Bir refrakter tuğla üretim sisteminin analizi ve tam zamanında bilgi akışının sağlanması
Analyzing a repractory brick production system and providing justin time information flow
- Tez No: 39894
- Danışmanlar: DOÇ.DR. SEMRA DURMUŞOĞLU
- Tez Türü: Yüksek Lisans
- Konular: Mühendislik Bilimleri, İşletme, Engineering Sciences, Business Administration
- Anahtar Kelimeler: Belirtilmemiş.
- Yıl: 1994
- Dil: Türkçe
- Üniversite: İstanbul Teknik Üniversitesi
- Enstitü: Fen Bilimleri Enstitüsü
- Ana Bilim Dalı: Belirtilmemiş.
- Bilim Dalı: Belirtilmemiş.
- Sayfa Sayısı: 115
Özet
ÖZET Bir kamu kuruluşu olan Kütahya Manyezit İşletmeleri Anonim Şirketi (KUMAŞ) 'nde performansın iyileştirilmesi ve verimliliğin artırılması için bir sistem analizi çalışması yapılmış ve sistem; üretim teknolojisi, stok durumları, organizasyon yapısı, form ve bilgi akışları yönünden incelenmiştir. Analizlerden elde edilen bilgilerin değerlendirilmesi sonucunda ; Yeni üretim teknolojilerinin kullanılması, ve sistemdeki kaynakların geliştirilmesi, organizasyon yapısının yenilenmesi, stokların azaltılması öngörülmüştür. Bunun yanında form akışlarında gereksiz yere yapılan ve zaman alan işlemlerin tasarrufu amacıyla; evrak işlemlerinde tam zamanında üretim felsefesi uygulanmış ve evraklar üzerinde süre açısından getireceği faydalar sunulmuştur. Tez giriş bölümü ile başlamakta, sistem analizi kavramlarının ve yöntemlerinin tanımlandığı ikinci bölümle devam etmektedir. Refrakter sanayi hakkında genel bilgiler üçüncü bölümü oluşturmaktadır. Dördüncü bölümde KUMAŞ için yapılan ve tezin uygulama kısmının ilk bölümünü oluşturan sistem analizi çalışması açıklanmış beşinci bölümde ise bu incelemelere getirilen çözüm ve öneriler yer almaktadır. Tez sonuçlar ve öneriler bölümü ile sona ermektedir. vııı
Özet (Çeviri)
SUMMARY ANALYZING A REPRACTORY BRICK PRODUCTION SYSTEM AND PROVIDING JUST IN TIME INFORMATION PLOW System and system analysis have been one of the most important and the most popular concepts in business literature within the last decade. A more general defination can be given for this concept is an integrated sets of procedures for basic business functions such as Sales Invoicing, Purchasing ect. System is also defined as a technique of problem solving, plannang, process, structure or methnodogy. Every firm has its own business system either it is in formal or informal structure. Expecially in small and yougn firms using many procedures is developed by time in informal ways, People who do the work know this procedures and applies them according to their experiences. These procedures work until the firm reaches to a point that one needs to make easier these activities and give them structural base. Because of the complexity of the activities and amount of the work increase, there will be some defeat in system which the firm applies. In contrast with the preceding approach, in formal structure, everbody knows what to do and standart way of business activities. By doing that the aim is to simplify the procedures and to put them in a formal and written structure to avoid arbitrary, Personel behavior. The other important aim is systems or procedure design is to make easier the process of decision making for those who are engaged with these activities and managers, and so that to use economically the company recourses. Because every activity which is not designed and defined results wasting the time. For this aim, at first, basic concept of systems analysis have been examined and explained in the second chapter. In the third chapter, the refractory industry has been introduced. The refractories industry utilizes various kinds of raw materials, natural and artificial, and in the course of brick making processes, relevant to pottery art is IXdisplayed. Although the fundamental purpose of the refractories industry is to raise profits to the maximum like other industries. The refractories industry compriser two production categories, conventional refractories and newly developed advanced refractories: conventional refractories are produced by blending natural raw materials, thereafter through molding, sintering and dressing, with the purpose of adding value to the products concerned. Advenced refractories are produced by utilizing the results of rnesearch activities. These two kinds of refractories are produced by identical technology and complement each other in the activities of enterprises. The research and development of refractories features a high percentage of success compared with other materials research. The reason is that refractories are characterized by multi-structural elements such as materials, pores, grains, ect., together with various conditions of manufacturing such as molding pressure firing temperatures, therefore a few improvments in the factors concerned bring a big result. However, research into refractories requires large amounts of money, due to the high temperature furnaces and repetitions of experiments using expensive artificaial materials. Most developed countries like Japanese and Israel allocate very large money for new technology and other research and development activities. Although Turkey has very big natural source and has a lot of plants producing refracteries, doesn't have a research and development department for advenced refractories. But Japanese and other developed countriy's refractories industry has made every effort to create top qualities utilizing raw materials imported from overseas, like the steel industry, and adding values by development of advanced technology. The high level of enthusiasm for R&D, and the consolidation of infrastructure supporting the performance of kilns and furnaces in the design, operation and construction fields of engineering have been made possible by the collaburation of the resources, human, natural sources, environment and R&D. xIn conclusion, the technology of refractories can be summarized by the following equation; Technology = Human Power x Enthusiasm x Environment magnesium is one of the most common elements found in the world. It appears in water (sea) and in mineral forms. The main applications are in order of process: glazing in the ceramic industry,, insulating material, fertiliser, cattle diary, pharmaceutical industry and refractory industry. The use of sintered magnesia is concentrated in the refractory industry, and there, only in a small part of the applications. Magnesite as a chemically basic material can only be used in processes which are also basic in order to avoid chemical reactions between product and refractory material, because the main purpose of the use of magnesite is to allow the furnaces to reach high temperatures and to resist to this temperatures. This kind of magnesite is called sintered (dead burnt) magnesite. In order to meet the growing demand for top quality raw magnesites with low Fe203, Si02 and CaO content. The change in stell making processer changed so drastically from Siemens Martin Furnaces to convertes Electric Arc furnaces that the refractory raw materials used at that time proved to be insufficient regarding their refractoriness. The change in technology in stellmaking required high purity refractory raw materials which are not available in Central Europe but were found in Turkey. The Turkish raw magnesite is cryptocry stall ine, very low in Fe2°3/ favorable c/s ratio (>1), low in total impurities. There are two types of row materials. 1. Natural raw magnesite 2. Synthetic raw magnesite. The magnesium carbonate, magnesite (MgC03), has a theoretical magnesia content of 47.6 %. It occurs in nature in two physical forms. Crystalline and cryptocrystalline. Synthtic magnesia can be obtained from seawater and brines under use of chemical process and high amounts of energy. Besides being very expensive in production. The quantities on the market are decreasing constantly due to increasing costs of production. In the forth section one of the biggest refracterios manifacturer, KUMAŞ (Kütahya Magnesite Works Coorperation) is being introduced. KÜMAŞ was founded in 1972 in order to produce the best quality magnesite ores of the world. After carrying the first stage investment, it began to produce dead burnt magnesite. Initially the dead burnt magnesite production capacity was 72.000 tons XIannually. Then the demand has increased farover the existing capacity. By the end of 1982, a series of additional investments, which aim to increase the production capacity of plant from 72.000 tons to 144.000 tons annualy, have been done. KÜMAŞ has the most suitable natural magnesite sources with a total reserve of 50 million tons in the region of Eskişehir-Kütahya-Bilecik where the best natural magnesite of the world occur. KÜMAŞ obtain all its raw material from these open pit area by putting out to contract these areas. Kütahya magnesite works cooperation can be introduced as follow; The raw ores, transported from the mines to sinter magnesite plant by trucks, are processed in the Ore Beneficiation Section. In this unit, the raw ore is seperated from the gangue mineras and the size reduction of the raw ore is done by means of crushing, intermediate-stocking, washing, screening and hand picking operations. At the same time, the other fraction of the raw ore is seperated from the liberated gangue mineral by magnetic seperation devices. Thus certain fractions, enriched by decreasing the Si02 and other gangue contents, are stocked in the concentrat storage area. Annually 335.000 tons of concentrate can be obtained in the Ore Beneficiation unit with full capacity. The concentrate coming from the Beneficiation unit is sintered in the two rotary kilns of 72.000 tons per year capacity each. These kilns are superior and adventageous than the vertical kilns, Because they can burn the material with wider range of size fractions. These rotary kilns, having the legnth of 110 m and the diameter of 3.1 m. They are lined with suitable refractories and fuel oil fired. The sintered temperature is above 1900 C, the products of rotary kilns are stocked after passing through the rotary kilns coolers sintered magnesite is delivered either directly or after additinoal crushing, grinding and screening according to the requirement of the customers. The basic refractory Bricks plant which was contructed near the existing dead burning plant was completed in 1989. This plant produces 20.000 tons of fired bricks 7.500 tons of Pitch bonded bricks 6.500 tons of chemically bonded bricks 10.000 tons of Mac-Carbon bricks and 3 0.000 tons of monolithics mortars. All these products is produced by using its own dead burnt magnesite. The refroctory bricks plant consists of XIIthese logical departmants ; preparation of raw materials and additives, Dosing, Mixing, Shaping, Drying, Tempering, Firing, Cooling, Sheet Encasing, Packing and material storehouse. In the late of the fourth chapter. The structure of the firm have been examined and current applications of bubiness systems determined by a series of conversations with the responsible people. Besides to these conversations related activities have been observed on the job. As a result all the important business activities and forms flow have been determined on the which are in the responsibility of all the middle level managers. In the chapter four, the paper flow between the vice managers of KÜMAŞ was searched and found that there are papers or reports flowing from one service to another daily and monthly. Expecially monthly papers take much time to prepare, because of being a lot. All the papers and reports can be seen in sketch in chapter four. In the chapter five the solutions and suggestions after systems analize, are being given. These solution and suggestion can be catogorized in four group. 1. Production Technology : Refractory industry and refractories raw material need working with high technology. In order to reach highest quality standarts, it is necessary to invest millions of Dollars in R&D and technological development. Without this it is impossible to competite with developed country in this industry. In this area it is not important to be a largest producer, bout to be the best producer. KÜMAŞ has plenty of raw material sources but. It should allocated money for R&D activities and apply new technologies to get good qualility product. 2. Stock Level : The reduction of steel and iron production lately has caused the reduction of refracteries too. And chenese and, Harth Korean dead burnt magnesite have been sold with quite low prices in the world market. So KÜMAŞ couldn't balance the Demand-Submit. In 1992 the stock level of KÜMAŞ products were 61.68 tons of brick, 145.163 tons of row material, 16.508 tons of Konsantrated row material, 15.046 tons of dead burnt magnesite. xm3. Organizational Structure : Now, there are too many uneaployment and unnecessary position in KÜMAŞ's organization. A lot of manager and chief's cadre are empty. So, the organizational structure of firm has been rearrenged. The unnecessary manager and chiefs' cadre are removed. 4. Contemporary manufacturing approach and methodology has been successfully applied to simplify administrative work. Work flow analysis and just in time principles in a paperwork operation save millions of dollars. So we examined the KÜMAŞ's paper flow for all the level of administration and found that there is unnecessary repetition in papers writting. The papers are caused to wait intentionally or unintentionally. And three examples are given for of paper work in KÜMAŞ. We also suggest some solutions for possibilities of reduction of paper work too. xiv
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