SODA SANAYII A.Ş.SODA FABRIKASI

SUMMER PRACTICEME 399

PREPARED BY:OSMAN ÇAĞLAYAN

UNIVERSITY OF GAZIANTEP2004

PART I

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.

1.4. MANAGEMENT OF THE ORGANIZATION:

As i have said before i have finished my training at SODA SANAYII AS.’s

revision plant in Mersin 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. SODA

SANAYII AS.’s revision plants are in relation with several countries in the

world directly by the central ISTANBUL-KARTAL office. SODA SANAYII

AS. Mersin revision plant was settled on 15.000 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 SODA SANAYII AS. MERSIN 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, SODA SANAYII AS MERSIN revision plant is placed in the first place among them..

1.5. THE STRUCTURE OF THE ORGANISATION:

SODA SANAYII AS MERSIN revision plant has 5 parts in it

INDUSTRIAL SALE

SODA SANAYII AS. MERSIN’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 SODA SANAYII

AS. MERSIN revision plant there are 5 employees.

SPARE PART

SODA SANAYII AS. MERSIN’s spare part department has 27 years experience

in obtaining spare parts in Turkey.It is a represantative of the firms below ;

Desired spare parts have been first bought by ISTANBUL-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

SODA SANAYII AS. MERSIN has 5 offices, 55 authorized services, 60 service

cars and 200 personels under the service equipments.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:

SODA SANAYII AS. MERSIN revision plant repairs heavy soda machines.

These sodas were sold in Turkey under the guarantee of SODA SANAYI AS.

MERSIN. 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 300,000,000 TL). 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 SODA SANAYII AS. MERSIN. Some of them are employers; we say that there are 36 employees in SODA SANAYII AS. MERSIN, 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. SODA SANAYII AS. MERSIN 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.

CONCLUSION

4.1. THE CHANGES OF SODA SANAYII AS. MERSIN :

SODA SANAYII AS. MERSIN has a good place in this market and this

situation may continue for a long time. SODA SANAYII AS. MERSIN 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 soda in

Turkey, in some Far East and Middle East Countries. But SODA SANAYII AS.

MERSIN has proved its quality and reliability among them.

SODA SANAYII AS. MERSIN’s products have high quality; the orders are

reached to the customers in the determined time interval. SODA SANAYII AS.

MERSIN 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 SODA SANAYII

SODA SANAYII AS. MERSIN revision plant has 10 engineers. All of

them are mechanical engineers. These engineers play very important role to the

management and Research-development processes.

SODA SANAYII AS. MERSIN is using Internet efficiently. There are two employees are working on the net, continuously. They try to find customer on the Internet. SODA SANAYII AS. MERSIN maintains good marketing and introductory activity.

SODA SANAYII AS. MERSIN’s working conditions are better than so

many factories, which are established in MERSIN.

Workmen have motivated with some rewards, premiums and lottery

prizes. So SODA SANAYII AS. MERSIN could take good efficiency from

workmen.

SODA SANAYII AS. MERSIN’s workmen are experienced in their

working field.

SODA SANAYII AS. MERSIN has three quality control certificates;

these are ISO 9002, TSE and Global. SODA SANAYII AS. MERSIN has a

qualified quality control expert.

SODA SANAYII AS. MERSIN sells its productions generally foreign

countries. For this reason, SODA SANYII AS. MERSIN employees a few

workers who knows English.

SODA SANAYII AS. MERSIN 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.

SODA SANAYII AS. MERSIN performs Research-Development

operations, effectively.

4.4. SOME ADVICES TO SODA SANAYII

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…