1 . INFORMATION OF ARCELIK

Arçelik was founded in 1955 and entered the Turkish household appliances sector by producing its first washing machine in 1959 and its first refrigerator in 1960. In 1968, Arçelik moved to its Çayırova facilities. In the 1970s and 80s, the company expanded its product range and opened its Eskişehir Refrigerator Plant in 1975, İzmir Vacuum Cleaner Plant in 1979 and Ankara Dishwasher Plant in 1993.

1999 was a year of growth and reorganization. Arçelik founded Ardem to manufacture

cooking appliances in June and brought under its roof Türk Elektrik Endüstrisi A.Ş. and Atılım ve Gelişim Pazarlama A.Ş. as a single legal entity. In January 2001, Arçelik A.Ş. took over the marketing and sales activities of Beko products that used to be marketed and sold by Beko Ticaret. The new organization model enabled the company to manage production and sales/marketing activities centrally and to increase productivity.

The Orbital washing machine created by the R&D Center attracted attention worldwide and won the first Technology Grand Award in 1998; it won the 2. Technology Grand Award in 1999 with its MQM (Motor Fault Detection) project.

The vision of Arçelik A.Ş. is to possess one of the ten most preferred global brands in our sector by the year 2010.

What is important for our Company is not simply to expand, and make profits, but to generate strategies which will allow us to maintain our competitive edge through continuous development, and secure our future greatness. In addition to our Arçelik, Beko, and Altus brands, brand names like Elektra Bregenz, Blomberg, Arctic, Leisure, Flavel, and Troila, which we have incorporated in accordance with our international expansion strategies, form a product spectrum that will satisfy all customer segments in international markets.

Arçelik A.Ş., with its innovative approach, is creating its own technology, and from a technological perspective, an impressive number of ideas developed in its R & D department are listed amongst the firsts in the world. With about 300 successful patent applications, Arçelik accounts for 10% of all the patent applications in Turkey, since 1996. Moreover, in the European durable consumer goods sector Arçelik is one of the first four companies with the highest number of patents to its name.

Arçelik, which in conformity to European standards, earmarks approximately 1.5% of its

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total annual turnover to R & D, employs 450 researchers in its central and operational R & D departments. Working towards the goal of acquiring technological leadership in its sector, our Company has won some very prestigious awards in the international arena in 2004, through the products it has developed.

For Arçelik A.Ş., with more than 75 million products in use in more than 100 countries of the world, customer satisfaction has always been one of the highest priorities. Therefore, we try to be in close contact with our customers, and continue our work with a view to providing the consumers with products and services that will satisfy their needs.

We are in the process of seeking new areas of co-operation, and building new strategic partnerships. In order to enhance product diversification, and to respond to diverse consumer requirements under the same roof, as of 2004, we have already started selling Motorola, Siemens, LG, Philips, and Sony-Ericsson cellular phones, and Sony electronic equipment. Our cellular phone spectrum has been enriched by Arçelik and Beko brand cell phones. Following in the footsteps of this development, we have included household furniture into our product spectrum. As of the end of 2004, we have opened more than 30 Arstil furniture outlets, in 20 provinces of Turkey. We are also planning to expand the product leasing method which we initiated within the last year, and which is specifically developed to meet seasonal requirements, in all the major cities. Again, in response to consumer requirements, we have produced the first washing machines in Turkey with payload capacities of 7kg, and 10 kg; thus perfecting a product spectrum ranging from a payload capacity of 3.5 kg, up to 10 kg, and responding to diverse consumer needs.

One of the most important factors that have made Arçelik A.Ş. an international corporation is loyalty to and for its principles. We have therefore identified veracity, transparency, and accountability as our “Corporate Management Policy”. Arçelik, not only provides high quality products and services, but also fulfills its public responsibility successfully.

Arcelik Bolu cooking appliances plant was established in 1997. Its was established Arcelik and Demirdokum with incorporation. Ardem was astablished on 191000 m2 field which was began production in 1981 of November.It was made modernization in 1944. And computers were controlled production line in conculusion technology.Then closed filed of Ardem was increased 41760 m2.Ardem was combined in big partner Arcelik in 1999.Therefor ıt was increased power of competition.

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Following the relocation of Elektra Bregenz production facilities to Bolu in 2003, this plant attained the highest production capacity under a single roof in Europe. In this plant, which achieved 89% capacity utilisation in 2004, an oven-stove combination kitchen range with electronic controls has been added to the product spectrum, with a view to increasing customer satisfaction. Meanwhile, production continues with the inclusion of the “New Line” series for Beko and for Blomberg, as well as further improvements in appearance and functions for the other products.

Beginning production date : November 1981Increase of production : 1987 – 1989- 1994Modernization : 1994 – 1995

There is the organization table in appendix – 1

2 . INTRODUCTION

I am going doing apprenticeship at production engineer management. I am going to investigate type of organization , standard application , control techniques and production planing , accounting , selling and purchasing and plant layout in organization and management of the plant. And i am going to investigate assembly line in this department. I am going to investigate factors noticed in selectio of plant location in general management deparment. I am going to investigate storage and stock layout in material department. I am going to investigate other auxiliary foundations in electric depatment. I am going to investigate productivity , quality control in investigation and development department and safety and workers & boss relation in workers & boss relations deoartment.

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3 . 1 ORGANIZATION AND MANAGEMENT OF A PLANT

3 . 1 . 1 Type Of Organization :

There is a simple orginazation application when made simple production at Arcelik cooking appliances plant. There is not relation of subalterntop. Blue and white collar commune can face to face establish communacation with manager. So hieroglyph structure is minimize and making simple procedure.

Produce manager has all direction of factory:

Produce manager Managers Team Leader

There is this shape a management flow. Workers and personnel are director of relay to have reponsibility and directed at spontaneous. Because this the workers are in production and know the workers. There si a the responsible in part of the realy.

Type of the management is TPM working and personnel working obtain partaker with refer to be or not be suggestion.

Managements use form , repot , work order , purchase plug bill , berakdown the repot. And they secure continue the processses this certificate.

3 . 1 . 2 Strandard Application :

Top management from bottom management and bottom management from top management continue communication with e-mail or conduced on Outlook or sap in computers. Furthermore workers continue the communication with immobile telephone or pocket telephone.

Center Related Segment Director Workers

Workers use form , ,report , and materials flow diagrams for communication.

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Production engineering director is started working when discerned the problems of group of the production , investiment. Fistly engineering take dominating process the personnels in own yhe deparment at releted to the group. Then the workers start estimated system design , limitation , work flow , workers and opsionel requisition. The workers group make the list of made working of system. Then they designate workings at the workes according to this the list. Lastly they make drawing of project , working flow , model analysis of target and feasibility survey.

3 . 1 . 3 Control Techniques And Production Planing :

Center factory in Istanbul make estimate request of the production. Orders come at the center factory in Istanbul . Marketing section take fatherland inner and fatherland external order. So Arcelik cooking appliances plant in Bolu make estimate of request and trasmit production planing in Istanbul. They control component and capacity with APO ( advanced programine optimizes ) the program. After the control they determine need of relay. Then they tell the resultes at the marketing. They make the production plan related to produces with mediation. APO program and working together with the marketing to looking this resultes.

There is serial production system in the factory. The factory is worked three relays , seven days and twenty four hours.

Material Flow Of System :

Tinplate ( roll ) Cutting Machine Transfer press ( It cut tinplate according ) Chassis production line ( to mainfest dimension ) Cam pres Hydraulic pres ( they figuration tinplate) ( then these tinplates are) ( side wall and gasring sole)

Produce depository Assembly Dye

Transportation Enameted

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Information Flow Of System :

Produce Direction Industrial Designation

Produce Development

Test Production

Serial Production

There are sport activities like table tenis , football , basketball , fitness. However there are the activities like backgammon , chess tournament , lectures , seminars , amusement , concerts , and starting working education.

There is half hour tea break and one hour eat break. There is total 1,5 hours break in eight hours efforts. Consequently workers must be working 6,5 hours in one relay.

There are three relays in factory. Workers change relay time at one weak. Working time is 08:00 – 16:00 for A relay , 16:00 – 24:00 for B relay , 24:00 – 08:00 for C relay.

Enterprise use this three relay system for nonstop. Workers usually make many accident in C relay. So engineers think , management must be take precaution for this relay. Workers are many productive.

There are convenient conditions of day working and politics for complacence of buyers. There are processes for complacence of buyers in innerfatherland and abroad. There is a awide service network. Management estimate complacence of buyers and complaint inquiries. This complaint and need estimate with internet mediation with online services.

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Workers arrive complainer buyer at minimum times and find the solution at problems. If necessary produce is changed with new produce for obtained complacence of buyer. Quality control department refer to these processes. Enterprise mind expectations of buyers. There are politics to application of enterpise. Quality and viroment politics are these politics.

Industrial design department start working to compose design when produce management decided production new produce. The produce development and produce the management department examine constituted design. Engineers make the drawing to approve produce , the necessary mold for the production indented for apparatus and other necessary investment. Then they start the probation production. They observe become the problems when production and getting precaution. Afterwards they start the serial production.

Production engineering management have following as signment in this system.

1. making mold and pursuance2. making necessary investmentes3. making operation planing of produce4. making necessary apparaturs5. making control side industry

3 . 1 . 4 Accountancy :

There is a computer system in enterprise. Automation deparment related all computer processes are aspect , repair and actually processes of computers in offices.

Computers always are online and interdependent with a portal. Arcelik cooking appliances plant use pespective development Arport. All workers devise cummunication with computers. Withal computers always are checked safety from direction and entering , leaving data in enterprise.

The enterprise is used 9,2 demand of ORACLE . this software can enforce manufactured entering – leaving for stok system. Some depatment is used ORACLE Microsoft SQL server 2000 version. This process is used apropos energy software. And there is labeling system aporos stockes. If enterprise is needed pedestal of data. Fistly is used ORACLE.

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SAP software is used at ORACLE pedestal of data , the production and the financial processes. The enterprise is used the UNIX operating system. This system is worked until making receipt from the entering of the produce at entegre form. There are the moduls like workers relation , the material , quality guaranty. Arcelik cooking appliances plant is used a software for workers relation which name is BILIN. The SAP and ERP are best softwares on today. These softwares are obtained best solution for the finance resource , the worker relation processes and the institutional service the management subject at the company.

SAP is used been activties while obtained all management and environment of process active checking. SAP and ERP are increased productivity and productivety. SAP is obtained buyer relation management , produce lifetime management , supplying chain management , relation with supplier management.

Financed is worked as center in Arcelik cooking appliances plant. SAP is used accountancy and finance working. Center enterprise is designated needed cash weekly. It is sended automatic payment report at center enterprise. So it is obtained cash flow from single hand.

Caculate Cost Of Production :

Total cost of production

1. total raw material and material2. direct worker3. amortisman

They are general production expenditure.4. copartner expenditure

Determine Cost Of Raw Material :

They use three methods while determined cost of raw material.

Avarage Method FIFO ( First In First Out ) Method LIFO ( Last In First Out ) Method

Arcelik cooking appliances plant ( Before name is ARDEM ) is used avarage method in 1996. Then it is used LIFO method in initially 1997. They will use first raw material is end entering material in storehouse at production according to this process.

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Engineers determine type and amount of raw material when make firstly design. And they determine all materials to be produce. Then they determine amount and expense while started production produce.

Example :

A1 0,5 kg ( 1 200 000 TL / kg )

A2 3 kg ( 1 000 000 TL / kg )

Price of material of produce = ( 0,5 X 1 200 000) + ( 3 X 1 000 000)

= 600 000 + 3 000 000

= 3 600 000 TL

This process is determined using cost of materials of total production. And we use this process for all produce.

Direct Worker :

Value of apropos direct relation the worker is 720 in the accountancy “ single order the determination planing ” . Direct relation cost the centers become ( disbursements relation of workers with the reverberation ) at account of direct workers expense . Arcelik cooking appliances plant have cost center direct relation with production ;

Mechanical Production Team Enameled And Dye Team Assemblage Line

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All produces are producing designation from cost centers ( how many workers and times , videlicet Standard time ) by production engineering management. And values of workmanship are distributed produces according to this Standard time.

Example :

Total production Standard time is 20 000 hours of all produces. And total values of workmanship is Y , Standard time of produce is 2,5

X ( distribution workmanship of produce ) = 2,5 / 20 000 XY

General Production Expenses :

Single order determination planing is 730. general producting expenses have its. These are electric , water , transport , project , survey expenses etc.

73001 personel expenses of enterprise

73002 material and energy expenses of enterprise

73003 other production expenses

73004 amartisman expeses relation with cost

73001 , 73002 , 73003 are copartner expenses.

( These are frazzle of machine , fixturs ration relation with production )

All companjes are designated measure of activity for distribution of this expenses.

These are ;

1. Production denomination2. cost of direct material3. cost of direct workmanship4. Standard time of direct workmanship5. machine time

Determine cost of produced of production :

Determine direct workmanship , copartner expenses and value of amortisman like upwards for number of productions. Unit cost is determined to split value of productions.

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3 . 1 . 5 Selling - Purchasing :

Buyying Process :

Related unit responser are following the using materials according to the works doing in the factory. Secondly the responser evaluates the requirings and prepares wanted slip and send to headmaster. This slip sends to buyying unit after approved by headmaster.This unit prepares after list and send to the different firms. Also the taken after list are evaluated and send to headmaster after approving send to firm reback. Ordering is done after taking approve from the firm. After payying conditions , delivering , and transporting operations are talked the last aggrement is done. The material is bought in this conditions and registreted in the firm. When the slip is taken , the slips are added and given to accountancy.

Exporting :

The other trade unit makes the required meeting with the customers and take the orders. This orders are in controls by firms. This controls send to related units. These units evaluate logistic , document , sending operations and laboratour , noleak and physical analysis. Prepare production plan and realite the suitable production operations. The exporting unit is also prepare the meetings with the firms and fix the customer firm. The product , after producing and quality controls , sends to packing and prepare for transporting. The transported product send to tarif with the related documents. They recontrolled in the tarif and send to the firms by ship. The exporting slips and documents are prepared and send do the firm. The firm make necessary applications about transporting operation.

Marketing : Out of country : The marketing with out of country start with the investigation of customer and

market. The firm investigations are realized by sorts of source such as internet and reviews. The products are introducing to the firms and send some samples to the firms and send some somples to the firms , that gived answer. They invitated to the factory. After all these applications the marketing relations can be stsrt. Sometimes headmaster goes to firms to visit customer, and international fairs. So new markets and customers can be find.

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In the country :

This type of marketing is same with out of country system although the visitiys are much more. Fast marketing is important , therefore meeting of mosters is beter than the

telephone and internet. Agreements are relay. Finding customer and having market is easier then out of country. Because communications is friendly .

The others taking and sending to the related units. According to these document production is occure and transporting is realised. Because of the fairs new firm can be find. Also directly selling tocustomer is realizing in the country. Therefore there is more active marketing in the country.

3 . 1 . 6 Plant Layout :

There is the plant layout table in appendix – 2

3 . 2 FACTORS NOTICED IN SELECTION OF PLANT LOCATION

3 . 2 . 1 Staff :

The factory has ten minutes distances with centrum. So personel is produced

everywhere of city at little times with service buses.

3 . 2 . 2 Water And Energy :

The factory is used electric , fuel , diesel , LNG and LPG as energy. Electric is Standard industry electric. The factory is obtained alittle eletric with electric system. LPG is came the factory from Aygaz in Izmit. The factory is not used water in procution. So there is not river or lake at environment. So the factory is needed open sea for transport. But the factoty is used water in city network with cleaning.

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3 . 2 . 3 Raw Material :

Eregli in Zonguldak is too near of Bolu .So the factory is obtained raw material neeeded very easy in ıron and stell factory of Eregli. It is obtained glass and other raw material from other factory in Bolu. Forexample Orim glass factory.

3 . 2 . 4 Selling And Delivery :

The factory is selling and delivery between Ankara and Istanbul . So produce is arrived at markeplace easly.

The factory is true election because of workplace , raw material , nearness of marketplace , transport easly , expanse , corresponding order ensconced.

3 . 3 STORAGE AND STOCK LAYOUT

The main purpose is to stock , transport , strorage and pack of the raw and helping materials without any problem.

The raw materials and products arranged on to the palets transport with the help of transpalets and forclifts. The speed of the forclift can not be pass 10 km / h. It can be used only by the qualified personel. The climbing and redour operations done carefully. The transporting capacity of forclift is 2,5 tons. Above this weight can not be transport. They are transported four packes too much.

The factory has automatic shelf system. This system is worked order. Fistly incident materials or produced materials are inscribed in computer. And materials are located on the transferer. It locate materials convenient shelf. If we will want this materials entering registered in formation of material. And we have these materials.

The raw materials are arranged on to the pallets according to the standards.

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Product must be determined by the naturel or worked tickets stocks work by the system of ordering. The product can be wait only on the pallets. The packing material , cleaning materials or order helping materials should be stock in an other stockages.

After this process , the packing can be applied with the required corditions. First the control of package and suitable is done.

Products transport to the trucks by the forclifts. The companies related with the transport are took informations. The trucks are controlled about cleaning. It must be clean no smell and dry.

3 . 4 OTHER AUXILIARY FOUNDATIONS

The enterprise has seven trafos. These trafos are worked with oil. They decrease 33 kvA than 0,4 kvA electrics.

Trafo 1 has 1,6 kvA capacity Trafo 2 has 1,6 kvA capacity Trafo 3 has 1,6 kvA capacity Trafo 4 has 1,6 kvA capacity Trafo 5 has 2,0 kvA capacity Trafo 6 has 1,25 kvA capacity Trafo 7 has 2,0 kvA capacity

There is a part to entering energy. This part name is origin cell. There are two orgin cell. Bolu line and Caydurt line ( Caydurt is district of Bolu ). The factory usually is used only line. And it is changed line in electric interruption.

So the factory is not needed generator. But the factory has four generators.

Generator 1 218 kvA dieselGenerator 2 230 kvA dieselGenerator 3 250 kvA dieselGenerator 4 4 kvA diesel

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The factory has electiric safety system. This system is formeted ring lines. Every trafos have two lines. Workers close using line in anybody accident. And they open other line. So the production do not lose time.

The factory is used LPG , LNG , fuel , diesel energy excluded from electric. The factory is spended 6 000 000 Mcal. energy in one mount. Tolarance + , - 1 000 000 Mcal.

The factory has three energy management. And the factory is made economy energy. For example the factory is changed lamp system. They are used floranses and obtained economy % 10.

3 . 5 PRODUCTIVITY AND QUALITY CONTROL

Workers demonstrate too signifacance at quality. There is a responsible quality guaranty deparment from quality. The enterprise is used quality management system. There are Works process at buyyer from direction system and providers. These processes are critertion of perfect model of Europe Founoution Quality Management ( EFQM ) estimated and browsed critertion of pefect model of Europe Founoution Quality Management ( EFQM ). Therefore workers designate improved and preventer processes in performance and composed values at all domain.

Enterprise is worked with Total Quality Philosophy to arrive at unit of aims in soul of team. So aim markets are increased and developed. It usually is worked direction of improving aproaching with output. It is used six simga methods to increase productivity at international degree and competetion degree.

Quality conrol is applied initial and result control at initial and result of production flow.

Quality management system of enterprise is made enumaration and confirm form of to carry out necessaries of ISO 9001 standards. Workers certify politics of Arcelik cooking appliances plant. There are ISO 9000 , ISO 9001 : 2000 and ISO 1400 standards. Quality control engineers administer these processes with center system. They use putting investigation.

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The factory is left out automatic system at stocked system at enterprise. In this way the factory is privented lost time of stock transporter and finding materials. And this processes are easly. In addition the factory is caused to go problems of mechanic part layout. They changed place of pres. So materials flow is put in order , decreased lost ay and increased out put. These processes are obtained improved.

Investigation - Development Working :

1 . General Activities :

Determine required basic condition for Project. Team leader of laboratory is responsible from this process.

Laboratory is responsible from tests on prototip production. These tests are made by team leader of laboratory engineer or necessary team technician with coordination.

Benchmarking workings with connected determination produce of rivals of Arcelik cooking appliance plant are made by laboratory. These workings are made by laboratory engineer under of the responsible of team leader of laboratory.

Brought conformable state at appliablity and useability thecnoloji developments in iner native country and external native country. These processes are responsible from team leader.

Determine conformable and qualification of patternes. Laboratory is made prepare some using regulations at the factory and

laboratory. Made taking , distribution and investigated of using all standards in the

factory. Made control initial pattern with coordination condition with quality guaranty

management. Laboratory team leader is responsible production development management

with represented national and international research development assemblies seminar.

Obtained calibration and attention. So the department is orderly and finding accident equipment easly.

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2 . Gas Activities :

Team technician and laboratory gas engineer make gas tests with used interested methods with watching by laboratory team leader.

These tests are applied like following :

At present and new design productions. At used present and new design productions. At production of rivals. At thinking used component of new productions. NF gas cerfication ( only laboratory gas engineer made ). CE gas cerfication ( only laboratory gas engineer made ). Prepared test methods , test proceduration and interested check lists. Variety laboratory techniques are brought useful state at present laboratory

with investigation. Prepared CE declarations at present at new design productions with interested

standards. After finish interested prduction tests , prepared report of production with these

tests. Designation and prepare tests using aparats according to comforable standards.

3 . Electric Activities :

Electric engineers and technicians make electric tests with using interested methods.

These tests are made like following :

At present and new design productions. At used present and new design productions. At production of rivals. At thinking used component of new productions. Make safety of produced tests according to Standard of interested EN and TS. Prepared test methods , test proceduration and interested check lists. Variety laboratory techniques are brought useful state at present laboratory

with investigation. Prepared CE declarations at present at new design productions with interested

standards. After finish interested prduction tests , prepared report of production with these

tests. Designation and prepare tests using aparats according to comforable standards.

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National Standards International Standards

- TS 616 - EN 30 - TS 2000 - PrEN 30.1 - TS 787 - PrEN 30.2 - TS 8943 - EN 60335.1 - TS 75 - EN 60335.26 - TS 4008 - BS 5386.3 - TS 10078 - BS 5386.4 - TS 9882 - IEC 335.1 - IEC 335.2.6 - IEC 335.2.9 - IEC 335.2.31 - IEC 350 - EN 60335.2.9 - EN 60335.2.31 - EN 55014 - EN 60555.2/EN 61000.3.2 - EN 60555.3/EN 61000.3.3 - EN 55104.2

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