Production
Quality in every detail
All modern household appliances include a lot of various plastic parts. To produce them maintaining high quality, on time and without losses is not an easy task. Therefore, the plastics workshop is one of the key departments of the Beko plant. Workshop managers and employees describe to us work and live of the team.
The filling is worth the effort!
Alexander Meshkov
workshop foreman:
– Our workshop is responsible for manufacturing of the “filling” for household appliances: tanks and front panels of washing machines, powder compartment lids, transparent and opaque refrigerator drawers with or without lids, light-conducting panels. All of the above come in different types and sizes. Here we cast plastic parts and paint them. Our first task is to provide all lines of the plant with plastic parts. But economic production and product quality are of the same importance. Therefore, we constantly monitor material consumption: every month we report on losses incurred and what measures we take to reduce this figure. Concerning quality standards, we fully realize: if we supply non-conforming products to the line, the problem will affect the entire plant. Therefore, the cost of our mistake is extremely high.
This may seem some kind of easy job: the planning department gives an order for specific items in a certain quantity - so we have to go and do it. But only those who have never worked in our workshop can think this way. Plans are adjusted according to requests for different models of equipment, and therefore it is necessary reconfigure the equipment quickly and at the same time the quality standard, time frame, quantity of raw materials and stay within the budget. This kind of work definitely cannot be considered as routine; you must be able to switch from one task to another very quickly.
Last year we introduced recycling of waste generated during painting: we found the way to recover solvent and reuse. This idea meets two goals at once: thriftiness and environmental friendliness of production. This decision is the merit of our employees to the full extent.
Essential Component
The workshop team is friendly, some members have been working since the the plant foundation, in 2006. These are the most experienced employees, they form the very backbone of the team. Many employees communicate outside of work – they spend their leisure together. By the way, these are mostly women, 90 percent. People who are not familiar with the specifics of work in the workshop are surprised: why? After all, there is an opinion that the plant is for men. But it is here that particularly painstaking work is carried out, requiring attentiveness and accuracy, and this is better done by women.
Experience in manufacturing is a critical component. Therefore, colleagues greatly appreciate those who have been working for many years, and are grateful to such people for mentoring young employees, keeping continuity of knowledge and skill.
Alexander Meshkov
workshop foreman:
– Our workshop is responsible for manufacturing of the “filling” for household appliances: tanks and front panels of washing machines, powder compartment lids, transparent and opaque refrigerator drawers with or without lids, light-conducting panels. All of the above come in different types and sizes. Here we cast plastic parts and paint them. Our first task is to provide all lines of the plant with plastic parts. But economic production and product quality are of the same importance. Therefore, we constantly monitor material consumption: every month we report on losses incurred and what measures we take to reduce this figure. Concerning quality standards, we fully realize: if we supply non-conforming products to the line, the problem will affect the entire plant. Therefore, the cost of our mistake is extremely high.
This may seem some kind of easy job: the planning department gives an order for specific items in a certain quantity - so we have to go and do it. But only those who have never worked in our workshop can think this way. Plans are adjusted according to requests for different models of equipment, and therefore it is necessary reconfigure the equipment quickly and at the same time the quality standard, time frame, quantity of raw materials and stay within the budget. This kind of work definitely cannot be considered as routine; you must be able to switch from one task to another very quickly.
Last year we introduced recycling of waste generated during painting: we found the way to recover solvent and reuse. This idea meets two goals at once: thriftiness and environmental friendliness of production. This decision is the merit of our employees to the full extent.
Essential Component
The workshop team is friendly, some members have been working since the the plant foundation, in 2006. These are the most experienced employees, they form the very backbone of the team. Many employees communicate outside of work – they spend their leisure together. By the way, these are mostly women, 90 percent. People who are not familiar with the specifics of work in the workshop are surprised: why? After all, there is an opinion that the plant is for men. But it is here that particularly painstaking work is carried out, requiring attentiveness and accuracy, and this is better done by women.
Experience in manufacturing is a critical component. Therefore, colleagues greatly appreciate those who have been working for many years, and are grateful to such people for mentoring young employees, keeping continuity of knowledge and skill.
“
The plastics workshop processes 20 tons of raw materials per day. Working schedule is uninterrupted and divided in three shifts, without holidays and weekends. Three shifts for washing machines and three shifts for refrigerators.
Alexey Filippov, Kistaman Alibekova, Vladimir Chekhlov, Svetlana Skvortsova, Olga Khoroshavina, Alexander Meshkov
We work in automatic mode
Alexey Filippov,
senior specialist:
– Our workshop has come a long way. When we started, we used semi-automatic operating mode. The moulder removed the parts himself and performed many operations manually. Now our casting process is automatic. And recently, full automatic control of the entire process and continuous monitoring were introduced. This is exactly what I am doing now. I was the first head of the workshop, in charge from 2006 to 2010. Today I am engaged in analyzing and support of the automatic control system.
We can learn production output of the machine at any moment and how many corresponding products have been produced. As a result, labor productivity has increased, quality have been improved, and safety monitoring has become more easy.
All equipment has interlocks - both of mechanical and electrical types. Our machines are serious devices: the injection molding machine develops force of 2000 tons and heats up to 200 degrees inside. So there should be no accidental exposures to the affected area. And, of course, each employee must undergo several levels of safety training.
In 2006, the workshop employed 40 workers, now this number increased to 140 persons, taking into account all sites, incl. manual painting, pad printing and casting of plastic parts.
When I came at the plant, there was no roof yet. We installed equipment, launched the first part, and had no idea what to do at all. Specialists from Turkey rendered assistance to us. During the process, we became friends and learned “Russian-Turkish” language. It was hard, sometimes I even had to stay at the workshop overnight, but it was interesting. I remember when I first came in January, and we were told that in the summer we would release the first washing machine. It was hard to believe. But on July 13, our first washing machine actually rolled off the assembly line. It was a sight to behold! It passed along the tape, accompanied by the general director and all the employees. And when the device reached the destination, it was really reason for celebrate!
Alexey Filippov,
senior specialist:
– Our workshop has come a long way. When we started, we used semi-automatic operating mode. The moulder removed the parts himself and performed many operations manually. Now our casting process is automatic. And recently, full automatic control of the entire process and continuous monitoring were introduced. This is exactly what I am doing now. I was the first head of the workshop, in charge from 2006 to 2010. Today I am engaged in analyzing and support of the automatic control system.
We can learn production output of the machine at any moment and how many corresponding products have been produced. As a result, labor productivity has increased, quality have been improved, and safety monitoring has become more easy.
All equipment has interlocks - both of mechanical and electrical types. Our machines are serious devices: the injection molding machine develops force of 2000 tons and heats up to 200 degrees inside. So there should be no accidental exposures to the affected area. And, of course, each employee must undergo several levels of safety training.
In 2006, the workshop employed 40 workers, now this number increased to 140 persons, taking into account all sites, incl. manual painting, pad printing and casting of plastic parts.
When I came at the plant, there was no roof yet. We installed equipment, launched the first part, and had no idea what to do at all. Specialists from Turkey rendered assistance to us. During the process, we became friends and learned “Russian-Turkish” language. It was hard, sometimes I even had to stay at the workshop overnight, but it was interesting. I remember when I first came in January, and we were told that in the summer we would release the first washing machine. It was hard to believe. But on July 13, our first washing machine actually rolled off the assembly line. It was a sight to behold! It passed along the tape, accompanied by the general director and all the employees. And when the device reached the destination, it was really reason for celebrate!
Andrey Barausov, service technician or adjuster
Andrey Bazhin, Operator for Software-Controlled Machines
In 2006, the workshop employed 40 workers, now this number increased to 140 persons, taking into account all sites, incl. manual painting, pad printing and casting of plastic parts.
Nadezhda Filippova,
master:
– I came to the plant when it was just opening, in May 2006. And we still have a lot of people who came with me at the same time. They work as adjusters and moulders; we have been in production for almost 20 years. For me, our team is like family. Therefore, I try to build trust relationships with new employees, so that people not only “follow master’s instructions,” but also understand that this is necessary for the success of our common business.
master:
– I came to the plant when it was just opening, in May 2006. And we still have a lot of people who came with me at the same time. They work as adjusters and moulders; we have been in production for almost 20 years. For me, our team is like family. Therefore, I try to build trust relationships with new employees, so that people not only “follow master’s instructions,” but also understand that this is necessary for the success of our common business.
Technician Sergey Efremov and repair team: Stanislav Avdeev, Roman Vasilkin, Ivan Vladykin
Trust but check
Vladimir Chekhlov,
engineer:
– My occupation is quality assurance. I interact with the relevant services of the plant, that make inspections in accordance with established criteria: they evaluate the parts and make measurements. My task is to conduct an analysis and to elaborate corrective measures in the case of detection of inconsistencies, thereby establishing an internal quality assurance system.
The production technology is as follows. First, we mix the granules we got and place it inside the hopper of the injection molding machine, for drying. They are then melted in a material cylinder. Then the resulting melt is fed under pressure into a mold, where the finished part is cooled. At the release point, it is removed by the robotic arm and transported to the molding table for inspection and refinement. Finished products is directed either to the assembly line or to our manual painting site. Here, using a spray gun, the operator manually coats the part with paint and transfers it to the oven to fix the coating. There is also a pad printing site.
Vladimir Chekhlov,
engineer:
– My occupation is quality assurance. I interact with the relevant services of the plant, that make inspections in accordance with established criteria: they evaluate the parts and make measurements. My task is to conduct an analysis and to elaborate corrective measures in the case of detection of inconsistencies, thereby establishing an internal quality assurance system.
The production technology is as follows. First, we mix the granules we got and place it inside the hopper of the injection molding machine, for drying. They are then melted in a material cylinder. Then the resulting melt is fed under pressure into a mold, where the finished part is cooled. At the release point, it is removed by the robotic arm and transported to the molding table for inspection and refinement. Finished products is directed either to the assembly line or to our manual painting site. Here, using a spray gun, the operator manually coats the part with paint and transfers it to the oven to fix the coating. There is also a pad printing site.
“
We have an invaluable employee - Sergey Gennadievich Efremov. This is our inventor and innovator. He can always find some original technical solution of any problem. He has no equal in this!
Liya Mayorova, electrical erosion specialist
Lessons of the moment
In our workshop, people work mainly under self-control. In our workshop, people mainly control their work independently. In order to get a high-quality part, without affecting any elements he monitors every minute of the process using special sample. Of course,we also control the correctness of operations performed, but the level of trust is very high. And hence everyone’s responsibility.
If any defect is detected, it is fixed immediately with description of the error that caused the problem. The information is entered into a database and a decision is made about what should be done and how. We call this “lessons of the moment.” There are special trainings are conducted on them - both for those who have been working for a long time and for newcomers.
At the beginning of the process we have plastic granules, and the output is a finished part, cast and painted. At the beginning of the process we have plastic granules, and the output is a finished part, cast and painted.
In our workshop, people work mainly under self-control. In our workshop, people mainly control their work independently. In order to get a high-quality part, without affecting any elements he monitors every minute of the process using special sample. Of course,we also control the correctness of operations performed, but the level of trust is very high. And hence everyone’s responsibility.
If any defect is detected, it is fixed immediately with description of the error that caused the problem. The information is entered into a database and a decision is made about what should be done and how. We call this “lessons of the moment.” There are special trainings are conducted on them - both for those who have been working for a long time and for newcomers.
At the beginning of the process we have plastic granules, and the output is a finished part, cast and painted. At the beginning of the process we have plastic granules, and the output is a finished part, cast and painted.
Alexey Akishin, painter
Svetlana Skvortsova,
technician:
- Manual painting requires professional skill, you cannot make mistakes, so everything must be perfect. We paint parts in anthracite and silver colors and create the look of washing machines. First of all, the buyer sees our work in the store. Many thanks to the workshop team, because without its support it would hardly have been possible to complete all the assigned tasks, and in particular to the foremen Olga Khoroshavina and Yulia Ptashnik. Mutual assistance and kind attitude towards each other are the key advantages of our team.
technician:
- Manual painting requires professional skill, you cannot make mistakes, so everything must be perfect. We paint parts in anthracite and silver colors and create the look of washing machines. First of all, the buyer sees our work in the store. Many thanks to the workshop team, because without its support it would hardly have been possible to complete all the assigned tasks, and in particular to the foremen Olga Khoroshavina and Yulia Ptashnik. Mutual assistance and kind attitude towards each other are the key advantages of our team.
Irina Glazkova, plastic molder
Kistaman Alibekova,
engineer:
– I working at large manufacturing enterprises have always attracted me. And when in October 2020 I was offered a job in a plastics production workshop, in a tampon printing area, I leaped immediately. I am responsible for planning at this site. Tampon printing is an interesting process that allows to transfer an image from cliche to the printed surface using a silicone tampon. When you see with your own eyes real material results of your efforts, it gives inspiration.
engineer:
– I working at large manufacturing enterprises have always attracted me. And when in October 2020 I was offered a job in a plastics production workshop, in a tampon printing area, I leaped immediately. I am responsible for planning at this site. Tampon printing is an interesting process that allows to transfer an image from cliche to the printed surface using a silicone tampon. When you see with your own eyes real material results of your efforts, it gives inspiration.
© Beko 2023