UNIVERSITY OF GAZIANTEP DEPARTMENT OF MECHANICAL ENGINEERING

ME 400 APPLIED ENGINEERING EDUCATION

Submitted to : Prof.Dr. MEHMET KANOĞLU Submitted by : ERDİ KARAÇAL Number:200960589 Tel:0553 455 3779 E-mail: [email protected]

May 2014

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CHAPTER 1 SANKO HOLDING A.S 1. DESCRIPTION OF THE COMPANY 1.1 COMPANY PROFILE SANKO was founded by Mr.Sani Konukoğlu in 1943.The headquarters of SANKO is located in the Southeastern part of Turkey city named Gaziantep.SANKO is one of the biggest textile groups in Turkey which has links to all over the world.SANKO has employed 12,000 people. SANKO's main product lines are yarns and knitted fabrics. Currently, SANKO has 500,000 spindles. Daily production capacity is 300 tons of yarn per day. 15 tons of capacity is 100% Cotton Melange, 15 tons in Blended yarns, 30 tons in Open-End production and rest is Ring Spun Production. SANKO also produces 150 tons of knitted fabric per day.

1.2 PRODUCTS OF THE COMPANY YARNS > Carded Ring Spun Ne 6/1 to 30/1 > Combed Ring Spun Ne 6/1 to 60/1 > Blends Ne 6/1 - 50/1 > Melange (blends and %100 cotton) Ne 6/1 - 50/1 > Open End (%100 cotton, blends, melange) Ne 6/1 - 30/1 > Fancy Yarn, Ne 6/1 - 60/1 > Compact Yarn Ne 6/1 - 60/1

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1.3 LOCATION OF THE ORGANIZATION The factory is at the second organized industrial region on Sani Konukoğlu street in Başpınar/Gaziantep.They don’t have any problems about logistics.As it seen clearly from the Figure(1), The products can be easily export the other countries like Middle East or another European countries with ships.Also raw material can be easily imported from another countries.The location of the factory is easy to reach. And another thing is; it is very easy to find labor-force in the region. And also the land the factory is established is big enough for whole the activities.

Figure(1):Factory Location Map

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1.4 ORGANIZATION CHART OF THE COMPANY Management Commitee

Sales Manager

General Manager

Quality Safety Manager

Factory Manager

Planning Man.

Responsible Person from Warehouse

Trade Manager

Quality Control and Lab. Chef

Purchasing Chef

Production Man Technical Works Man. Production Chef(combe )

Human Resources Man.

Maintena nce Chef

(cotton) Energy Chef

Production Chef (carde) Responsible Person from Warehouse

Assistant Administr ating Chef

(yarn)

I have worked at red painted region on the chart of organization.

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Purchasing Manager

Personnel Chef

Managerial Works Chef

Responsible Person from Warehouse ((material)

CHAPTER 2 INTRODUCTION Mechanical engineering is one of the most important work area in today‘s world. This makes the education of mechanical engineering students fairly important. We are able to notice the place of engineers in wide range of areas not only in the industry but also in the social life. As being mechanical engineer candidates, we should start getting experienced in the professional life and summer practice programs are the first serious one.The ME 199 ,ME 299 and ME 399 summer practice programs are based on the production techniques that are used in the company and it is required to make observations about the processes that are carried out. The main aims of this intern engineering practice program ME-400 are; - To improve the professional knowledge, ability and behaviours by practice. - To provide the adaptations of the real professional life in real conditions. - To provide an opportunity to be introduced with the machines that are not available in our university. - To learn the sophisticated administration methods. - To improve and reinforce the theoretical and practical knowledge on production techniques that are acquired from courses.Practise has been done in discipline and seriously prepared report including the examined things in the factory is an important part in an education of an engineering student and it will also be useful for the future. Moreover it is important to get used to the factory atmosphere as it is another world with its own rules and relations among employees; especially among engineers and worker. The aplications techniques employed in this. I have been at Sanko Textile for 4 months.I have worked at Mechanical Maintenance and Repair Department.The aim of this practice is to gain technical experience about mechanical engineering. Everyone who will be a mechanical engineer must know very well about all these work areas.We are learning the engineering life in this practise. Observing the engineers and technicians finds out the engineering problems and how to solve them.This is the report for the mechanical engineering practise outside the school. In this report the basic machines of the application of engineering and the industry are being introduced.

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I am mechanical engineer so I didn’t any idea about how is the yarn can be produced?Which machines are used to produce yarn and how are the steps of production? After this point Manufacturing Steps are explained.

2.PRODUCTION STEPS Process Layout is set to Appendix A 1. ROBOT 2. Carding 3. Cer 4. Cord 5. Ring 6. BOBBIN 7. HUMUDITY KETTLE (Fiksaj) 8. Resting 9. STOCK Transport

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2.1 ROBOT (BLENDOMAT) Cotton is taken by the buyers in the marketing department. The pressed cotton comes to factory in big trucks. Next the cotton is taken to robot machine. Robot is opening the cotton and at the same time it takes some cottons in it but not more then 10 mm.

Figure(2):Robot

Figure(3): Working Princible of Robot

After that the cotton comes to a machine which is called “Metal Separator”. At here strange materials are chosen and taken by this machine. Like stone or iron pieces. Then the cotton comes to mixer.The machine mixes the cotton. After the cotton comes to separator again. But this is a little diffrent. Because this machine takes the different colors of cottons.This machine does not takes any stones or irons.

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2.2 COMB After separator machine, the cottons comes to combs. At here the cottons are pressed and combs produce cotton in strip form and it filled containers in strip form.

Figure(4): Comb

2.3 CER The cotton which comes to strip form comes to pasajcer machine. At here, the cotton enters the machine from six containers and it leaves in one strip and fills in into only one container. The machine gives number to cotton which

is wanted.Also second pasajcer is used to

improve the homogeneity of the strip.

Figure(5):Cer Machine

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2.4 CORD MACHINE Then the cotton goes to cord machine. This machine twists the stripped cotton and the stripped cotton comes to wool yarn form.

Figure(6) Back View of Cord Machine

Figure(7):Front View of Cord Machine

2.5 RING MACHINE Next the cotton comes to vater ring machine and this machine takes the cotton which is in wool yarn form and forms it to string form. The strings surrounded to bobbins.Each machine has 1008 piece of bobbins.Nearly each bobbin is 190-200 gr.And with a small calculation at each production interval nearly 185 kg yarn produced.

Figure(8):Vater Ring Machine

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2.6 BOBBIN MACHINE After the string surrounded to bobbins, the bobbins comes to bobbin machine by wheelbarrow.The machines take the bobbins from the wheelbarrow itself and than it covers to an empty bigger bobin too.In the factory bobbin machines are like work of art.The automation programmes and pneumatics of this machines are awesome.. While the machine doing this process it controls the string last time. If there is a mistake the machine fixes it. For example; if there is a different colour string, the machine cuts that coloured part. Or if the string is too much thick or less thin, the machine cuts those parts and corrects the mistake.

Figure(9):View of Bobbin Machine with Different Angles

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2.7 HUMIDITY KETTLE After the bobin machine, the bobbins are tken the stock room. But before it, we give them some humudity. We give humudity in humudity kettle. The ratio is, the %8.5 of the weight of the string. With this way we protect the string. And the strings are put into nylon pack not to lose their humudity. With this way if the product does not sell easily, its life will be longer. And after the stock, if there is an order, the factory send the products with trucks.

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CHAPTER 3 3.ANOTHER INFORMATIONS ABOUT FACTORY 3.1.PREVENTATION OF THE POLLUTION OF THE ENVIRONMENT AT THE FACTORY I have also worked with occupational health and safety expert whose name is Ömer Faruk Küçük.He is also a textile engineer. At the factory,there are very strick controls to prevent pollution of the environment.The working area is always cleaned by the responsible personels. Scrap places to put rubbishes systems : this is a system which was setted up to collect waste things and prevent danger of them to environment. Plastic refuses ; This refuses are send related factories for providing reuse. Papers refuses ; Again this refuses are send related factories for providing reuse. Metal and Metal chips ; This scraps are again sold to foundry for providing reuse by melting. Wood ; If possible, this refuses are used for doing tracks(palets).If not possible,They are sent being rubbish.

3.2.STANDARD APPLICATIONS Some standard applications done in organization are; - examine of the daily production plan, - quality control of the product, - periodic maintenance of machines, - cleaning of the departments, - controlling the amount of the raw-material at the storage, - controlling the amount of the product at the storage, - preparing the production plan.

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Some controls that are done in this organization are; Measurement of temperature and humidity of the department, Software settings of the machines on the production line, Hardware settings of the machines like, gear’s number, roller’ number, Machine’s output data sheets, Imperfection of the raw material, Wasted material at the production time I have done lots of calculations about how many tones are lost in the daily production? Some machines gives some errors during the day in the production line so they are stopped and this stopping cause some lost on production.My important task is calculation of this loss of production.There are lots of formulation which comes from textile engineering.The tones of yarn is related to its number,the machine rpm (rev/min) and another factors.They know that approximately this much production is produced with formulation.There will be some loss and my important task is finding this loss and its subject.

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DISCUSSION AND CONCLUSIONS UME is one of the best innovations made in recent years for University of Gaziantep.There are many short comings to the new application. Besides, there are also benefits Firstly,I thank to my university to offer us this opportunity. I hope this program will be better for following students. I think this program is very useful for me.I have improved myself about production of yarnsThanks to my chief called Hazal Oruç who is Mechanical Maintanence and Repair Engineer.She has helped me everytime.Whenever I asked something, she gave the answer. I have worked at the maintanence department of the factory.In textile industry machine maintanence is directly effect the quality of production. I have also knowledge about compressors with screw or aerodynamics and industrial air conditioners.I have been nearly all the departments of the factory. Due to intern programme I am self-confident now.The last year of my education life I have always thought that Can I find a job ?? or Can I perform engineering?? I have been there 4 months and I realize that I can perform engineering very well.I can not see any difference with me and engineer who is just start working there.Also I have big advantage to know english.I can easily say that whereever I will go, I can adapt there easily. Also I have some problems but I don’t want to say them in this report.This problems were ripen me.I always said that as an intern engineer ; there is a last necessary bridge to pass.After that bridge ,my professional life will begin.After finishing university a new and different life is starting maybe easy or maybe hard it changes the view angle of person which look but a thing is certain life really wants more and more that you can give. As a result Thanks to all my masters,my chief Hazal Oruç and my friend Ahmet Taşdemir.

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APPENDIX A

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