NAKNAKSANSAN NAKSAN is holding companyNAKSAN is holding company

that produce and market plastic that produce and market plastic packagepackage

Address:1.Organize Sanayi Bölgesi 18,Cadde NO 13

27120 Gaziantep, Türkiyephone: (+90 342) 337 37 37 Fax: (+90 342) 337 13 20

(+90 342) 337 26 20Web: www.naksan.com.trE-mail: info@naksan.com.tr

HISTORY OF NAKSAN

The Nakiboglu family, entered into trade in 1940's with a store founded to

sell "almost everything" from small items of hardware to houseware as todays

modern department stores. Selling PE film, Greenhouse Covers and plastic bags in

the same store during 1960's, when the plastic sector began to widen in Turkey

also, took the family in this field of industry where they focused all their attention on

and investments in this sector

The family started a wide marketing and distribution facility ,which brought

increasing damand towards the plastic products and thus founded NAKSAN in

1979,with extrusions and one bag _making machine .

NAKSAN is now the leader company of the group , which has been growing

consistently and has soon become one of the largest 500 Turkish industrial

organization since 1995.Since then with its successful management and innovative

conception ,NAKSAN today with a capacity of 100,000 tons per annum and more

than 1000 employees and its strong financial structure has achieved to become a

world -wid known company exporting to over 40 countries.

Managers and more than 1000 employees of Naksan have shared the

responsibilities and team spirit.We have aimed to present product s and services of

iniversal quality and high standards and thus to become the symbol of reliability ,

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consistency and esteem for our customers, vendors and for all the organizations we

cooperate with.

We have been trying to implement and adopt the recent developments in the global

market with a good timing .Until now we have not avoided any sacrifice for

development .

From the very first day we have paid attention to act on listening to the needs of our

customers .No matter the size of the customers we have been trying to provide

the same perception of their needs for quality and services .

In the long run the contributions of our customer oriented structure focusing on

values of people , has shown us the benefits to become much more committed to

this concept.

With its professional and creative staff , NAKSAN can provide all pre-printing

services such as photo shooting ,graphical or photographic designs, film

posing ,chromaline and plate engraving within its reproduction and graphics

department equipped with latest technology like, DUPONT, AGFA , APPLE -

MACINTOSH ART -PRO, NEXUS systems.Having the latest technologies in this

field increases our flexibility and capabilities .

Naksan has included three different company firms which are NAKSAN PLASTİC

INCORPORATED COMPANY, NAKSAN CHEMİSTRY INCORPORATED

COMPANY and NAKSAN COLLECTİF COORPORATION .All of them have

established total 100,000 m2 area .20,000 m2 of an area is opening and 80,000 m2

of an area is closing .

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In 2004,according to the İstanbul Industry Associations has given istatistical

knowledge ,Naksan Plastics & Commerce has been 288.row between industrial

firms with having 109.738.237.000 TL ~74.000.000 USD negotiable .

PURPOSE AND SCOPE OF THE ENGINEERING PRACTICE

The aim of summer practice is to maket he student get familiar with the

organization in which he/she is kikely to take part in after graduation .Particularly ME

399 Summer Practice fort he junior students sends the to be mechanical engineer

into the kitchen where materils are melted , cut , formed and prepared for service.

Engineering is largely problem solving and mechanical engineering is no

exception. Five steps in problem solving are maybe defining the problem , analysing ,

modelling , synthetizing and developing a solution. Last four are entirely used - even

with simplifications – during school work but the first one simply belongs to the

teachers or the authors of the books. Factory work introduces the engineering

student to the real world and the actual problems which engineers usually encounter

with. It forces him/her to define the problem , prepare a real-life-solution and execute

it. With this property , it is rather attempt to get used to use the practical and applied

aspects of mechanical engineering in accordance with the theoretical background

acquired at school. From a point of view it can be identified as a reinforcement and

improvement of the previously completed coursework , especially ME101, ME 201 ,

ME 203 and ME 223 , and a heating-up for the sophomore year courses all of which

actually define the engineering study. It is also a means to get familiar with the

human relations - from bottom to top – which is the key to manage people.Lastly , as

a rule , summer practise obviously clarifies the doubts which are sure to appear in

mind and first of which is : “ What does an engineer actually do?” . And maybe

determines the field and the kind of business the student will want to make further

study on.

With these objectives , ME 399 concentrates on the factory as a production

centre. For a clear understanding of the fundementals of manufacturing , it leaves

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aside the administrative and organizational units until another summer practise and

focuses on the production units.

In this report the units in which actual manufacturing is carried on . A brief

description of these units are given and the functions are studied.

Machines ,machine tools and their functions in the factory are explained along with

some of the products they manufacture.

PRODUCTION METHODS

EXTRUSION

Blown and Cast extrusion of PE and PP film ,are the first stage of our production

where the polymer is melted and then cooled to become a film .At this stage ,the

polymer is in granules is given its basic physical

characteristics(Thermal ,Optical,Mechnical ,Size ,Colour) with the right formula with

respect to the requirements of the product it is meant to be .The extrusion is made

on mono or coex ,(up to 7 layers )extruders with the required sizes (width from 2

cm to 12 meters ,thickness from 6 microns to 2000 microns ).

NAKSAN ,which employes a vast range of extrusion machines , has a capacity of

350 tons / day,

PRINTING

NAKSAN, employs also the latest flexo printing machines 8 coloured central

impression ASTRAFLEX and NOVOFLEX of Germany's world wide famous

Windmöller & Hölscher. The flexo printing technique has developed very well and

has reached to the quality of offset and tiffdruck printing technique in terms of visual

quality. Moreover the minimized set up time of the printing units is giving us the

advantage of being able to execute our orders sooner and therefore sooner.

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LAMINATON

Lamination is another method for producing a material with required structure by

forming out layered film from films of different features. In order to produce films with

visual protection, strong permeability, printed or non-printed Aluminum, Polyethylene,

BOPP and CPP are laminated into each other. At this stage, NAKSAN can carry out

chemical lamination by glue with two components solventless that is in accordance

with the food regulation. In addition to the advantage of PE and CPP extrusion lines,

lamination serves to combine PE/PE PACKAGING FILMS FOR DETERGENTS and

BOPP/CPP Pasta packages.

CONVERTING

In this section, film rolls are processed in the slitting and bag making units that have

the latest technology, and becomes hundreds of final products such as diaper bags,

bread bags, freezer bags, garbage bags, Soft Loop Handle, Reinforced Patch Handle

and Vest Style Carrier bags. Our products, which are packed after this process, are

transferred to our product warehouse to be stocked ready for shipment.

REPRODUCTION

Production in high standards requires

continuous control and R&D studies.

For this reason NAKSAN, has

adopted continuous development and

productivity as its principle. NAKSAN

as one of the market leader in its field has not avoided any feasible investment

required and expected with respect to this principle. Today, with a team of expert

engineers and laboratory staff and with its testing and experiment instruments of

advanced technology, quality is not just a word in NAKSAN.

EXPORT

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The company , which has gained an important market share and accumulation of

knowledge in the local market , has increased its attention foreign markets.With

the joining of 3rd generation family members in the management , the company

started concentrating on exports and focusing on world markets . The company

has entered into a striking performance process with its young and dynamic staff,

especially between 1999 and 2002 ,export increased by 1800%..

FINANCIAL STRUCTURE

Despite the three big economical crises which have taken place in Turkey and

narrowing local and foreign markets NAKSAN has achieved to preserve its healthy

growth and financial stability by moving to production of speciality products where

It increased its market share both within the country and in foreign countries.

MISSIONS & RESPONSIBILITIES OF NAKSAN ORGANIZATION

The Management Committee Chief: controls and arrangment all activity of

company.guide the selling ,finance ,accounting activities of organization .

The Management Committee Chief Assistant :responsible all developments of

personnal and production activities .

The Manager of Building and Real Estate : to pay attention on buildig activities of

company and control it

The Manager of Project and Investment : manage the activity about future project

and investment that company has long time

The Manger of Selling : provide production that well known by the inside and

outside market sector .

The Manager ofAccounting : follows all customer's current bill , bank bill ,monetary

activities ..

The Manager of Finance : control and follow to be coming and going money

order .responsibility all foreign currency ,tax revenue ,..

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The Manager of Marketting: responsible of marketing activities and coming

orders ,seasonal orders which selling increase or decrease range

The Manager of Factory : plans administrating production flowing ,is interested in

all step from ordered stage to forward to the customer .

The Manager of Press-Cast: plans production flow of the raw material that order

comes until goods goes to the customer ,markets .

The Manager of Production Planning : persuits all production flowing on the raw

material .Prevents the delay of customer order's.

The Manager of Human Resources: organize all function about

human ,worker ,managarial worker and technical staff member in factory

The Manager of Personnal: responsible all activity about worker.ie irregular

attendance ,their salary , advance salary…

The Superıor of Managerial:implements the all judgement and project relevent in

factor .

The Manager of Quality Insurance _Enterprise : responsible carrying out

occupation connection with qulity insurance on product that is produced .provide the

much yield .

The Manager of Buying: responsible of busines occupation relevant on buying.

The Manager of Information and Transaction : search the new information

tecknology that provide to factory facility in working .

The Manager of Foreign Exchange : responsible all activity about export &import in

factory .

PRODUCTION SYSTEM

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Machines: as a fundamantal inputs

*the machines mark and the number of machines informations are given

appendix 1

Power: as a fundamental inputs.

Labour: as a fundamental inputs.Naksan have had almost 1500 worker .1200

of this number have worked in pruduction area. Remaning of worker heve

worked in managerial office.

Palatte

Internal Packaging

Sack

Thread

Label or sticker

External packaging

Nylon with balloon

Parcel band

Bobbin : films are covered on the bobbin

Paint : pruduction or goods are painted any wanted colours

Box : it makes easy to transporation

Strech film

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Many members makes much profit in production system .Hence , the Naksan

go towards this member implementation. This factors are participated in Naksan

Qualıty Values;

Here Qualty Values :

1-Additivity

2- Solition focus

3- Confidence

4-Difference

5-Responsibility

The all production planning that is in Naksan is given below .

Input : required process planning for production .

Source : machine , raw material ,some methods an documantation .

Output: iplements the process planning as right and productivity while goods

are produced.

Period of measurement and control : control the all processes step by step and

continous improve .

Goal: constitude standard .

Reference documantation . Activity follow programmes (FTP)

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There are many important factor when the firm decide that when ,what, how

much it is produced .

These are;

Time of the order that is produced.

Amount of the order that is wanted by customer.

Time of the orders that are immediate goods must be produced quickly

Properties of the orders that are wanted by customer and must be

known how much time are required this process.

Activity Follow programmes research and record all depertmant activity detail

step by step.All activity times and production times are showed by the

programmes.

There are many documantation that are used the production planning and

production activities between the worker and engineerings.These are;

Attraction command documents

Press comand documents

Cutting command documents

The knowledge on the customer's orders is transferred this documents

paper.

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When the time of any customer 's order are taken formens take this

document from production planning qualified and transmit to the machines

's workers and production is begined

*attraction and press document is added to appendix 2

The NAKSAN 's capacity is limited that with many factors are very

important for company.These are ;

Customer's Demand : It is very important that the volume of the customer

demand can be forcasted on break even points according to the internal

and external market .

Condition of Market : Packaging ' cost and capacity situation that any

amounts are required .

Competition Environment : Volume of the selling that the competition firms

have .

Firm's Capital Situation : This firms ' production capacity is bounded it's

capitals. Needs of the plastic of the external and internal market is

independent .So it produces as it's capital.

Generally ; Naksan Plastic have worked whole capacity .But capacity is to

become rough sometimes

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Basically

Between June - january - February , it works 80% of capacity

Between january -April- May , it works 90-100% of capacity .

The decrease of the selling of the shrink in winter because of the decrease

of the drinking and decrease of the tent .

Naksan Plastic produced approximately 55 000 tone in 2002.Then , in

2003 ,it is production rate is increased with 20% .So it reachs 65 000

tone .it is forcasted that will be 75 000 tone in 2004 .

Price of the production and amount of the production have increased for

three years . by 20% ..Hence the new machines and much raw material are

bought .

Rought of the petroleum price in the world market efficient the firm's

decision .

Genarally ;some of the raw material is taken from PETKİM.So the firm's

decides price of plastic according to the PETKİM raw material' s price .

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attraction and press document is added to appendix 2

DATA PROCESSİNG CENTER

Used software , the properties of software and used area in NAKSAN .

ACTIVITY FOLLOW PROGRAMMES : for all process planning and

control from taking any customer 's order s to transformation it .

Briefly; many process are done by this programmes (AFP)

1-System Management

2-Production Planning

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3-Production

4-Envanter Planing

5-Transmit

6-Quality Control

UNITY: It is an assistant of production planning ..It provides

information that gives about how much raw naterial is used , when

this process is finished and goes ,also gives information about price

of goods.

MS OFFICE: It provides istatistical control that many process are

done by the firm's worker and personnal and is used internal

comminication and share general documantation .

GOUGE PROFILE ANALYSER :measure the micron distribution of

films.

SERIES IX:is used in Quality Control works

LINK : controls personnal exit and entrance to the firm work

time .Also it evaluation of the personnal' performance

USED COMPUTER EQUIPMENT IN NAKSAN PLASTIC

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As server , 15 computer is used in NAKSAN.Every server has 200 GB HD and

4GB RAM .

Al computer have a connection with Internet .The use of some computer isn't

permission by the manager .Only it is active internal comminication Data

Processing Center responsible all equipment related to computer and set

up ,establish..

RAW MATERIALS

Raw materials are used that are called AYPE ,LDPE , LLDPE, HDPE , Polyethylen

(PE) , Polypropylene (PP) ,cyristal clear polystyrene (PS) ,High Impact

Polystyrene (HIPS). e.t.c in NAKSAN . So plastics are made of this materials .

Plastics are organic ,man -made materials .The components

that determine their technological and physical behaviour are

polymers, which are characterized by long chains of repated ''

monomeric'' units.Polymers used in plastics were originally

obtained by the chemical modification of organic natural

products but are nowdays mainly produced by the polymerization of relatively

simple compounds (monomer) derived from the petrochemical industry.

Plastic is a material that contains as an essential ingredient one or more organic

polymeric substances of hihg molecular weight . It is solid in its finished state and ,

at some stage in its manufacture or processing into finished articles can be

schaped by flow.

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Many plastics are processed in a highly viscous state at high temperature and

pressures .Terms such as plastics .matieres plastiques ,plaste and plastmass have

been based on the absolote definition of thet kind of flow as '' plastic '' flow .

Synthetic fibers and textile s ,natural and synthetic rubbers and adhesives and

points ,which may in some cases accord with the abose definition , are not

considered plastics . However , there are no sharp boundaries between rubbers

and plastics- elostomers ,and many bases used for adhesives,

point ,fibers ,chipboards ,e.t.c are also used for plastics in molded form .

This raw materials are bought from PETKİM ,VATAN CHEMISTRY , NAKPA in

Turkey . However , Naksan have imported big part of the raw materials that are

imported from Soudi Arabic ,Russian ,Italy ,Israel,Azerbeycan .

For this reason , importation provides lower cost and high quality and much

verification of raw material in external country .

There are additivity sub- material that is used for production of plastic.

-UV( Ultraviole)

-IP( Infrared)

-ANTIFOG

-EVA (Ethylvinilasetat)

These sub-material provide an increase power and ressistance of the plastics .

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Naksan Plastic had import rate that is 50 000 000 USD. Only had export rate

that is 18 000 000 USD in 2003 . Naksan have had much profit that is an

important because of increase export rate for 2 years .

PRODUCTION

Naksan Plastic Industrial and Commerce in plastic sector have maintained plastic

production .Naksan produces many different plastic goods .

-Industrial Shrink Films

-Industrial Shrink Hoods

-Heavy Duty Bags

-Sacks

-Bags

-Nylon Bag

PRINTED OR UNPRINTED

- Sacks ,Bags

-Freezer Bags

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-Garbage Bags

-Bread Bags

-Lamination Films

-Printing Films

-Surface Protection Films

-Greeenhouse Films

-Mulch Films

-Agricultural Films

-Irrıgation Pipes

Naksan carrier bags are one of the most effective promotional products . Academic

research shows that one carrier bag reaches around 400 visual contacts.

High Environmental Awareness: Naksan carrier bags keep their promise -even

after repated use after repeated use as carrier bags 57% of household use

Naksan carrier bags to store valuables or collect their refuse .Naksan carrier bags

are made of environmentally friendly polyethylene and therefore recyclable free

of toxic and heavy metal materials ,are neutral in water and burn without harmful

resides.

Versatility: Layout of sizes , styles and print of carrier bags are almost

unlimited .Top quality print of up to 8 colors with glass or mat links ,bags with loop

or punched out handle .let us know your requirements.

Confidence : Your customers will frequently ask for Naksan carrier bags as they

offer the following major advantage ;

-High load capacity

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-Food approved

-Practical use

-Weather ressistant

-Best Print quality

Naksan carrier bags are the number one Because they are produced to a high

production level under constant quality control.

QUALITY CONTROL SYSTEM

Naksan Plastic Industrial and Commerce Quality Policy .

-Naksan services the best quality to customers and personnel feel proud of with

Naksan

-The life philosopy of the Naksan is continous

improve, continous development

-Every person in Naksan works to this policy as

active

-Service the best quality , the best service with lower cost and price .Thus,

Naksan is the first in the sector competition .

-The mean of policy is customer 's , worker's pleasure and to have reached much

profit .

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-The important of policy is environmental protection and cleaning ,

-The important point of policy is honsty against worker's personnel, and customers

-The firms wants to reach high technology and provide investigation for new

things and implementation . new development

Generally;

1-Quality control : to becoming raw material are controlled for appearance ,

packaging , quantity , marking .Related to process planning and standardized

Are controlled then equipment are defined according to the reason and they set

to free or refused .

2-Proses Quality Control:Proses Quality control is done whenthey are produced.If the

produced goods have problem,It goes wastage that mean is transformation and goes

to produce.

3-Exit Quality Control:When the finishing goods and transfering good to the

custamer,the part of finishing good are taking and implement the end control

processing.This activity is reperted by AFP .Transmit of the goods isn't permitted

without Quality Control permition document.

To Be Done Test in Quality Control

1-Thickness of Films Test: Test is a sensivity and electronic machine.It gıves micron

change grafic.

2-Thermal Stick Test :gives information the film at how temperature does stick.

For example; AYPE 115-1250C

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YYPE more 1250C

3-Etüv Test :is done for shring film and Shrink hoods .It measure elognation rate of

the plastic .

4-Tensile Compression Test:This test is done bobbin that how much is comperessed.

5-Dort-Drop Test: measure the resigtere of the film .

6-Hose Test :Measure the physical appearance of the film.

7-MFI Viscosity Test (fluidty):At defined a temperature is giving and measured the

amount of plastic that goes over 10 seconds

8-Cof Test (fiction):It measure slipper iness of the plastic .

9-Kerone Test :mease the quality of Printed Goods.

10-Briliance or Brigtness Test:

11-Opak Test :

Naksan have had a TSE EN ISO 9000 -2001 certificate . not only management of

organization but also production planning processes are arised with ISO 9000 -

2001 certificated .If there are no standarts, we would soon notice .Standarts

enormous contribution to most aspects of our lives - altough contribution is

invisible .It is when there is an absence of start importance is brought home .

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ISO 9000 concerned with '' quality mangment '' . This mean organization does to

enhance customer satisfication by meeting applicable regulatory requirements

and continually to improve in this regard.

STOCK

There are two types of production in Naksan Plastic.

1- Production for order .

2- Production for stock

Naksan Plastic have had private order that is given by customer 's for 2-3 years .

If it is possible that the customer can want to current order after any time . So the

firm forcasted and stock the much amount of different goods in stocks area .For

standardised order is given by customer production begins and stocks .For

example ; Nylon bags and sacks.

The best and guarantee way of decide for stock that how much ,what , when will

be produced .So they will forcasted the amount of stock goods acoording to the

volume of past selling to the customer .The Long Term Production Planning is

controlled by AFP(ACTİVİTY FOLLOW PROGRAMMES).

All direct raw material , sub-material , the finishing goods or orders are kept in stock

ares . These are ;

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-Bobbin Stock Area

-Box Stock

-Packaging Stock

-Painting Stock

-Contribution Stock

-Safety Stock Area

-Ballon Rolle Stock

-Naksan Standardised Stock

-Standardised Stock

Victoria ,Polyolast,Paziplost for firm

-Expert Private Stock for bags

-Evaluation Stock

-Waiting Stock Return Stock

CONCLUSION As declared in the introduction part of the report, the aim of the summer practice is to

improve the theoretical & practical knowledge on mechanical engineering study. And the

scope of the ME 399 Summer Practice is the production methods. The summer practice

for junior year students depends on the analysis of production techniques and application

of school knowledge in industry.

In summer practice, I think I had useful practices on production techniques and I see

what is going on in the factory about production. And I think I got knowledge about

application of theory in practice. I think my summer practice was corresponding with the

aim of the summer practice and I worked on the scope of the summer practice.

In the summer practice I had chance to see stages of production and what is the

role that Mechanical Engineers play in production. I saw that the most important role

belongs to Mechanical Engineers. In every stage, planning of production, adjusting the

machines, arranging the operations ad preparing the operation page that means almost

everything in production, determining the machine tools, time etude of operations,

jobshop investments are the duties of the office engineers. Also Mechanical Engineers

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have great duties in jobshop. The continuity and quality of the production is the

responsibility of Mechanical Engineers in the jobshop. The use of machine tools, the

quality of products, to follow the workers, to determine why the productions faulty if there

is an error, are classified in the duties of jobshop engineers.

Mechanical Engineers have much duty also in assembly. Besides these Mechanical

Engineers have great duties in quality control. Most of the stages of production control are

carried out by Mechanical Engineers.

Mechanical Engineers have some duties on mechanical maintenance. The

maintenance of machines, to repair when there’s an error at machines, to establish and to

move the machines are the duties of Mechanical Engineers at the mechanical

maintenance. Mechanical Engineers have also duties at directory, the finance and

commercial departments of the company.

Also in summer practice I had chance to see the production and apply my

knowledge to practice. In the factory I saw all the stages of production. It was actually

educational. I saw what is going on in production. What is the production sequence?

What are the operations after a half-product or a raw material came to factory? How a

part is machined? How the controls are done? I found answers to such questions.

At all I see what is going on in a factory. I believe that the only practice area for

a Mechanical Engineering student, is a factory. I think that I have applied my

theoretical knowledge on production and drawing, to practice. Moreover I can say

that I saw how engineers use their knowledge in production.

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