DESCRIPTION OF THE COMPANY

Name of the company : Mercedes-Benz Turk A.Ş.

Location of company: Konya Highway P.K. 19 68100 Aksaray

Phone number : 0 382 215 16 39

Fax number : 0 382 215 13 55

Internet adresses : www.mercedes-benz.com.tr

www.daimlerchrysler.com

Organizational structure of the company : Look at Appendix 1.

Number of engineers employed : 82

Mechanical engineers : 61
Industrial engineers : 13
Electrical and Electronical engineers : 7
Chemical engineers : 3
Metallurgical engineers : 2
Computer engineers :3
Physics engineers :1
Worker : 567
Other officers : 65

Total personel number : 714

Main sphere of activity :

Production of light duty trucks, heavy duty trucks and unimogs for Turkey and
exporting to other countries.
The production scale includes light ATEGO to heavy AXOR with ACTROS
vehicles, Unimogs and partial production to the factories in Mannheim, Ulm and
Istanbul for the production of buses.
At the same time the substructures of buses are produced at Aksaray Truck
Plant.

History of the company :

Mercedes-Benz Türk was established in Istanbul in 1967 under the name

"Otomarsan" as a partnership between Daimler-Benz AG (36%),
Mengerler Ticaret T.A.Ş. (32%) and Has Otomotiv (32%).
The Company started the production of 0 302 type buses in 1968.
In 1970, only 2 years after its foundation, the Company started to export and of
the 36.000 buses produced, over 12.600 buses have been exported to date. In 1984 the
Company was appointed as the general representative of Mercedes-Benz in Turkey,

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added with new partners to the enterprise and started a new investment necessary for
production of trucks. In 1986, parallel to the growth potential of Turkey, the Truck
Plant started production in Aksaray. In November 1990 the company name was
changed to Mercedes-Benz Türk A.Ş.
The company currently employs 2.800 personnel. Due to increasing export
activities Mercedes-Benz Türk built a new bus plant in Hoşdere, which became active
in December 1994.
Mercedes-Benz Türk has recently increased its capital to TL.
57.000.000.000.000. The shareholders of the Company are DaimlerChrysler AG
(66,91 %), Overseas Lending Corporation (18,09 %), Koluman Holding A.Ş. (7,04
%), Türk Silahlı Kuvvetlerini Güçlendirme Vakfı (5,00 %) and Makina ve Kimya
Endüstrisi Kurumu (2,96 %).
Since its foundation Mercedes-Benz Türk has sold approximately 36.000
buses, 35.000 trucks and 1.000 midibuses from ist own production in addition to
20.000 cars since 1989 when the Company activated the importation of passenger
cars. Mercedes-Benz Türk, currently produces intercity and municipality buses at
Hoşdere and Davutpaşa Plants and light and heavy duty trucks at the Aksaray Plant.
Mercedes-Benz Türk is the first company in the Turkish primary automotive
industry to get the ISO 9002 quality certificate, obtained in 1994 for Aksaray and ISO
9001 quality certificate, obtained in 1995 for Davutpaşa and Hoşdere production
plants.
Furthermore Mercedes-Benz Türk has the certificate for ISO 14001
environment management standards since May 2000 and the certificate for ISO
9001:2000 and ISO/TS 16949 since March 2002.

If we mention about the history of the company with years;

 1967 Otomarsan was published

 1968 Production of the buses „0302“ was started
 1970 The first exports
 1984 MBAG General Turkey Representative
 1986 Aksaray Truck Factory was found.
 1990 Commercial Fame „Mercedes-Benz Turk“
 1994 Aksaray Truck Factory took the certificate of ISO 9002
 1995 Hoşdere Bus Factory was found.
 1995 Hoşdere & Davutpaşa plants took the certificate of ISO 9001
 1997 Aksaray Truck Factory took the certificate of ISO 9001
 2000 Hoşdere & Davutpaşa plants took the certificate of ISO 14001
 2001 Aksaray Truck Factory took the certificate of VDA 6.1
 2002 Hoşdere and Davutpaşa plants took the certificate of ISO/TS
16949:1994

General information about the company :

Mercedes-Benz Turk Inc. Aksaray Factory is in the heart of Turkey and

located approximately 260 km south to Ankara. The population of Aksaray city,
which is situated on the foot of 3253-meter high volcanic Hasan Mountain, is around

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120.000. Aksaray is known as a gate to famous place called Cappadocia, which is
well known with the unique stone formation „Fairy Chimney“.
Mercedes-Benz Türk’s truck plant in the province of Aksaray started
production in 1986.Since then more than 35,000 trucks have been manufactured at the
plant and sold primarily in the local market.
The annual production capacity of factory has reached to 10.200 units after a
considerable investment amount of 75 million Euros. On the 60.000m2 area by using
industrial roboters in order to support dive painting with the methods of cathodization
and unrefined structure, the same quality standard has been obtained with sister
factory in Wörth. High quality standard, which has been approved by the successful
certificates like ISO9001 and VDA 6.1, is an important base for a successful export
strategy.
16 people has started for a 3-year training as analog with the dual system in
Germany The development center which is established in the factory structure in 1998
and this would be an important base for a successful future. The main features of the
training are quality management, engine technology, information technology,
automotive electronics, and hydraulic and pneumatic sections.4 official teachers are
responsible for the training of students with modern development facilities including
an electronic and hydraulic-pneumatic laboratory.
Aksaray Factory is on the way to future together with high quality standard, modern
vehicles and well-trained team
Producing trucks of the same quality as those produced in Germany,
Mercedes-Benz Aksaray Truck Plant will soon start exports to Central and East
European countries.
In addition, Aksaray Truck Plant is catching up with its’ German counterparts
in terms of both product types and product quality and this has enabled Mercedes-
Benz Türk’s ancillary industries to export components to Mercedes-Benz Truck
Plants in Germany.

Factory Area :

Factory has an area of 546.000 meter sq. Distribution of the departments on

this area is shown on a table in Appendix 2.

Subsidiaries of the factory in Turkey and other countries :

9977 parts are imported from 21 countries. These parts are shown on a table in
Appendix.
3482 domestic parts are obtained from the firms in Turkey. The number of
firms according to where they are located on a table in Appendix 3.

I will tell you about other plant of Mercedes-Benz A.Ş. in Turkey,briefly.Its

important tell about them because Aksaray Truck Plant is allways have knowledge
about production.Also this company produces substructures of buses in part and body
department.
We can define these plants; have a relationship between each other.Hoşdere bus
factory and Davutpaşa Plant are mentioned plants.

HOŞDERE BUS PLANT

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 The main objectives of the Company in setting up a second bus production
plant in addition to the Davutpaşa Plant which has been in bus production for 28 years
until 1995, are to increase the capacity and productivity, to broaden the product range
and to improve quality to the level to export to West European markets. The Hoşdere
Bus Plant has been planned as a two-stage project and the first stage has been
completed with an investment of DM 65 million.
The Hoşdere Bus Plant, comprising of a paint shop, assembling and finishing
units at the completion of the first stage of investment, produces in cooperation with
the Davutpaşa Plant. The bodies of the intercity and city type buses manufactured at
Davutpaşa are conveyed to the Hoşdere Facilities by special transport, where after the
painting, assembling and finishing processes, they are ready to be delivered to the
customers.
The Hoşdere Plant has an initial production capacity of 3.000 buses/year, and
it is planned to increase this to 4.000 buses/year at the final stage.
The Hoşdere Plant, presently the most modern bus production facility of the
world, has 52.500 m² covered area built on a total of 326.025 m² of land. The
combination of line production and stationary working sites (box) instead of the
conventional line production provides the necessary flexibility to the plant to produce
different models simultaneously and more over, time losses during manufacturing can
be minimized.
Mercedes-Benz Türk, for the first time in the world, has applied at the Hoşdere
Plant the air cushion technology in bus production. Having a very favorable effect on
working conditions in ergonomic terms, the air cushions are used not only for
conveyance of bodies between the assembling stations, but also for various stages of
assembly.

DAVUTPAŞA PLANT

Being the sole bus production plant of Mercedes-Benz Türk from its
establishment to the end of 1994, Davutpaşa Plant has been completely reorganized to
a body manufacturing plant with the most advanced body manufacturing technology
after start of operations at Hoşdere Plant. Hoşdere and Davutpaşa Plants are working
in cooperation and intercity and city type bus bodies manufactured at Davutpaşa are
conveyed to Hoşdere for painting, assembling and finishing processes.
Davutpaşa Plant has 24.314 m² closed area on a land of 35.400 m².

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 INTRODUCTION

The subject of ME 299 summer practice is to learn the manufacturing

methods&techniques used in the department and the mission of ME 299 summer
practice is generally to get the student be familiar with the applications of production
techniques which have been learned during the academic year. It also shows the way
to the student of professional life that waits him/her after graduation. For mechanical
engineering, an automotive factory is an ideal place with the above situations in hand.
Therefore, I have decided to do my summer practice at Mercedes-Benz Turk Aksaray
truck factory.This summer practice report also includes what I observed and what I
have done during thirty day, in this factory.

This program is also intended to acquaint the students with the practical and
applied aspects of their theorethical engineering background they have acquired so
far. Most of the students get a lot of theorethical information when they are studying
at their depatments before graduation. However, they do not know how to use these
theoretical information to do some practical jobs. For this reason, this summer
practice is very beneficial to the students, in that they have the chance to learn
practical aspects of what they have learned before.
In MBT Truck Plant there are different machines which are used for various
processes. Different parts can be produced by using these machine tools.

In the report, the following topics will be presented:

1) Departments of Aksaray truck plant

2) Production systems of the company
3) Production techniques used in the company
4) Description of the production techniques and properties of the machines and
machine tools which are used in the company.
5) Phosphating process.
6) The measurement room and 3-D control instrument
7) The production steps (work flow) for tanswerse beam.
8) The information about CATIA, CAD/CAM operations and SWAN used in the
company.
9) Technical drawings of sample workpieces produced by using machine tools and
explanation of everystage in the production of parts.
10) Cost analysis for 2 of these products
11) The general information about KAIZEN office which I joined at a period of my
summer practice.

Having represented the above topics, a conclusion where the data gained and
the experience obtained during the summer practice will be assessed and
recommendations will be presented.
Finally, an Appendix will be given. In this section all the related data, tables
and drawings.

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 REPORT
DEPARTMENTS OF THE AKSARAY TRUCK FACTORY

P-T/ EGP (Production Process Planning):

In this department, short and long term investments as well as labor force and
other utilities are planned. Besides the the economical side of these duties, this
department is responsible for holding the production smooth and without problems.

The Production Process Planning Group is responsible of preparing vehicle

assembly plans, determining the need for labor force according to production times
and production plans, finding out monthly productivity and calculating investment
and economicality.

Also the Facilities and Production Equipment Planning Group is responsible

of designing of buildings and facilities necessary for production and of planning and
accomplishing the equipment. Our Construction Group fulfils the duty of prior
investigation and construction of moulds, appliances, patterns, special apparatus and
transportation vehicles and tools.

P-T/EGS (Technical Services):

The duties for the Technical Services are given below:

 Keeps Aksaray Truck Factory and social facilities continuously operative.
Remedies the failures that may occur at factory in general and apartments,
minimizes the failures by preventive and periodical maintenance.
 Provides the power requirement of the factory
 Operates the heating, cooling and ventilation systems.
 Procures and stores the usage, cooling and fire extinguishing water.
 Provides recycling of the environmentally harmful materials occurring at factory
in general.
 Executes environmental, power and waste management.
 Manufactures the Mould, Apparatus and other production equipment. Performs
maintenance and repairing works on current equipment, performs measurement
and control works.
 Operates the boiler with pressurized air.
 Upkeeps and irrigates the gardens and grassy spots.
 Performs the carpenter’s workshop and packaging operations.

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 Issues and coordinates the agreement to be entered into with subcontractor
companies for maintenance and repairing works to be performed outside the
factory. In appendix section there are some photos.See appendix 4.

AVW/ Kaizen:

This department is responsible of making improvements by organizing

workshops with members coming from each part of the production. These workshops
occur once in three weeks. Due to maintenance of the Body Production sub-
department in the plant, a Kaizen workshop will not be held during this summer
practice.

P-T /QA (Quality Assurance):

In this department, the samples from the supplier factories and production sub-
department are measured for dimensions, chemical composition metallurgical
properties according to technical drawings and necessary standards. Under QA
department, there are three laboratories:
 Metal laboratory
 Chemical laboratory
 Measurement techniques laboratory

At the measurement techniques laboratory, there is a 3-D measurement

instrument which is controlled by two programs: ZETT MESS and CATIA. The
dimension information is taken from CATIA and measurement is done with ZETT
MESS.
At the metal laboratory, the instrument list is as follows:
 Tensile test mechanism
 A photon microscope (1500x) with digital photograph machine
 A photon microscope (80x)
 Spectrometer with 22-element recognition ability
 Acid Bath (to make a welded section visible)

In addition, some training programs such as welding training are held at the
QA Centrum.

P-T/OSS (Plant Logistics):

This department is responsible for the supplement of the raw materials as well as
semi finished products. Also it is accountable to find the subcontractors and
companies that are qualified enough for services. Besides these, when some parts will
be produced domestically, nearly all planning is done by this department. Industrial
engineers are concentrated here and operational research (a main branch in industrial
engineering) studies are often take place.

CEO/HR (Human Resources):

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 This department is responsible of hiring employees, salary duties, and education
of the stuff, organizing the internships and management of the coordination between
departments. These jobs are done while keeping the company aims in mind.

P-T/PDB (Parts& Body Production):

In this department, the substructures of the buses built at Istanbul and Mannheim
bus plants are assembled. Generally, the chassis frames of these vehicles are produced
in three or four parts according to their length. Besides some small parts for both
buses and trucks that can be shaped by metal forming techniques (excluding chip
removals) are manufactured. The methods used in the department are as follows:

 Pipe cut-off processes

 Pipe forming processes
 Phosphatising operation
 Sheet iron cut-off processes
 Sheet iron forming processes

For assembly, Spot and Gas Metal Arc Welding techniques are used. The cut-
off processes are done with guillotines, drills, Trumpf benches and presses. The
forming processes are held with Abkant benches, presses and pipe forming machines.

Also in this department bus substructures are produced. The body of buses has
three production steps:
1. Chassis fabrication
2. Frame fabrication
3. Sheeting

The chassis band is formed with two separate bands: one each for the city and
the travel bus. The chassis is constructed by assembling the front, center and rear
substructures according to the description of production. Cutting the side members in
form of the side walls follows welding of several parts into chassis. After the final
controls, the chassis is transported to the band of frame fabrication.

At the frame station, the side wall, ceiling, front and rear frames are assembled
with the chassis. The intended parts are welded, the defects in welding are corrected.
After the interior and exterior abrasion the vehicle is transported to the sheeting
station.

At the sheeting station, the pedestal and the drum are welded to the vehicle. At
lift station the side wall, ceiling, front and rear sheets are tacked by moving the
vehicle up-and downwards. Following the body operations and the final controls, the
vehicle is transported to the paintshop.

After painting, the floors of the luggage compartment are pasted, the front and
rear covers are assembled. The polyurethane foam is applied to the rear buckles. After
final controls, the vehicle is ready to be transported to Plant Hoşdere.

P-T/PDA (Assembly Production):

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 The final department is Assembly department. The parts coming from all other
production lines is united here. There exist two lines, namely SKT/LKT band and
SKN-C/UNIMOG band. These are the types of trucks produced in Aksaray plant. The
SKTs (SchwerKraftTruck)are heavy duty trucks and their tonnage varies between 18
tonnes and 32 tonnes; while their power can be up to 280 PS. The LKTs
(LeichtKraftTruck)are light weghed trucks and have maximum power of 170PS while
their tonngeis up to 15 tonnes. On the other hand, SKNCs are heavy-duty towing
trucks and UNIMOGS are military vehicles.

There exist three other sub-departments in the Assembly Production:

 The Paint shop
 Axle and Motor assembly
 Trimming lines

First one is (as understood from its name) is responsible for KTL and painting.
By the way, KTL is a cathodic electrodeposition paint method that is fully automated.
There are 13 different baths in KTL and a conveyor system dips in and draws out the
cabins automatically. The axle & motor assembly is a small production line since
these parts come from Germany as nearly finished assemblies. The last band is the
trimming line, in which empty & painted cabin is fully assembled up to its stereo
radio-cassette player.You can see pictures and explanations in appendix 5.

Truck Deliveries Department (M/TVD) :

Direct marketing of the domectic production and export products to the

public sector and municipiality is main duty of this department . It also helps
other departments in planning the amount of production according to
costumer needs . Truck Deliveries Department describes the market ,
determines productional , service and financial needs of the costumers and
estimates market aim of the plant .In accordance to these aims it determines
the sellers‘ aims , directs and controls the sellers and coordinates daily
commercial relations . Also this department plans advertisement , education and
other activities concerning the advertising of the vehicles produced
Other departments of MBT :
 PEW : In this department the materials coming from outside of the
factory are prepared to enter the production lines.

 DT : Before starting, it must be mentioned that no summer practice

trainee is allowed to enter this department. In this department, some
prototypes such as UNIMOG U-4000 models are assembled and tested.
The only R&G studies are done here.

 F/COT (Financial Control of Truck Department):This

department is responsible for cost calculations of characteristic datas
given by other departments such as EGP.Common expenditures and
investment budgets are detrermined by this departmant , in addition
this budget is controlled and arranged to prevent any financial

9
 mistakes .Responsibles check prices of the parts and compare the
parts so that they can buy the most suitable ones . Inventory
management , orientation of inventory and audit is performed by this
department .Furthermore Mercedes Benz Türk Financial Control
Department plays an important role for detremining marketing
strategies as a part of Euro Truck Group of Dfaimler-Chrysler
company.

PRODUCTION SYSTEM OF THE COMPANY

To understand the production system of Mercedes-Benz turk Aksaray truck

factory, it is sufficient to state that the organization is mostly an assembly one. That
means, most of the segments of productsare not produced in the organization. They
are ordered and supplied from different places. After that, they are added to
production. These parts are usually imported or come from the west part of Turkey.
These are mostly engines and axis parts. Some of these parts are provided by
Daimler-Benz’s other factories.

The kind of the vehicles and the production quantities are determined by the
orders of customers. In production particular requests of customers are also
considered. For instance, military type vehicles are produced due to particular
requests of the military forces. Since the production in M.B.T. is on an assembly line
and the equipment is arranged so that the product always follows the same routing
throught layout, the organization uses product layout. The products go on the same
assembly line and all the segments of the products and the equipment are near to this
assemnly line. Due to type of the products, needed parts are assembled to the
products. Although the organization is an assembly one, some part of the vehicles are
produced in the organization. In the departments where these parts are produced
process layout is observed, because all similar equipments and operations are grouped
in the same departments. Most of the drilling, milling and bending operations are
done in this department. Another two departments in which process layout is observed
are painting and phosphating departments. Moreover, all phosphating works are made
in the phosphating department.

THE PRODUCTION TECHNIQUES USED

IN THE COMPANY

Cutting and Forming processes:

In nearly all industries involving manufacturing, the most important types of

production are cutting and forming processes. Some popular examples are turning,
bending, forging, milling etc. ın this section, I will explain the techniques used in
MBT factory:

1)Lathes:
This type of workbenches are used for chip removal from the inside and
outside of the workpieces. At the same time this is convenient for cylindrical sheet
metals. There are different types of lathes. For example, universal, copy and revolver

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types of lathes. Copy and revolver types of lathes are used for serial production. In the
technical services workshop, universal lathes are taking place.

According to process places, there are two methods of turning. These methods
are inside and outside turnings. At the same time turning can be classified as in width
and longitudinal turning due to sign of action.

There are cylindrical, straight, taper, face and form turnings. Cylindrical
turning is used for cylindrical workpieces. The cutting direction can be parallel or
perpendicular to axis of the workpiece. The most useful types of turning methods are
rough turning which is done with big forward action and small angle adjustment, and
fine turning which is done with small forward action and big angle adjustment.

There are four lathes in the factory. One of these is Tezsan Universal Lathe.
The information about this lathe is given below:
 Max. revolution : 2000 rpm
 Min. revolution : 22,4 rpm
 Max. capacity of process : 1500mm (length) & 300mm(diameter)
 Max. capacity of threading : 40mm
 Min. capacity of threading : 0,5mm
This lathe is digital and has 0,01mm tolerance. In addition, borax oil is used
for cooling in this lathe. See Appendix 6.

Lathe chucks :
In the factory, four different types lathe chucks are used.
1) Three and four jaws American chucks
2) Chuck with clamp
3) Smooth chuck
4) Swivel chuck
In general, American chucks are used in the company.

2)Turning Lathes :
Turning is the process of machining axisymmetric parts which have circular
cross sections. This cutting can be both external and internal. On the lathes, operations
other than turning such as threading, knurling, boring etc. can be done.

There are four mechanically controlled lathes in the factory, each are spindle
engine lathes.
The operations done in these lathes are :
Straight turning
 Taper turning
 Facing
 Internal forming
 Threading
 The tool is fed inward the workpiece perpendicular to axis in
the straight turning. When an angle other than 90° is made during the
feeding of the tool, it is called taper turning. If this angle is 90° and the
tool is fed up to other side of the workpiece, this is facing. In facing, a flat
surface is produced. In internal forming, a previously drilled (it also can

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 be done on lathes) hole in the workpiece can be reshaped or brought to
specific dimensions. As it can be understood from its name, threading is a
process of machining a smooth cylindrical surface to a screw surface.

As said there are four lathes in the MBT factory and all four belong to
Technical services department. One of these is 1991 model TAKSAN engine lathe.the
tolerances and capabilities of this machine are as follows:

 Max. rotational speed : 1800 rpm

 Min. rotational speed : 16,5 rpm
 Max. dimensions of the workpiece : 1440 mm length/ 300mm
radius
 Min. threading capability : 1 mm
 Max. threading capability : 36 mm
 Tolerance : ±0.2 mm

During turning, three different chucks are used for holding the workpiece.
These are as follows:
 Three jaw dependent (self centering) chuck
 Four jaw independent chuck
 Clamp chucks (two jaw)

The first two types are also called “American chucks” and used widely. For
example, three jaw types are used to clamp circular or hexagonal parts. On the other
hand, clamp chucks are seldom used and their hold capability of workpieces is
limited.

Finally, two different tool types are used in the processes: hardened tool steels
and ceramic tool steels. Most lathe operations are done by simple single point cutting
tools. Ceramic tools are insert type so they have very rigid forged tool holders.
Generally they are triangular in shape and for one use. They can be grinded for
resharpening but the rake angle may not be correct in this process, which will cause a
lot of trouble. The hardened steels are air steels, which means they austenized and
cooled at the air environment to form martensite. They are fit to hot working and
contain very high alloy content.

3)Drilling :
In manufacturing, it is normal that holes are produced more than any other
shape and a large proportion of these are made by drilling. Therefore, drilling is an
important process. Although drilling appears to be a relatively simple process, certain
aspects of it cause a lot of trouble. These problems are asymmetric tips, unjustified
angles, blind cutting edges etc.

There exist many drill bench types but only two types are used in the plant:
 Plain type drilling bench
 Radial semiuniversal type drilling bench

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 Two plain and three radial types are available in the factory. One of them is
TAKSAN 5050 semi-universal type drill. Technical properties of this machine is as
follows:
 Max. power : 5 kW
 Nominal current : 11 amper
 Nominal voltage: 380 volt
 Control voltage: 220 volt
 Weight: 3 tons
 Auxilary voltage: 24 volt
 Max. worktable angle : ±45° with respect to column
 Max. drill length : 160 mm
 Max. drill radius : 65 mm
 Min. drill radius : 1 mm
 Holder type : Morse tapered

The last two limits are for classical type drills. There are some hand made
drills that have outstanding cutting dimensions but they are all out of standards.

Reaming, trepanning, counterboring, countersinking and spot facing can also

be done using these machines. Max. sensitivity of the reamers is 1/1000 mm. In all
these machines, borax oil is used as the coolant when needed.

4)Milling machines :
Milling constitutes a very large area of manufacturing. Since its compatibility
with the production needs is extremely higher, this technique is used widely in all
parts of the manufacturing processes. To define, milling is a basic machining process
by which a surface is generated progressively by the removal of the chips from the
workpiece fed into a rotating milling cutter. The removal direction is perpendicular to
the axis of the cutter. There are a lot of milling types but only those involved in the
Aksaray plant will be mentioned.
The milling machine types and their brand names are as follows:
 RECKERMANN Vertical head semi-universal milling machine. This
machine is numerically controlled. Worktable can tilt up to µ 30 degrees.
 TAKSAN Vertical head semi-universal milling machine. This machine
is nearly the same as the above one except its mechanical control
 MKE horizontal milling machine. No special property.
 MAZAK FJV-35/60 CNC milling machine. Fully automated and have
an Intranet connection with several CATIA computers. Have a special
language called MAZATROL.
The RECKERMANN has a power table and has the properties:
 Max. rotational speed : 2300 rpm
 Min. rotational speed : 56 rpm
 Max. milling length : 1100 mm
 Max.milling height : 350 mm
 Max.milling width : 350 mm
 Tolerance : ±0.02 mm
Also, TAKSAN has similar properties:
 Max. rotational speed : 2300 rpm

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  Min. rotational speed : 56 rpm
 Max. forward action : 287 mm
 Tolerance : ±0.02 mm
 Max. dimensions of the workpiece : 500*500*150 mm (height, length,
width)
Technical data for MKE machine will not be given because due to oldness of
the machine, its catalogue could not be found.
The last one, MAZAK CNC machine has the following properties:
 Max. process dimensions : 1740 mm in x-direction
860 mm in y-direction
640 mm in z-direction
 Max. table weight carry capacity : 2500 kg.
 Max. rotational speed : 10 000 rpm
 Tolerance : ±0.002 mm

This machine works on Windows 95 and it has a special program called

MAZATROL. In this program, all actions are specified as three-digit codes. This
machine can also work with CATIA. The algorithm will be specified by the
programmer and the source code is written by the program itself. While working from
CATIA, the machine can work in all three dimensions but when it is switched directly
to MAZATROL, it can work on 2,5 dimensions. In other words, the machine can
work on either x-y plane or z-direction. Due to this reason, it can not make curvilinear
motion in x-z or y-z plane while cutting. This restriction is due to movement program
style of MAZATROL. The coordinates are just given by start and finish points. The
code given for curvilinear motion is recognized as it is only in x-y direction by the
compiler.You can see a photo about this CNC in appendix 7.

Besides, this machine has a 40- tool magazine and it changes its tool
automatically against heat occurred during cutting. There is an internal cooling system
for tolls and oil which is pressurized and used to oil the components of the CNC
milling machine. The ability of processing more than one workpiece at once is a far
greater advantage for time saving.

Milling operations can be classified into two broad categories called peripheral
milling and face milling. Each has many sub-categories. In peripheral milling, the
cutter teeth are placed at the side surface of the cylindrical body of the tool. This
surface is parallel to the axis of the cutting tool. The resulting cutted surface is the
reverse (contour) of the cutter profile. In face milling, the cutter teeth are placed onto
the surface, which is perpendicular to the axis of rotation.
Besides these two other differentiation exist between milling methods :
 Upward milling
 Downward milling

Upward milling is a classical method in milling. The cutter teeth rotate reverse
the movement direction of the workpiece. To illustrate; see appendix milling 1. This
action tends to loosen the workpiece while to destroy any looseness of the feed screw.
The chip begins to form in a thin manner and gets thicker while cutting. Downward
milling is the opposite of the above one. The cutter edges move in the same sense as
the workpiece. This is a modern way of milling because generally this type of milling

14
causes a smoother surface. The disadvantage for the downward milling is the
requirement of a tightened feed screw. Any looseness results in chattering and a bad
surface.

Now, we can talk about the milling cutters available in the company. The most
used types are shank types due to quick changing of the cutting tools. The cutter types
are as follows:

 Plain cutters : Most used cutters. Generally have helical cutting edges.
This type has both arbor and shank types. A broad range of dimensions is
used for cutting.
 T-slot cutters : These are also generally shank types. Slots are used in
preparing the welding workpiece hold mechanisms. Up to 200 mm
diameter cutters are available in the workshop
 Insert type cutters : For milling hardened steels, these ceramic insert
cutters are used. These cutters are for one use. In other words, the cutters
can not be resharpened. Generally 8 inserts are placed in a tool holder but
up to 12-insert hole cutting tool holder may exist.
 Two lip cutters : These cutters are fit used as a drill and then starts to
cut off. This process provides a lot of time saving.

5)Presses :
A press is a device that can transmit pressure to workpieces in order to process
cut&form applications. Many types exist but hydraulic presses are far most common
ones. The reason behind this is the high-pressures that hydraulics can reach most
effectively. Besides these, mechanic presses are also used for quick and light
applications since hydraulic ones are too slow for specific jobs. Also pneumatic
presses are widely used.
Main items of presses:
 Crank arm
 Brake
 Clutch
 Hammer
 Connecting rod
 Main engine

In the right side of the press machines,clutch exist whereas in the left side
there is a brake system.Hammer is connected to the crank arm by connecting
rod.Hammer is always at the top.These presses work with the aid of a pneumatic
system.In order to calculate press power,revolution of the motor ,the weight of the
hammer and the placement of the crank should be considered.

When a movement is given to the motor,the movement is transferred to

volant by the belts.When a movement is given to the pedals, air is sent to both clutch
and brake system by electric valves.The power of the air affect the power of the
springs in the brake system.This weakens the crank arm.At the same time the air
went to the clutch exceeds the power of the springs and provides the transfer of the
volan’s movement to the clutch.Therefore hammer moves and goes up and down.By

15
the way,no more air is sprayed.Finally, the power of the springs hold the hammer at
the top.This movement of hammer is called forging.

In MBT Aksaray, there are a total number of 9 presses working. 5 of them

are exantrick and therefore mechanic. In addition to this, 3 of them are hydraulic and
1 of them is pneumatic. The technical information about these machines is as follows:
 DIRINLER Exantrick press : Capable of 2500 kN force application.
This machine is used for piercing, blanking and forming of thick sheet metals
and pipes.Type of this machine is CDÇS 2500 P 81HS.Its motor power and
revolution is 22 kW and 1455 rpm.Its stroke length and number is138 mm and
51 per minute.Its weight is 18 tons.Its noise level is 80 decibel.Maximum
volant revolution is 350 per minute.
 DIRINLER Hydraulic press: Capable of 1600 kN forward- 630 kN
backward force application. Max. power of the machine is 22 kW. Max.
ram stroke length is 550 mm. Used of rapid forming applications of sheet
metals.
 VATAN Exantrick press : Capable of 1600 kN and has a power of 15
kW. Max.pressure used for the activation is 6 bars.Number of strokes is 60
also ıts stroke adjustment is 5-150 mm.Its weight is 15940 kg.Its
revolution is 1500 rpm. It is generally used for blanking of sheet metals
and square drilling of profile pipes.
 TESBİHÇİ Exantrick press : Capable of 60 tons and has a power of 55
HP.Its weight is 3 tons.Stroke number in one minute is 55.This machine is
old therefore ıt is produced in 1988. Used for piercing any workpieces.
 ERKEKOĞLU Exantrick press : Capable of 75 tons and has a power
of 75 HP. Its stroke number in per minute is 54.Usage is the same as the
just above one.
 COŞKUNÖZ Hydraulic press : Capable of 100 tons. The max.
pressure applied in the machine is 260 bar.This machine is also old,ıt is
produced in 1986/6. Used in narrow but thick sections.
 ERKEKOĞLU Exantrick press : Capable of 200 tons and has a power
of 25 HP. Used in the technical services for piercing and blanking. Also, it
is used for prototype mold testing. In other words, the new molds that will
be used in serial production are first examined while working in this press.
 YİŞ hydraulic press : Capable of 55 tons and the max. pressure 180
bars applied in the machine. This machine is used for only forming
(bending etc.)
 HİDROPNÖMAK Hydraulic press : Capable of 60 tons and the max.
pressure of 200 bars. The purpose is the same as the above one.You can
see some pictures about hydraulic and exantrick presses in appendix 8.

6)Other bending and cutting machines :

Abkant press, trumpf bench, optical cutter, guillotine, pipe and profile bending
machines fall into this category. For each machine, detailed information is given
below:
 Abkant press : This press is used as a sheet metal bending
device. For every different shape, it has a specific guide. The
mechanism works in this way; two holder guides support the sheet
metal, as one of them is the contour of the shape of the desired. Then
the lower guide moves in a radial path and bends the plate. Max. force

16
 that abkant press can apply is 800 kN and max. length of the
workpiece is 2550 mm.Its manufactured by Eisen Y-Hammerwork in
1991.Its type is FHP 8-25.
Nominal current is 28 amper.Voltage is 380 volt but ıts pilot voltage is
220 volt.See appendix 9.
 Trumpf cutting bench : This bench is used for duplicating a 2-D
template made of sheet iron. A reader head is moved on the template
while the machine cuts the workpiece in a 1:1 ratio. Maximum
thickness of the plate can not exceed 2,5 mm. Max. force that trumpf
bench can apply is 75 kN.See appendix 10.
This machine is used in bus substructure and sheet iron part
production workshop.
Pressure which will be applied by machine is proportional with
width of sheet iron.This workbench is suitable to mass production.
 Optical cutting bench : The operation mechanism is nearly the
same as the trumpf bench. There exist two differences. First, while
trumpf bench cuts with a saw mechanism, the optical bench works
with an oxyacetylene flame cutter. The second difference is that the
template used in this machine is a drawing instead of an iron plate.See
appendix 11.
 Guillotine Cutting Machine:This machine is used for cutting
the sheet iron to get peripheral dimensions of the sheet iron. This
machine applies pressure vertically.Pressure which will be apply by
machine and cutter settings are made with respect to width of sheet
iron.If the width of sheet iron increases,pressure which must be
applied by machine will be increase.Replacement of part is set,then
pedal is pushed down,so sheet iron is cutted with desirable
dimensions.Up to 3100 mm wide and 12 mm thick plates can be
cutted with the help of this machine. The brand name of the machine
is BAYKAL MGH 3100*12 and there are two machines of this
type.This machine is produced in 12/1998.Its oil capacity is 220 lt.Its
motor power is 30 kW,voltage is 380 volt.Its dimensions are 4000 mm
length,2000 mm width,2000 mm height.Also ıts weight is 10800 kg.
 Pipe and profile bending machines : These long machines are
used as bending mechanisms of long, straight pipes or profiles (such
as square or rectangular cross section). These machines are cold
working machines. A small device called “bending rod” (in Turkish
“malafa”) is inserted through the pipes so as to prevent the buckling or
wrinklage of the pipes. All bending machines have one measurement
control table. Four bending machines are available :
 LANG CNC bending machine : Works with Hydraulic
mechanisms. Up to 110-bar pressure can be achieved.
Bends pipes with diameters between 30 mm and 110
mm.See appendix 12.
 CRIPPA CNC bending machine : Works with hydraulic
mechanisms. Up to 26-bar pressure can be achieved. Pipes
having diameters between 10 to 30 mm are bended. These
two machines (this and the above one) have both CNC
programs integrated with them.

17
  LANG NC profile bending machine : Works with
hydraulic pressure but the bender jaw have a variable
rectangular shape. A total of 26 digits combined as two and
four digits program controls the bending action. Two of
these machines are in use.

7)Shapers :
In shaping, a single point cutting tool is fed into the workpiece in a straight
manner. This type of machining is used for very small volume production. A single
machine is involved in the factory for the workpieces suitable of the shaper. The
properties of the machine is given below :
 Max. length of the workpiece : 500 mm
 Max. width of the workpiece : 520 mm
 Max. speed of the shaper : 150 stroke per minute
 Min. speed of the shaper : 13,5 stroke per minute
 Max. feed : 20 mm
 Min. feed : 1 mm
The tool material is generally air hardened steel. The reason behind that is the
ideal composition of toughness and hardness of the air steel.You can see a shaper in
appendix 16.

8)Saws :
Sawing is a machining process in which cutting action is done by very narrow
gaped cutting teeth. The cutting tool for sawing is also called “blades”. The material
wasting is minimum, therefore this method is used widely. All materials can be
sawed; metals, plastics, wood etc. In the factory, two types of sawing machines are
used: Band saws and circular saws. Band saws have a linear shape and they are
rotated through a closed path. The size of the workpiece is not very important. The
only criterion is the length of the cut. Circular saws are very different in shape
compared to band saws. Their sizes must be bigger than band saws according to
workpieces. The technical properties of some saws are given below. (I could not
achieve the data for circular saw since it is made in SSSR and the alphabet is
Cyrillic):
 JAESPA vertical band saw machine :
 Max. cutting speed (rotational): 160 m/min.
 Max number of teeth per minute : 4000 1/m
 Blade length : 4400 mm
 Max. blade width : 13 mm
 Max. height of the workpiece : 280 mm
 UZAY horizontal band saw machine :
 Max. cutting speed (rotational) : 84 m/min
 Max. width of the workpiece : 500 mm
 Max. height of the workpiece : 300 mm

The cutting speed and the use of coolant depend on the workpiece properties
such as width, hardness etc. There are tables for adjusting the sawing machines.You
can see apicture of saw in appendix 15.

9)Grinding :

18
 Though grinding is not a material removal process, it is explained here
because its unity as an abrasive machining process in the factory except lapping.
Since close dimension control can be achieved, it is an important process. In the
factory, quartz sand abrasives are generally used. The types of grinding processed in
the factory is given below :
 Conventional surface grinding
 Cylindrical grinding
 Cylindrical internal grinding
There is a grinding machine with horizontal spindle and reciprocating bench.
The technical properties are as follows :
 Name : TAKSAN face grinding machine
 Max. rotational speed : 5600 rpm
 Max. dimensions of the workpiece : 1000 mm length 300 mm width
400 mm height
 Tolerance : 0,01 mm
 Type of workpiece holder :
electromagnetic
These processes are usually done for either grounding the workpiece (bringing
to necessary dimensions) or cleaning the surface from chip residues or
corrosion layers. Tool post grinders are also used when needed.

10)Welding processes:

Welding is the process of combining two similar parts with the help of heat and
pressure and bonding material between them. Welding is stronger than the other
metals of combining. Because of this reason, welding is more advantageous than the
other methods. However, some problems can appear because of heat.

Sometimes pressure can be included but in MBT Aksaray -generally–only

temperature is used for the joining. Many types of welding exist due to a very broad
range of materials’ properties those will be bonded.
The quality of a weld depends on several criteria. Some of them are as
follows:
 Material properties: The crystal structure of two materials should be
similar. Since there is always diffusion between them, it is extremely
important to have similarity in order to achieve uniform and rigid bonds.
Another factor that affects the weld quality is the shape of the metals. If
surface flatness could not be achieved, diffusion process and filling the
gaps between them would be interfered which will result in a non-uniform
weld.
 Contaminants & inclusions: The inclusions that can enter in the weld
part will be very dangerous. The reason behind that is the stress
concentration, which occurs around the inclusions. This can be avoided by
providing a protective atmosphere around the welding area.
 Temperature: Temperature is important because it drastically affects
diffusion rate and by implication weld strength. It also has a connection
with material microstructure. When temperature exceeds some critical
values, ferrite can transform to martensite, which is a very brittle phase.

19
 This type of formations can be prevented with preheating the workpiece or
alloying them.

Although this type of precautions would be taken, non-uniformity in some

cases will no be avoided. This is a limitation of the welding process, but since
welding is generally stronger than even the original parts, this method is widely used.

Three types of welding are used in the plant: spot welding, Oxyacetylene
welding and gas metal arc welding. These processes are explained below:

1) Spot welding :
It is the most widely used type of welding in the truck production. Since nearly
all production is a huge assembly process, spot welding is a good choice. Especially
in the cabin assembly part, a standard type of spot welding machine is in the
production system. In this sector, there are two robotic arms used for cabin roof
assembly by means of spot welding. The technical properties of standard spot
welders and robots are given below:

 Standard spot welders: BOSCH PSS 2036.0

(47 currently in use)
Current range : 4 000 - 16 000 A
Input voltage : 380 V
Output voltage : 7,5 V
Frequency : 50 Hz
Min.&Max. plate thickness : 1-4 mm

 KUKA NIMAK 6050 industrial robots :

These robots have six axes and therefore six motors each. Max. weight
that robots can carry is about 350 kg. They can use four different welding
guns. Three types of roofs are joined: short roofs for LKT, long roofs for LKT,
high roofs for SKT and SKN-C.

Both robots work with Windows system and a program named S7 400
PLC. A special language of its own is used while programming. They can
work both dependently and independently. Since robot arms do not have
specific perception mechanisms, scanning laser sensors regulates working
space. In case of unauthorized entry, whole process immediately stops. These
arms also work on 380 V and 50 Hz. The max current is 18,11 kA.

2) Gas Metal Arc welding :

Gas Metal Arc Welding is used for substructure of buses and trucks while Spot
Welding is used to assembly truck cabins.

A roller automatically supplies the wire electrode. Generally helium gas is used
for shielding the arc but also other inert gases such as neon can be used. The
difference between gases is the heat transfer rate. Seldom change of the wire electrode
the utmost advantage of GMAW. In addition, there is no slag formation, which far
accelerates the process.Also you can see a picture of welding robot in app. 16.

20
Other methods of welding which are used at M.B.T. :
 Resistance welding
- Resistance spot welding
- Resistance seam welding
- Projection welding
 Electric welding
- Electric arc welding
- Preventing gas metal arc welding
- Submerged arcwelding
- Electroslag welding
 Electron beam welding
 Laser beam welding
 Oxyacetylene fusion welding
 Oxyfuel gas welding
- Oxyacetylene gas welding
- Pressure gas welding

PHOSPHATING PROCESS

The zinc phosphate pretreatment process reacts with the metal surface to
form a non-metallic crystalline coating.The coating is resistant to alkaline corrosion
by products and inhibits underfilm corrosion.It also serves as a non-conductive
insulating layer to isolate corrosion sites and by ist structure,physical anchoring sites
for the primier applied over it.Zinc phosphate coatings have been used successfully
for years to enhance the adhesion of organic finishes.

Phosphate coatings representing the lastest technology will contain

zinc,nickel, iron, manganese as apart of the chemical composition.Phosphate baths
have also been formulated to apply coatings equally well to all the different metallic
surfaces.The typical processing sequence includes the following treatments.

1. Body shop cleaning / Precleaning

2. Cleaning(2 stages)
3. Rinsing
4. Rinse conditioning
5. Phosphating
6. Rinsing
7. Post-treating
8. Deionized water rinsing

If we tell briefly these eight step,we can observe phosphating in

cleaning,rinsing, conditioning,phosphating and post-treating subheadlines.
1. Cleaning:

In Mercedes-Benz Türk A.Ş. cleaning process occurs in baths with

neccessary chemical reactants.In this plant only parts are given to baths.Aim of
process to remove excessive dirt,grinding dust and heavy oils.A precleaning step is

21
used to remove sealer,chalk,and ink marks.Alkaline cleaners containing builders and
surfactants are used to remove processingand stamping oils and soils from the metal
surface.

2. Rinsing:

Rinsing removes the residual processing chemicals from the previous stages
that would interfare with subsequent operations or compromise the performance of
the coating system. The final deionized water rinse is especially critical to remove
any salts that may contaminate the electrodeposition primier bath.

3. Conditioning:

Conditioning agents are colloidal suspensions of titanium phosphates

applied prior to phosphate deposition in a rinse step, or seperately in a spray
riser.They nucleate crystallization of the phosphate coating,which resuls in a dense
phosphate coating of small crystal size.

4. Phosphating:

In the phosphating step,the metal surfaces react with an acidic

solutioncontaining zinc,nickel and / or manganese as their acidic phosphate salts.The
change in pH at the solution causes solubilty changes and growth of phosphate
crystals that are integral to the surface.

When phosphated sheet is processed in the assembly plant phosphate

washer, cleaner strength must be controlled,and two phosphate systems
involved must be closely matched to avoid appearence and performance
prblems.

5. Post-treating:

Although the most commonly used post-treatments contain chromiumions,

new types have been developed that are based on organic monomers or polymers
and / or inorganic salts.You can see a picture of phosphating department in appendix
17.

MEASUREMENT ROOM

Basic duties :
• To make measurement of the first samples taken for parts to be given to the side
industries for production.
• Make calibration of all the measurement equipments within the factory, if their
calibration is not made in the factory make them to be calibrated outside of the
factory.

22
• Making measurement control of apparatuses, mechanisms and fixtures to give
approval.
• Giving numbers (first time) to the parts which comes for controlling, afterwards
making annualy periodic controls of these numbered parts.
• Forming a problem solving group for errors that can be produced in the
production stages and controlling the parts during production.
Duties of problem solving group :
• Make control of the bands
• Giving the decision „ready for sale“ to a finished product
• Make control of a finishedproduct weekly

3D instrument :
This instrument is used for three dimensional measurements and it is used with
computer. All of the measurements of a part are done as to a reference point.
Duties of 3D instrument :
1. Measurements of truck, military vehicle, substructure of bus and parts of vehicles
2. Measurements of apparatus
3. Controlling of sample
4. Marking
5. Controlling of cylindrical parts‘ measurements
6. Measurements of angled and dimensional parts

PRODUCTION OF PART NAMED TRANSWERSE BEAM

The turkhish mean of this part is “enine taşıyıcı”.It is used in bus production to
produce substructures.This substructures are sent to Mercedes-Benz Bus Plant to
Istanbul.
To produce this part five production step is required.Profile which dimensions
40x40x2 is taken from PDB production workshop.

First step : This level is cutting with appropriate dimensions.Circular saw

machine is used for this operation.Its purpose is cutting profile.Before cutting profile
we controlled profile dimensions and revolution number of machine.Profile is placed
to machine table ıts angle settings are done.Also machine volecity is setted with
respect to machining part dimensions.Maximum machining height of saw is
setted.profile is cutted and first step is completed.

Second step : With dirinler exantrick press tip of the profile is become
empty.This press is used for cutting the various sheets and pipes also drilling and
bending processes by help of moulds.Appropriate mould is placed to press for
dimensions and emptisizing of tip of profile is completed.

Third step : Drilling holes with 6 mm diameter.Drillers is used for this

operations.6 mm metric edge is connected to driller and process is finished.

Fourth step : Drilling holes with 8 mm diameter.Driller is used for this

process.8mm metric edge is connected to driller and process is completed.

23
 Fifth step : This process name is phosphating.Its purpose is to have a
resistance to corrosion and oxidation.

CATIA CAD/CAM OPERATIONS AND SWAN

Catia :
Catia is one of the most important CAD/CAM/CAE programs in the world.
This program gives solutions to the following problems;
 In product design and production
 In applying enterprise based on competition
 In process development
 In productivity
Catia is a relative simple program used in consumers‘ products,fabrication,
electrical and electronical products, otomotive, plane, ship and process production
factories.
Catia provides easy to use solutions tailored to do needs of small and medium
sized enterprises as well as large industrial corporations in all industries:
 Consumer goods
 Fabrication and assembly
 Electrical and Electronics goods
 Automotive
 Aerospace
 Ship building and process plants
Its leading edge solutions and technologies for computer aided design
manufacturing and engineering including data management let people achieve their
digital product definition and simulation goals. All necessary changes on the digital
modal for a concurrent optimization of design and manufacturing can be easily
implemented. Therefore, engineers can minimize the risk of late expensive
modifications and reduce the number of iterations by designing right the first time.

CAD/CAM operations :
CAD/CAM training and improvement studies are continuing in the factory in
order to program and operate the high-tech CNC Vertical Processing Centre
optimally. The goal is to process the formed surfaces by CAM programming on basis
of the solid patterns drawn in CATIA: In addition to this the highly valuable form
moulds are designed and manufactured in workshops, and the technology is closely
followed. First trials of CAD/CAM applications proved to be successful and it is
commenced to manufacture the moulds of I-Tafel Querträger which were decided to
be adopted at first.
There is a CNC bench which i used for CAD/CAM operations in the technical
services workshop.See Appendix.
Complex parts can be processed on the CNC benches and very smooth
surfaces are obtained.See Appendix.

SWAN :
It is the system used in partner side industry entegration project. Side industry
entegration comprises an effective data communication and standardization of data
communication. Technical drawings (CAD datas) drawen in M.B.T. is sent to the side
industry via offline media such as band, disket or plot. In data communication within

24
CAD, communication of different application and system platforms are compulsory.
Data communication processes are saved and they can be provable if needed. SWAN
can give answers to these demands.
The advantageous of SWAN are as follows:
 Time saving
 Revision chance of CAD datas sent
 Making archieves of sent/taken datas and communication processes
 Comfortable usage and high automatizing rate
 High data security
 Rescuing from useless processes

TECHNICAL DRAWINGS

The technical drawings which are drawn by engineers are given to mechanical
workshop administration depertment during offer period. After the offer is given, the
technical drawing is given to the technical worker. The technical worker examines
drawings and then he prepares the workpieces according to properties of materials.

Technical drawing 1 :
Part number : A 666 00 01 01-01
1) The dimensions and thickness of this part are given in the technical drawing.
2) According to this drawing the part is cutted rougly by means of optical cutting
bench.
3) After cutting unnecessary sections of material, side and face measurements are
adjusted by using the milling bench.
4) The axis of holes are found and points are put at the marking bench.
5) Pin and center holes are drilled at columnar drilling bench.
6) Two pins are produced by using lathes.
7) The heat treatments of these pins are done.
8) After these processes the parts are assembled to plate.

Technical drawing 2 :
Part number : A 666 00 01 01-05
This part on apparatus has a centring duty. This part includes two different
sections. These sections are classified as male and female parts.
1) Firstly, the female section is processed by means of a lathe.
2) After that the other section is processed according to tolerances given.(For
example, diameter 20 H7/d6).
3) The heat treatment is applied to these parts, which are made of C 45, at 800°C and
then they are cooled in salty water.
4) After these processes, these parts are present for assembly.
See Appendix 13 for technical drrawing 1and 2.

COST ANALYSIS FOR TWO PRODUCTS

The cost analysis for technical drawing 1 :

25
Density = ρ = 7,8 g/cm³

Volume of the part =V = 85*75*25mm³ +2*Π *5²*30 mm³

= 164 085 mm³
= 164,085 cm³
mass = m = V * ρ
= 164,085 * 7,8
=1279,863 g
= 1,28 kg
(1) The cost of materials = 1,28 *700 000
= 896 000 TL
(2) Materials common expenses = 896 000* 0,003
= 2688 TL
(3) Total material cost = (1) +(2)
=898 688 TL
(4)Pay of a worker = 6 hours * 3 212 502 TL/hour
= 19 275 012 TL
(4) Production common expenses = (4) * 4,90
=94 447 558 TL

TOTAL PRODUCTION COST = (3) +(4) +(5)

TOTAL PRODUCTION COST = 114 621 258 TL

The cost analysis for technical drawing 2 :

Density = ρ = 7,8 g/cm³

Volume = V = Π *12²*125 + Π *18²*115 + Π *22²*45 + Π *12²*57

= 211 610,88 mm³
= 211,61 cm³
mass = m = V*ρ
= 211,61*7,8
= 1650,565 g
= 1,65 kg

(1) The cost of materials = 1,65 *700 000

= 1 155 000 TL
(2) Materials common expenses = 1 155 000* 0,003
= 3465 TL
(3) Total material cost = (1) +(2)
=1 158 465 TL
(4) Pay of a worker = 8 hours * 3 212 502 TL/hour
= 25 700 016 TL
(5) Production common expenses = (4) * 4,90
=125 930 078,4 TL

TOTAL PRODUCTION COST = (3) +(4) +(5)

TOTAL PRODUCTION COST = 152 788 559 TL

26
 KAIZEN OFFICE

“Kaizen” – The Continuos Improvement Processes began in September 2000

in Aksaray with the assist of the Kaizen – Team in Stuttgart UT. Kaizen Office in
Aksaray became a member among the Kaizen Offices in the Commercial Vehicle
Division with the aim of the implementation of the DCPS.
Kaizen Basic Trainings were accomplished prior to the workshop week. The
Basic Trainings last a whole working day, including theoretical informations about
Kaizen techniques , as well as some practical exercises about the ‘Just in Time’
production.
Kaizen Workshops are realized every six-weeks since then with two workshop
teams with the coordination of expert Kaizen trainers. Every workshop team consists
of app. 10 members and a Kaizen trainer.

Production engineering :

The Production Engineering Workshop was established in 1998 by the needs

of the new product project.All 50 product prototypes were built in our Prototype
Workshop with qualified engineers and assembly experts since 1999. The appropriate
assembly instructions and reports have been prepared during this process in order to
assist the main assembly lines. The workers from the assembly lines were trained
about the new products and assembly techniques. The know-how was transmitted to
planning engineers.
The Prototype Workshop has an area of app. 500 m2 and an additional office
building of 200 m2. Four mechanical, one industrial and another two
electrical/electronical engineers work in the team.
The other examples of improvement examples will be explain later. See
appendix 14. for some examples of kaizen

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 CONCLUSION

Looking from the student point of view, MBT Aksaray gave me an incomplete picture
of the life after school. Through this summer practice, I have met a lot of people, got
familiar with mechanical engineers and have listened their experiences and tried to
complete this picture.
As every organization, MBT- Aksaray was not perfect. I have seen some
points, which can be made less time-consuming or more efficient. I suggested some of
these ideas and through these conversations with department Administrators, I have
tried to learn how an engineer should think in very different aspects. One of these
suggestions was about a manipulator for installation the front window to the cabin.
Presently, two workers are responsible for installation. Though front window is a
sensitive part, no automatization is involved in this sector. Being Waterproof is an
important property of these windows but there were some quality problems with
achieving waterproofness. With an appropriate manipulator nearly all problems will
be solved and only one worker can do the same job. On the other hand, when looked
from the economical aspect of view, the cost of a manipulator with guidelines to
install the part properly is calculated and the result was a disaster. The given money
does seem to return back within 8 years. Since the philosophy of the plant allows only
up to 5 years return-back, this project does not seem feasible. The cost was calculated
as much as 15 000 Euro. The only advantage is the incoming quality rise but
department engineers have felt to seek other ways for solving this problem.

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 Although I have been designated to body production department, my chefs
allowed me to go and search every single area of the plant. This freedom provided me
a summation of the answers of the questions “What is produced? How is it produced?
Is there any other way? etc.” This was a good earning for my upcoming engineering
life.

Besides these, I have attended some training like “Welding Introduction,

Quality Gates, Failure Mode Effect Analysis etc.”. These training gave me an idea of
improvement studies and their fields.

In conclusion, I can say that working in a production environment as a student

was such an enjoyful experience for me because while I were doing my job , I knew
that in the future these experiences will carry me to a bright career. I must thank all
the employees in my department for giving me as much information as they can
although their hard work made them too busy.

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