KOÇ UNIVERSITY

College of Engineering

DEPARTMENT OF
MECHANICAL ENGINEERING
MECH 391
SUMMER PRACTICE REPORT

Serkan Bölükbaş
Özen pres
02/08/08
 KOÇ UNIVERSITY
COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT
MECH 291/391 SUMMER PRACTICES I and II

1. The general regulations for the Summer Practice I and II are given in the “Koç University,
College of Engineering, Common Regulations for Summer Practices I and II.”
2. The practice should be performed in
a. a factory with a manufacturing department or
b. a machine shop with adequate equipment.
3. The practice must be supervised by a mechanical engineer.
4. Students are recommended to do the Summer Practice I and II in different companies and in
different departments.
5. Students are recommended to be exposed to the following topics
a. CAD (Computer Aided Design)
b. Production processes
c. Assembly
d. Quality control
e. Research and development.
6. The “Summer Practice Report” should have four major parts: description of company,
work/project summary, project description, and appendices as explained below. The report
should be 20 to 30 pages excluding the cover pages and appendices. The report must be
written in English and typed 1.5 spaced with 12 pt fonts. All pages must be given page
numbers. All figures, pictures, sketches, tables etc. must be also numbered appropriately.
Appendices are optional and there is no page limit for them.
a. The first part of the report should describe the company (including the full title of the
company, a brief history of the company, core business, departments, products, and
major tools and equipment used for design, development, manufacturing, and testing.)
b. The second part should give a work/project summary on a daily basis including
student’s and supervisor’s signatures at the bottom.
c. The third part should describe the projects undertaken by the student during the
practice. This part of the report should include
i Description of the department where the work is performed
ii List of typical products
iii Description of products and where they are used
iv Manufacturing processes and machines used for at least 3 typical products
v Technical details for these typical products:
 technical drawing (to be put into appendix)
 dimensions and tolerances
 materials used and their properties
 what processes and machines to be used
 assembly (where to be assembled)
 production schedule and production flow chart
 quality control methods and testing procedures.

The student should also document brief descriptions and working

principles of the machines, quality control instruments and
measuring tools that they work on.
d. The fourth part is optional and includes appendices.
 7. References should be included at the end of your report and they should be cited properly in
the text.

SUMMER PRACTICE REPORT

Student Name: Serkan Bölükbaş

Starting Date: 30/06/08

Completion Date: 25/07/08

Total Working Days: 20

Summer Practice #: 2

Company : Özenpres Makine Sanayi ve Ticaret LTD. STİ.

Department : Manufacturing

Address : TOSB - TAYSAD ORGANİZE SANAYİ BÖLGESİ 1. CADDE,

16. YOL, 6. PARSEL P.K:41410 ŞEKERPINAR / GEBZE /
KOCAELİ

Tel: 0262 658 12 00 (Pbx)

Faks: 0262 658 12 09

e-posta: ozenpres@ozenpres.com

Contact Person

Name: Mete AKKALYONCU

Department: Technical Supervisor

Phane: 0262 658 12 00 E-Mail:makkalyoncu@ozenpres.com

Work
Date Work / Project Description
Day

1 30/06/08 Exploring the factory and understanding the working path.

2 01/07/08 Exploring the factory and understanding the working path.

3 02/07/08 Exploring the factory and understanding the working path.

4 03/07/08 Investigating and working at the assembly or montage department.

5 04/07/08 Investigating and working at the assembly or montage department.

6 07/07/08 Observing the works at the mold making department.

7 08/07/08 Working with the cutting machine at the mold making department.

8 09/07/08 Observing the works at the machines in mold making department.

Being included in the works with milling machine at the mold making
9 10/07/08
department.

Investigating the works in the technical office of making mold

10 11/07/08
department.

11 14/07/08 Observing the designing programs like UGS NX 3.

12 15/07/08 Observing the designing programs like UGS NX 3.

WORK / PROJECT SUMMARY

Student’s Signature: Date:
Name of Supervisor:
Supervisor’s Signature: Date:
 WORK / PROJECT SUMMARY (Continued)

Work
Date Work / Project Description
Day

13 16/07/08 Be included and learning how the design a mold for press machines.

Learning the working path to make a mold after getting the design of the
14 17/07/08
mold.

Learning the working path to make a mold after getting the design of the
15 18/07/08
mold.

Working at the warehouse to learn how to package the out coming

16 21/07/08
materials and parts.

Working at the warehouse to learn how to package the out coming

17 22/07/08
materials and parts.

18 23/07/08 Observing and investigating the works at the press machine department.

19 24/07/08 Investigating and including in the works at the press machine department.

20 25/07/08 Be included to the works at the quality control department.

21*

22

23

24

*
Work days after 20 are optional. You may use it in the case of half working days such as holidays and
weekends
Student’s Signature: Date:
Name of Supervisor:
Supervisor’s Signature: Date:
1. INTRODUCTION...................................................................................................5

2. COMPANY DESCRIPTION...................................................................................7

3. WORKING DAYS................................................................................................10

4. SUMMARY AND CONCLUDING REMARKS....................................................29

5. REFERENCES....................................................................................................30

Appendixes.................................................................................................................30

6
1. Introduction

First of all, this internship program was beneficial for me not only to get information
about manufacturing process of automobile industry products, but also to be informed about
these companies and working principles of a manufacturing departments.

I spent my internship period by observing manufacturing processes, making mold for

presses, packageing, montaging. I observed how they process the car parts from sheet metal.

Press department has different machines to stroke on the sheet metal like excentric or
hydraulic press. According to consumers’ demands, products are produced for special
numbers and qualities. All products are tested according to some criteria such as metal
quality, exterior surface quality and physical properties and dimension truthness before
packaging and transporting.

I spent time at all of the deparments to learn the process step by step and learn about
what a machanical engineer can do to develop these departments. In these type of car industry
manufacturer’s factories has the same consept of getting the raw material (sheet metal),
process on it by press, quality control of the processed first ones to continue, making the last
corrections, montaging, packaging, transporting to the ordered company. Also I learned that
the mold making department is too benefical for the company in terms of money, time, and
work quality.

Working at all the departments, help me to learn about all the works. I learned about
machines, designs and processes at departments of press and mold making. I learned to
montage and what for done these parts are when I am working at the montaging department.
Also I learned to packaging and transporting at the warehouse. Lastly I learn how to control
the quality and all properties of outputs at the quality control department.

7
2. Company Description

(ref no: 1)

Ozen Pres has been founded in 1976, to perform it’s activities in the field of
automobile sub-industry. It has developed in parallel with the devoloping automobile industry
within the country and continues to grow furter. Currently Ozen Pres is continuing it’s
activities on a closed area af 7000 m2.

The company performs sheet stamping, welding and assambling of the parts.
Although, most of the matrices and fixtures that the Özen pres Makine Sanayi ve Ticaret
LTD. STİ. uses in their production processes are manufactured by theirselves, they also
obtain support from the auxilary industry.

Mainly the company specialize on the seat tracks, car jacks, chassis and body parts.

Main customers are:

 Ford Otosan
 Isuzu (AIOS)
 Otoyol (Iveco)

8
The company has really stricht rules of quality policies so I would like show you them as:
Quality and Environmental Politics of Özen pres Makine Sanayi ve Ticaret
LTD. STİ.
-Keep customer satisfaction to high level

-Continuous improvement on production quality

-Improve the company’s staf with up-to date trainings

-Continuous improvements on First Time Through

-the company use their sources with respect

TURNOVER RATE

(ref no: 2)
This table shows that the Özen pres Makine Sanayi ve Ticaret LTD. STİ. Makes the
work with the companies of Ford, Major, Isuzu, Bplas and others. This table shows the
selling and profit amounts of the company for the years at 2005, 2006, 2007. This company

9
makes works mjorly with the Ford company. Also we can see that the profit ratio decreases
down for 3 years from 2005 to 2007.

These are the certifications of the company can be seen below which are significantly
important for the company nad their goals.
CERTIFICATIONS
 TS-ISO 16949 Quality System Certificate
Certification Date: 17 MAY 2007
 MMOG Certification
Certification Date : 5 JUNE 2007
 TS-EN-ISO 14001 Environmet Certification
Certification Date : 23 JULY 2007
 Q1 Quality System Certification
Certification Date : 10 DECMBER 2007

(ref no: 2)

Also the company has new projects and goals so the Özen Pres Makine Sanayi ve
Ticaret LTD. STİ.
NEW PROJECTS
 Tototetsu (Meeting Stage)

 Trakya Cam (Signed)

 Visteon (Quotation send)

10
  Alarko Carrier (Quotation send)

 Assan Hanil (Signed)

 Honda (Meeting Stage)

 ZF SACHS (Quotation send)

 CF. Gomma (İtalya) (Quotation send)

 Accenture (Polonya) (Quotation send)

 CRH Hyundai (Almanya) (Quotation send)

 Trelleborg Automotive (Germany) (Quotation send)

The collar count of the company can be shown by a table below,

(ref no: 2)

3. Work days
WORK DAYS 1 and 2 - JUNE 30, JULY 01 :
Exploring the factory and understanding the working paths.

First and second days, I go to the factory as they told me at 8 o’clock. Our instrustors met
with us at the gates of factory and they took us to administrative building center. We
introduced and talked each other. We had lunch at noon. After lunch we were informed about
the factory’s history, founder, shareholder list, products, financial situation. Then we were
informed about general work safety rules which is accepted by Özenpres Makine Sanayi ve
Ticaret LTD. STİ. And they informed us about what we must do when we are in factory and
how we could protect ourselves against states of emergency which are earthquake, injury,
fire, flood etc. And then, I met with my supervisor who is a mechanical engeener. He show
me the departments at the factory and informed me about the departments in the factory. He
divided my internship days for the departments so I can get parts in different departments as
my internship continues.
WORK DAY 3 - JULY,02 :
Continue to exploring the factory and understanding the working paths.

11
 This third day I go to the factory at 8 o’clock again and this time my supervisor
started to give short explanations about the working paths to understand them easily.
Work path at Özen Pres Makine Sanayi ve Ticaret LTD. STİ
 Firstly the gathering the sheet metal. At this part the sheet metal which is packed with
different size and packets to the factory with the trucks. The quality of the sheet metal
is too important for the company because the press machines will process them with
very strong hittings.
 Secondly, the cutting the sheet metal as the machines users or the design of the parts
instructs.

(ref no: 2)

 Thirdly, press machine department which includeds 12 press machines with different
properties which I will mention later. At here sheet metal will be prosssed by press
machines to get the expected shape of output and design of the product.

12
 (ref no : 1)
 Fourth path is weld room which inclueds 6 weld machine to make some modifications
on the products of the output of the press machines.
 Fifth path is the montage department which the workers makes the montage of the
products with other outputs to get the last shape and design of the ordered product.

(ref no: 1)
 Finally, the warehouse department which the output products are packed and
contained and sent to the ordered companies.

(ref no: 11)

13
WORK DAYS 4, 5 – JULY 03, 04:
Investigating and working at the assembly or montage department.
At these days my supervisor told me to work at the montage department to see the
products which are meden by the Özen pres Makine Sanayi ve Ticaret LTD. STİ. At this
department of montage the first day (work day 4) I watched the workers who were getting together the
different parts to get a whole working output. For example: the workers were working on the car seat
mechanism. They were gathering the parts like the buttons, holding arms, rails of the seat and they
summed up with the seat of a Ford transit car front seat mechanism. This mechanism seen complex to
me first times but I get the gathering steps and I tried too. I gather the arm mechanism first which
allows the seat to bend on or back. Also I gathered the button sockets to the mechanism which is a
place to specific options for seat. Then I gathered the rails of the seat which allows the seat to
go forward or backward.
I can show you the montaging steps by the pictures stpe by step.
1) truck seat

a) This is the main body with b) This part is the modified c) This part is modified with
basic arms and rails. with plastic grabbings and feet. seat base and some springs.

2) Car seat

These are the ones which the rails, springs, and arms are gathered together. Also you
can see clearly the arm which moves the seat front or back too.

14
 Moreover to these, I worked on the Isuzu company ordered parts. I gathered the trucks
gas pedals and some other parts which you can see below.

(ref no: 3)

WORK DAY 6 - JULY,07 :

Observing the works at the mold making department.

(ref no: 2)
My supervisor intruduced me to the mold making department chief. This department
contains two parts. Part one is the technical office and the part two is the workshop which the

15
designs converted to the molds. I introduced with al the workers in this department and I
started to watch the working path in this department.
Working Path in the mold making department
1) getting order of a product
2) designing the product
3) processing the materials used in mold making
4) using the machines like CNC, tel erezyon, metal cutting saw, milling machine etc.
5) sending the mold to the press room.

WORK DAY 7 - JULY,08 :

Working with the cutting machine at the mold making department.
The workshop chief gave me a steel block which has dimensions of length: 15cm,
height: 10cm, and width: 5cm. He wanted me to cut this block into same 2 halfs with the
metal cutting saw. At first he and I changed the saw which became blunt. We took of the saw
and put a new saw and we weld the 2 tips of the saw with the help of a small welding
machine on the metal cutting saw machine. After replacing the new saw, I started to work on
the block to divide is to equal half. It was a hard and long work because the block had too
strong resistance to the saw so I needed to push the block more hardly. The block was too
hard so it broked the turning saw , then I changed the saw again. After all we made cleaning
jobs in the workshop and make some calculations on the cutted half blocks because the chief
needed them to repair an old mold.

WORK DAY 8 - JULY,09 :

Observing the works at the machines in mold making department.

16
I observed that the workshop workers was dealing with too many machines like CNC, tel
erezyon, stoning machines, sanding machines, milling machines, turning machines and other
workshop tools. I will explain some of the machines and functions below.

CNC machine: We used this machine to operate on a metal block without hand only with the
computered codes. The abbreviation CNC stands for computer numerical control, and refers
specifically to a computer "controller" that reads G-code instructions and drives a machine
tool, a powered mechanical device typically used to fabricate components by the selective
removal of material. CNC does numerically directed interpolation of a cutting tool in the
work envelope of a machine. The operating parameters of the CNC can be altered via a
software load program. With the increased automation of manufacturing processes with CNC
machining, considerable improvements in consistency and quality have been achieved with
no strain on the operator. CNC automation reduced the frequency of errors and provided
CNC operators with time to perform additional tasks. CNC automation also allows for more
flexibility in the way parts are held in the manufacturing process and the time required to
change the machine to produce different components.

17
(ref no: 2, 3)

Tel erezyon: This machine is very important because it uses electrical wire to cut the metal
and this wire has a diameter of 5mm so it can open holes or paths on the metal sheet easily. It
fills its inside with water and gives electiricty after all it circulates wire to cut the metal. This
machine can work with even manually or computer based codes like CNC machine.

18
 (ref no: 1, 2)

Stoning machines: This machine was used by workers so clean the object and also to open
new paths or landslips on the object.

Sanding machines: We used this machine to clean the objects. This device is throwing a thin
and really fast sand to the object. This operation makes the object clean and also it can peel
the paint out of the surface of the object.

Milling machines: A milling machine is a machine tool used for the shaping of metal and
other solid materials. Its basic form is that of a rotating cutter which rotates about the spindle
axis (similar to a drill), and a table to which the workpiece is affixed. In contrast to drilling,
where the drill is moved exclusively along its axis, the milling operation involves movement
of the rotating cutter sideways as well as 'in and out'. The cutter and workpiece move relative
to each other, generating a toolpath along which material is removed. The movement is
precisely controlled, usually with slides and leadscrews or analogous technology. Often the
movement is achieved by moving the table while the cutter rotates in one place, but
regardless of how the parts of the machine slide, the result that matters is the relative motion
between cutter and workpiece. Milling machines may be manually operated, mechanically
automated, or digitally automated via CNC (computer numerical control).Milling machines
can perform a vast number of operations, some of them with quite complex toolpaths, such as
slot cutting, planing, drilling, diesinking, rebating, routing, etc.

19
 (ref no: 10)

Metal cutting saw machine: This is a device for cutting up bars of material or for cutting out
shapes in plates of raw material. The cutting tools of sawing machines may be thin metallic
disks with teeth on their edges, thin metal blades or flexible bands with teeth on one edge, or
thin grinding wheels. The tools may use any of three actions in sawing: true cutting, grinding,
or friction-created melting.

Turning machines: The engine lathe, as the horizontal metal-turning machine is commonly
called, is the most important of all the machine tools. It is usually considered the father of all
other machine tools because many of its fundamental mechanical elements are incorporated
into the design of other machine tools.

20
(ref no: 9)

WORK DAY 9 - JULY,10 :

Being included in the works with milling machine at the mold making department.
After I observed the machines, I started to be included in the works at the milling
machines. The worker who is using the milling machine gave me some basic informations
about the operations on a metal block. He was cleaning the top face of a used and servicing
the mold to be used again. Firstly, I watched him for a long time to become used to the job.
Then he let me to get a 1 mm thickness from the top of the block. I arrenged the measurement
from the control panel while I was getting the center as referance. He gave the control of the
milling machine some little times for easy operations. I made some little operation until the
end of the day.

21
 (ref no : 7,8)

I can show you easily from these

pictures how the worker let me work on
milling machine. He putted the block on
the table and squezed it with t slots. He
found the origin by using the
handwheels of tabble feed and cross
feed. He arranged the speed of the
spindle by sprrd control knob and v belt.
After all he decreased the highness of tip
by using the quill feed handle.

WORK DAY 10 - JULY,11 :

22
Investigating the works in the technical office of making mold department.

After I worked at the workshop of the mold making department. The chief of the
department put me inside of the technical office to see some design making. The worker at
the technical office was using the UGS NX 3.

(ref no: 1, 2)
They got the orders by the way the product outcoming from the press machines. Press
machines are very strong machines that pushes down the sheet metal in to the mold to give it
the shape of the ordered product.

WORK DAYS 11, 12, 13 - JULY,14, 15, 16 :

Observing the designing programs like UGS NX 3.
Be included and learning how the design a mold for press machines.
I used the UGS NX 4 at our university in my second years 2. semester. They first
design the below part which is the bed of the mold. After that they design and mate the
female part of the mold. They mate them with bolts. The female part is the part where the
male part mates in it by the pressing action of press machine. The female part contains the
outer boundaries of the outcoming product and also the curvetures of the output can be given
by the female part. Also the male part is designed by the UGS NX 3 workers. The male part
must be maden by the hard metal to press over the female part to squezee the sheet metal.
Then they design the the top part which mates with the press machines hitting part. The most
important parts are the calculation and the places of the springs between the female and male

23
parts. These springs are putted to separate the female and the male parts after the pressing
actions occurred.

(Ref no: 2)
You can see the female and male parts (red and blue) easily and how they got together
by the springs and shock absorbers. Also you can see that the below and the top parts of the
mold. And the part that they called kayıt which is the grey part. This part helps the female
part to give the curvatures to the pressed sheet metal.

24
WORK DAYS 14, 15 - JULY,17, 18 :
Learning the working path to make a mold after getting the design of the mold.

At first the design part must be finished to complete the mold completely. After calculating the
mold’s capacity and strength and the bear against the pussing strength of the press machine. Then they
order the steel blocks as the design wants. The size, height, width, hardness, surface cuts are really
important so they calculate these by looking the properties of the press machines. These steel blocks
goes in to the CNC machine to be cutten to have the female and male and kayıt parts. But the CNC can
not do all the work so milling machine can complete the job of the CNC machine. If the outcoming
metal’s surface is rough so they make the sandin and stoning process to make it cleaner and flatter.
The tel erezyon machine makes the little radius holes or the small openins or the paths with
small thickness.The metal cutting saw can cut the metal as if thye want in sizes. Another thing is
important for milling machine that the head of the milling machine’ s spindles can be adjusted with the
angles so the tip of the milling machine can go inside of the metal with an angle which is the CNC
machine can not do.After they made the female, bottom, top, male, kayıt, parts they started to
collobrate them with bolts and they putted some springs between the female and the male parts. You
can see a design at the bak of the project addition.

WORK DAYS 16, 17 - JULY,21, 22 :

Working at the warehouse to learn how to package the out coming materials and parts.

My supervisor made me to work at the warehouse to show me how the produced things packed
and setted ready for transporting them to the ordered company. I controlled over a container and made
them counted and packed with right smaller boxes. Also I learned how to arrange the parts in the
boxes. I putted the information in to the system of transporting and made the boxes ready to be
transporting with trucks. I got the print outs of the forwarding properties of the materials on a ticket
and I taped them on the boxes. I learned how to arrange and put the materials as the ordered and
regular way.

WORK DAYS 18, 19 - JULY,23, 24 :

Observing and investigating the works at the press machine department.

Investigating and including in the works at the press machine department.

25
 At my 18th day, my supervisor introduced me with the chief of the press machine
department. This department contains 12 press machines with different types. I would like to
mention about the types.

Excentric press : An eccentric press which can be constructed a single connecting rod
machine or a twin connecting rod machine is described. The press includes a stroke
adjustment means having a support lever which is articulately connected at the joint between
the two portions of a lever arrangement. The articulation joint is guided on an adjustable path
of movement and the foot point of the support lever is guided variably in its position on a
circular arc, the center point of the circular arc coinciding with the position of the articulation
point which corresponds to the bottom dead center of the ram. As a result, a change in the
ram stroke does not change the bottom dead center of the ram, only one ram stroke being
executed per connecting rod revolution.

(Ref no: 3 , 4)

I got some information about the excentric press while I was watching the workers on
my 18th day. I found the press’ property tables and work on them. These tables shows that the
maintenance and reparation report, and the properties of the press. I added 3 reports of press
machines. One of them is excentric press and you can see the properties of that press. It’s

26
capacity is 80 tons. The producer factory of this press is Özan Kardeşler. Technic properties
are the bottom table has dimensions of 505x825, the excentric is 150 and the maximum
height is 400 cm. Also it’s power is 5,5 kw. You can see the detailed properties at the addition
of report.

(Ref no :1,2)

This is another type of excentric press which I added the properties to the report. . These
tables shows that the maintenance and reparation report, and the properties of the press. This
press has a capacity of 400 tons. The producer factory is Tesbihci. The detailed technical
properties are the top table’s dimensions are 850x1500, and the bottom table’s dimensions are
1000x1500. The excentric is 200. Max height is 660cm and the minimum height is 360cm.
Also it’s power is 22 kw.
Hydraulic press : The hydraulic press depends on Pascal's principle: the pressure
throughout a closed system is constant. At one end of the system is a piston with a small
cross-sectional area driven by a lever to increase the force. Small-diameter tubing leads to the

27
other end of the system.Pascals law: Pressure on a confined fluid is transmitted undiminished
and acts with equal force on equal areas and at 90 degrees to the container wall.A fluid, such
as oil, is displaced when either piston is pushed inward. The small piston, for a given distance
of movement, displaces a smaller amount of volume than the large piston, which is
proportional to the ratio of areas of the heads of the pistons. Therefore, the small piston must
be moved a large distance to get the large piston to move significantly. The distance the large
piston will move is the distance that the small piston is moved divided by the ratio of the
areas of the heads of the pistons.For example, if the ratio of the areas is 5, a force of 100
newtons on the small piston will produce a force of 500 newtons on the large piston, and the
small piston must be pushed 50 cm to get the large piston to rise 10 cm. This is how energy,
in the form of work in this case, is conserved and the Law of Conservation of Energy is
satisfied. Work is force times distance, and since the force is increased on the larger piston,
the distance the force is applied over must be decreased. The work of the small piston, 100
newtons multiplied by 0.5 meter (50 cm) is 50 joules (J), which is the same as the work of the
large piston, 500 newtons multiplied by 0.1 meter (10 cm).

(Ref no : 1, 2,4)

I got some information about the hydraulic press while I was watching the workers on
my 18th day. I found the press’ property tables and work on them. These tables shows that the
maintenance and reparation report, and the properties of the press. I added 3 reports of press
machines. One of them is hydraulic press and you can see the properties of that press. This

28
press has a capacity of a stroke is the 125 tons. Also it has a power of 12 kw. The producer
company is Tomruk. The detailed technical properties can be seen at the addition of the
report’s end. If I mention about the properties, it has a top table of dimensions are 100x1050
and the bottom table of dimensions are 1010x 1030. The maximum height is 600cm and the
minimum heigth is 240 cm. It’s model is TK 140S.
At my 19th day, I helped the workers of the presses and asked them more questions. I
understanded that there are some types of presses and molds for different types of products.
Some of them needs more strong strokes and some of them needs much more speed and
regulate. I understood the technique of the presses.

WORK DAY 20 - JULY,25 :

Be included to the works at the quality control department.

Quality control is a procedure or set of procedures intended to ensure that a

manufactured product or performed service adheres to a defined set of quality criteria or
meets the requirements of the client or customer. Quality Control is similar to, but not
identical with, quality assurance . quality assurance is defined as a procedure or set of
procedures intended to ensure that a product or service under development (before work is
complete, as opposed to afterwards) meets specified requirements. quality assurance is
sometimes expressed together with Quality Control as a single expression, quality assurance
and control.

In order to implement an effective Quality Control program, an enterprise must first decide
which specific standards the product or service must meet. Then the extent of Quality Control
actions must be determined (for example, the percentage of units to be tested from each lot).
Next, real-world data must be collected (for example, the percentage of units that fail) and the
results reported to management personnel. After this, corrective action must be decided upon
and taken (for example, defective units must be repaired or rejected and poor service repeated
at no charge until the customer is satisfied). If too many unit failures or instances of poor
service occur, a plan must be devised to improve the production or service process and then
that plan must be put into action. Finally, the Quality Control process must be ongoing to
ensure that remedial efforts, if required, have produced satisfactory results and to
immediately detect recurrences or new instances of trouble.

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 In this factory at my last day I was sent to the quality control department to see how
they inspect the production output quality. The workers in the department firstly look at the
dimensions of the output are right or wrong. They look at the width, height, length, radius of
curvatures and holes. After that they look at the hardness and the strength of the output
product. And they look at the surfaces of welding to see if the welding is ok or not. They look
these products in detailed way because the production of materials are under their control. If
something bad is skipped then all the products has that mistake. (ref no: 5)

I also find out an operation and control ınstruction card and added it to this report.
This report mentions to the workers what and how they must work on the machines and
metal. The work safety, the machines and process path, the control of quality is showed at
these reports. The safety work rules are at the beginnig of the pages. You can see the page no
are showing the process no. this report has 5 pages in addition so the process is on 5 steps.

These are the steps of the making the top

Step 1 : Cutting the band
Step 2 : Cutting the encompassing limits
Step 3 : Curling
Step 4 : Punching holes
Step 5 : Blowing the metal
carrier baricade. Firstly cut the band of the
sheet metal. Cutting the encompassing limits
means that cutting the shape of the ordered
product. Curling is giving the curvature by
stroking on the sheet metal. Punching holes
means that makinh holes on the metal by
pressing. And the last one is blowing the metal
means that giving little radiused blowings on
the sheet metal.

You can see the process control instructions on the additions of the report, the work
safety tools and the using steps of the machines and the work safety instructions. Also the
control of the materials can be seen on the additions.

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4. Summary and Concluding Remarks

In conclusion, It was very beneficial internship for me because I learned how a factory
survives and carry on working all the time. I witness the processes and the steps of the
working path in a manufacturer company. I gained knowledge about the automotive industry,
basic working principles of manufacturing lines and working conditions of a mechanical
engineer as manufacturing engineer in manufacturing department during my summer
practice. Additionally, I got much information about different kinds of manufacturing the
metal parts of automobiles and got much information about different kinds of machines used
to produce and process materials. Admittedly, it was interesting to observe manufacturing of
products which we often consume in daily life.
Observing preparation of car parts with a long working path shows me how important
that the order, safety and hard working is. I did not learn only about application of production
methods, but also about theoretical data gained during the process. I also saw that how good
quality sheet metal is used in this industry.
Furthermore, I observed all steps, from preparation of the materials to packaging, of a
production line. It was beneficial for me to see any possible problems may occur in
manufacturing. So, it was a good experience to learn how to solve problems both occurred in
mechanical area like problems caused by workers and problems occurred in technical area
like breakdown problems of machines.
Additionally, I learned working principles of many machines used in manufacturing
lines with some details and tricks. I realized the basic idea of management the manufacturing
department is based on the management of staff in that department. So, observing the
relationship between managers and staff was useful to understand the responsibilities of a
manufacturing engineer.
On the whole, I obtained much information about the basic concept of machine industry,
manufacturing process in a automobile parts manufacturer company, working principles of
equipments in this line, production of confectionery and responsibilities of a mechanical
engineer.

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5. References
1. http://www.ozenpres.com/products_opsparcalar.asp
2. http://www.ozenpres.com/Sunum/Presantation.pdf
3. http://www.ozenpres.com/makineParkimiz.asp
4. http://www.freepatentsonline.com/4630516.html
5. http://en.wikipedia.org/wiki/Hydraulic_press
6. http://whatis.techtarget.com/definition/0,,sid9_gci1127382,00.html
7. http://www.sherline.com/images/millfig1.gif
8. http://images.google.com/imgres
9. http://www.mfg.mtu.edu/cyberman/machining/trad/turning/lathe.jpg
10. http://www.germes-online.com/direct/dbimage/50290498/Milling_Machines.jpg
11. http://www.mezzaninefloorsystems.co.uk/mezzanine-warehouse.jpg

Appendixes
Appendixes are added at the end of this report. These additions are collected from the factory.

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