CONTENT

CONTENT ........................……………………………………….............…...2

1. LIST OF FIGURES ......................................................................................3

2. INTRODUCTION ........................................................................................4

2.1. About BCS Metal Factory .................................................................................4

2.2. Organisation Chart …………………………………....…………….........…..6

3. PURPOSE OF PRACTICE..........................................................................7

3.1. Scope of Summer Practice ................................................................................7

4. THE PRODUCTS OF THE FACTORY ....................................................8

5. ORGANIZATION OF MANAGEMENT OF A PLAN..........................................10

5.1. Type of Organization.......................................................................................10

5.2. Standard Applications........................................................................................11

5.3. Cost Analysis...................................................................................................11

5.4

.Accounting.......................................................................................................126.

FACTORS NOTICED IN SELECTION OF PLANT LOCATION …....126.1.Location…………………………………………………………………………………..12

6.2.Transportation……………………………………………………………….……………126.3.Raw Material……………………………………………………………………………...136.4.Water And Energy………………………………………………………………………..137.STROGE AND STOCK LAYOUT………………………………….……13

8. QUALITY CONTROL PROCESS ………………………………….…....13

8.1. Access control ………………….…..……………………………………..…13

8.2. Process control .………………………………………………………….......13

8.3. Final control .…………………………………………………………...…....14

8.4. Calibration ……………………..………………………….……………...…14

8.5. Used Measurement Tools For Quality Control ……………………………….....15

9.ASSEMBLY LINE……………………………………………...………..…17

10.SAFETY AND WORKER-BOSS RELATIONS …………………….….17

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11. CONCLUSION ………....………………………….……..........................18

12.APPENDIX ..................................................................................................19

1.LIST OF FIGURES

Figure 1 ………………………………………………………………………………..4

Fıgure 2 …………………..............................................................................................6

Figure 3……………….................................................................................................. 8

Figure 4………………...................................................................................................8

Figure 5…………….......................................................................................................9

Figure 6..………….........................................................................................................9

Figure 7…………….......................................................................................................9

Figure 8…………….......................................................................................................9

Figure 9…………….......................................................................................................15

Figure 10…………….....................................................................................................15

Figure 11………….........................................................................................................16

Figure 12………….........................................................................................................16

Figure 13………….........................................................................................................16

Figure 14…………………….........................................................................................16

Figure 15……………….................................................................................................15

Figure 16…….................................................................................................................16

Figure 17…….................................................................................................................17

Figure 18…….................................................................................................................17

Figure 19…….................................................................................................................17

Figure 20…….................................................................................................................17

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2.INTRODUCTION

2.1 About BCS Metal Factory

Figure 1.

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Adress: Ceyhan yolu üzeri 10. Km Adana Yan Sanayi içi Adana/TurkeyPhone: (0322) 3466433

BCS Metal,metal processing industry is the pioneer and a dynamic company of Turkish

metal industry, was founded in 1981 under the name of the Güneydoğu Çelik Kasa.

Manufacturing steel boxes of money and has a very special industry projects during this period

was opened the door of the foreign markets as Germany and Russia.

In 1988,BCS Metal, the international market experience to strengthen its infrastructure and

production company, was the Turkey’s most important automotive component supplier of

Mitsubishi and TEMSA.It gets a very large place in automotive industry in a short time and it

increased its cooperations with TEMSA.Today it works with Mitsubishi-TEMSA and it

exports its 80% of components of buses’ and trucks’ cahssis and their another kinds of

subcomponents to Europe and America. 3000 kinds of sub-assembly metal parts are

manufactured for TEMSA production lines and they are delivered on time.

BCS Metal has two offices in Gaziantep and Adana, was located on 1800 m 2 land and work

with about 250 qualified workers. Its investments,which is being earned for the facility in

Sakarya 5000 m2 closed area with a total of 10000 m2 meters is about €5,000,000. This

investment was for technology and facilities and buying the first laser profile cutting machine

in Turkey. And the other important machine is laser cutting machine capable of cutting sheet

metal with the dimensions of 2500*8000 which is the second machine in the world.

In 2007,BCS Metal began manufacturing and exporing the excavator

buckets.Germany,France and Russia are the bigest bazaar for earth mover machines’

component. So they aimed the big supplier for these countries.In 2007 the 3% of the

manufacturing was exported but today the 80% manufacturing is exporting the other countries.

For 2007 the annual turnover is €9,000,000.

BCS has two quality certificates, TS:EN ISO 9001: 2000 and TS 16949.

BCS METAL, past experience of the team who managed to convey the understanding ofthe

future, who believe in continuing education is the understanding of human

resourcesand business processes implemented throughout all his work so far with the concept

oftotal quality as well as behind, in front of everything is committed to maintaining the trust of

customers in the future.

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2.2 Organisatıon Chart

.

Figure 2

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GENERAL MANAGER

AYM COORDINATION

LOGISTIC

ACCOUNTİNG AND CHANCELLERY

QUALITY CONTROLMANAGER

ENTERANCE QUALITY CONTROL MANAGER

PROCESS QUALITY CONTROL MANAGER

FINAL QUALITY CONTROL MANAGER

PRODUCTION MANAGER

CANTER PRODUCTION TEAM LEADER

BUS PRODUCTION TEAM LEADER

COMPONENT PRODUCTION TEAM LEADER

UNFINISHED PRODUCT TEAM LEADER

R&D AND PROJECT

R&D TEAM LEADER

3.PURPOSE OF THE PRACTICE In this practice, the purpose is changing of our theorical knowledge to practice. To see

differences in school life from working life.The other purpose is interwiev to engineers and

learn important things from them and to examine machines and real working area, to see life

of engineers closerly because we will do same things after graduation.The most imporant

thing that this summer practice provide us is thinking as an engineer

I was in BCS Metal company ,I learned some important things which are not learned in

university. I learned that engineer is not only a technical person he is a manager at the same

time, he is a worker, I mean he has to know everything but there is a problem about our

department in Gaziantep University we learn the technical information very good ,but we do

not learn managment there is not any lesson about management however our teachers

sometimes mention about managment in company ,it is not enough.

Scope of Engineering Practice

1- Organization and management of a plant

a) type of organization

b) standart applications

c) control techniques and production planing

d) accounting

e) selling – purchasing

f) plant layout

2- Factors noticed in selection of plant location

a) staff

b) water energy

c) raw materials

d) selling and delivery

3- Storage and stock layout

4- Other auxiliary foundations

5- Productivity , quality control

6- Assembly line

7- Safety and worker-boss relations

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4.THE PRODUCTS OF THE FACTORY BCS metal supplies systems and components to autumotive, agricultural machines industry and works with TEMSA ,Mitsubishi and MAN. The international market experience to strengthen its infrastructure and production company, was the Turkey’s most important automotive component supplier of Mitsubishi and TEMSA.It gets a very large place in automotive industry in a short time and it increased its cooperations with TEMSA.Today it works with Mitsubishi-TEMSA and it exports its 80% of components of buses’ and trucks’ cahssis and their another kinds of subcomponents to Europe and America countries such as France,Germany,Russia and etc.

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Figure 3. Figure 4.

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Figure 5. Figure 6.

Figure 7. Figure 8.

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5.ORGANIZATION OF MANAGEMENT OF A PLAN

5.1 TYPE OF ORGANIZATION

In BCS Metal company products are produced by product layout. In this process only one

type of product are produced and machines are arranged in the order of operation the product

must be standardized and manufactured in large quantities.

Advantages of Product Layout:

high through-put

usually less skilled labour required

lower total material handling cost

lower total production time

less work-in-progress

high level of performance due to greater incentive for group of workers

less floor area required per unit of production

simple production control, fewer records and lower accounting cost

Disadvantages of Product Layout:

Inflexible to design, processing and volume changes

High initial capital investment required

Susceptible to absenteeism, breakdown and dispute

Difficult lo balance lines

11

5.2. STANDARD APPLICATIONS

Some standard applications done in organization are:

- examine of the daily production plan,

- quality control of the product,

- periodic maintenance of machines,

- cleaning of the departments,

- controlling the amount of the raw-material at the storage,

- controlling the amount of the product at the storage,

- preparing the production plan.

5.3.COST ANALYSIS

Cost according that deals with the determination and analysis of the cost of particular

processes jobs or departments within the company. Such cost accounting become the basis of

cost control systems and budget control system. Cost control and budget control are both

essential in the operation of a modern industrial. They permit management to plan ahead and

to know when to make changes in order to fulfil the plan. Cost accounting is the job of taking

overall business cost and separating them into greater detail according to unit of product

produced, operation performed or ordered. Cost accounting provides information for the

following purposes:

1-Cost determination

2-Cost for pricing

3-Cost for managerial decision

4-Cost control

There are three basic elements which are calculated in BCS. They are direct material cost ,

direct labour cost, and overhead

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5.4. ACCOUNTING

The accounting department maintains this company’s financial records. Also, it provides

information and services on the followings;

1. Cost accounting

2. Financial reports

Financial reports generally include financial position of the organization and the process of

the getting money from a bank or somewhere for a new Project

6.FACTORS NOTICED IN SELECTION OF PLANT LOCATION

The great many factor should be considered if a plant is to be located advantageously .

Their relative importance will depend upon the particular situations. Although the selection of

a plant to location is a management responsibility, the specific geographic location of a plant

site will have a definite bearing on the factory layout. The overall plot with access to public

utilities, water , highways and the market must be carefully considered in planning a new

facility.

6.2.Location

Availability of location of factory is an important factor for selection of plant location.

Conditions such as weather, proximity of the plant to the market , availability of skilled

workers, taxation ,proximity to raw materials or resources, and location of suppliers

6.2. Transportation

The Cost of transportation are important when considering the transportation factor for

plant location. BCS Metal company was established out of the city for trucks work easily.

Transportation for products is supplied by only trucks.

For employee, there are a lot of companies In Adana Yan Sanayi and all companies’

transportation for worker is consociate. This system provides saving money for all company.

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6.3.Raw Materials

The position of raw materials will obviously influence the location of industries.Some

industries by the nature of their manufacturing processes are forced to be located near raw

materials sources. The aim is generally to select a location which minimising overall raw

material transportation cost.

BCS Metal A.Ş is not used raw material directly, in factory mostly assembly processes is

done, that’s why there is no problem for factory not to be near raw material source.

6.4.Water And Energy

The factory is used electric as energy. Electric is Standard industry electric. The factory is

not used water in procution. So there is not river or lake at environment and it is not

necessary.

7.STROGE AND STOCK LAYOUT

There are two storage;

1)raw material storage

2)assembled product storage

Stock control:

Providing quality and efficiency in the manufacturing, making improvements continuously.

According to the report prepared for the production activities, determining the needed

materials and taking them from the stocks. Telling the needed materials to the departments.

Stock controls are made by computer system which name is GUSTO. They control the

material quantity by using this program. If materials are needed, they are supplied from

TEMSA or BCS company in G.antep by this program.

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8. QUALITY CONTROL PROCESS

8.1. Access control

-sheet material

-Profile material

-welding wire

-nut-bolt access control

8.2. Process control

-Approval of seeded

-welding machine control

- measurement Tools control

-welding control

-fixture control

8.3. Final control

-Welding control

-Bracket control

-Labeling

-shipping control

8.4. Calibration

Calibration is the metrology measuring science.It should be more sensetive than normally

measuring.

Using machine for calibration:

SIP 550 Measurement Machine:it is measuring until 0,00001 µm.Its inside diameter is

450 mm,outside diameter is 550 mm.

15

Fig 9. SIP 550 Measurement Machine

Other tools for calibration:micrometer, calipper, marking gauge, dial indicator, go, no go

etc.

Adventage of calibration:

All measuring process are reliable.

Producing fails are measuring step by step.

All pieces are well-adjusted.

8.5. Used Measurement Tools For Quality Control

Figure 10. Callipper

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Figure 11. Marking gauge Figure 12. Radius gauge

Figure 13. Go and No Go

Figure 14. Feeler gauge Figure 15. Universal protractor

Figure 16. Micrometers

17

Figure 17. Dial indicator Figure 18. Laser measurement

Figure 19. Nivo Figure 20. Tesa multi gage

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9.ASSEMBLY LINE

There are foremens who are responsible each department in the factory thus assembly line

depend on these foremens also there is an controler, control this line.And also quality

controllers control this line. Already this factory works as almost a assembly line. An

assembly line is a series of assembly stations through which a product must pass in an orderly,

established manner. The tasks must be assigned to the various work stations according to the

produce requirements so that the wasted time over whole process is a minimum. An idle

situation would involve a line in which all the stations would have equal work content

measured in terms of time assigned to them.

10.SAFETY AND WORKER-BOSS RELATIONS

Workers use safety material which are suitable for their special purposes as grinding

glass, gloves,hamlet,work shoes,work clothes, and at define time make training of safety for

worker.Workers can directly come into contact with boss,but it is not easy , becouse worker

should use very good this changes,some times worker may act or speak foolish.

In the BCS Metal, workers and boss relations are very important. So certain time

period , boss makes meetimgs with adminisrative comitee personnel and workers. Aim of this

meetings is toimprove relations between all personnel in the company. In the meetins, they

talk about their problem and study to find solutions. Boss frequently vists the production area

to observe workers and their works. Boss is interested in worker’s problems. Thus boss win

worker’s confidence. I think that, that is very good things. Because in the some other

companies there are no relations between boss and workers. Thus workers don’t like their job

and production get be smaller. But in the BCS Metal, there are studies to improve workers to

love their job and workers give attention to their jobs. In the event that, administrative

comitee personnel are forced to do some works. Thanks to boss’s experiences. Difficult works

can be done. While I was in the BCS Metal. Boss helped buying departments personnel about

raw materials company.

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11.CONCLUSION

In conclusion, the summer practice had been a very useful experience to visualize the

theoretical knowledge and to gain skills directly applicable to future career. It is impossible to

say that management so easy . Manager is responsible for planning , directing and organising

work. Planning and execution of a work is very difficult ,so should be separated from each

other . This will make the people work at their highest level of efficiency.Most important

thing I learned which an engineers who worked for a company must have very good

management characteristic. So, the engineering students should be aware of this fact and try

to have their summer practice in the most appropriate way.

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APPENDIX

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