CHAPTER 1

INTRODUCTION

First, so thankful and appreciates to the Faculty of industrial engineering,

Eastern Mediterranean university had endeavored for us the opportunity to further our

skills in the industrial training section. Undoubtedly, I had gained some basics of working

experience as well as social skills during my first training. I faced what I learned in

classes, it was a big opportunity to observe 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.One of the most courses that involved in my training is Ergonomics . It makes the

factory looks different form all the sides . The way how time managed and how humans

energy is consumed strategically in order to minimize the cost and maximize the profit.

1
 CHAPTER 2

DATA ABOUT THE COMPANY

2.1 Title

Ciddi Mutfak Ltd.

2.2 Address And Web Homepage

Web Home page: http://www.ciddimutfak.com

Lefkoşa/ Alayköy Industrial Zone 4. St, TRNC.

Tel: 0392 235 8088

Fax: 0392 235 8089

E-mail: info@ciddimutfak.com

2.3 Brief History of the Firm

Ciddi Mutfak firm is located in Alayköy / Lefkoşa industrial , The company has been

established by Hussein Ciddi in K.K.T.C since 2000 it was started with the name the

family name since it is family business " Ciddi Mutfak ". It has been in the markets

since 2000, when it was established.

2
2.4 Employment Data

There are 12 workers who are currently working at the factory of the company. There

are two engineers employed in the facility and one industrial engineer.

2.5 Approximate Annual Sales, Market Share, Competitors

The company is focusing in two main products wardrobe and kitchens. The company

controls 40% of the market share with two main competitors in the industry market as

Prestij and Ozok Mobilya , due to its annual sales which is approximately 4.76 million

Turkish lira and it’s trying to increase its products each year to control the market.

2.6 The Main Products Of the Company and the Raw Materials Used

The main product of the firm are:

 kitchen.

 wardrobe.

 doors and normal houses.

 Kitchen Cabinets.

 Bathroom Cabinets.

The raw materials that are used:

o Chipboards: the sizes of the chipboards are: 366 cm* 183 cm, thickness
8mm.

o Medium Density Fiberboard: 240 cm* 120 cm or 280 cm* 110cm

o Steel Sheets

o Wood

3
 CHAPTER2

GENERAL PRINCIPLES OF MANAGEMENT AND

ORGANIZATION

The organizational chart of the company is shown in the figure 1, we can see that

Huseyin Ciddi who is the owner of the company is directing the organization . The

organization has different departments, where in each department there is one manager

who is responsible for directing the different activities. In this firm the production

department is the major department in the organization, which consists of the production

floor that contained different workstations that work together in order to produce the

desired products.

There are two main types of products in the firm, which are kitchens and wardrobes, and

they are constructed according to customer’s orders. The workshops and the departments

of the company are designed directly to integrate and communicating in order to

accomplish the organizational goals. In order to assure the quality of the products and

maintain the reputation of the company, in the company there is a quality control

supervisor who is responsible to ensure the production complying with the company

standards and quality expected along each production phase according to customer

4
demands. In the company each unit are connected together and under vision of the

administrative in order to make sure that every job is going on schedule.

Most businesses have separate departments for sales and production. Each department

depends on the other. For example, the sales department might be planning an

aggressive sales campaign based on seasonal merchandise. However, before it can

aggressively advertise the campaign, it needs to be sure the production department has

the capability to produce enough products to meet the anticipated demand.

There is a small problem, which I noticed that the raw material is not order in use and

they are not labeled, so when they are getting the raw material. They are wasting time to

get the specific one.

3.1 Organization Chart of the Company

Figure 1: Organization chart

5
3.2 Organization of the Company
ASSEMBLLY

Organization chart of Cidde Mutfak Company shows the structure of the company and

the relationships among the departments, and as we can see the CEO directing all the

disarmaments in order to control and manage all the departments to achieve the

company goal. The organization has different departments, which in each department

there is one manager who is responsible for directing the different activities. In this firm

the production department is the major department in the organization, which consists of

the production floor that contained different workstations that work together in order to

produce the desired products.

3.2.1 Other Engineers in the Firm

Table 1 Firm Engineer

Name of the Engineer Position Title Responsibility

Bora Dellaloglu General Project Manager Plant management and

manger
Controlling by planning

production amounts and

scheduling orders

Aycan Ogural Production Industrial Engineer Technical Requirement

planner
Planning

6
3.2.2 List of Engineers in the Firm other IEs and Students Trainer

Table 2 Interns of the Company

Name of the Student University Name Topics they mainly focus
Departments

Production

Environment

Production Processes
Zahir Almhayni Eastern Mediterranean Industrial
Plant Location and
University Engineering
Layout

Data Management

Production capacity

Ali Faragy development

Eastern Mediterranean Manufacturing Mechanical

University Engineering Engineering

Maintenance

3.3 Professional Ethics

The company has not published a code of ethics till now, so I think publishing a code

of ethics will help the employees and workers to understand and know their rights and

take their responsibility. The company should allow the workers to report for anything

they think it is wrong and establish a report policy to increase the trust between the

workers and it will be good for both sides the workers and the company.

7
 CHAPTER 4

MANUFACTURIN SYSTEMS

4.1 Manufacturing Engineering

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

joining, bending, grinding and drilling.

The flow process chart of a wooden table produced along a production line is shown as

below:

4.1.1- Transport the wood to the panel sewing machine.

4.1.2 -Cutting the wood with panel machine using cutting machine

4.1.3-Transport the wood to the edge bending machine'

4.1.4-Edge bending

4.1.5 -Transport to the CNC machine and we can see the CNC machine

8
 4.1.6-Drilling the holes

4.1.7 -Transport to the assembling unit

4.1.8-Assembly and fixing the parts together

4.1.9-Inspection

4.1.10 -Transport to storage

4.1.11Storage

4.2 Productivity

Under the large competition from the companies and the evolution of the recent progress

in all areas and sectors. Every company aims to increase the productivity system to get

rid of waste and that by producing only required quantities, at the right time and the best

quality without influenced the product cost. The waste is an over cost of the product

without giving any addition to it. Using new and high technically machines to the facilitate

will make the work easier for the workers in the factory so they increased productivity in

less time with good quality. They are tables using wood, which considered as a raw

9
 Output
material to calculate the productivity we use the formula ( ¿ ) when the wood
Input ¿

purchased in a year is 90 wood sheet and produced 6000 tables, according to the data the

productivity is 66.6 small table\sheet.

4.3 Machines Used in Production

4.3.1 Drilling Machine

A drilling machine is a tool used for drilling holes in various types of wood, plastic and

metal. The bench drill is bolted down for safe drilling of such materials. The pillar drill

is a larger version of the bench drill and has a long column enabling it to stand on the

floor functions the same as the bench drill but can drill larger pieces of material. [2]

Figure 2 Drilling machine

4.3.2 Bending Machine

10
This machine is designed for use in a high production application and high cycle

application. Hydraulic bending machine the gears or gear or chain conveyor or

mechanical movement does not have wheels or electric breaks so they do not required a

lot of maintenance . with infinite speed settings , safely and efficiently using.

11
 Figure 3: Bending Machine

CHAPTER 5

ANALYSIS OF PRODUCTION SYSTEMS

5.1 Production Environment

The company has a strategy with has no inventory or storage. They are producing

based on order Build-to-order manufacturing is used by companies to create products to

the exact specifications requested by a customer. There are advantages and

disadvantages to this strategy of manufacturing. On the positive side, the products are

tailored to a customer's needs which ensures customer satisfaction and companies do not

have to worry about having inventory that does not sell. On the negative side, businesses

12
have a low supply of ready-to-sell products and customers have to wait longer to obtain

their customized products.

The build-to-order strategy eliminates unnecessary inventory from an employer's

stockroom or shelves. Instead of an employer sitting on numerous products that don't

sell, the build-to-order strategy only sells inventory specifically ordered by a customer.

The employer does not have to worry about losing money due to unsold items. It also

gives employers the ability to offer new customizations and products without having to

worry about selling old inventory. [3]

5.2 Safety

5.2.1 Hazards associated with production

The nature of the factories that they have some common hazards such

 Noise and heat: there is a lot of machines which has make a lot of nosy

sounds and bring heat during the production process which can affect the

hearing of the workers and increase the temperature while most of the

factories don’t have cooling system.

 Hazards related to the drilling machine that there is Possibility of sharp,

extremely hot steel ‘swarf’, flying at high speed in the direction of the

operator.

13
  There are safety gloves called AB5.They can withstand nail, axes, and even

blades for use in industrial settings like mining ,forestry and fishsing.They

are made with nitrile cotton , and one other key martial.

5.2.2 Occupational Accident

Workers at the firm are well trained to perform specific tasks each in his field. They

are also trained to deal with simple accidents that occur during production. First aid

boxes are available but if it is a serious situation the worker can directly transported to

the hospital which is close to the factory.

5.2.3 Safety management in the organization

There are many duties and responsibilities must be in the safety management to avoid

any accident during the production. The company have a medical report for all the

workers condition before they start to work to know , if they have an allergic or any

contagious disease to take it under consideration. As a trainer in their company the give

me some instruction in order to keep me safe during my work in the company such as

wearing safety shoes and to avoid touching or operating any machines alone.

5.3 Work Study

5.3.1 Productivity ratios

Ciddi Mutfak 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 helps to improve the productivity of the martial.

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

are determined at the end of production for each operation ratio.

14
5.3.2 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.

 Part lists : Wood , PVC , Glass , Aluminum , plastic and joints

Transport the PVC to warehouse

Hold it for a certain time PVC transported for cutting. Cutting

Drilling

Transport for binding

Binding

Inspection the part

Transport to assembling department

Stock for assembly

Part assembly

Transport for storage

Storage of final product

15
 Figure 4: process chart for PVC window assembling

5.3.3 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.

 Part lists : Wood , Iron , Plastic , screw , joints , frame and borders

Transport the PVC to warehouse

Hold it for a certain time PVC transported for 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

5.3.4 Standard Time Calculation and Purpose

The purposes of using standard time in the firm are;

16
  Reduce inventory between the various stages of production from the supplier to

the customer.

 Reduce supply time.

 Reduce cost.

 Prevent crashes and defective product.

 Access to the smooth flow of traffic full of materials, parts and full product.

Ten (10) cycles were timed and each element was rated. These results appear in the

Table below.

Table 3 Standard time for five elements

1 2 3 4 5 6 7 8 9 10 Rati Tsele Tnor Allow Tstan
ngs cted mal ances dard
Element 1 11.1 69. 128. 188. 248. 308. 307. 427 487. 545. 120 11.46 13.76 5 14.48
5 7 15 58 09 15 32 .25 22 99
Element 2 23.3 82. 141 201. 260. 320. 380. 440 499. 558. 110 12.7 13.97 5 11.71
2 57 21 6 28 35 .75 87 67
Element 3 34.0 93. 151. 211. 271. 331. 391. 451 510. 583. 100 10.91 10.91 5 11.48
2 09 99 99 81 32 78 .65 68 35
Element 4 47.4 106 165. 226. 285. 344. 405. 464 523. 583. 80 13.57 10.86 5 11.43
.62 88 04 1 89 52 .63 97 85
Element 5 58.2 117 176. 236. 296. 356. 416. 475 534. 594. 70 10.79 7.55 5 7..95
.16 57 41 16 12 24 .44 66 3
Total 57.05
Tstandard secs

5.3.5 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.

5.3.6 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

17
produces 1000 windows. The accountant determines the spent 17,500$ on direct

material, 8,500$ on direct labor cost, 8,000$ of factory overhead costs.

17,500$ + 8,500$ = 26000$

5.4 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 Ciddi Mutfak 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.

Table4: Job and description

Job Description
Manager Accomplishes department objectives by managing staff; planning and

evaluating department activities.

Skilled worker Lays out, fabricates, and installs sheet metal.

Welds and performs related construction tasks.

Ranking Method of Job Evaluation: It ranks each job relative to all other jobs, usually

based on some overall factor like ‘Job difficulty.’ There are several steps in the job

ranking method:
18
 1. Obtain job information

2. Select raters and jobs to be rated

3. Select compensable factors

4. Rank jobs

They are using the simplest method and they are not using any incentive.

Labor productivity can be improved by allowing the workers to switch their job from

time to not get bored from their work and get another skills dealing with different jobs

and departments.

5.5 Plant Location and Layout

The company built its factory based on:

 Location, with respect to the marketing

 Area.

 Raw material supply

 Transport facilities

 Availability of labor

 Availability of utilities: water, fuel, power.

 Availability of suitable land

 Environmental impact, and effluent disposal

5.5.1 Layout of the Plant

The layout of the facility is divided into many sections. Each section is prepared to

suite its function. There is a department for management where the offices are located

there general manager, secretary and the accountant. On the production area, the layout

19
is divided according to the type of the operations. There is a cutting department where

all cutting machines are near to each other to make the processes easier and faster. All

the departments have special needs which is available by the layout to serve its

functions.

20
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

In Ciddi Motfak firm the major pollutants, which are affecting the environment, are

resulting of releasing of the various gases, which are came from the production floor;

1. Air toxics

2. Carbon monoxide (CO)

Unfortunately, the firm currently is using a simple environmental management policy in

order to protect the environment. Which in my opinion this act can reduce the reputation

of the company, because these gases are harmful for the environment and cues a serious

toxic to the air. So they can add filters to reduce the harmful gases.

5.7 Waste

The firm can apply some methods in order to minimize these wastes, which cause

harmful impact on the environment. For the gases that are released from the firm, it

could use filtration method that reduces the hazards and for the waste of plastic it should

be carefully disposed.

20
The environmental management policies of Ciddi Mutfak Company deal with issue

carefully in order to minimize the hazards affect for that the organization achieved that

purpose by consistent control of the operation inside the firm. I think the company

should set 5S system to reduce waste and optimize productivity through maintaining

workplace and using visual cues to achieve more consistent operational results.

5.8 Energy

The company has no renewable energy and most of the factories in Cyprus are using

electricity. There are many houses using solar energy with and it has a lot of demand

here so I think using solar energy will reduce the cost and it will be a good choice to

consider it.

5.9 Water Consumption

In every factory or workshop, water is one of the most important elements. It is 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 and the most used one in

Cyprus. That used generally in every workshop or factory of mass production like Ciddi

Mutfak 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.

21
 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 Ciddi Mutfak

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

1. The cutting department receive the parts from the ware house.

2. A route sheet that specified the part list.

3. Give the dimension to cut these parts according to the customer needs.

4. After operating this process the cutting department label this parts.

5. Send it to the next department.

22
6.1.2 List of Computer Software Used in Each Department

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

1. Auto Cad: is 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.

Using the three programs mentioned above , the company can order and save their

data to make the work more organized and faster.

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 affected

by inflation according to different daily rate of exchange.

23
 CHAPTER 7

CONCLUSION

Finally, I would like to say that the training program was both productive and rewarding.

I would also like to express my gratitude to everyone involved in the training. This was

my second training in Cyprus and I have noticed that most of the factories are producing

a high quality product inspite of the limited abilities and facilities at their disposal.

24
 REFERENCES

1. http://www.ciddimutfak.com/about-us.html

2. https://www.reference.com/home-garden/drilling-machine-f8db56b6704b9947 3

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

25
 APPENDIX
Appendix A: Production area

26
27