TABLE OF CONTENTS

TABLE OF CONTENTS................................................................................................................ 1

LIST OF TABLES .......................................................................................................................... 4

LIST OF FIGURES ........................................................................................................................ 5

INTRODUCTION .......................................................................................................................... 6

CHAPTER 2 ................................................................................................................................... 7

DATA ABOUT THE COMPANY ................................................................................................. 7

2.1 Title ....................................................................................................................................... 7

2.2 Address and web homepage .................................................................................................. 7

2.3 Brief history of the firm ........................................................................................................ 7

2.4 Employment data................................................................................................................... 8

2.5 Approximate Annual Sales, Market Share, Competitions .................................................... 8

2.6 Main product of the firm and raw materials .......................................................................... 8

CHAPTER 3 ................................................................................................................................... 9

GENERAL PRINCIPLES OF MANAGEMENT AND ORGANIZATION ................................. 9

3.1 Management functions .......................................................................................................... 9

3.2 Organization of the company ................................................................................................ 9

3.2.1 Other engineers in the firm ........................................................................................... 10

3.2.2 Responsibilities............................................................................................................. 11

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 3.3 Professional Ethics .............................................................................................................. 11

CHAPTER 4 ................................................................................................................................. 12

MANUFACTURING SYSTEMS ................................................................................................ 12

4.1 Manufacturing Engineering................................................................................................. 12

4.1.1 Productivity .................................................................................................................. 13

4.1.2 Machines used in production ........................................................................................ 13

4.1.2.1 Bending machine ....................................................................................................... 13

CHAPTER 5 ................................................................................................................................. 16

ANALYSIS OF PRODUCTION SYSTEMS ............................................................................... 16

5.1 Production environment ...................................................................................................... 16

5.2 Safety................................................................................................................................... 16

5.2.1 Hazards associated with production ............................................................................. 16

5.2.2 Occupational accident................................................................................................... 17

5.2.3 Safety management in the organization........................................................................ 17

5.3 Work Study ......................................................................................................................... 18

5.3.1 Productivity ratios......................................................................................................... 18

5.3.2 Part Lists ....................................................................................................................... 18

5.3.4 Process flow chart for door assembling ........................................................................ 20

5.3.5 Standard time calculation and purpose ......................................................................... 22

5.3.6 Unit cost determined ..................................................................................................... 22

5.3.7 Unit cost calculation of windows produced ................................................................. 22

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 5.3 Job evaluation and wage incentives .................................................................................... 23

5.4 Plant location and layout ..................................................................................................... 23

5.5.1 Layout of the plant ........................................................................................................ 23

5.5.2 Material handling equipment ........................................................................................ 24

5.6 Environmental management ................................................................................................ 24

5.7 Waste ................................................................................................................................... 24

5.8 Energy ................................................................................................................................. 25

5.9 water consumption .............................................................................................................. 25

CHAPTER 6 ................................................................................................................................. 26

INFORMATION SYSTEMS ....................................................................................................... 26

6.1 Data management ................................................................................................................ 26

6.1.1 Information flow within the cutting department........................................................... 26

6.1.2 List of computer software used in each department ..................................................... 26

6.2 Cost accounting system ....................................................................................................... 27

CHAPTER 7 ................................................................................................................................. 28

CONCLUSION ............................................................................................................................. 28

REFERENCES ............................................................................................................................. 29

APPENDIX ................................................................................................................................... 30

3
 LIST OF TABLES

Table 1 firm engineer .................................................................................................................... 10

Table 2 windows part list .............................................................................................................. 18

Table 3 doors part list .................................................................................................................. 18

4
 LIST OF FIGURES

Figure 1 organization chart ............................................................................................................. 9

Figure 2 bending machine ............................................................................................................. 14

Figure 3 Cleaning welding machine ............................................................................................. 15

Figure 4 process chart for PVC window assembling .................................................................... 20

Figure 5 process chart for PVC door assembly ............................................................................ 21

Figure 6 production area ............................................................................................................... 30

5
 CHAPTER 1

INTRODUCTION

During the last four years I attended a lot of lectures in many courses but I could not

Imagine how I could apply this courses in the real life. And how I could connect the different

approaches through my work.

I did my second training in ELPEN (PIMAPEN) Ltd. Company.it was for fifteen days, I made

a rotation inside the company through different departments.

During my training I faced what I learned in classes, it was a big opportunity to observed the

real work and apply different approaches in order to understand the courses that I learned, and

in order to be an industrial engineer this training change a lot of my thoughts and give me a

clear idea about how is the real life.

In this report I will give a brief idea about PIMAPEN Company, The management function in

this firm, Chart of the organization and the relation between departments, Introduce the work

force inside the company, Highlight the responsibility in each department, How the company

deal with ethics issues , The manufacturing process, The production system, the rules and

regulation of safety and if there any improvement that can be apply, the part list and the flow

chart of the products, analyze the work study, job evaluation and wage incentive, the plant

location and layout, environmental management, data management, cost accounting system.

6
 CHAPTER 2

DATA ABOUT THE COMPANY

2.1 Title

The company name is ELPEN (PIMAPEN) Ltd. Company.

2.2 Address and web homepage

Web homepage http://www.pimapen.com.tr

Email: el-pen@superonline.com

Address: buyuk sanayi bolgesi Famagusta, Cyprus.

2.3 Brief history of the firm

PIMAPEN Company was founded in 1963.and start provide PVC windows and doors in 1982.

All of the raw materials are imported from Turkey. The company also export products to other

countries such as Italy and sales offices in 18 countries. The production area is over 9,000

meters square. The work force of the company currently is 11 workers.

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2.4 Employment data

The human resources division has the all the data of the employees and these data are kept in order to

recognize each labor in the company. For each labor they have the main details like address,

phone number, if they have any allergic, and many useful data.

2.5 Approximate Annual Sales, Market Share, Competitions

The annual sales of the company is approximately 200,000 dollars, this firm provide a very good

quality so they have a big market share rather than the other company and for that they are facing

a small competition in the market of PVC doors and windows.

2.6 Main product of the firm and raw materials

The main products of the company are windows and doors. Almost all the parts that they use

for production are imported from Turkey and some of raw material are from local market. The

raw materials that used are seals, screws, lead free raw material and handles.

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 CHAPTER 3

GENERAL PRINCIPLES OF MANAGEMENT AND

ORGANIZATION

3.1 Management functions

The management functions in the company are planning, staffing, coordinating controlling and

organizing. Where the planning taking place in top management in order to increase the

productivity and assure the expanding of the company and by leading the workers by guiding

them to improve the work conditions.

3.2 Organization of the company

PIMAPEN

CEO

PURCHASING MARKITING FINANCIAL PRODUCTION

DEPARTMENT DEPARTMENT DEPARTMENT DEPARTMENT

WARHEOUSE ACCOUNTANT PRODUCTION

ASSEMBLLY

Figure 1 organization chart

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In the above the organization chart of PIMAPEN Company. It shows the structure of the company

and the relationships among the departments in order to represent the structure of the organization.

The chart of the organization show the flow of the information through the department in different

aspect it is a tools use to plan for change.

The organization chart help to understand the structure of the company which provide a

specific job position in order to arrange every worker in exact department which provide more

details for the workers for which departments they are belongs and who is the supervisor in

each department in order to increase the productivity.

A Chief Executive Officer CEO directing all the department in order to achieve the

organization goals, there is four main departments which are the purchasing department, the

production department, the marketing department and financial department.

3.2.1 Other engineers in the firm

NAME POSITION ROLE

Abdullah Civil Engineer Director of the firm

Emirzadeoglulari

Sunday Production manager Direct the different activity

Mo9hammed Jindal internship supervisor

Table 1 firm engineer

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3.2.2 Responsibilities

For each department its carry a certain responsibility the CEO is directing the firm in order to

achieve the organization goals by planning and directing the activity of the firm. The

purchasing department responsible for purchase the necessary raw material and assure that

every things is available to continue the work without any delay. The marketing department is

responsible for communicate with customers and take all orders and send it to production

department also they are responsible for advertisement. In the production department they

takes the orders form the marketing department and assure to finish all orders on time, also

they are responsible to arrange the warhorse. The financial department responsible for all

accounting issues and for the salary of the workers.

3.3 Professional Ethics

For PIMAPEN yes they had publish an ethics code, which helps the workers to perform their

job functions according to the ethical principles. During my training period I did not notice

any ethical procedure within the company that allows the workers to report for anything they

think it wrong, so the company does not have any report policy which lead to decrease the

company name in the market and reduce the trust between the workers, which is not in the

benefit of the company.

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 CHAPTER 4

MANUFACTURING SYSTEMS

4.1 Manufacturing Engineering

There are many manufacturing processes used in the company which they are cutting, joining,

bending, grinding and drilling.

 First they bring the PVC part and cut it according to the length order using

Cutting machine. In the firm there is two types of cutting machine one of them is

manual cutting machine and the other is CNC cutting machine, also the use manual

cutting machine to cut the steel part.

 The second operation is the drilling, first they drill the steel part and enter it inside the

PVC bar for isolation. Then they drill some holes to fix the steel bar with PVC bar.

Also they have two machines for drilling one is manual and the second is CNC.

The third operation is grinding in order to have a good surface finishing they use a

grinding machine then they send it to joining.

 Finally, the last process is joining which involves the welding of two plastics to make

permanent sticking together to have the last shape. It offers superior strength. In order

12
 to perform this it should walk through three steps for welding of the plastic which they

are pressing, heating and cooling.

4.1.1 Productivity

In order to increase the productivity in PIMAPEN company they attempt to use machining

process in order to make the job easier and faster this process help the firm to produce large

quantity in short time and reduce the number of workers which will lead to contribute the best

interest of the organization.

4.1.2 Machines used in production

4.1.2.1 Bending machine

The bending machine is used to bend the PVC parts, in order to be able to create curved frames

for doors and windows. The PVC parts have strong material and we cannot just bend it because it

will break so we need to make them able to be bend through rising the temperature at some

certain level it could be reshape according to the customer order.

13
 Figure 2 bending machine

4.1.2.2 Cleaning welding machine

The cleaning welding machine is used for the joining of two corners of the PVC doors and

windows. the machine produce high heat which enable to clean any extra pieces exist on the

surface of the product which is based on some measurments and it can be done either

automatically or manually.

14
Figure 3 Cleaning welding machine

15
 CHAPTER 5

ANALYSIS OF PRODUCTION SYSTEMS

5.1 Production environment

PIMAPEN company produce based on the order, when they receive an order they start to

produce in different word they have limited production this strategy has advantages and

disadvantages, they minimize the holding cost when they do not storage any finish good which

consider an advantages but on other hand the delivery time will be longer a little bit because

they produce based on customer order which count as disadvantages.

5.2 Safety

5.2.1 Hazards associated with production

There is some kind of hazards exist in the company which are:

 Noise: the production area which contain the machineries produce noise which can

affect the hearing of the workers.

 Heat: inside the facility there is any type of ventilation which can reduce the heat that

coming from the machines and from weather especially in the summer where in

Famagusta the weather is too hot.

16
  Hand tools: in production area the workers use some hand tools which can be a special

hazard.

5.2.2 Occupational accident

PIMAPEN workers are trained to perform their jobs, everyone in his position can reduce the

chance of any accident. However, if any sample accident happen there is a first aid box, but if

the workers have a serious injury they will take it to the general hospital which is close to the

firm location. Otherwise one of the workers will take his place in order to continue the

production.

5.2.3 Safety management in the organization

The company are so concern about the safety of their workers, when the workers apply to work

for PIMAPEN Company they take further details about his medical condition and if he has any

allergic also they provide a first aid box for any accident and if any worker need for treatment

they send him to the general hospital. When I started my training in PIMAPEN Company they

give some instruction in order to keep me safe during my work in the company:

1. I have to wear safety shoes.

2. Avoid of carrying any heavy parts.

3. Avoid of touching or operating any machines alone.

4. I must know the rules and regulations of the company.

5. Some operation need to wear a special clothes or using gloves.

17
5.3 Work Study

5.3.1 Productivity ratios

PIMAMEN Company does not have any critical issue which based on the materials, where the

record of the cost of the material is known and the materials are imported from turkey which

are the main source of the raw material.

For the overheads they are known at the end of any production of the product. Finally, the

labors cost are determined at the end of production for each operation for making the

productivity ratio at a minimal level.

5.3.2 Part Lists

WINDOWS
Handles
Hinges
Fasteners
PVC profile
Table 2 windows part list

DOORS
Door closure hook
Gasket
Latch
Liners
Table 3 doors part list

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5.3.3 Process flow chart for window assembling

The process chart for assembling the windows which shows the flow of material from the

warehouse to the finished goods. The figure below shows the process flow chart for windows

assembly.

Transport the PVC to warehouse

Hold it for a certain time

PVC transported for cutting.

Cutting

Drilling

Transport for binding

Binding

Inspection the part

19
Transport to assembling department

Stock for assembly

Part assembly

Transport for storage

Storage of final product

Figure 4 process chart for PVC window assembling

5.3.4 Process flow chart for door assembling

The process chart for assembling the doors which shows the flow of material from the

warehouse to the finished goods. The figure below shows the process flow chart for doors

assembly.

20
Transport the PVC to warehouse

Hold it for a certain time

PVC transported for cutting

Cutting

Drilling

Stock after drilling

Transport for binding

Binding by machine

Inspection the part

Stock for assembling

Assembly door parts

Transport for storage

Storage of finish goods

Figure 5 process chart for PVC door assembly

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5.3.5 Standard time calculation and purpose

The purposes of using standard time in the firm is in order to;

 Minimize the process time

 To eliminate unnecessary work

 Contribute payment of wages

 Control the labor cost

5.3.6 Unit cost determined

In general the unit costs are determined at the end by allocating all direct and indirect labor

cost in addition of overheads cost of the products, after that the unit cost is determined by cost

drivers that help in calculating the overhead cost for each product.

5.3.7 Unit cost calculation of windows produced

In order to calculate the unit cost of window, we need to determine all type of cost like

purchasing cost, transporting cost and the time spent on each unit to be produced. After that by

dividing the total cost by the number of units produced. For example they produces 4,000

windows. The accountant determines the spent 16,500$ on direct material, 7,500$ on direct

labor cost, 6,000$ of factory overhead costs.

16,500$ + 7,500$ + 6,000$ = 30,000$

30,000
=7.5 $/each.
4,000

22
5.3 Job evaluation and wage incentives

Job evaluation helped the company to promote worker, by categorized the workers on their

experiences and dedication to the work after that the company can promote and give some

extra for high evaluation scores. Unfortunately the PEMAPEN Company does not apply any

of job evaluation or offer to the workers any incentive which in my opinion is not good for the

company because it decrease the relation between the labor and the company. The incentive

system is very good it give the workers more motivation in order to increase the productivity

which as the end will be back with benefit for the organization.

5.4 Plant location and layout

There is many factors considered for the location of PIMAPEN Company which are close to

markets, which give an advantages to be recognize and easily be notified by customers. The

firm is located in the industrial zone of Famagusta city, also the firm is near to the general

hospital.

5.5.1 Layout of the plant

The layout of the facility is divided into many section in each section is prepared to suite its

function there is a department for management where is the offices are located there the general

manager, secretary and the accountant. On the production area the layout is divided according

to type of the operations there is a cutting department where all cutting machines are near to

each other. All the department has special needs which is available by the layout to serve its

functions.

23
5.5.2 Material handling equipment

The material handling equipment is different from department to another. Where there is a

trolleys are used to carry the materials that undergone to cutting department. For heavy

materials they are carried by forklift. Finally the finished goods are transported by van and

distribute to the customers.

5.6 Environmental management

PIMAPEN Company produce PVC doors and windows, the PVC part are imported from

Turkey so in Famagusta they do not produce any types of product they just apply some process

on this material which does not make any impact on the environment but still there is some

kind of pollutions such as;

1. Noise pollution which are came from the machines that are used in the firm.

2. Air pollution which are coming from some machines that release gases.

5.7 Waste

The firm can apply some methods in order to minimize these waste which cause harmful

impact on the environment. For the gases that are released from the firm it could use filtration

method that reduce the hazards and for the waste of plastic it should be carefully disposed.

The environmental management policies of PIMAPEN Company deal with issue carefully in

order to minimize the hazards impact for that the organization achieved that purpose by

consistent control of the operation inside the firm.

24
5.8 Energy

The company in general does not use any kind if renewable energy. My suggestion to director of

the firm to use Solar System as second source of energy by connect the drain of solar system to

the main electrical board for two reason:

1- Reduce the cost.

2- In case of electrical problems form the distribution panel they can Use it as second source

of energy.

5.9 water consumption

Water is one of the important elements in every factory or workshop. It’s for general utilization

like cleaning the firm or in baths and sometimes it’s used in specific applications like as mean

elements for producing the product or for cooling the tools of the machine.

One of the traditional sample ways of water consumption that used generally in every workshop

or factory of mass production like PIMAPEN is to attach a tank of water to the manual cutting

machine by using special pipes to return the used water to the machine again. For example In

CNC machines which is so sensitive and accurate machine they used pipes with filters to prevent

the tools from Impurities.

25
 CHAPTER 6

INFORMATION SYSTEMS

6.1 Data management

The information are passed through all departments, in order to have well-structured and

remain the communication function available which helps the firm for efficiency and

productivity in all departments. The flow of the information between departments gives a clue

to all departments and keep update it about all processes. In PIMAPEN Company the flow of

information apply through phones, emails and fax. When the marketing department receive an

order they send it for purchasing department to ensure that every material needed are available

then they send it to production department to start production, in the same time the accountant

update the data about this process, and prepare an invoice for the customer.

6.1.1 Information flow within the cutting department

The cutting department receive the parts from the warehouse with a route sheet that specified

the part list and give the dimensions to cut this parts according to the customer needs, after

operating this process the cutting department label this parts and send it to the next

department.

6.1.2 List of computer software used in each department

There is many software that are used inside the company like;

26
 1. Auto Cad: is a software used to design the products and give detail draw with full

information of dimensions it is used in production department.

2. Microsoft Excel: this software has many functions it is use in many departments.

3. Microsoft word: mostly it is used by the management department to write letters and

reports.

6.2 Cost accounting system

The cost accounting system or product costing system is used by firms to estimate the cost of

the products in order to calculate the profitability also make an analysis, inventory and for cost

control. In the company it is the responsibility of the accountant to calculate all these data and

prepare reports. The costs are calculated by calculating the direct materials and indirect

materials, the cost of both the direct and indirect labors, at the end by adding up all these costs

of both the direct and indirect materials we will find the cost.

Turkish lira (TL) is the currency that used in the company. The products are effected by

inflation according to different daily rate of exchange.

27
 CHAPTER 7

CONCLUSION

PIMAPEN Company is an assembling company that makes PVC doors and windows in very

good quality which no other firms in Cyprus has the same quality, I did a rotation inside the

firm which contained sections and departments. I got a lot of information from management

department they teach me some managerial skills in controlling, organizing, leading and

planning. During my training in the production department I got learned how to do a different

process and how produce a product and follow the instructions. Also through my training I

understand how the safety is very important aspect that we have to give it a priority. In addition

my daily contact with the labors I got some skills that allowed me to know how to deal with

them especially to respect them and to know their problems and how to solve these issues in

order to make their job easier and safer which lead to increase the productivity, this training

gave me a prove that everything I learned through my study through all the past years and all

theoretical study will be used and applied in the practical life as an industrial engineer.

28
 REFERENCES

1. http://www.pimapen.com.tr/

2. http://ie.emu.edu.tr/lec/lecturer.php?lec=INDUSTRIAL+TRAINING&course=ieng310/mane

300

3. http://www.accountingcoach.com/

4. http://www.pvc.org/en/p/the-pvc-production-process-explained

29
 APPENDIX

Figure 6 production area

30