Production
The first creation stage
Beko mechanical production shop is the place where everything starts Metal doors, housings, drums, and components for refrigerators and washing machines to be produced are manufactured here. The workshop personnel are well aware that assembly shops and production in general depend on their work.
Masters of robots and presses
During each shift, the workshop produces a total of about 16,000 units of various types of products: 2,000 cases and walls of washing machines, 1,000 drums, 3,000 doors, top covers and panels of refrigerators and about 10,000 brackets. The main working materials are cold-rolled, galvanized strip and stainless steel of different thicknesses. It is processed by cold stamping without preheating; also with the use of bending and perforating machines; metal drawing and cutting is performed. For each part and model (there are more than 20), mechanical and hydraulic presses use its own stamp appropriate to its size and configuration. Recently, new equipment was launched - 5 dies for production of the front walls for Grundig models. New processes for Grundig models have also been introduced - metal riveting and a new welding station for the body of washing machines.
During each shift, the workshop produces a total of about 16,000 units of various types of products: 2,000 cases and walls of washing machines, 1,000 drums, 3,000 doors, top covers and panels of refrigerators and about 10,000 brackets. The main working materials are cold-rolled, galvanized strip and stainless steel of different thicknesses. It is processed by cold stamping without preheating; also with the use of bending and perforating machines; metal drawing and cutting is performed. For each part and model (there are more than 20), mechanical and hydraulic presses use its own stamp appropriate to its size and configuration. Recently, new equipment was launched - 5 dies for production of the front walls for Grundig models. New processes for Grundig models have also been introduced - metal riveting and a new welding station for the body of washing machines.
You can’t do without headphones in the workshop - it’s noisy here, because work is going on at the same time on automated lines: a line for washing machine cases, washing machine drums, two lines for side panels of refrigerators and a line for refrigerator doors. Including several powerful 400-ton presses equipped with robotic manipulators. Operator controls press operation, changes the program for the next model, and checks the product quality. Drums for washing machines are made of stainless steel. They are manufactured in different volumes, for loads from 3.5 to 7 kg. First, a metal bar is cut into strips, perforated and twisted into a ring, then the end part is rolled to this ring and the amplifier is attached. Additionally, the workshop produces more than 10 types of brackets and holders that will be needed during assembly.
Such products, in various models and in large volumes, are produced by a workshop team that consists of 89 people. Personnel work in three shifts because there is equipment that works 24 hrs. Highly respected experienced team engineers, responsible for the equipment and technology: Alexander Makarov, Mikhail Chugunnikov, Denis Efimov and Alexey Tokarev. Work shifts are managed by highly competent masters Marina Semyonova, Alexey Yakimov, Irina Kasatkina, Artem Kovalkin, Sergey Bochenkov and Lyubov Markova All of them are great professionals who have mastered production down to the fine points.
Such products, in various models and in large volumes, are produced by a workshop team that consists of 89 people. Personnel work in three shifts because there is equipment that works 24 hrs. Highly respected experienced team engineers, responsible for the equipment and technology: Alexander Makarov, Mikhail Chugunnikov, Denis Efimov and Alexey Tokarev. Work shifts are managed by highly competent masters Marina Semyonova, Alexey Yakimov, Irina Kasatkina, Artem Kovalkin, Sergey Bochenkov and Lyubov Markova All of them are great professionals who have mastered production down to the fine points.
Nikolay Koblov,
head of mechanical production shop
Has been working for the company since 2006. He started his work at the factory as an equipment adjuster, then in 2011 joined the mechanical production shop as a technician, worked as an engineer, a group leader, and finally has headed the shop since December 2022.
I came here in the period when everything was put into production, so I know all the processes, all the equipment inside and out. I came to the line of appliance bodies, then I worked on the line of drums, then I was transferred to the line of doors and again to the appliance bodies – I worked everywhere in a circle like this. It is unique experience cause it makes it possible to understand all processes from the inside. You know what problems an employee may encounter when performing a particular task. We have a very good, responsible team - every team member attach great importance to development, growth and work at Beko. Our people are growing in line with the production growth: new models, new processes, and equipment appear regularly. Automated line operators are improving their skills. I highly appreciate each of the employees, I believe in everyone; the entire factory ultimately depends on their attention and responsibility. We are a start-up production company. Neither the painting shop nor the assembly lines can do without our products, so we should not have any failures. Twice a day I report to management about the every process performance and give an ideas concerning possible optimization or improvements. We strictly control the quality of the output products.
Of course, working with metal requires compliance with a special production culture and safety precautions. Therefore, the workshop is equipped with special fences, reflective lines, and PPE is used.
head of mechanical production shop
Has been working for the company since 2006. He started his work at the factory as an equipment adjuster, then in 2011 joined the mechanical production shop as a technician, worked as an engineer, a group leader, and finally has headed the shop since December 2022.
I came here in the period when everything was put into production, so I know all the processes, all the equipment inside and out. I came to the line of appliance bodies, then I worked on the line of drums, then I was transferred to the line of doors and again to the appliance bodies – I worked everywhere in a circle like this. It is unique experience cause it makes it possible to understand all processes from the inside. You know what problems an employee may encounter when performing a particular task. We have a very good, responsible team - every team member attach great importance to development, growth and work at Beko. Our people are growing in line with the production growth: new models, new processes, and equipment appear regularly. Automated line operators are improving their skills. I highly appreciate each of the employees, I believe in everyone; the entire factory ultimately depends on their attention and responsibility. We are a start-up production company. Neither the painting shop nor the assembly lines can do without our products, so we should not have any failures. Twice a day I report to management about the every process performance and give an ideas concerning possible optimization or improvements. We strictly control the quality of the output products.
Of course, working with metal requires compliance with a special production culture and safety precautions. Therefore, the workshop is equipped with special fences, reflective lines, and PPE is used.
Quality control and assessment is an important part of the workshop’s operation. This also applies to control of production processes and compliance with labor safety regulations. A clear structure, planning and management of processes, performance monitoring and evaluation -all these aspects are necessary for successful work performance.
But the most important thing is to check that the finished product meets the stated requirements. Despite the fact that the workshop operations automated as much possible, and the production of cases requires human assistance only during machine programming, each part, without exception, is checked for compliance with the geometric parameters, dimensions, thickness and other requirements specified in the technical documentation. Particular attention is paid to assessing the surface quality of the part. The surface must be smooth, even and free of visible defects such as scratches, marks, cracks and dents.
Visual inspection is carried out after the panel comes out of the press. An important step is checking the geometric parameters of the panels, such as dimensions, straightness and flatness.
The quality of washing machine drums is closely monitored. The finished drum must be perfectly balanced and its inner surface must be absolutely smooth. Perforation of the drum side wall of the drum is done automatically on special machines, the rear wall is made separately. Then the drum is assembled, riveted - this is, perhaps, one of the few manual operations in the workshop - and checked for tearing and beating; it should not “walk”. But it is not the end of the checking. An employee uses a special nylon glove to smooth the inner perforated surface, checking for burrs. After all, in the washing process, the drum should not spoil clothes and leave puffs. And only after this manufactured parts are transferred to other workshops.
But the most important thing is to check that the finished product meets the stated requirements. Despite the fact that the workshop operations automated as much possible, and the production of cases requires human assistance only during machine programming, each part, without exception, is checked for compliance with the geometric parameters, dimensions, thickness and other requirements specified in the technical documentation. Particular attention is paid to assessing the surface quality of the part. The surface must be smooth, even and free of visible defects such as scratches, marks, cracks and dents.
Visual inspection is carried out after the panel comes out of the press. An important step is checking the geometric parameters of the panels, such as dimensions, straightness and flatness.
The quality of washing machine drums is closely monitored. The finished drum must be perfectly balanced and its inner surface must be absolutely smooth. Perforation of the drum side wall of the drum is done automatically on special machines, the rear wall is made separately. Then the drum is assembled, riveted - this is, perhaps, one of the few manual operations in the workshop - and checked for tearing and beating; it should not “walk”. But it is not the end of the checking. An employee uses a special nylon glove to smooth the inner perforated surface, checking for burrs. After all, in the washing process, the drum should not spoil clothes and leave puffs. And only after this manufactured parts are transferred to other workshops.
Checking the inner surface of the drum with a glove
Artem Kovalkin,
workshop foreman
Has been working in the workshop for almost 3 years. Within a year has become a 3rd category master.
– My job is to ensure connections between structural divisions. I like the production process. You understand that you are involved in concrete and useful activities. We are all focused on results so that the assembly ultimately produces production in accordance with the specified plan and even more. We have many excellent employees, true professionals, responsible and capable people, and it’s just impossible to list them all. For example, Alexey Gorshkov and Alexey Vostrikov, who work on an automatic housing production line. Or Vitaly Kapranov on the Grundig production line. He launched this line, trained people. As a result, the employees he trained joined 4 other shifts. Our core team is well established; people have been working for many years. Moreover, a person can master several different lines, and we are even interested in this. We need universal operators. In Beko, nothing prevents growth if you have desire and diligence. We recruit and train people. We have great prospects for growth, if a person treats the matter with a soul and is interested in it - there are no barriers.
workshop foreman
Has been working in the workshop for almost 3 years. Within a year has become a 3rd category master.
– My job is to ensure connections between structural divisions. I like the production process. You understand that you are involved in concrete and useful activities. We are all focused on results so that the assembly ultimately produces production in accordance with the specified plan and even more. We have many excellent employees, true professionals, responsible and capable people, and it’s just impossible to list them all. For example, Alexey Gorshkov and Alexey Vostrikov, who work on an automatic housing production line. Or Vitaly Kapranov on the Grundig production line. He launched this line, trained people. As a result, the employees he trained joined 4 other shifts. Our core team is well established; people have been working for many years. Moreover, a person can master several different lines, and we are even interested in this. We need universal operators. In Beko, nothing prevents growth if you have desire and diligence. We recruit and train people. We have great prospects for growth, if a person treats the matter with a soul and is interested in it - there are no barriers.
A highly professional, friendly team is the key to the enterprise success. The highest qualification for operators of automatic and semi-automatic cold forming equipment is category 4. These people form the backbone of the workshop. The masters know that they can always rely on them. And today there are a lot of such employees in the workshop. They have been working on different lines for a long time: at the production of housing, front wall, doors, panels, drums, etc. They train and raise newcomers so that in the future they will become highly qualified specialists and operators of the highest categories. And then some of them can become a technician, an engineer, or a manager. We have seen such examples many times. People feel like one team, bound by common goals and objectives. And all doors are open for development, both personal and general. There is a point based motivation system that provides bonuses and promotions. You can master related functionality, increase your skills within your line, and even take part in realization of projects. Given the will. Every month, the shop manager, engineers, and foremen collectively summarize the work of the entire team. If I didn’t love my job, I wouldn’t have devoted so many years to it, the workshop employees say.
Work performance, professionalism of management and employees, and an effective personnel training system indicate that the workshop will touch many another heights.
Work performance, professionalism of management and employees, and an effective personnel training system indicate that the workshop will touch many another heights.
Alexander Makarov,
engineer
Has been working at the factory since 2008. He worked in the repair and equipment section, in the electromechanical service, and in the plastics production workshop. And now he manages the operation of presses and automatic lines.
– Every day when I come to work, I know that new tasks that require skill and experience are awaiting me We have complicated equipment and It's interesting to work with it. Seven automated lines, a coordinate-turret press that cuts sheets for various models, 2 mechanical presses for components and 4 hydraulic ones. And also a full robotic complex for the production of the front walls: it includes 4 presses and 5 associated robots. Once the part is ready, the robot comes in and picks it up. And all this functions are managed by one person - the operator. It is important that every detail is made correctly; every millimeter matters.
It is planned that a new line for Grundig models will be installed in the workshop in 2024. So, we are expanding. Of course, we will need new employees. Now the turnover is small, but new posts and new lines are opening.
engineer
Has been working at the factory since 2008. He worked in the repair and equipment section, in the electromechanical service, and in the plastics production workshop. And now he manages the operation of presses and automatic lines.
– Every day when I come to work, I know that new tasks that require skill and experience are awaiting me We have complicated equipment and It's interesting to work with it. Seven automated lines, a coordinate-turret press that cuts sheets for various models, 2 mechanical presses for components and 4 hydraulic ones. And also a full robotic complex for the production of the front walls: it includes 4 presses and 5 associated robots. Once the part is ready, the robot comes in and picks it up. And all this functions are managed by one person - the operator. It is important that every detail is made correctly; every millimeter matters.
It is planned that a new line for Grundig models will be installed in the workshop in 2024. So, we are expanding. Of course, we will need new employees. Now the turnover is small, but new posts and new lines are opening.
Robotic arm in action
Marina Semenova,
workshop foreman
Has been working at Beko since 2006. She was an operator, foreman, dispatcher. And since 2018, she became the master of the mechanical production workshop.
- In each shift, 25 people work at different processes. Over the years, people became really close to each other. We appreciate everyone. People help and support each other. Psychologically, the atmosphere is friendly and business oriented. For me, the Beko plant is not just a workplace. I’ve been here from the very beginning and I wouldn’t trade my plant and team for anything else. Here I feel the unaffected joy of collaborating with good people. And I generally value our products most of all. All household appliances at my home are produced by us. They say: “You are a Beko fan.” Well, yes, I'm not hiding it. I know how we create them - we make with understanding that we make each item as for our own use, Attention to details, comfort and quality are the key factors making them so attractive. And therefore, for me, Beko mark is the guarantee of quality and reliability. And I am proud to work alongside like-minded people. We have an excellent team.
workshop foreman
Has been working at Beko since 2006. She was an operator, foreman, dispatcher. And since 2018, she became the master of the mechanical production workshop.
- In each shift, 25 people work at different processes. Over the years, people became really close to each other. We appreciate everyone. People help and support each other. Psychologically, the atmosphere is friendly and business oriented. For me, the Beko plant is not just a workplace. I’ve been here from the very beginning and I wouldn’t trade my plant and team for anything else. Here I feel the unaffected joy of collaborating with good people. And I generally value our products most of all. All household appliances at my home are produced by us. They say: “You are a Beko fan.” Well, yes, I'm not hiding it. I know how we create them - we make with understanding that we make each item as for our own use, Attention to details, comfort and quality are the key factors making them so attractive. And therefore, for me, Beko mark is the guarantee of quality and reliability. And I am proud to work alongside like-minded people. We have an excellent team.
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