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Geographical Location Coğrafi Konum From Istanbul to Sivas approximate 10 hours by the taxi, one hour by the plane 2
TOTAL LAND/TOPLAM ALAN : 195.500 m² COVERED AREA/KAPALI ALAN : 62.558 m² FUTURE FOUNDRY NEW FUTURE MACHINING NEW 3
EMPLOYEES / ÇALIŞANLAR SENIOR MANAGERS AND ENGINEERS / ÜST DÜZEY YÖNETECİ VE MÜHENDİSLER : 17 OTHER MANAGERS /DİĞER YÖNETİCİLER : 22 TECHNICIANS /TEKNİKERLER : 16 QUALITY DEPARTMENT PERSONS / KALİTE BÖLÜMÜ PERSONELİ : 24 OTHER WORKERS / DİĞER OPERATÖRLER : 307 TOPLAM / TOTAL : 386 4
EMPLOYEES EDUCATION ÇALIŞANLARIN EĞİTİM DÜZEYİ 140 120 (% 36) 100 80 (% 26) (% 24) 60 (% 14) 40 20 0 PRIMARY 5 YEARS - İLKOKUL 5 YILLIK PRIMARY 8 YEARS - İLKOKUL 8 YILLIK HIGH SCHOOL - LİSE HIGHER EDUCATION - YÜKSEK OKUL 5
SALES USD
R&D CENTER HAS 6th PLACE IN TURKEY IN TERMS OF PROJECT CAPABILITY 7
TO EXPORT TO 42 COUNTRIES IN 6 CONTINENTS 6 KITADA 42 ÜLKEYE İHRACAT 8
PRODUCT RANGE/ ÜRÜN ÇEŞİTLİLİĞİ
INVESTMENT PLAN YATIRIM PLANI 10
ESTAS AWARDED WITH 3 NEW PROJECTS 11
CREDIT RATING REPORT
EXIMBANK CREDIT LIMIT 13
PRODUCTION METHODS & CAPACITY ÜRETİM YÖNTEMLERİ VE KAPASİTE 3 DIFFERENT PRODUCTION METHODS ARE USED IN ESTAS CAMSHAFT PLANT. CAST IRON METHOD, ASSEMBLED CAMSHAFT METHOD AND STEEL MACHINING METHOD. ESTAŞ KAM MİLİ FABRİKASINDA 3 FARKLI ÜRETİM METODU KULLANILMAKTADIR. DÖKÜM YÖNTEMİ, MONTAJLI KAM MİLİ YÖNTEMİ VE ÇELİK İŞLEME YÖNTEMİ. ABOUT 2.000 DIFFERENT CAMSHAFTS UP TO 3.000 MM LENGTH WITH STEEL AND CHILLED/DUCTILE IRON. YAKLAŞIK 2.000 FARKLI KAM MİLİ 3.000 MM UZUNLUKTA ÇELİK VE CHILL/SFERO DÖKÜM MALZEMEDEN İŞLENEBİLMEKTEDİR. 14
FOUNDRY / DÖKÜM ESTABLISHMENT YEAR-KURULUŞ YILI : 1991 LAND-ALAN : 15.078 m² COVERED-KAPALI ALAN : 7.136 m² CAPACITY-KAPASİTE : 20.000 TONS / YEAR-YILDA 20.000 TON EMPLOYEES ÇALIŞAN : 100 PRODUCTS-ÜRÜNLER : CHILLED- DUCTILE- GRAY CASTING / CHİLL-SFERO-GRİ DÖKÜM 15
PRODUCTION METHOD ÜRETİM METODU THE FOUNDRY HAS WORLD-CLASS EXPERTISE IN PRODUCING CHILL CASTINGS. A METHOD OF HARDENING WEAR SURFACES DURING THE CASTING PROCESS CHILL DÖKÜM ÜRETİMİNDE DÜNYA STANDARTLARINDA UZMAN. AŞINMA YÜZEYLERİNİN DÖKÜM SIRASINDA SOĞUTULARAK SERTLEŞTİRİLDİĞİ BİR METOD 16
PRODUCTION METHOD ÜRETİM METODU Classical weight reduction with Quartz tube Samples for Shell core casting Shell core application has 15 % weight advantage according to Quartz tube application 17
CAMSHAFT MACHINING PLANT ESTABLISHMENT YEAR / KURULUŞ : 1977 CAPACITY/ KAPASİTE : 3.000.000 PCS / YEAR-YILDA 3.000.000 ADET EMPLOYEES /ÇALIŞAN : 259 PRODUCTS /ÜRÜNLER : KAMMİLİ / CAMSHAFT, KÜLBÜTÖR MİLİ / ROCKER SHAFT BALANS MİLİ / BALANCE SHAFT MATERIAL USED/KULLANILAN MALZEMELER : CHILLED AND DUCTILE IRON, STEEL / CHİLL VE SFERO DÖKÜM, ÇELİK 18
CAMSHAFT MACHINING PLANT 19
CAMSHAFT MACHINING PLANT 20
ASSEMBLED PRODUCTION Knurling operation is applied on the surface of end piece by Estaş. Broaching operation for cams is done in order to increase strength of the cams on tube by ESTAŞ. Each tube has a hexagonal section formed by cold-pressing technique and Knurling operation is applied by ESTAŞ. 21
ASSEMBLED PRODUCTION Cam and journal ring parts assembled to tube by broaching.. Sprocket tube will be assembled by close fit. 22
PRODUCTS / ÜRÜNLER The Estas machining plant includes the latest automated equipments in use today - multi-axis mills, drills, lathes, grinders, and super-finishers with inspection and quality-control check-stations throughout the plant. Steel Camshaft / Çelik Kam Mili SAE 8620H, SAE 1050, 16MnCr5 23
HEAT TREATMENT EMPLOYEES ENGINEERS / MÜHENDİSLER : 2 TECHNICIANS /TEKNİKERLER : 1 QUALITY DEPARTMENT PERSONS / KALİTE BÖLÜMÜ PERSONELİ : 1 OTHER WORKERS / DİĞER OPERATÖRLER : 9 TOPLAM / TOTAL : 13 24
HEAT TREATMENT CAPACITY MAX. CEMENTATION CAPACITY DIA.150 mm LENGTH 1200 mm MAX. INDUCTION HARDENING CAPACITY DIA.150 mm LENGTH 1800 mm GAS CARBURAZING FURNACE : 7 DEEP FREEZING : 3 INDUCTION HARDENING FURNACE : 3 TEMPERING FURNACE : 1 ANNEALING FURNACE : 1 MANGANESE PHOSPHATE BATH : 1 COPPER PLATING BATH : 1 CRACK CONTROL STATION : 1 TOPLAM / TOTAL : 18 25
RESEARCH AND DEVELOPMENT SECTION OPENING OF : 11.08.2011 TOTAL AREA : 1540 m² RESEARCHER : 16 TECHNICIAN : 40 SUPPORT STUFF : 6 TOPLAM / TOTAL : 62 26
DEPARTMENT OF EDUCATION EĞİTİM BÖLÜMÜ 27
QUALITY CONTROL DEVICES 28
STOCK AREA 29
LEAN PRODUCTION SYSTEM 30
CERTIFICATES 31
CERTIFICATES 32
CERTIFICATES 33
UNIVERCITY EDUCATION PARTNERSHIP PROGRAM 34
AWARDS / ÖDÜLLER 35
AWARDS / ÖDÜLLER 36
O.E.M. CUSTOMERS O.E.M. MÜŞTERİLERİMİZ DENMARK/DANİMARKA ENGLAND/İNGİLTERE GERMANY/ALMANYA GERMANY/ALMANYA AUSTRIA FRANCE/FRANSA RUSSIA INDIA TURKEY/TÜRKİYE TURKEY/TÜRKİYE TURKEY/TÜRKİYE TURKEY/TÜRKİYE SWEDEN/İSVEÇ USA/ABD USA/ABD POLLAND ITALY ROMANIA BRASIL ARGENTINA BUKH DIESEL RICARDO AUDI /BOSCH JENBACHER BOSCH PSA/RENAULT AVTOVAZ TATA/RENAULT/MAHABAL/MAHINDRA OYAK-RENAULT TÜMOSAN (FIAT) TÜRK TRAKTÖR (FIAT) FORD SCANIA CUMMINS-WOODWARD-CATERPILLAR GE-WAUKESHA FIAT FIAT DACIA IVECO LATIN PSA 37
O.E.M. CUSTOMERS O.E.M. MÜŞTERİLERİMİZ
MILESTONES 1977- Establishment of Estas camshafts / Estaş Kam mili fabrikasının kuruluşu 1991- Opening of casting plant / Döküm Fabrikasının açılışı 1997- Receipt of first Quality Document (ISO 9001) / İlk Kalite Belgesinin alınması (ISO 9001) 2004- ISO/TS 16949 certification 2005- First Fuel Pump Camshafts production to original producer / Orijinal üreticiye ilk yakıt pompa millerinin üretimi 2011- Opening of inhouse gas carburizing units / Gaz karbürizasyon ünitelerinin açılışı 2011 - Establishment of R&D Center certification by Goverment incentive program 2012 Starting of INOTECH 12K Lean Production studies / INOTECH 12K Yalın Üretim Çalışmalarına başlanması 2012- ISO 14001 Environmental Management Systems / Çevre Yönetim Sistemi 2012 - OHSAS 18001 - Health & Safety Certification / OHSAS 18001 İş Sağlığı ve Güvenliği 39
XPI PROJECT PERFORMANCE 40
DELIVERY PERFORMANCE 41
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