The problem with many polyurethane foams (PPU) is excessive airing, which leads to the formation of voids on the surface and inside the finished foam. This affects not only appearance, but also important physical and mechanical indicators. PU foam production is a very delicate chemical process, and the end material characteristics directly affect the finished product quality. Therefore, it was decided to launch a project in order improve polyurethane foam quality. We also included the problem of overspending of chemical components in the project.

To improve the quality of the mixture poured, we indicated optimal technological parameters of the equipment. Improvements also concerned adjustment of equipment to eliminate excessive airing of the system, its blockage and provide precise dosing. To reduce the overconsumption of chemical components, component supplying pumps were calibrated, a monthly dosing accuracy control procedure was introduced, instructions for this operation was written, and equipment adjusters undergone training. Then the optimal of PPU masses for the hull filling were determined along with adjustments to SAP.

The project implementation made it possible to reduce the chemical component overspending level by 17%, and to reduce the number of defects caused by the “air void” defect (tightening) by 25%. In future we plan to continue work in order to improve the filling of hulls with polyurethane foam. Measures will be aimed at excess air exhaust from the hulls during PPU foaming process and improving its distribution inside the hull.

For our workshop operations we use plastic scraps as raw materials: we melt it down and reuse in the production of parts. By the end of last year, the stock of recycled material in the shop had increased too much, and we set the goal of reducing this stock.

We did a full material circulation analysis to find out where more raw materials can be used and reduce scrap or waste amounts. Within two months, we analyzed all groups of equipment (extruder, molding section, crusher), assessed waste percentage and utilization efficiency for raw materials. Finally it was detected that 95% of problems are related to the equipment adjustment, its operating modes and wear and tear of some components. Over the 6 following months, we gradually introduced improvements - by initiating new modes and technological parameters.


Thus, by November we managed to reduce the volume of recyclable materials in the workshop by 50 tons. We have also been able to significantly reduce the percentage of rejects after parts molding as well as flash formation percentage. The final results of the project can be summed up after overall material inventory.

In 2021, we received an order from product management: to launch a new product for our plant - washer-dryers.

At the first stage of the project, we evaluated possible suppliers and, together with the technical development department, ordered the necessary equipment - injection molds for plastic and dies for metal parts. At the same time, we consulted with our Turkish colleagues and, according to their experience, determined the order making procedure and place. At the same time, our department team worked on adapting our production line to new kind of products, we found out to what extent materials we have allow us to launch such production. A little later, the quality department joined the project, because the product prototype must undergo post-assembly testing and all the problems, if any, must be fixed. Our planning, purchasing and logistics department performed very serious and hard work. Despite all geopolitical changes of this year, they managed to establish contacts with foreign suppliers and organize the equipment delivery. I am very grateful to our management for their help in solving difficult situations, our department team and all the employees of the plant who used their best efforts for this project implementation.

Unfortunately, we didn’t manage to complete the project this year, because we still didn’t receive part of the equipment due to sanctions, and new production launch was constrainedly postponed, tentatively until the summer of 2023. Now we continue resolving this problem, considering at the same time the prototype preparation. After the project completion, we will be the first company producing washer-dryers in Russia.

The purpose of our project is to provide local content in manufacturing of parts for washing machines Prologue, which are currently produced in Turkey and Romania. It is necessary in order to reduce the cost of finished products, avoid problems associated with delivery delays and obtaining of certain amounts of parts, and also to reduce the percentage of scrap caused by damage during transportation.

We have ordered 10 molds for production of parts, as well as instruments and fixtures for ultrasonic welding of plastic parts, pad printing tools and screen printing equipment. Most of the parts will be produced in our factory, using equipment available. Some plastic parts for us will be produced by a Russian supplier using our molds.

The project completion is scheduled for March-April 2023, which will provide an opportunity to reduce the cost of each Prologue washing machine by minimum 4 euro.

We were tasked with achieving consistent quality in the production of counterweights for washing machines and eliminating the problem of loose seals for refrigerators and freezers.

When we began to study these problems, we came to the conclusion that obtaining high-quality counterweights requires complete change of the chemical composition proportions, revision of the part reinforcement and replacement of the filler with fine fraction of crushed granite (size 4–5 mm). We chose a supplier with a good production and laboratory base, who was ready to conduct tests upon our requests, and produced the first batch of counterweights. During laboratory testings, new counterweights withstood very high compressive load (up to 125 kg per cm2) and became more monolithic. As a result, the number of defects on the production line has decreased.

We have also detected that during compactor transportation from supplier to assembly site, the compactor sagged on the carts, which caused futher problems in refrigerator assembling process. It was offered to transport compactor using strips fixed on carts, which can be cut from defective plastic cases of refrigerators. Due to this, the number of errors determined after the final control decreased 2.5 fold. Now we try to use only 2 corners (20 x 20 cm) instead of the whole plank on both sides. If it will be determined that such a method also effectively prevents compactor sagging, this will significantly reduce material costs. The final project results will be summed up at the end of the year.

Plans for the next year

- In November and December, - as Anna Golovanova, a project management specialist, said, - in parallel with the global work efficiancy of work and personnel performance assessment project office is working on summing up of the results, finalizing project target maps and preparing documentation. At the same time, we initiated application of the project proposals for 2023. It is important to start project planning in advance in order to conduct feasibility and cost-benefit study, coordinate its budget, allocate human resources and so on.

The fundamental principle of Beko's project activity is to encourage various kinds of projects with product represented not only by financial savings.

Such projects values can be digitalization, optimization of business processes, environmental aspects, personnel development, brand promotion and, of course, taking care of our customers. All this is extremely important for the enterprise continuous and sustainable development.

We encourage cross-functionality in teams, involving employees from different departments.

The project office is always open to support project managers and their teams at all project stages.

In 2023, we plan improve our processes and instruments even more, focusing on employee training and developing necessary skills and competencies.