A) TABLE OF CONTENTS

B) Company Description

3..5

C) Introduction

6..7

D) Report
I) Production Processes

8..16

COLD FORMING
Shearing
Bending
Straightening
Deep Drawing
WELDING TECHNIQUES
II) Observation of Production Processes
* Technical Specifications of Manufacturing Machines

9..30

Presses
Fortune Holland Line
Welding Machines
Robots
* Five Example Products

31..35

Rail
Lower Seal Plate
Heater Support
Rail Holder
Decorative Frame

Adjustment Handle
* Cost Analysis of Rail and Lower Seal Frame
E) Conclusion

36..37
38..39

F) Appendix
1A: Dishwasher Models Produced
1B: Organization Structure
1C: Number of Engineers Employed

2: Technical Drawings of
Rail
Lower Seal Frame
Heater Support
Rail Holder
Decorative Frame
Adjustment Handle

B) DESCRIPTION OF THE COMPANY

ARCELIK A.S.ANKARA DISHWASHER PLANT

The plant was started to built on 22 SEPTEMBER 1992. On 15 September
1993 the test production started at Assembly Line and on 20 October 1993 the series
production was started. (After transferring of production machinery from Arelik
ayirova Plant, all the dishwasher production of Arelik has been in Arelik Sincan
Plant.
The total building cost of the plant is 52 million U.S. Dollars. 41 million
Dollars of the total cost is used for production machinery and one over four of these
machinery is from local producers
Arelik Ankara Dishwasher Management is located in Sincan Organized
Industry Region. Total close processing area of the factory is 18400 m2 and total area
of the plant is 109000 m2. There are two main Assembly Lines in the factory; First
Assembly Line, which is called Bosch Band, produces models for local market. Second
Assembly Line, also called Whirlpool Band, is producing models which are sold to a
German company called Whirlpool. First and second Assembly Lines produce 1200
and 400 dishwashers per day, respectively. Because of a license agreement made by
Bosch and Arelik, Arelik can only sell its products in Asia and Africa by using its own
name. Some of the models produced in First Assembly Line are given in Appendix 1A
There are 78 white collar and 230 blue collar workers employed in the plant.
The organization chart is given in the Appendix..... As seen in the organization chart
three production and four support areas are bound to the plant manager. These are
Assembly Area Manager, Inner Production Area Manager, Product Development Area
Manager, Quality Assurance Area Manager, Human Resources Area Manager,
Accounting Manager, Information System Chief.

Assembly area manager leads Whirlpool and First Assembly Lines. These
departments are formed of mechanical engineers, industrial engineers and
electrical engineers. They are responsible from the arrangements needed to
obtain necessary products for the optimum working of the Assembly Lines and
solving all the problems related to it.

Inner production area manager and his team is responsible from mechanical
production of the production of the dishwasher, welding and painting of the
produced parts, the selection, working and order of the production machines. This
section is formed of mechanical engineers, mainly.

Product development area manager and his team is responsible from development
of the parts used in the old models and development of new dishwashers. This
section is one of the rare design labs in Trkiye. It is formed of mechanical
engineers thermodynamics, fluid mechanics and machine design.

Quality assurance area manager and his team is responsible for determining the
factors that affect the daily quality points and making the necessary
arrangements. This includes the factors about working and education of the white
and blue collars and how optimum performance can be taken from them. It is
formed of mechanical and industrial engineers.

Human resources area manager is responsible from the quality and well being of
the white and blue collars working in the plant.

Accounting manager is responsible for the salaries and cost analysis of the products
used in the plant, products produced in the plant.

Information system chief is responsible for Internet, intranet ( a network joining all the
computers in all Arelik Corporation facilities), software aplications and their
education in the plant. In all Arelik facilities same format of the softwares are used in

order not to loose the integrity of the different parts of the whole and these softwares
are developed and selected by the main information systems department in Istanbul.
The number and duties of engineers employed in these sections are given in
Appendix 1C

C) INTRODUCTION

The aim of the Summer Practice program is to reinforce and improve the
theoritical and practical knowledge on production techniques and engineering drawing
acquired in the previously completed coursework. Also application of the knowledge

gained, in real life is an objective so that a new angle of peception can be obtained
while studying future courses.
In the six week summer practise at Arelik Dishwasher Plant, production
techniques is examined and grouped. Also each production unit is grouped and
technically examined for better understanding and noting of the product-production
relationship. This observation is guided by the knowledge obtained from ME 202
Manufacturing Technology Engineering course; while also improving our
understanding over this courses subjects. The observation of manufacturing processes
and machines aided us solidfy the concepts and groups learned in the previous courses.
Technical drawings of sample work-pieces and stages in the prodction of these
samples is als included in this report which is a direct application of ME 113 and ME
114 Engineering Drawing courses. The repeating of the drawing skills in the summer
practise gave us a real life experience and usage of these skills not in examples but in
solid state.
The last part of this report covers the cost analysis of the sampled parts (or
products), being a fundamental practise for future studies on engineering management
and economics. The important concept of cost-product-customer relationship is
understood better by the observation of company policies.
As aresult, during this practise the student comes face to face with the real
objects, real processes, real problems and should be able to come up with real
solutions. Thus, the student will be able to see mechanical engineering as a life earning
job. Also the student should earn enough experience so that he can addept business
life, as an engineer, more easily and quickly.

D) REPORT

I) THE GROUPING AND EXPLANATION OF THE PRODUCTION

PROCESSES USED IN ARELIK DISHWASHER PLANT

The manufacturing processes in Arelik Dishwasher Plant can be grouped into

two categories:

1) Cold Forming

2) Welding Techniques

1) COLD FORMING

Plastic deformations of metals below recrystallization temperature is known as

COLD WORKING and is generallyperformed at room temperature. Cold Working
has a number of distinct advantages and have become extremely important
The advantages of Cold Working processes are:
1) No heating is required.
2) Better surface finish is obtained.
3) Superior dimensional control is achieved.
4) Wear, Strength and fatigue properties are improved.
5) Directional properties can be improved.
Some disadvantages are:
1) Higher forces are required.
2) More powerful equipment is required.
3) Metal surface must be clean and scale free.
4) Strain Hardening occurs.
Cold Working processes are particularly well suited for large volume
productionwhere quantity the involved can readily justify the cost of the required
equipment and tooling.
Forming operations typically utilize material that previously has been casted or
molded. In many cases the materials pass through a series of shearing or forming
operations, so the form of material for a specific operation may be result of all the

priory operations. The main purpose of forming is to modify size, shape and physical
prperties of material.

a) SHEARING:
Shearing is the mechanical cutting of materials without the formation of chips
or the use of burning or melting. When the two cutting blades are straight, the process
is called shearing. When the blade geometry is curved, as in the edges of punches and
dies, the process has special names, such as blanking, piercing, notching, shaving and
trimming.
In simple type of shearing process, as the punch descends against the
workpiece, the metal is first deformed plasticly into the die. Because the clearence
between the two tools is only 5% to 10% of the thickness of the metal being cut, the
deformation is highly localized. The punch penetrates into the metal, the material flows
into the die and the opposite surface bulges slightly. When the penetration reaches
about 15% to 60% of the thickness of metal, the amount depending on the material
ductility and strength , the applied strength exceeds the shear strss and the metal
suddenly shears or ruptures through the remainder of its thickness. The two stages of
shearing process, deformation and fracture, can often be seen on the edges of the
sheared parts.
If the punch and die have proper clearence and are mainted in good conditions,
sheared edges may be produced that are sufficiently smooth to use without further
finishing. The quality of the shear can be further improved if the strip stock is clamped
firmly against the die from above, the punch and die are maintained with the proper
clearence and alignment and the movement of the piece through the die is restrained
with an opposing plunger or rubber die cushion applying pressure from below the

workpiece. These measures cause the shearing to take place uniformly around the edge
rather than randomly at the weakest points.
Piercing and Blanking:
Piercing and blanking are shearing operations wherein the shear blades take the
form of closed, curved lines on the edges of the punch and die. They both involve the
same basic action with the difference being primarily one of the definition. In piercing,
the piece being punched out is the scrap and the remainder of the strip becomes the
desired workpiece. Piercing and blanking are usually done on some form of mechanical
press.
The basic components of piercing and blanking die sets include a punch, a die
and a stripper plate. Theoritacally, the punch should be of the dimensions such that it
would just fit within the die with a uniform clearence approaching zero. On its
downward stroke, it should not enter the die but should stop as its base aligns with the
top surface of the die. In general, however, the clearence is generally between 5% to
7% of the stock thickness and the punch enters the die by a small amount.
Most commonly used die structure is progressive die set. It consists of two or
more sets of punches and dies mounted in tandem. The strip stock is fed into the first
die, where a hole is pierced as the ram descends on the first stroke. When the ram rises
the stock is moved into the position under the blanking punch. Positioning is
accomplished automatically by a stop mechanism that engages in a previously punched
hole. As the ram descends on the second stroke, the pilot on the bottom of the
blanking punch enters the hole that was pierced on the previous stroke to ensure
accurate alignment. Further descent of the punch blanks the completed washer from
the strip and at the same time the first punch pierces the hole for the next washer.
Thus, a finished part is completed with each stroke of the press.

10

b) BENDING:
Bending is the plastic deformation of metals about a linear axis with little or no
change in the surface area. When multiple bends are made simultaneously with the use
of a die, the process is called forming. The various bend axes can be at angels to each
other, but each axis must be linear and independent of the others for the process to be
classified as a true bending operation and be treatable by a simple bending theory.
Bending causes the metal on the outside to be streched while that on the
outside is compressed. The location that is neither streched nor compressed is known
as the neutral axis of the bend.Since the yield strength of metals in compression is
somewhat higher than the yield strength in tension, the metal on the outer side yields
first, and the neutral axis is displaced from the center of the surfaces. In fact, the
neutral axis is generally located between one third and one half of the way from the
inner surface, the preciese location depending upon the bend radius and the material.
Because of the preffered tensile deformation, the metal is thinned somewhat at the
bend, the thinning being more pronounced in the center of the sheet where the material
can not freely pull in along the axis of bend.
Angle Bending: A bar folder can be used to make angles bends up to 1500 in the sheet
metal under 1.5 mm thick. The sheet of metal is inserted under the folding leaf and
moved to proper position. Raising the handle actuates a cam causing the leaf to clamp
the sheet. Further motion of the handle, bends the metal to the desired angle. Bar
folders are manually operated and are usually less than 4 meters long. Bends in heavier
sheet or more complex bends in thin material are generally made on press brakes.
These are mechanically or hydraulically presses
Roll Bending: Plates, sheets and rolled shapes can be bent to a desired curvature on
forming rolls. These machines usually have three rolls in the form of a pyramid, iwth
the lower rolls being driven and the position of the upper roll being adjustable to

11

control the degree of curvature. When the rolls are supported by a frame on each end,
one of the supports can often be swung clear to permit the removal of closed shapes
from the rolls. Roll Bending machines are available in awide range of sizes, some being
capable of bending plate up to 150 mm thick.
Draw Bending and Compression Bending: The most commonly used types of
bending in Arelik Dishwasher Plant are Draw Bending and Compression Bending.
Many modern bending machines utilize a clamp and pressure toll to produce bending
about a form block. Draw Bending is perhaps the most versatile and accurate means of
bending. The workpiece is clamped against a bending form and the entire assembly
rotates to draw the workpiece across a pressure tool. In Compression Bending
the bending form remains stationary and the pressure tool traverses along the
workpiece.

c) STRAIGHTENING:
Straightening has as its objective opposite of bending and is often performed
before the cold forming operations to assure the use of flat or straight material. Two
different techniques are quite common. Roller leveling subjects the material to a series
of reverse bends. The sheet is passed through a series of rolls with progressively
decreased offsets from a straight line. As the material is bend back and forth, it is
stressed slightly beyond the elastic limit, thereby replacing any permanent set with a
straight or flat profile.
The sheet may also be straightened by a process called strecher levleing. The
sheets are gripped mechanically and streched slightly beyond the elastic limit to
produce uniform length and desired flatness.

d) DEEP DRAWING:

12

Deep Drawing of closed cylindrical o rectengular containers, or similar shapes

the depth of which is greater than the smallest dimension of the opening, is one of the
most important and widely used of the manufacturing processes.
There are basically two types of drawing and both involve multiaxial or curved
axis bending. In the shrink forming, there is circumferential compression resulting from
the decrease in diameter and the metal may compensate by thickening. Since the metal
is thin, however, an alternative response is to relieve the circumferential compression
by buckling or wrinkling. In strech forming there is a circumferential streching that
occurs and corresponding thinning of material. This thinning can be the cause of
tearing during forming such as premature failure of the part under corrosive
conditions.
To draw a part without wrinkling, tearing or undesirable variation in thickness,
the flow must be controlled. This usually accomplihed with some form of pressure ring
or pad. In single action presses where ther is only one movement of the slide, spring or
air pressure is used to control the flow of metal between the upper die and pressure
ring. When double action presses are available, with two or more independent rams the
force applied to the main slide. This permits the pressure to be varied as needed during
the drawing. For this reason, double action presses are usually specified for drawing
more complex parts, while single action presses can be used for the simpler types of
operations.

2) WELDING TECHNIQUES
Welding is a technique in which the two materials, usually metals, are
permanentaly joined together by coalescence resulting from a combination of
temperature, pressure and the metallurgical conditions. The particular combination of
temperature and pressure can range from high temperature with no pressure to high

13

pressure with no increas in temperature. Thus welding can be accomplished under a

wide variety of conditions and numerous welding processes have been developed and
are used routinely in manufacturing.
The welding processes differ not only in the way in which temperature and
pressure are combined and achieved but also with regard to the attention that must be
given to the cleanliness of the metal surfaces prior to welding process. If high
temperatures are used, most of the metals are more adversly affected by the
surrounding environment. If actual melting occurs, serious modification of the metal
may result. The metallurgical structure and quality of the metal can be affected, often
adversely, by heating and cooling cycle of the welding process. These effects and their
possible consequences should be considered in the design of a product and in selecting
the joining process.
I) Resistance Spot Welding: In spot welding the parts are lapped and held in place
under pressure. The size and shape of the electrodes control the size and shape of the
welds, usually circular. Designing for spot welding involves 6 elements: tip size edge
distance, contacting overlap, spot spacing, spot weld shear strength and electrode
clearence.
Spot Welding machines vary from small manually operated units to large
elaborately instrumented units designed to produce high quality welds, as on aircraft
parts. Portable genotype welders are available forces where the assemblies are too
large to be transported to a fixed machine. Spot Welds may be made singly or in
multiple, the latter being generally by special purpose of machines. One type of
multiple spot welder employing two transformers may be used in cases where in the
introduction of iron parts into the throat of conventional single spot welder would
cause axcessive power loss due to chocking effect. Current passe sthrough one set of

14

electrodes, in a line, and back through the other set. Spacing of electrodes is important
to avoid excessive shunting of welding current.
ii) Resistance Seam Welding: This type of welding is being used in Arelik Dishwasher
Plant in the making of inner tubes of dishwashers made for Whirlpool Company. The
Seam Welding process is a series of spot wlds made by circular or wheel type
electrodes. The weld may be a series of closely spaced individual spot welds or
overlapping spot welds or a continious weld nugget. The weld shape for individual
welds is rectangular or oval; continious welds are about 80 percent of the width of the
roller face.
Machines for seam welding may provide for the rotation of one or both rollers.
Three general types are available: longitudinal, circular and universe. Interrupters are
necessary to provide the control of the heat effect and allow cooling, under pressure.

15

II) THE OBSERVATION OF MANUFACTURING PROCESSES AND

PRODUCTS MANUFACTURED IN THE PLANT

THE TECHCICAL DATA ABOUT MANUFACTURING MACHINES USED IN

THE PLANT

A) PRESSES

Straight side presses (mechanical eccentric presses)

Manzoni (315 ton)

Nominal power: 3150 Kn.

Strokes per minute: 15-50 n.
Number of con-rods: 2 n.
Main motor power: 45-11 kW.
Rated distance from BDC: 12.5 mm.
Weight : 52000 kg.
Nominal energy at strokes: 40 kJ.

Some of the parts produced by this press are :

16

kick strip, front top support, front reinforcement, counter weight bracket, rear top
support , inner door bracket, lower spray arm, motor bracket
Manzoni (100 ton)

Nominal power: 1000Kn.

Strokes per minute: 30-90 n.
Number of con-rods: 1 n.
Main motor power: 20 kW.
Rated distance from BDC: 6.35 mm.
Weight : 10000 kg.
Nominal energy at strokes: 6.3 kJ.

Some of the parts produced by this press are :

rinse aid arm, lower spray arm washer ,detergent arm, thermostat bracket, heater
bracket, reinforcement.

Rovetta (315 ton)

Rated force 12.5 mm from bottom of stroke: 3150 kn.

Stroke per minute: 15-50 n.
Main motor power: 58 kW.
Slide adjustment motor: 4 kW.
Some of the parts produced by this press are :
lower seal plate, cabinet frame support, rail , top plate bracket , cabinet frame

17

Triple action hydraulic presses

Emanuel (700 ton)

Total power with united slides: 7000 kn.

Slide speed: 550 mm/s.
Molding power of slide:2000 kn.
Blankholder speed: 550 mm/s.
Molding power of blankholder: 5000kn.
Molding power of slide: 2000 kn.
Power of inside/outside slide return: 200/400 kn.
Motor power: 255+10 kW.

Emanuel (200 ton)

Working thrust: 2000 kn.

Slide speed: 290 mm/s
Power of the main motor: 45 kW.
Blank holder speed: 130 mm/s.
Working speed at full power: 16 mm/s.
Working speed at half power: 30 mm/s.

Some of the parts produced by this press are:

inner door, rear case cover

18

Transfer press

Rovetta (800 ton)

Max. capacity at 15mm of the bottom of stroke: 8000 kn.

Stroke of slide: 400mm.
Number of transfer station: 1+4+1 n.
Number of transfer axis: 3 n.

Some of the parts produced by this press are:

outer door, side wall

B)TECHNICAL DATA FOR FORTUNE HOLLAND LINE

Lubricant spraying installation

Pressure vessel :

Max pressure 6 bar

Contents 120 lt.

Spray guns :

WA-xv-n-1 , 5 mm.

Valves :

24 V DC

Lubricating installation

Grease pump:

contents 5 L.
filling bottom connection
19

Oil pump:

contents 30L.
filling top of reservoir
plunger-rnd 8 mm.

Distributors
Hose

Pneumatic installation:

Cylinders
Valves

24 V DC

Hose

Aeroquip

6*12, 7-2556-4
12*9-2556-8

Bosch
Normal pressure
Adjusted pressure

LW4-LW6-LW9

6/8 bar
5/6 b

Electrical Installation

The electrical controls are designed in accordance with Bosch-Seimens standards, with
following main parts:

- programmable controls
- 1 main control panel
- cabinets for PLC control system
- cabinets for mains supply and motor controls
- all cabling with plugs/sockets
- proximity switches LED and plugs

20

-PLC cabinet with heat exchanger and temperature control

- main power supply 380V , 50 Hz
- Control voltage 24 VDC
- programming with Siemens PG 675 unit

Hydraulic installation

Pressure

P1 = 130 bar

Pressure

P2 = 300 bar

Control pressure

X = 70 bar

Oil amount

2000 Liters

Cooling water

2 - 3 bar max. 15 C

C)WELDING MACHINES

Welding line of inner body (station 14)

line pressure : 6 bar

welding pressure : 5.5 bar
welding unit : n 16 71.01.A03
secondary voltage :5.6 ,5.9 , 6.3 V
primary voltage : 380 V / 50 Hz

Welding line of inner body (station 31)

welding pressure : 5 bar

21

secondary voltage : 2.2 V

primary voltage : 380 V / 50 Hz
welding current : 60
pulsing : yes
welding speed : 0.75 mt./min.

Welding line of inner body (station 31)

welding pressure : 5 bar

secondary voltage : 2.2 V
primary voltage : 380 V / 50 Hz
welding current : 60 %
pulsing : yes
welding speed : 0.75 mt./min.

Welding line of inner body (station 41)

welding pressure : 5 bar

secondary voltage : 2.2 V
primary voltage : 380 V / 50 Hz
welding current : 55 % / 60 %
slope up time : 15
pulsing : no / no
continue : yes / yes
welding speed : 3.5 mt./min.
22

 Welding line of inner body (station 61)

welding pressure : 5 bar

secondary voltage : 2.2 V
primary voltage : 380 V / 50 Hz
slope up time : 29
welding current : 50 %
pulsing : no
continue : yes
welding speed : 3.5 mt./min

Welding line of inner body (station 91)

welding pressure : 5 bar

welding unit : n 2 b 61.01. A05
secondary voltage : 4.8 V
primary voltage : 380 V / 50 hz.
welding time : 8
pause : 0.5

Welding line of inner body (station 103)

welding pressure : 4 bar

welding unit : n 8 P2DA-51.25.12 (MC) + e1260.01.521

23

secondary voltage : 5.6, 5.9, 6.3 V

primary voltage : 380 V / 50 Hz.
Approach : 20
welding time : 03
pause : 02

Welding line of inner body (station 112)

welding pressure : 3 bar

welding unit : n 8 P2DA-51.25.12 (MC) + e1260.01.521
secondary voltage : 5.6, 5.9, 6.3 V
primary voltage : 380 V / 50 Hz.
Approach : 20
welding time : 03
pause : 00

Calend & seam weld & seam roll machine

line pressure : 6 ATM

welding pressure : 5 ATM
register pressure : 4 ATM
seam rolling pressure : 4 ATM
N. 2 seam welding units : 1027.01.300
secondary voltage : 3.16 , 4.22 , 6.33
primary voltage : 380 V / 50 Hz
protective cooling gas outlet pressure : 5 ATM
24

approaching : 00
spot : 00
pause : 00
welding current : 60 %
pulsing : no
continue : yes

D) ROBOTS

General

Five industrial robots IRB 6000PT are serving four presses dedicated for production
of inner door and rear case cover. Together with the robots there are three turntables
and two lubrication devices in the line.

Depending on the choice of the run mode , one robot picks the blank sheets from a
turntable and thereafter handles it through the lubrication device. After the lubrication
operation the robot loads the first press. The sheets in the following press steps are
handled by the other robots.

A master control device is to control the whole robot line .Choose of production
mode can be made from the master control cabinet. There are four different modes to
run the line.

- Run mode 1 : inner door production

25

- Run mode 2 : rear case cover from press A to press B

- Run mode 3 : rear case cover from press D to press C
- Run mode 4 : rear case cover as a combination between Run mode 2 and run mode 3

Robot 1:

Robot 1 is equipped with a gripper for handling blank sheets. The gripper can handle
sheets for both Inner Door and Rear Case Cover without any adjustments. Sheets are
handled from turntable to lucubration device and into Press A. Robot 1 has
communication with turntable , lucubration device , Press A and Robot 2.

Axis 1 on the robot is equipped with a limit switch for hardware interlocking of
start signal to press. The contact is open when the robot gripper is in the press die. On
the control cabinet there is a lamp for warning and error indication to the operator.

Robot 2:

Robot 2 is equipped with a gripper for handling of stamped sheets. The gripper can
after a small adjustments handle sheets both for Inner Door and Rear Case Cover .
Robot 2 has communication with Press A , Press B, Robot 1 and Robot 3.
Axis 1 on the robot is equipped with a limit switch for hardware interlocking for
start signal to press. The contact is open when the robot is in the press die. On the
control cabinet there is a lamp for warning and error indication to the operator.

Robot 3:

26

Robot 3 is equipped with a gripper for handling of stamped sheets. The gripper can
after a small adjustments handle sheets both for Inner Door and Rear Case Cover .
Robot 3 has communication with Press B, Press C, turntable , Robot 2 and with Robot
4.
Axis 1 on the robot is equipped with a limit switch for hardware interlocking for
start signal to press. The contact is open when the robot is in the press die. On the
control cabinet there is a lamp for warning and error indication to the operator.

Robot 4:

Robot 4 is equipped with a gripper for handling of stamped sheets. The gripper can
after a small adjustments handle sheets both for Inner Door and Rear Case Cover .
Robot 4 has communication with Press D, Press C, Robot 3and with Robot 5.
Axis 1 on the robot is equipped with a limit switch for hardware interlocking for
start signal to press. The contact is open when the robot is in the press die. On the
control cabinet there is a lamp for warning and error indication to the operator.

Robot 5:

Robot 5 is equipped with a gripper for handling of stamped sheets. The gripper can
after a small adjustments handle sheets both for Inner Door and Rear Case Cover .
Robot 5 has communication with lubrication device, turntable , Press D and with
Robot 4.
Axis 1 on the robot is equipped with a limit switch for hardware interlocking for
start signal to press. The contact is open when the robot is in the press die. On the
control cabinet there is a lamp for warning and error indication to the operator.

27

THE OBSERVATION OF FIVE PRODUCTS MANUFACTURED IN THE

PLANT

PRODUCT 1 : RAIL

First step in the making of rail is roller leveling of the sheet metal which is a
straightening process. The sheet passes through a series of rolls with progressively
decreasing offsets and leaves with a straight and flat profile.
Then the sheet enters 315 Tone Rovetta Press. The press contains a progressive die
set specially prepared for rail .These die sets are stored and changed in the plant every
day according to the production schedule. First two steps are the opening of the eight
0.5mm diameter holes which are on the left and right sides of the rail .These two
strokes are piercing operations. The following two operations are compressive bending
operations in which two successive bendings are done to finish the parts.
The last stroke of the Rovetta press is done for removing of the removal of the
finished product from the part one stroke behind it. The finished part is then carried
away by a sliding band and into a container where the newly made rails are checked by

28

operators and where the separations of the parts including defects are made. The
operator also resets the machine when a defected or deformed part causes the press to
stop operating. The cleaning and storing of the trimmed and pierced waste sheets from
a storage compartment under the die is also one of the duties of the operator. When the
container is full worker carry it to the nearby storage areas where the finished parts
await their times for production.
PRODUCT 2: LOWER SEAL PLATE

First step in the making of seal frame is roller leveling of the sheet metal which is a
straightening process. The sheet passes through a series of rolls with progressively
decreasing offsets and leaves with a straight and flat profile.
Lower seal plate is produced in a 315 Tone Rovetta Press. A progressive die is used
for the production of the part. The first stroke is a punching operation which opens
nine 0.8cm diameter holes in a line. Next stroke opens two 0.5cm diameter hole on the
two sides of the sheet. Third stroke of the press trims the corner parts of the sheet in a
rectangular pattern. Fourth stroke is a shallow drawing operation which forms 0.25cm
radius edge.This is followed by two successive compressive bending operations. Last
stroke cuts the part from its predecessor and the sheet.
. The finished part is then carried away by a sliding band and into a container where
the newly made lower seal plates are checked by operators and where the separations
of the parts including defects are made. The operator also resets the machine when a
defected or deformed part causes the press to stop operating. He or she is also
responsible for necessary oiling of the press when necessary. The cleaning and storing
of the trimmed and pierced waste sheets from a storage compartment under the die is
also one of the duties of the operator. When the container is full worker carry it to the
nearby storage areas where the finished parts await their times for production.

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PRODUCT 3: HEATER SUPPORT

First step of making a heater support is roller leveling which is a straightening

process. The sheet passes through a series of rolls with progressively decreasing
offsets and leaves with a straight and flat profile.
Heater Supports are being produced by a 315 Tone Rovetta Press. A
progressive die set is used for production of the part. The operation time is one stroke
of the press. The first stroke is a shearing operation. Second stroke is a bending
operation for formation of ends with 4. 00 mm radius. The last stroke is blanking
which forms 10.00-4.00 mm rectangular holes.
The finished part is then carried away by a sliding band and into a container
where the newly made oneschecked by operators and where the separations of the
parts including defects are made. The operator also resets the machine when a defected
or deformed part causes the press to stop operating. The cleaning and storing of the
trimmed and pierced waste sheets from a storage compartment under the die is also
one of the duties of the operator. When the container is full worker carry it to the
nearby storage areas where the finished parts await their times for production.
PRODUCT 4: RAIL HOLDER

First step in the making of rail holder is roller leveling of the sheet metal which is a
straightening process. The sheet passes through a series of rolls with progressively
decreasing offsets and leaves with a straight and flat profile.
Then the sheet enters 100 Tone Manzoni Press. The press contains a progressive die
set specially prepared for rail holder. These die sets are stored and changed in the plant

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every day according to the production schedule .The first stroke of the die is used for a
shearing process in which corner parts of the sheet is cut off. Second stroke is a
piercing operation in which a hole of 0.8 cm diameter is cut open. In he third stroke a
compression bending operation is done to bend the rectangular part of the rail
holder.The next stroke bends the trapezoidal parts of the product.
The last stroke of the Manzoni press is done for removing of the removal of the
finished rail holder from the part one stroke behind it. The finished part is then carried
away by a sliding band and into a container where the newly made rail holders are
checked by operators and where the separations of the parts including defects are
made. The operator also resets the machine when a defected or deformed part causes
the press to stop operating. He or she is also responsible for necessary oiling of the
press when necessary. The cleaning and storing of the trimmed and pierced waste
sheets from a storage compartment under the die is also one of the duties of the
operator. When the container is full worker carry it to the nearby storage areas where
the finished parts await their times for production.

PRODUCT 5: DECORATIVE FRAME

First step in the making of rail holder is roller leveling of the sheet metal which
is a straightening process. The sheet passes through a series of rolls with progressively
decreasing offsets and leaves with a straight and flat profile.
The shets which are for Decorative Frame are first sheared. The second
operation is blanking to prepare holes in the form of a rectangle with dimensions 3.001.00 mm. Third operation is trimming. This operation is done by a 315 Tone Manzoni
Press. After all these operations it is bended 90o in only one step. The die and the

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punch are dsigned for this operation to be done in one step. Also there is a determined
extra small angle for the springback.
The finished part is then carried away by a sliding band and into a container
where the newly made oneschecked by operators and where the separations of the
parts including defects are made. The operator also resets the machine when a defected
or deformed part causes the press to stop operating. The cleaning and storing of the
trimmed and pierced waste sheets from a storage compartment under the die is also
one of the duties of the operator. When the container is full worker carry it to the
nearby storage areas where the finished parts await their times for production.

PRODUCT 6: ADJUSTMENT HANDLE

The adjustment handle is produced by a Co-Industrial Plant whose name is

GALSAN. The technique for the production of this part is known as plastic injection.

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COST ANALYSIS OF TWO OF THE PRODUCTS OBSERVED

There are three factors in the cost analysis of a product.

First factor is the cost of the raw materials used in the production and scrap
materials from the production. This amount is called raw material cost and is calculated
by the multiplication of the unit stock cost (TL per KG) with amount of material used
in the product (KG).
Second factor is the labor. Labor is calculated by the addition of different man cost
per hour values for each process the product goes through . These man cost values are
multiplicated by the ratio of the time spend on the specific process to the total time the
production takes and then added together to find a final value which is TL per piece.
Third factor is factory overhead which includes energy costs , upkeep and control of
the machines etc.

Name: Lower seal plate

Stock Number: 1804580000
Quantity: 233322 KG.
Material cost per Kilogram: 222000TL.

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Raw Material

51.797 TL.

Labor
Factory Overhead

817 TL.
2.090 TL.

__________________________
TOTAL

54.704 TL.

Name: Rail
Stock number: 1802040000
Quantity: 136276 KG.
Material cost per Kilogram: 305000 TL.

Raw Material

41.564 TL.

Labor

2.941 TL.

Factory Overhead

7.524 TL.

__________________________
TOTAL

52.029 TL.

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E) CONCLUSION

Arelik Dishwasher Plants systematic is well defined and used, taking its
objectives as economical, flawless and fast production with increasing quality. This
system reveals that a plant can not be thought as different parts but a whole with one
goal which should be understood and progressed for by every member as a whole.
From this we can understand that Arelik is a fine example of advanced engineering
and production site.
Organization of the plant succeeds to decrease the gap between the gap
between the plant manager, engineers and workers by creating less managment layers
and arranging the working and studying spaces in a way that both white and blue
collars are together.
Organization structure divides the engineers to different specialized areas each
focused on a different aspect of the plant like assmbly, inner production, human
resources, quality assurance etc. In these areas mechanical, industry and electrical
engineers are working together as teams.
Manufacturing area of the plant is one of the most modern ones in Trkiye.
Altough there not any casting and material removal process, forming and welding
processes are used throughout the plant. Layout of the machinery and advanced
techniques used are aimed toward faster production. Usage of robots in vital areas
reduces the error percentage as well as saving a lot of time.
The research and developement section of the plant is also one of the most
developed design centers in Trkiye. It developes new parts for current models as wll
as designing new models. Advanced systems and programs like I-DEAS, can be
observed in this section which are advanced applications of ME 113 and ME 114
courses.In the working section every engineer has at least one computer of his own.

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All of them know how to use Microsoft word, excel, power point and acces.
Communication is done by an advanced network including all computers in the factory.
Also a daily education of the blue collars presentations and the quality circles are
prepared by computers.
In addition to all of these engineers believed in me to work in projects,
including Poka-Yoke Zero Quality Control System which is planned to use at Arelik
to solve problems. I have designed an apparatus using Poka-Yoke system in order to
stop wrong assemblation of knobs, which is now being used at the First Assembly Line
(Bosch Band). Also the second idea to fasten the Whirlpool Band is now discussed by
the quality circles.
As a result, I can say that this summer practise was very efficient for me to see
where and how a mechanical engineer works and the mechanisms of a large factory
which is a first step to become an enginner.

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