MAINTENANCE UTILITIES WORKSHOPS 1 CHIEF MAINTENANCE UTILITIES WORKSHOPS

MAINTENANCE, UTILITIES & WORKSHOPS 1

CHIEF, MAINTENANCE, UTILITIES & WORKSHOPS ORGANIZATION CHART 2

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OBJECTIVES n n REDUCE THE BREAK RATES DUE TO MECHANICAL AND ELECTRICAL CAUSES BY PROVIDING EFFICIENT REPAIR / MAINTENANCE PROGRAM IN WORKSHOP, MANUFACTURING EASY SPARE PARTS OF THE MACHINERY ON A BASIS OF STOCKS AND PROVIDE EVERY KIND OF SHARPENED BLADES ON TIME n TO TRAIN THE EMPLOYEES n PROVIDE CONTINUOUS IMPROVEMENT AND RENOVATION 4

THE TECHNIQUES USED FOR OPERATIONS n BREAK INTERFERE n PREVENTIVE MAINTENANCE APPLICATIONS n Q. I. T ACTIVITIES n MACHINERY MANUALS n INSIDE AND OUTSITE TRAININGS 5

PRODUCTION MACHINERY INVENTORY 6

SELECTING MAINTENANCE TYPE THE MACHINES AND UNITS HAVE BEEN EVALUATED ACCORDING TO A-B-C ANALYSIS CONCERNING SIX BASIC PARAMETERS: S OCCUPATIONAL HEALTH & SAFETY Q QUALITY W WORKING HOURS D BREAK IMPORTANCE F FREQUENCY M MEAN TIME TO REPAIR A AND B TYPE MACHINES ARE SELECTED FOR PERIODIC MAINTENANCE, WHILE C TYPES ARE SELECTED FOR PREDICTIVE MAINTENANCE. RATES OF MACHINE TYPES: A = 41 % B= 7% C = 52 % 7

WRAPPING MACHINE A B C S OCCUP. & SAFETY Important Medium Not important Q QUALITY Important Medium Not important W WORKING HOUR 24 hour/day 8 -24 hour/day 8 hour/day D BREAK IMPORT Line stop Important break Reserve machine F FREQUENCY > 3 / month 0, 5 -3 / month < 0, 5 / month M MTTR > 120 dk 30 -120 dk < 30 dk 8

MAINTENANCE AT SWEDISH MATCH-TURKEY 1. BREAK MAINTENANCE (Emergency maintenance) 2. PREVENTIVE MAINTENANCE APPLICATIONS a) Periodic Maintenance n Daily and weekly (periodic maintenance forms) n Annual (revision maintenances-4 weeks and dated maintenances) b) Predictive Maintenance n Weekends maintenances (Trouble areas are diagnosed during production and maintenances are carried at saturdays). NOT: All maintenance jobs are registered to “Machine Follow Up Files” of each machines. 9

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WHO MAKES MAINTENANCES ? n n THERE IS NO ANY SPECIAL MAINTENANCE TEAM. THE PEOPLE WHO ARE RESPONSIBLE FOR THE PRODUCTION, ARE ALSO RESPONSIBLE FOR THE MAINTENANCE AS WELL. WORKSHOP EMPLOYEES SUPPORT THE MAINTENANCE. 15

TECHNICAL STAFF FOREMAN MECHANIC SHIFT MECHANICAL WORKSHOP 1 5 1 ELECTRICAL WORKSHOP 4 - 3 ASSEMBLY 5 6 2 PRINTING AND BOX 2 2 2 SPLINT LINE 2 - 3 ARTWORK (FILM PREPARATION) 1 HEAD COMPOSITION & STRIKING COMPOSITION - 1 16

• MAJORITY OF TECHNICAL PEOPLE ARE GRADUATED FROM TECHNICAL HIGH SCHOOL. • TRAININGS ARE GIVEN TO ALL TECHNICAL EMPLOYEES (General Mechanical Education, Lubrication, Pneumatic, Bearing, Etc. ) • THOSE COURSES ARE GIVEN AT THE TRAINING ROOM BOTH THEORETICAL AND PRACTICAL. 17

MECHANICAL WORKSHOP MACHINERY n n n 2 1 3 1 1 2 TURNERS MILLING MACHINE SURFACE GRINDING MACHINES SHAPER HACKSAW WELDING MACHINES -AT MECHANICAL WORKSHOP, SPARE PARTS ARE MANUFACTURED OR REPAIRED, KNIVES THAT ARE USED IN PROCESSES ARE GRINDED. -PLUS NEW IMPROVEMENTS AND RENOVATIONS ARE DESIGNED AND MANUFACTURED. 18

BREAK RATE DUE TO MECHANICAL AND ELECTRICAL REASONS: ~ %1, 5 19

SPARE PART MANUFACTURING and PURCHASING Workshop Small and easy spare parts are produced at our mechanical workshop (ex. bushing, pin, screw, shaft, key, pulley, etc). Domestic companies More complicated and hard to make parts are ordered to domestic companies in Bursa or Istanbul (ex. gear, cam, creasing plate, eccenter sleeve, etc). Arenco Sensitive and most complicated parts are ordered Arenco (ex. mould block, holder, steel band, el couplings, etc). 20

SPARE PART MANUFACTURING and PURCHASING (cont. ) According to our ‘Purchasing Flowchart’, warehouse responsible follows the quantity of spare parts from stock. Our technical personnel can also inform spare part needs by filling the notebook existing in warehouse. Warehouse responsible prepares demand form and makes confirm of Maintenance Chief and Factory Manager. For private parts, we send technical drawing and/or sample of part to manufacturer. Purchasing staff follows manufacturing by purchasing forms. Whenever parts came to the factory, people who demanded part should come to the warehouse and check part whethere is a mistake or not. If it is O. K. then the part is received. If something is wrong, the part is sent back or rejected to manufacturer. For this process, a special accept/reject form is used 21

FIRE PROTECTION · Swedish Match-Turkey is insured against any damage including natural disasters. · We follow up strict preventive program conforming to AON’s periodic audits. All preventive measures have been taken against fire. Fire extinguishers have been placed at fire risky points. · There is water piping ring installation. Many hydrants and hose cupboards are located at different places on this installation. · Fire system water is supplied from water pool that has 1000 m 3 capacity. · Finished good warehouses have sprinkler system for fire fighting. · There are three deep water wells in factory area (Total flow rate: 45 l/s) 22