ÇUKUROVA İTHALAT VEİHRACAT TÜRK AŞ.

SUMMER PRACTICEME 399

PREPARED BY:UMUT KOCA

UNIVERSITY OF GAZIANTEP

2002

PART I

1. ME 399-ENGINEERING PRACTICE JOURNAL

I completed my last summer practice journal, which is called ME 399-

Management and Organization, at ÇUKUROVA İTHALAT VE İHRACAT

TÜRK AŞ.’s revision plant in Adana. I think that it is very usefull for an

engineering student to learn about a managing process.

1.1. PURPOSE AND SCOPE OF THE SUMMER PRACTICE:

Mechanical Engineering Faculty’s students of Gaziantep University undergo

training course three times whole our engineering education life. These training

courses are (ME 199, ME 299, ME 399). At the same time, these are very

important and very necessary. For this reason, we must try to utilize these

courses as much as possible.

There are several important aims of this engineering practice journal. Generally

speaking the aim is to prepare the student for future that will need this

experiences. At courses that we took in our school gave us very big amount of

knowledge. This engineering practice journal is also necessary for transform our

knowledge to practical application. This is the first application while becoming

an engineer. We are also learning to keep all criteria in mind at the same time.

Some of these important points are material used, necessary technique to

produce and cost. Cost of a material includes labor, energy unit material price

etc.

Manufacturing requires tools and machines that can produce economically as

well as accurately. Economy depends to a large extent on the proper selection of

the machine or process that will give a satisfactory finished product. The

selection is influenced, in turn, by the quantity of items to be produced. Usually,

there is one machine best suited for a certain output. In manufacturing, mostly,

general-purpose machines such as the lathe, drill press, and planer may prove to

be the best type, since they are adaptable, have lower initial cost, and require

less maintenance. However, a special-purpose machine should be considered for

large quantities of a standardized product. The selection of the best machine or

process for a given product requires knowledge of all possible production

methods. Factors that must be considered are volume of production, quality of

the finished product, and the advantages and limitations of the various types of

equipment capable of doing the work.

1.2. GROUP COMPANIES

1.2.1.TURKCELL

1.2.2.K.V.K.

1.2.3.YAPIKREDI

1.2.4.AUER

1.2.5.GUNES

1.2.6. AKSAM

1.2.7.ÇİMSATAŞ

1.2.8.HOBIM

1.2.9.BMC

1.2.10.BAYTUR

1.2.11. ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.

1.3. THE ORGANIZATION:

Turkey’s leader in heavy construction machine sector ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. was established in 1943.It has 8 offices overall Turkey.

ISTANBUL- TOPKAPI (central office)

ISTANBUL- KARTAL

ADANA

ANKARA

BURSA

İZMİR

ANTALYA

DİYARBAKIR

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. one of a very few big corporation of the estate, which has a 59 year experience of trade and industry. There are several firms and establishments in it such as; Liebherr, Fermec, Krupp, Ingersoll-Rand, C.M.I., Manitou, Sumitomo, Link-Belt, Hyster, Tennant, Nedalo, Niigata, Turbomeca, Pramac Lifter, Donaldson, Clevite, ITR, Solideal.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has the certificate ISO

9002. Turkish Standardization Institute (TSE), International Standardization

Organization (ISO) and Global (which is a standardization organization, too)

prove ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. ’s quality

individually. All of these organizations’ quality certificates are valid, effective

and popular all over the world. Some of the establishments and firms have these

certificates in ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. (as

explained later). These quality certificates are very good references for in the

domestic and foreign markets.

1.4. MANAGEMENT OF THE ORGANIZATION:

As i have said before i have finished my training at ÇUKUROVA İTHALAT

VE İHRACAT TÜRK AŞ.’s revision plant in Adana in the city of the one of

famous industry and trade city of Turkey.

There are 36 staffs in this plant, 36 of 10 are employ in the management, trade,

research-development, etc. departments. The remaining are the workers.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.’s revision plants are in

relation with several countries in the world directly by the central

İSTANBUKL-KARTAL office. ÇUKUROVA İTHALAT VE İHRACAT

TÜRK AŞ. ADANA revision plant was settled on 10.000 m2 area closed. It

continues its work under the guarantee of ISO, TSE, and Global.Heavy

construction machines are continuously repaired for twenty-four hours daily for

seven days a week by experienced craftsmen and engineers. This plant is highly

technological and uses the special machinery and equipment dealing with

today’s technology..

Normally, the reconditioning and maintenance process does not stop except the

power cuts. Power cut problem is very important trouble in Turkey. Actually,

this is not acceptable situation, but in Turkey the power cuts are ordinary

situation and the people and industrialists are became familiar with these

interruptions. Unfortunately, this problem is going from bad to worse day-by-

day and whole the people and industrialists are influenced.

There are 36 employees in ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.

ADANA revision plant 26 of them are workers. There is one shift in this plant.

There are 25 workers in one shift. This shift is; from 08:30 am to 18:00 pm.The

watchman is the only person who works in different shift. Meanwhile if there is

an immediate problem or work a craftsmen should go without regarding the

normal work time.

There are lots of firms, which repairs heavy construction machines in Adana. If some of the economical and constructional factors are considered, ÇUKUROVA

İTHALAT VE İHRACAT TÜRK AŞ. ADANA revision plant is placed in the first place among them..

1.5. THE STRUCTURE OF THE ORGANISATION:

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. ADANA revision plant has 5 parts in it

INDUSTRIAL SALE

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.’s industrial department is

the leader of the turkey for the subjects below:

*Generators

*Cogenerating Systems

*Forklifts

*Land Forklifts

*Personnel Lifters

*Ground Cleaning Machines.

This department also gives importance to AR-GE activities.In ÇUKUROVA

İTHALAT VE İHRACAT TÜRK AŞ. ADANA revision plant there are 5

employees.

MACHINERY SALE

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. makes its own beko-loader

with it’s own design.Besides them ÇUKUROVA İTHALAT VE İHRACAT

TÜRK AŞ. is a represantative of ;

LIEBHERR for excavation machinary, INGERSOLL-RAND/ABG for road

equipments,MANITOU for land forklifts FERMEC for beko loaders,KRUPP for

hydraulic breakers,IRMER-ELZE for compressors,GEHL for mini loaders.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. ADANA revision plant

there are 5 employees working for this department.

SPARE PART

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.’s spare part department

has 59 years experience in obtaining spare parts for heavy construction

machinary in TURKEY .It is a represantative of the firms below ;

Desired spare parts have been first bought by İSTANBUL-KARTAL office

(central ofiice) from foreign countries then they are distributed to the other

ofiices acoording to need.There are 6 employees working for this unit.

SERVICE

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has 5 offices, 55

authorized services, 60 service cars and 200 personnels under the service

equipmensts.There are 4 kinds of services :

*Exterior Services

*Atelier

*Cogeneration Services

*Authorized Services

In Adana there are 11 employees working in atelier.They are also responsible

for the exterior services.

ACCOUNTING + MANAGEMENT

There are 9 employees in this department.

1.6. MAIN SPHERE OF ACTIVITY:

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. ADANA revision plant

repairs heavy construction machines. These machines were sold in Turkey

under the guarantee of ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.

This plant is one of the service of these machines.

The Liebherr Used Machines Center offers an up to date overview of all used

machines available at the various Service-Stations of Liebherr. At present, the

selection includes constantly more than 100 excavators, wheel loaders, crawlers

and mobile cranes. The comfortable machine search helps to find the desired

machine in no time and provides direct contact to the Service-Station in charge.

FIRST COST ANALYSIS:

Basically; the first cost analysis may be done like the following way:

1.6.1. EXPENSES:

Some expenses must be done to produce and distribute the productions to the

customers. The main expenses of the PLANT are the followings. The workers

work 28 days in a month, so this factor is used all of the calculations below.

1.6.1.1. GENERAL EXPENSES:

[Spare part expense]

[Electricity] + [Water]

[Worker’s Pay] + [Insurance Premiums]

[Taxes] + [Bank Loan Interests and Bank Loans’ Paying Back]

[Packaging + Transporting]

[Rent Expenses]

[Machine Amortizations]

1.6.1.2. WORKER’S PAY:To calculate the amount of the worker’s pay, we use some data. But these results are not exactly the same values with the actual data. These are approximate results.

In Turkey, there is a standard worker salary system, which is called “Minimum Wage” (about 250,000,000 TL = 150 $). This salary system is applied all over the country. The truth of the matter is that, this salary is not enough to survive a good life in Turkey or even any other country in the world, maybe except some African and 3rd world countries. This problem is another important problem of our country. Most of the workers, actually most of the people living in Turkey, complain high cost of living. There are 36 employees in CUKUROVA REVISION PLANT Some of them are employers; we say that there are 36 employees in CUKUROVA REVISION PLANT, and 36 of 26 are workers.

Average worker’s salary is, 250,000,000 TL. Monthly payment t o workers: 16 x 250,000,000 = 4,000,000,000TL to experts: 9 x 550,000,000 =4,950,000,000 TL to engineers and managers apprx: 7 x 1,000,000,000 =7,000,000,000 TL totally =15,950,000,000 TL

Extra expenses for workers are; Worker clothes (purchased two times in a year): one cloth’s price

20,000,000TL20,000,000 x 2 x 9 = 360,000,000TL (annual cloth expense)

30,000,000 TL / month (monthly cloth expense) Daily food expense per worker 2,500,000 TL

2,500,000 x36 x 30 = 2,700,000,000TL / month (monthly food expense) Worker transportation expense per worker

600,000,000 TL / month (monthly transportation expense) Service transportation cost per month apprx. : 10,000,000,000

Total monthly expenses:

29,640,000,000 TL / month =355,680,000,000 Tl/year

1.6.1.3. COST ANALYSIS:

All of the following calculations are done with respect to the specifications of the repaired machines. CUKUROVA REVISION PLANT officially works 30 days in a month.

The standard repaired machine specifications are:

Apprx.  250 machines repaired in a year.

250 x 8,000,000,000 =2,000,000,000,000 TL/year

Monthly electric bill 35,000,000,000 TL

Total Electricity expense per machine =35,000,0000,000x12 =420,000,000,000 TL / year

Monthly total expenses (as calculated above) = 775,680,000,000 Tl/year

total expense per machine = 775,680,000,000 /250 =3,102,720,000 Tl/machine

8,000,000,000-3,102,720,000 =4,897,280,000 tl/machine4,897,280,000 x250 =1,224,320,000 TL in a year.

1.6.2. THE FACTORS AFFECTED EXPENSES AND PROFIT:

These simple calculations based on the standard repaired machine. The expenses and profit depends on so many factors. Some of these factors are listed below:

1.6.2.1. DIMENSIONS OF THE PRICE:

If the repaired machines have different sizes in price from another, which are mentioned above and named as “standard ”, the expenses increase and the profit decreases or vice versa.

Here is an explanation for designing a machine

Liebherr Litronic 912 Backhoe Excavator

 

Introduction

 

The prototype Liebherr Excavator is a very large hydraulic actuated machine which has an operating weight of over 20 tons. It is a marvel of strength and versatility for earth moving, and has an interesting range of related activities.

The bucket capacity is 1,40 cubic metres, and the four cylinder direct injection turbo charged diesel engine has an output of 130 hp. The machine can lift a load of 5 metric ton at minimum radius. The diesel engine and many functions are under electronic control, which minimises energy loss and maximises power and efficiency. It drives a variable displacement axial piston double pump and is fitted with an electro-hydraulic regulator which react in seconds to changing requirements of power and speed.

The machine consists of a rugged under-carriage with tracks and hydraulic drive motors. The low machine centre of gravity provide exceptional stability. The final drive to each track and also the swing is an axial piston motor and planetary reduction gear.

The upper-carriage includes engine and oil pump, electronic control, drivers cab and controls, which include joysticks on the arms of the chair, foot pedals for swing control, and digital instruments to monitor oil temperature and pressure and engine RPM. The drivers cab is roomy and has oversize windows for all round view of the jobsite.

The gooseneck boom is operated by dual hydraulic rams, and the stick and bucket each have separate hydraulic rams. Several attachments and add-on kits are available for the machine, including longer extended reach goosenecks, clamshells, grapples, hammers, shears and augers.

In following the original design, one becomes aware of interesting features that are not at first obvious. One of these is certainly a low centre of gravity which decreases the possibility if tipping over while lifting a heavy load, perhaps while itself standing on uneven ground. To provide for this, the tracks are set well apart, and the machinery is as close to them as possible.

An obvious requirement is that the roller bearing should have great stability and rigidity while allowing easy rotation at fast speed. Notice how the boom is set directly over the roller bearing on an 'A' frame, so that the weight is taken vertically downwards. But there are also large tilting offset loads generated when the machine is working, and the central bearing must be able to withstand these.

One cannot but be extremely impressed by the shear power of hydraulic actuation. Not only must the Boom, Stick and Bucket be moved from positions which seems to have a poor mechanical advantages, but they must do a day's job of work moving hundreds of tons of material. The working life of such a machine might be as much as seven to ten years, which implies a high degree of reliability and construction from good quality materials.

In years gone by, a spade was required to dig and move earth and materials. Now, one person has his hands on levers which move tons with the greatest of ease, precision and speed, and he can do it consistently and for prolongued periods of time.

The Meccano Excavator

If one could build a model of this machine, in a scale which allowed for sufficient room for motors, actuators and controls, perhaps one could share in the power and dexterity which the driver must surely feel when he takes charge. This is especially so, if one can arrange the levers as in the prototype.

It is not presently possible to use miniature hydraulics in a model of this type. In order therefore to build a model which will work smoothly and with the correct speed for each movement, simulation of the motions are required. There are various methods of achieving this, including coaxial cables, lead screws and sliding mechanisms controlled by cables running from motor driven winches. It is this latter method which has been found to be highly reliable after extensive experimentation, and gives a smooth and powerful linear drive.

It is not at all clear in the photographs how the three movements work which are actuated by hydraulic rams. The mechanical motion is hidden. All three employ wire actuated trolleys running on guide rails. The wires are moved by winches which are geared to electric motors.

The Boom is moved by a trolley in the chassis. A drag rod links the trolley to a large crank extending below the bearing point of the Boom. One of the design features is to make this crank as long as possible, in order to increase its mechanical advantage.

In the case of the Stick and the Bucket, although trolleys are once more employed, they are in the Boom and the Stick respectively, and must be linked by long wires to their actuating motors.

A rod projects backwards from the back of each of the two pistons within the hydraulic cylinders. This requires that there is sufficient room proximally behind the attachment point at the base of each cylinder for the rod to move to its full extent. This space had to be carefully designed into the machine without making

it obvious. The trolley is attached in each case to the end of this rod by a drag rod.

As building progressed, it became apparent that the model would have a great weight, and this itself influenced design and construction. It required constant testing, building and rebuilding to achieve the desired results. Another consideration was to have reliable mechanisms, which would be able to perform repeated operations without undue maintenance.

How large should such a model be? A great deal depends on the space for machinery, including size of motors, reduction gearing and levers. The present scale of approximately 1:9 has been chosen to allow space for all the necessary mechanisms needed and to assist in building a scale model. It was thought essential to have each movement working smoothly and at the correct speed. It was not one of the requirements to have the machine do a job of work, but to provide a challenge for model building and control, and a taste for the driving experience.

The tracks must be able to take the machine load, and provide smooth motion. In a search for reliability, it became apparent that a non standard method of locating and driving the tracks was required. Eventually a simple design for the drive sprocket and idler wheel using Teflon was found.

The roller bearing has to provide great stability to the superimposed very heavy rotating super-structure where the weight distribution is not symmetrically distributed. The solution was found in hook rollers, which provide a smooth and positive action, and great stability. The chassis of the super-structure is built directly over the roller bearing, and the four hook rollers gain purchase directly from the underside of the chassis. Above the chassis, the 'A' frame is also directly built on the chassis, so that all the forces are concentrated together.

 

Modular Construction.

The model was designed to be built in sections, each of which must be fully completed before final assembly. Great attention should be paid to pre-fitting, in order to make final assembly easy. Once the model is completed, the cables running in the boom and stick prevent their easy disassembly. The model can however be very easy dis-assembled into two halves between roller bearing and sub-chassis. The completed model is extremely heavy. The weight is more than 16 kilos or over 35 lbs.

A suggested building program is now presented, and the building instructions that follow are arranged in accordance with that program. The constructor however might wish to follow another order of building, and there is no reason why this cannot be done as long as the final assembly instructions are meticulously adhered to. The following sections have been grouped for assembly and easy reference purposes.

Section A - Chassis, Cab and Roller Bearing

Section B - Machinery Framework and Mechanism

Section C - Sub-chassis, Track Frames and Tracks

Section D - Cab Side Panels, Hood, Covers and Drivers Cab

Section E - Boom, Stick and Bucket

Section F - The Hydraulic System

Section G - Control

 

Builder's Notes:

The italicised text is interspersed with builder's notes and comments about the machine and it's mechanical and Meccano features and these might be studied before commencing construction.

Method of Control

Control of the model was an important consideration. As mentioned, it was a requirement of the model that it could be driven in a way that simulated the driver's own experience. This means joystick control. In the prototype, the driver has a joystick in each hand, both of which have x and y motion. Using these, and

the foot pedals, he is able to easily control the speed of six motors in both directions which result in quite complex digging and movement operations.

It is intended that pulse width modulation control for the six main motors can be achieved, known as 'armchair control', using centre off joysticks, which automatically control motor speed and direction. This provides smooth power through the entire range of motion. If the joysticks are arranged as for the driver, a good simulation can be obtained. An alternative and simpler way however can be achieved through direct current control using switches and potentiometers.

Great attention was given to the use of parts to provide a strong structure and an attractive appearance. It is hope that you will enjoy building and operating this model, and find it a pleasing challenge.

One day, it will be possible to actually power the model with a type of hydraulic actuator. Experiments are continuing to realise this possibility. It has been found that if two exactly similar double acting cylinders are connected by hydraulic tubing, the displacement of fluid from one cylinder to the other, if one piston is mechanically driven, will match the return flow from the driven cylinder. The actuation is smooth and extremely powerful. This raises exciting possibilities, for the basis of many modern machines is hydraulics, and Meccano has lacked the ability to faithfully reproduce these mechanisms. We have been told that the scale of Meccano prevents the employment of actual hydraulics, which includes oil pumps, spool valves with electrical/electronic control, oil reservoirs, and reliable leak proof hydraulic cylinders, pistons, connections and glands. So perhaps the cylinder to cylinder method will be the best way to go in the future.

CONCLUSION

4.1. THE CHANGES OF ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. IN THE HEAVY CONSTRUCTION MACHINES MARKET:

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has a good place in

this market and this situation may continue for a long time. ÇUKUROVA

İTHALAT VE İHRACAT TÜRK AŞ. is known as a reliable firm. This position

is not easy-obtainable condition and also is not easy-maintainable place. This

situation needs hard working, attention and patience.

There are some good rival firms, which are dealing with the heavy

construction machines in Turkey, in some Far East and Middle East Countries.

But ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has proved its quality

and reliability among them.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. ’s products have high

quality; the orders are reached to the customers in the determined time interval.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. looks at itself critically all

the time. There is no place for irresponsibility in this firm.

As it known that, in Turkey, generally, workman’s fee and constant

payments is lower than the other countries. It could think that, this is a good

advantage for foreign market.

4.2. SOME TROUBLES:

Some troubles prevent development and growing up to the firms, factories

and establishments. For instance; Turkish governments’ supports are not enough

to the small-scaled and the middle-scaled companies about some activities, this

factor has been restricted to development motion.

An important trouble is Transportation in Turkey. Transportation is

generally done with trucks. Trucks move slowly, consumes much fuel, pollutes

air, cause traffic jam, for traffic accident to be likely for them, and they can

carry small amount of load. These factors affect the profit and performance.

Also they increase the delivery period. To prevent these losses, first of all, a

good railway system must be established as a network all over the country and

some foreign countries, and fast trains must be used to transport goods. Also, the

harbor system must be established. These systems were established in Europe

and in the U.S.A. so many years ago.

High taxes and high inflation are other important problems for

industrialist and people living in Turkey. For example, the industrialist must

give 40 % of their profit to the government under the name of “Tax of

institutions”. The percentage of the taxes is very high with respect to given

services by government. There are a lot of taxes like Tax of institutions. By the

way, the people are oppressed under the taxes, too. The income is low, the taxes

and inflation is high. This is an injustice application.

Some of other important troubles are; power cuts, lack of water

(sometimes), etc.

4.3. POWERFUL BEHALVES OF CUKUROVA

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.ADANA revision

plant has 10 engineers. All of them are mechanical engineers. These engineers

play very important role to the management and Research-development

processes.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. is using Internet efficiently. There are two employees are working on the net, continuously. They

try to find customer on the Internet. ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. maintains good marketing and introductory activity.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.’s working

conditions are better than so many factories, which are established in ADANA.

Workmen have motivated with some rewards, premiums and lottery

prizes. So ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. could take good

efficiency from workmen.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ.’s workmen are

experienced in their working field.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has three quality

control certificates; these are ISO 9002, TSE and Global. ÇUKUROVA

İTHALAT VE İHRACAT TÜRK AŞ. has a qualified quality control expert.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. sells its productions

generally foreign countries. For this reason, ÇUKUROVA İTHALAT VE

İHRACAT TÜRK AŞ. employees a few workers who knows English.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. has completed its

institutional activity yet. It has professional management staff, so all decisions

have not taken by owners and by this way some mistakes can be prevented.

ÇUKUROVA İTHALAT VE İHRACAT TÜRK AŞ. performs Research-

Development operations, effectively.

4.4. SOME ADVICES TO CUKUROVA

The control of entrance and exit should be controlled carefully.

The places, which are around the plsnt, should be more clean.

There is no good surrounding arrangement. This must be done.

An air conditioning system should be set up to the managerial

departments for summers. In my opinion, this system can increase the

performance of the employees.

An air circulation system should be set up in the plant.

Some tools should be found such as pressing machines, milling machines,

etc…