSING COMPANY’S LOCATION

ÇUMITAŞ has been built in Tarsus where is between two big cities which are Adana and Mersin. So, side industry is not problem for factory. And young people power is found here. Drinking water is bought from Tarsus Municipality, cleaning water is found from well, electricity is bought from Çukurova Elektirik A.Ş. ÇUMITAŞ and Çukurova Elektirik are found in similar holding which is ÇUKUROVA HOLDİNG. So electricity is given here continuously.

In addition to these, ÇUMITAŞ factory is built on central road E-5. So, transport is very easy to this company. Mersin is a harbour city and Adana has an airfield, so international transport is made easily. For example Perkins Engines are come from England to Mersin with seaway, than they are transported to hear on E-5 road.

I m seeing, geography location is most important for a factory. So before the factory building, location investigation will be made very well.


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STORE AND STOCK CONTROL

One industry engineer and two workers make store and stock control’s works. Stories are classified seven groups according to types of materials.

*Deposit Store*Side Industry Store*Metal Plate Store *Entering Store*Spare Part Store*Row Material Store*Imported Material Store

In addition to these, given back, scrape and half row material areas are found in entering.

I want to give some knowledge about workflow in store.Firstly the materials that are taken from out, are unloaded to deposit

store. Take delivery of coming material stabilize of them. And entering quality controller makes quality controls of them. The materials are approved settle to describe upward according to types of materials.

All works are documented in store. For example entering to deposit store document at deposit store, quality control document and report at quality control section at store. Store entering and consignment documents are prepared according to quality control report.

In addition to these, many documents are prepared in store section. For example wastage materials and scrap delivering document, store return document, store request material form etc. These documents are given at store and stock control appendix section in my training report too.

*Wastage Material and Scrap delivering Document:

It is necessary for the material, which is broken-down in factory, can be through to scrap area. It has 5 copies, one copy is sent to accountancy, second is sent to production and planning section, third is sent to general director assistant, one copy is sent to scrap area, and last one is documented in store. According to amount of the materials, which are thrown to scrap area, costs are decreased from general cost price at accountancy section with this document.

*Store Return Document:

It is used for the materials, which are their mistake are found after the entering, are returned to seller firm. It has 3 copies, one of them is sent to production and planning section, other is sent to quality control section, last one is send to accountancy department.


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*Store Material Request Form:

It is used inside of the factory. If any section needs any materials, this section is sent this document to store. It has 3 copies, too. These copies are sent to production and planning section, accountancy and delivering.

In addition to these, one industry engineer controls stocks with HOBIM computer programme in store. Number of materials and quantity of materials are loaded to computer with their control number. Similar control number is found control card is found on materials. Store entering, store exit, transfer between sections etc. documents are prepared with this programme. These documents are given at store and stock control appendix section in my training report, too.

On the other hand production trees are found in this programme according to all types of working machines. This programme is not only used here, but also it is used at accountancy, buying and marketing section, too.

Furthermore, stocks are controlled with some instructions in store. These instructions are checked and renewed every year. I want to give a few instructions for some materials.

Stock Of Electronic Materials Instructions

1. You have to stock them on track or bunks.2. They have to been keep n normal room condition temperature.3. Their upper side must be closed with clear nylon bag.4. Electricity keys or plugs are not found around the tracks and

bunks of materials. 5. They have to been stocked on the insulating materials for example

on woods.

Stock Of Leakness Materials Instructions

1. Store stocking: Firstly take a nylon bag, then packed on cartoon box

2. They have to transport to assembly band or cylinder room with forklift.

3. These materials must be kept in nylon bag on cylinder room or on assembly section. When they are used, will take from nylon and assembly where it is used.

Stock Of Paints, Thinner, Paste, And Other Burning Materials Instructions

1. When these materials are bought from firm, put on tracks, then they will be gone to deposit store.

2. Quality controller has to control them.


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3. The materials that are okayed, are gone to store with forklift (the track’s height must be equal between 25cm and 30 cm from ground)

4. These are stocked in to the distance other burning materials.5. They are stocked according to material stock number.6. Fire extinguishers have to found around the stocked area.7. These areas must be projected from hot air.8. It has not to smoking in these areas.

Stock Of Honing Pipe Instructions

1. Pipes must be projected from water and dump.2. Pipe’s two open ends must be closed.3. They must be stocked in clear area.4. If you don’t use them at a long time, they must be controlled once

one every 3 months, if it is necessary they will be attention or lubricated.

5. Old stocked pipes are put on front side, new stocked pipes put to back side.

These instructions and many instructions are put on every windows glass in store.

POWER CENTERS IN FACTORY

ÇUMİTAŞ has one transformer that its capacity is between 800kw and 1000kw. 30,000kw electricity, which is come from TEAŞ, is reduced to 400waat with this transformer. And one generator that its capacity is 400kw, is found here, too.

In addition to this 2 boilers are found here. Their capacities are hot water and hot air need are obtained from these boilers.

Furthermore, 3 compressors are found in factory. 2 compressors are

called with pistons, last one is called with gears. Their capacities are from to

. I have interested one compressor. So I want to give its properties;

Gear Rotor Air CompressorModel : SSR-ML50Pressure : 7.5 barTotal Power : 57,5kw

Capacity :

Dimensions : 2590*1067*1042Weight : 944 kgNoise level : 75 dBA


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WORKS FOR INGREASING OF PRODUCTION

Increasing production department is not found at ÇUMİTAŞ. But this company is a member of MASS. Mass organizes a lot of seminar for explain the importance of increasing of production. And education notes are sent to members who are not gone to seminar, by Mass.

In addition to these, during my training period I saw some works for it. These works are shortly:

*New working machines are bought to company. For example, although factory has two plate cutting machines, which are oxygen and plasma, they have bought a new plate-cutting machine that is laser cutter machine.

*Minimum two workers are educated about CNC Turning, Laser Cutter, Vertical and Horizontal Production centers. So, only these machines are worked at 2 watches.

Furthermore, committees have been established between departments interested with production. Periodic meetings are prepared for it. And they are working with ISO standard. Most important thing is, costumer’s pleasure according to them. And market condition is important, too.

On the other hand, I think, if workers and engineers work in good conditions (for example good salaries, good healthy etc) production will be increase. If workers love their jobs, they will make their works very well.


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QUALITY CONTROL

Row, half row and produced materials are controlled on every stage in this section. It is made in two stages in ÇUMITAŞ. One of them Entering Quality control is made in entering store, last one is made in factory.

Quality control in entering store:

All materials, which have been bought to factory, are controlled here. Material dimensions, leakness , hardness are tested here. They have some missions. These are shortly;

1. Row and half row materials are controlled.2. Materials, which have been controlled, are sent to store completely.3. Firms that work with ÇUMİTAŞ, are visited and educated by

entering quality controller.4.All given materials must be documented here.

Lastly, some cards are taken in materials here. If materials have some problems, they will be sent back to firm. During this operations, red card that means return to produced firm, is attached to materials. If materials are taken okay from quality controller, white card will be attached to materials. It is called accepted materials card that means these materials can be used for production. These cards are given at quality control appendix section in my training report, too.

Quality controls in factory:

Quality control works are made all section fastidiously. They are made in factory on these sections;

*Iron plate production quality control*Welding quality control*Milling, turning, CNC, stoning etc quality control*Assembly quality control

I want to give some knowledge about these quality control sections

*Iron plate production and welding quality controls:

Materials that have been cut with CNC cutting machines are controlled according to technical drawing. If they are taken okay, they will be sent to whatever department according to technical drawing. Only one worker is working here. After the pressing, welding and cutting operations parts are controlled by him.


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If materials are suitable according to technical drawings that are drown by designers, white control card will be tied on them.

If parts are not suitable;a- If it is possible for correction of problems, yellow cards will be tied

on parts.b- If it is not possible, blue control card is tied on them.

Blue card means, produced material is not useful for assembly. It has to be sent to scrap. These cards have 3 copies. First copy is sent to production and planning section, second is documented in quality control section, last one is tied on parts. These documents are given at quality control appendix section in my training report too.

*Milling, turning, CNC, stoning etc quality control:

Produced materials are come to here with technical drawings. Part dimensions and surface quality are controlled here. If all parts are in their tolerances, white cards will be tied to them similar to welding quality control. Blue and yellow cards are found, too and they are used on similar problems in welding department.

In addition to these, if parts number is increasing, percent of controlled parts will be degreased.For example;

Between 2 and 8 pieces………………………2 parts are controlledBetween 151 and 280 pieces…………………5 parts are controlled

*Assembly quality control:

It is the last quality control in factory. After the assembly operations, machines are worked with their maximum capacities. If whatever material is failed, it will be sent to necessary section for improving with yellow card. I every thing okay, quality control exit card is prepared for these machines. And one copy is put in machine and one copy is send to accountancy department. This card copy is given at quality control appendix for MEK 15ET forklift.


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ASSEMBLY DEPARTMENT

Planning Of Assembly:

Produced materials, single parts, ready parts, engines etc are assembled to each other in montage section. One mechanical engineer and ten workers are working here. When material is designed in design room, assembly plan will be started. All parts must be designed at lover assembly cost by designer. As I said before quality controllers are controlling all parts at all steps. Part performance, clear, taken scrap of it etc are checked. If everything is okay assembly operation will be started.

Assembly plan is included technique drawing that is necessary for assembly and some instructions that are included assembly flow. They are described at assembly plan.

*Flow line for together assembly*Necessary apparatuses, and helper materials*Control and measuring materials*Time for assembly operation

Everything that is necessary for assembly is added to assembly plan.

Organization Types Of Assembly:

*Serial Assembly:

Construction groups or finished parts are assembled to machine on bands. During these operations, bands can be active or fix. This method is used for big and serial productions. At serial montage, all parts are passed in front of workers.

*Fix Assembly:

All parts are assembled on constant, fix stand. Advantage of this assembly is, big machine parts are not moving to another area during the assembly. On the other hand, it has a disadvantage that is all parts are moving in one area.

Production time at serial assembly is smaller than fix assembly. Because all workers are working on only one type work at serial montage.

There are four assembly bands, which are two Beko Loaders and two Forklifts in ÇUMİTAŞ. I want to explain them step-by-step.

Forklift Assembly In ÇUMİTAŞ:

Firstly, I explain Forklift montage step by step.


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Industrial machines that ÇF15 ET, ÇF25D, ÇF30D, ÇF40D, ÇF60D, ÇF70D and ÇF80D, are produced on forklift bands. Firstly engine is assembled in engine assembly area. Perkins 104-19 engines, which are come from England, are used on ÇF15ET electricity, ÇF25D and ÇF30D diesel forklifts. Perkins 104-04 engines are used on ÇF40D, ÇF60D, ÇF70D and ÇF80D diesel forklifts.

Back axle is assembled at end of the assembly area. Radiator and groups of masts are assembled. Electrical situations are prepared in electricity room. Rakors are put on commend valve, steering wheel unite, hydro engine, hydraulic pump, hydro static pump, are fitted to divell engine. Hydraulic house pipe is prepared according to space. Brake cylinder and valve are assembled to each other. I want to give it step by step,

-Engine has been assembled to body-Water and oil cooling parts are fastened-Back axle is fastened-Steering wheel unites-Hydro engine-Brake and tilt blocks are tied-Tilt cylinder is assembled-Brake valve and cylinder are assembled-Hydraulic hoses are assembled-Hydraulic oil filter is tied-Oil fitting pipe filter is fastened-Float, fuel depot are assembled-Electric situations are assembled-Tries are put on axles-Broke hydraulic depot is assembled-Gas pedals are assembled-Hydraulic oil, which is no: 46, is filled in oil tank-Antifreeze that is concentrated with water, is filled in radiator-Accumulator is tied to engine-Steering wheel cycle is assembled-Air filter is tied -Exhaust is assembled -Cabin is assembled-Masts assembly is made

At the last of the assembly operation, hydraulic oil cooling water and oil level are controlled. Pressure barometer is tied on hydrostatic pump. Machine is worked and looking to pressure. Pressure value must be equal to between 430MPa and 450Mpa. If average pressure is not in this distance, its mean machine had breakdown. After the repair, machine is tested at maximum condition. After the last control machine is sent to paint section. Machine is painted here. Lastly, machine is sent to consignment section.


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828 Beko Loader Assembly In ÇUMİTAŞ:

Now, I want to explain Beko Loader montage step by step.Front and back axles are put on assembly car after the opened their box.

Front and back bodies are assembled to these axles with 816 bolts, which are M18*170. Torque value must be equal to 250 Nm. 2 steering wheel cylinders main command valve and brake pipes are assembled in to back body.

Engine pre-assembly has been made in Engine room. Hydrostatic pump, gear pump, four engine ears are assembled to engine. After these operations, engine has been tied to body with wooden wedge.

Hydraulic system hoses are assembled according to assembly directions. Hydraulic and water cooling will be tied to body, after the pre-assembly. Then cooling hoses, which between engine and cooling mechanism, are tied to them.

Exhaust silent part, exhaust project plate and exhaust pipe have been assembled on to the back body. Oscillation bearings are assembled with 24 bolts that are M16*140.

Hydro motor are assembled with 4 bolts that are M12*55. Hoses are tied between hydro motor and hydrostatic pipe.

Two lifts and one tilt cylinders, front cam, manavela joints, one lable have been assembled to front body step by step.

Lower part of the cabin has tied to upside of the body. Steering wheel unites and colon, indicator panel, gas and brake pedals, brake block, accumulator box have been assembled in cabin. After this assembled part is lifting with winch to back body unite, it will be assembled.

Steering wheel unite2s hoses, fan hoses, engine caput, seat, seat commend hand have been assembled.

After the electrical situations and control panel had been assembled, engine oil, engine cooling fluid, hydraulic system oil, gear oil, and differential oil will be filled to their depots. Then system air and brake air are taken out. Tires have been assembled. Finally all mechanisms are taken down with winch.

Now, Beko montage is started,Main body is put on assembly car. Slide has been assembled to front of

the main body with four cylinders. Two turning cylinders have been assembled to left and side of the slide, and two turning joints are tied to these cylinders with two pins.

Then all cylinders have been assembled to system. For example, stick cylinders, ladle cylinders, foot cylinders etc.

Main commend valve, which has eight functional properties, has been assembled. All system’s hydraulic hoses have been tied from main commend valve to machine.

After the beko has been assembled to loader, it will send to quality control section for last control. As I explained before, machines are tested at their maximum capacities. If machines have some problems, necessary section will work for repairing it. If is it is taken okay from control, it will wait for selling.


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WORK SAFETY

For a long time ago, workers healthy and safety were unimportant for ÇUMİTAŞ like other companies in Turkey. During this condition, work efficiency and factory were getting to dangerous. So, work and worker safety had been important for here. Rules and instructions were come in to force for it. But in a short time, these were not enough for necessary safety.

At the end of the works and searches, work healthy and work safety have found. If necessary describe to work safety and healthy, it is a systematically and scientifically work for projected worker’s healthy from dangerous things during the production in factory.

Aim Of It:

1-Project To Workers: It is a main subject about it. Workers are projected from work accident

and job illness.2-Production Safety: Especially, it is importance for economy. If you obtain production safety,

efficiency of production will be increased. Here most important thing is human, too. If you project workers very well, workers will love their jobs and work power will be increased.

3-Company Safety: When some working machine is repaired, explosion and fire dangerous

will be controlled. Factory safety will be obtained with some taking measures. Associations have published some instructions and safety sings for work safety and prevented accident. And they must use in all companies. Everybody, who works in factory, have to listen this rules. If only one person don’t listen this rules, himself, work friends and company’s machines will be thrived to dangerous.

Safety Sings:

They (instructions, forbidden, warning and saving) have been put everywhere for increasing safety in factory. I want to give some information about them.

1-Instructions Sings: It has a circular shape and their colour is blue and white. Something is

ordered for human healthy. For example, you have to take projected glasses during welding curuf will be cleaned with hand spiral stoning machine.

2-Forbidden Sings:


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It has a circular shape, too. Procedure, which is forbidden, shows with black shape on white surface. And red-white frame and slash are shown on white plate, too. It is used in very dangerous area.

For example some fluid that can be evaporate at normal room condition and easily burning gas can be mixed with air. These mixtures are very dangerous. Fuel oil, acetylene, acetate and thinner are the best examples for these gases. Forbidden sings that must be said don’t smoking and don’t use open fire here, have to put here.

3-Warning Sings:It has an equilateral triangle. It’s sharp side is upward. Black and yellow

colours are used in them. They have been put in poisonous and acid depots.

4-Saving Sings:It is a square or rectangular shapes. It is painted with white and green

colours. For example white plus sing shows pharmacy trick for firs help.

Although these sings are found in one factory, work accidents will be happened. Some reasons cause these accidents. These reasons are divided by two categories that are from human and from technology. If worker don’t know dangerous, don’t think it, don’t pay attention about it, accidents can be done. These problems are removed with safety seminars and educations.

As I said sometimes, we have problems from technology. If materials are up to their yield strength, going to ultimate strength, they will fracture. So, machine elements are controlled with known periods.

On the other hand, you can abstain from accident with prevent safety precautions. These are;

*Workers must inform deficiency that is on machine and other working materials to their manager

*Sharp, pointed materials must be not transported in clothes.*Clocks, rings and similar suffixes have to taken out before the work.*Dangerous areas have to signed and curtained. *Wheels, gears and similar mechanisms have to keep in projected boxes.*Explosive, poisons, burning and acidic materials boxes have been

signed and projected perfectly.*Workers, who are working in welding and stoning sections, must be

dress projected clothes.*Deflected cables of electrical parts have been changed with new cables.


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WORKERS AND BOSS RELATIONSAlthough, Karamehmets have this factory, general manager is interesting

all works in factory. I have made chat with engineers, workers and other officer during my training period. I worked to interested about good and bad sides of company. According to my impressions;

General manager had been changed this year. Old manager had hard rules. So anybody was not happy from engineers to workers. But now, general manager is more soft person. In addition to this, he eats his lunch with workers at dinning hall.

On the other hand, workers are working in bad condition still. Ventilation system is not enough for summer air. So, air temperature increases to 40-50 at summer days. I think this problem is removed at very little time.

At the end of, I think, if workers and boss relations are very good, boss, workers and company will win.


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CONCLUSION

I spent my six weeks in Çukurova Makine İmalat ve Ticareti A.Ş. Before this period I didn’t anything about organization of company, buying and marketing in factory, accountancy works in a factory etc. But in this training period I worked in all these departments step by step. During these times, I had chat with personals, engineers and workers and I made some works about these subject. . In my opinion these chats and works are given me very important advantages.

Now, according to me, I have vital information in my mind about all these importance things. And I worked to give some suggestions in last of the all section in my training period.

In addition to these ÇUMİTAŞ has very values working machines in factory (5 CNC machines, 1 vertical, 1 horizontal producing centres, laser cutting machine etc.). I found to investigate about all machine. I am sure these will be useful to my engineering life in the future.

Why not, may be I will be working here in the future.


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APPENDIX……….……………………...1

MACHINES

CATALOGUES


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APPENDIX……….……………………2

PRODUCTION PLANNING

DOCUMENTS


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APPENDIX……….……………………3

ACCOUNTANCY DOCUMENTS


27

APPENDIX……….……………………...4

BUYING &

MARKETTING DOCUMENTS


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APPENDIX……….……………………5

STORE &

STOCK CONTROL DOCUMENTS


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APPENDIX……….……………………6

QUALITY CONTROL

DOCUMENTS


Documents

COMPANY’S NAME - mustafa Cigal€¦ · Web viewNow as Çukurova in production of forklift hydrostatic system is being implemented as accepted the greatest technological and