RETROFIT
Time for a positive change
A person's workplace is often called a second home. Indeed, one cannot help but agree on this one. Statistically, one-third of our lives belongs at work. So, we have launched the upgrade and improvement process, so that our home – Beko plant – becomes even better. Let my colleagues cover our progress this year.
ASSEMBLY LINE TRANSPARENCY
Alexey Shipunov,
Program Leader – Industrial Engineering:
– Projects related to production retrofit and upgrade at the plant are being implemented constantly. This year, it was of high importance that we relocated the preparatory operations and equipment from the main assembly line to the preparatory area.
Since this kind of work required a lot of time and additional preparation to be made, we decided to do it during the winter holidays and production shutdown. We had to to move the equipment from the assembly line, connect it to all utilities (electricity, compressed air, IT support), organize work places, develop and create the transportation line for materials. It took the coordinated efforts of a large team of specialists from different departments to ensure the good timing. Main preparation of the infrastructure for the new site was carried out by the EMS, technical development (OTR), IT and Equipment Repair and Maintenance Departments. Equipment relocation and preparation of work spaces was arranged by the Production Department together with the Technical Department. Equipment installation and start-up was made the production department together with the Equipment Repair and Maintenance Department and the IT department.
Thanks to the coordinated work of the production departments, competent management of assembly line foremen and specialists, all sections began their work with the launch of production lines on time, which made it possible to deliver semi-finished products to the assembly line on time and without delay.
Alexey Shipunov,
Program Leader – Industrial Engineering:
– Projects related to production retrofit and upgrade at the plant are being implemented constantly. This year, it was of high importance that we relocated the preparatory operations and equipment from the main assembly line to the preparatory area.
Since this kind of work required a lot of time and additional preparation to be made, we decided to do it during the winter holidays and production shutdown. We had to to move the equipment from the assembly line, connect it to all utilities (electricity, compressed air, IT support), organize work places, develop and create the transportation line for materials. It took the coordinated efforts of a large team of specialists from different departments to ensure the good timing. Main preparation of the infrastructure for the new site was carried out by the EMS, technical development (OTR), IT and Equipment Repair and Maintenance Departments. Equipment relocation and preparation of work spaces was arranged by the Production Department together with the Technical Department. Equipment installation and start-up was made the production department together with the Equipment Repair and Maintenance Department and the IT department.
Thanks to the coordinated work of the production departments, competent management of assembly line foremen and specialists, all sections began their work with the launch of production lines on time, which made it possible to deliver semi-finished products to the assembly line on time and without delay.
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After the subassembly sections were relocated, the assembly line acquired a refreshed look, increasing the image of the work stations.
Of course, we faced occasional difficulties, such as transportation of materials and semi-finished products, additional planning and staff management. And although the main and most important part of the work has been completed, improving the image of assembly lines is a on-going process that requires an integrated approach and coordinated work of all departments of the enterprise, and it will keep keep going.
LET THERE BE LIGHT!
Andrey Shamov,
Main Engineer:
– Illumination of some production areas was insufficient for quite a while and was less than 50 lx (lux). Therefore, it was decided to improve the lighting and install modern LED lamps without bulbs with a smaller power consumption and much higher luminous flux.
We had lamps with 160 W fluorescent lamps that did not provide adequate illumination of work areas and passageways. The lamps were open-type, and collected a lot of dust and dirt, which reduced insufficient light flux as it was. We were busy with partial replacement of the lamps with LEDs, but best results were yet to be achieved.
To replace the lighting, we hired a contractor, as further work required special lifts. On behalf of the plant, Alexander Kubarev, power engineer of the EMS, was in charge of the formalization of terms of reference and monitoring the compliance of the completed work with the requirements of the terms of reference. All work was carried out in two stages over the year.
At stage one we drew up the terms of reference requiring the installation of the lamps with illumination intensity of at least 250 lux, natural white color and uniform illumination. The main evacuation routes must have lamps with emergency lighting units, i.e. those that operate when the main power supply is shut. We made an illumination analysis where we saw in general what the new lighting would look like at every shop. After this, the old lamps were dismantled, new ones were purchased and installed, and the lighting behaviour was changed by reconstructing the distribution cabinets.
Andrey Shamov,
Main Engineer:
– Illumination of some production areas was insufficient for quite a while and was less than 50 lx (lux). Therefore, it was decided to improve the lighting and install modern LED lamps without bulbs with a smaller power consumption and much higher luminous flux.
We had lamps with 160 W fluorescent lamps that did not provide adequate illumination of work areas and passageways. The lamps were open-type, and collected a lot of dust and dirt, which reduced insufficient light flux as it was. We were busy with partial replacement of the lamps with LEDs, but best results were yet to be achieved.
To replace the lighting, we hired a contractor, as further work required special lifts. On behalf of the plant, Alexander Kubarev, power engineer of the EMS, was in charge of the formalization of terms of reference and monitoring the compliance of the completed work with the requirements of the terms of reference. All work was carried out in two stages over the year.
At stage one we drew up the terms of reference requiring the installation of the lamps with illumination intensity of at least 250 lux, natural white color and uniform illumination. The main evacuation routes must have lamps with emergency lighting units, i.e. those that operate when the main power supply is shut. We made an illumination analysis where we saw in general what the new lighting would look like at every shop. After this, the old lamps were dismantled, new ones were purchased and installed, and the lighting behaviour was changed by reconstructing the distribution cabinets.
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The first thing we did was replace the lighting above the assembly lines and the passageways next to them. Stage two was about installation of the new lighting at the mechanical production shop, the plastics processing shop, the refrigerator preparatory production shop and in the subassembly area between the conveyors.
As of now, the lighting at the main production shop has been completely replaced, but there is still some work to be done within the plant. It was very nice to hear that employees appreciated our efforts and the quality of lighting in the work spaces.
INTEGRAL STYLE
Natalia Kazennikova,
Production Process Efficiency Enhancement Department Specialist:
– The production process efficiency enhancement department took part in the implementation of a production facilities upgrade project. Posters, equipment signs, announcements were designed in a uniform style, arranged new foremen's rooms.
My priority tasks were to identify equipment, materials, lifting mechanisms and fix the design of signs at our plant.
It took to collect and systematize information for each department, get the dimensions and quantity of the signs. Anastasia Muradova was in charge of design development. The work still continues.
Natalia Kazennikova,
Production Process Efficiency Enhancement Department Specialist:
– The production process efficiency enhancement department took part in the implementation of a production facilities upgrade project. Posters, equipment signs, announcements were designed in a uniform style, arranged new foremen's rooms.
My priority tasks were to identify equipment, materials, lifting mechanisms and fix the design of signs at our plant.
It took to collect and systematize information for each department, get the dimensions and quantity of the signs. Anastasia Muradova was in charge of design development. The work still continues.
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We defined three categories of equipment signs in the following areas: “Automation”, “Traceability of Electronic Components”, and “Quality Control Points”. The amount of information we processed was so large that we ordered over 500 signs.
This year as well we once again engaged a contractor to paint the indoor production areas so that our employees could work in comfortable conditions.
We cannot carry out some work at all shops at once, since the plant is very large and all changes have to be carried out in stages. This time we specified three departments to be improved: plastics recycling shop, washing machine assembly line and painting shop.
In order for the design of foremen's daily meet-up room – the foremen's’ room – to correspond to the overall style of the company, it was decided to develop a more functional and presentable design option. We agreed on the layout and dimensions of the future room with the plant management, and then handed it over to a third-party organization for production.
The first prototype was installed at the washing machine assembly line. Since we were completely satisfied with the result, we continued making changes at other shops.
We cannot carry out some work at all shops at once, since the plant is very large and all changes have to be carried out in stages. This time we specified three departments to be improved: plastics recycling shop, washing machine assembly line and painting shop.
In order for the design of foremen's daily meet-up room – the foremen's’ room – to correspond to the overall style of the company, it was decided to develop a more functional and presentable design option. We agreed on the layout and dimensions of the future room with the plant management, and then handed it over to a third-party organization for production.
The first prototype was installed at the washing machine assembly line. Since we were completely satisfied with the result, we continued making changes at other shops.
GOOD REST IS A MUST
Anastasia Muradova,
Senior Internal Communications Group Specialist:
– New comfortable recreation areas have been created inside the shops, where the employees can now take a break, recharge and get in the mood for work, and simply chat with colleagues in calm surroundings.
We started off with the re-branding of Beko. This served as the impetus and motivation to give our plant a new life and improve conditions for employees. The recreation areas were planned even before the corporate design update, but in the end it all came together as one large project, divided into several key tasks.
The design project was developed from scratch. In agreement with the management, it was decided to completely change the previous standard of the recreation area in order to improve the ergonomics of the space.
Anastasia Muradova,
Senior Internal Communications Group Specialist:
– New comfortable recreation areas have been created inside the shops, where the employees can now take a break, recharge and get in the mood for work, and simply chat with colleagues in calm surroundings.
We started off with the re-branding of Beko. This served as the impetus and motivation to give our plant a new life and improve conditions for employees. The recreation areas were planned even before the corporate design update, but in the end it all came together as one large project, divided into several key tasks.
The design project was developed from scratch. In agreement with the management, it was decided to completely change the previous standard of the recreation area in order to improve the ergonomics of the space.
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Many factors were considered: increasing the area and number of seats, landscaping, available comfortable equipment, furniture and electrical appliances. We drew on various references from other projects, examples of recreation areas of our Turkish colleagues, but first and foremost we took into account the wishes and expectations of our employees about it.
The refrigerator assembly shop greatly assisted us at places where it was decided to arrange the first recreation areas. Everyone, from the foremen to the managers, gathered feedback and brought it to us.
Now the project has already been implemented, everything is installed, but we continue the improvement process. We conduct weekly inspections, organize the necessary troubleshooting work, take notes, and a plant specialist occasionally comes to take care of them. All this leads to a new standard for recreation areas, which we will install in future sections at other shops. This is very important work that is done jointly with many departments of production, personnel, administrative department, supply, electromechanical service, labor protection. Every employee invests their best effort.
Now the project has already been implemented, everything is installed, but we continue the improvement process. We conduct weekly inspections, organize the necessary troubleshooting work, take notes, and a plant specialist occasionally comes to take care of them. All this leads to a new standard for recreation areas, which we will install in future sections at other shops. This is very important work that is done jointly with many departments of production, personnel, administrative department, supply, electromechanical service, labor protection. Every employee invests their best effort.
Sergey Telitsyn,
Team Leader of the Administrative Department:
– When creating the concept of recreation areas, our main task was to organize a space at the shop in the right way, so any employee could sit back, relax, recharge and get back to work. And our team aced this task. We tried to take all the employees' ideas into consideration, and as a result we got coffee machines and snack machines installed in the new recreation areas, and the design included greenery and live plants.
Team Leader of the Administrative Department:
– When creating the concept of recreation areas, our main task was to organize a space at the shop in the right way, so any employee could sit back, relax, recharge and get back to work. And our team aced this task. We tried to take all the employees' ideas into consideration, and as a result we got coffee machines and snack machines installed in the new recreation areas, and the design included greenery and live plants.
Nikolai Beltyukov,
Refrigerator Assembly Shop Manager:
– We had recreation areas before, but they certainly lacked tables and seats for our employees (only 6 chairs per 52 site employee), and all the equipment we had to offer was a water dispenser. After the reconstruction, our recreation areas became more spacious as modern comfortable furniture was installed (including storage cabinets for kitchen utensils), purifiers (cleaning, cooling devices or water heaters), coffee machines and snack machines. I would like to thank everyone who was engaged in the implementation of that highly importance project. Our employees gave their highest rates to the new recreation areas and they are ready to share their opinions on any improvements and upgrades there might be added.
Refrigerator Assembly Shop Manager:
– We had recreation areas before, but they certainly lacked tables and seats for our employees (only 6 chairs per 52 site employee), and all the equipment we had to offer was a water dispenser. After the reconstruction, our recreation areas became more spacious as modern comfortable furniture was installed (including storage cabinets for kitchen utensils), purifiers (cleaning, cooling devices or water heaters), coffee machines and snack machines. I would like to thank everyone who was engaged in the implementation of that highly importance project. Our employees gave their highest rates to the new recreation areas and they are ready to share their opinions on any improvements and upgrades there might be added.
A HALL? A MUSEUM!
Anastasia Muradova,
Senior Internal Communications Group Specialist:
– Another important stage of the retrofit was the upgrade of the hall design and the organization of the plant museum.
As with the recreation areas, the solution to this problem also started off with the design project. We prepared several mockups, agreed with the management and approved the best option, then we chose a contractor and started the repairs in the summer.
Of course, as with any renovation, there were changes and adjustments that were required to be made during the process. I think this was one of the most exciting and interesting projects where employees from completely different departments took part – the administrative department, technical development department, IT, electromechanical service, supply department, accounting department, HR department. The changes were ambitious – we changed floor tiles, ceiling and lighting, and covered the wall with plasterboard. We kept working at day and even at night.
Anastasia Muradova,
Senior Internal Communications Group Specialist:
– Another important stage of the retrofit was the upgrade of the hall design and the organization of the plant museum.
As with the recreation areas, the solution to this problem also started off with the design project. We prepared several mockups, agreed with the management and approved the best option, then we chose a contractor and started the repairs in the summer.
Of course, as with any renovation, there were changes and adjustments that were required to be made during the process. I think this was one of the most exciting and interesting projects where employees from completely different departments took part – the administrative department, technical development department, IT, electromechanical service, supply department, accounting department, HR department. The changes were ambitious – we changed floor tiles, ceiling and lighting, and covered the wall with plasterboard. We kept working at day and even at night.
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None of these projects would have been well-implemented without the help and motivation of the people involved, which, in my opinion, is very valuable and encouraging.
At the final stage of the renewal, the work on a museum has been launched. We tried to be mindful of all the key events of the entire plant life. And this was not only about the evolution of our products, but also the memorable events, achievements of the plant and the people who run it. Our museum has a a special value. Its every block can be renewed over time if necessary, and we might add new stages and vivid episodes from the life of the plant that only confirms how unique and inimitable it is compared to standard museums, which means we have achieved the result that we aimed to.
UPGRADED AND EXPANDED
Andrey Matveev,
Building Engineer:
– Every year our company carries out repair work to keep production and utility facilities working. This year, a fairly large scope of both repair and construction work on new departments was completed. On-site repairs were conducted not only by the third-party contractors, but also by the force of our employees. In this respect, we recruited qualified construction workers and purchased the necessary equipment and tools. I would like to cover one of the repairs works individually: this is the work on replacing the floor covering on the staircase of the entrances to the household appliances shop and the front gate entrance. The main requirement was to find a durable covering for the staircase that would primarily ensure safe passage of the employees regardless of the weather conditions and season, and also have strength, wear resistance when exposed to chemical agents and an optimal cost in terms of pricing policy. When performing these works, we faced many challenges like lifting and installation of the initial granite steps over 120 kilograms each. To perform this operation, a special device was made with the help of the welding shop, the combined use of which with the forklift almost completely shut the door on the need of the manual lifting of granite steps. When performing these works, I would like to give credit to the employees for their great contribution and professionalism: Mikhail Markov - foreman of the welding shop, and the following workers: Umrbek Matyakubov, Ganzhabai Abdullaev and Rasul Zhumaniyazov.
Andrey Matveev,
Building Engineer:
– Every year our company carries out repair work to keep production and utility facilities working. This year, a fairly large scope of both repair and construction work on new departments was completed. On-site repairs were conducted not only by the third-party contractors, but also by the force of our employees. In this respect, we recruited qualified construction workers and purchased the necessary equipment and tools. I would like to cover one of the repairs works individually: this is the work on replacing the floor covering on the staircase of the entrances to the household appliances shop and the front gate entrance. The main requirement was to find a durable covering for the staircase that would primarily ensure safe passage of the employees regardless of the weather conditions and season, and also have strength, wear resistance when exposed to chemical agents and an optimal cost in terms of pricing policy. When performing these works, we faced many challenges like lifting and installation of the initial granite steps over 120 kilograms each. To perform this operation, a special device was made with the help of the welding shop, the combined use of which with the forklift almost completely shut the door on the need of the manual lifting of granite steps. When performing these works, I would like to give credit to the employees for their great contribution and professionalism: Mikhail Markov - foreman of the welding shop, and the following workers: Umrbek Matyakubov, Ganzhabai Abdullaev and Rasul Zhumaniyazov.
From left to right: Rasul Zhumaniyazov, Umrbek Matyakubov, Ganzhabai Abdullaev
Alongside with the repair of the entrance group staircases, we also worked on the arrangement of storage facilities. Based on the results of competitive bidding in terms of these works, we invited specialized construction organizations. Thanks to the joint work of many departments (procurement department, electromechanical service), in the third quarter of this year, two frame-tent warehouses with over 3,000 square meters of a total area were put into operation. The purpose of their construction was the temporary storage of components and products arriving at the enterprise that turn into from household appliances after complex technological processes at production assembly lines. We and all of the enterprise service branches have goals and tasks to be done within the set deadline, like reconstruction of the polyurethane foam shop, major repairs of the roof covering of the household appliances shop.
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To perform this operation, the welding shop made a special device, the combined use of which with the forklift almost completely shut the door on the need of the manual lifting of granite steps.
KEEPING ON WITH THE RETROFIT
Stanislav Miroshnikov,
Factory Business Unit Director:
– In 2024, with our joint efforts, we managed to do a lot to make our plant look better and make it comfortable for work. But a retrofit is not just a project, but a non-stop, stepwise process. And we intend to continue next year. We will gradually carry out repair work and replace equipment at the plant where it is really necessary. After all, the plant is our second home, and keeping it working is a common task to do.
Stanislav Miroshnikov,
Factory Business Unit Director:
– In 2024, with our joint efforts, we managed to do a lot to make our plant look better and make it comfortable for work. But a retrofit is not just a project, but a non-stop, stepwise process. And we intend to continue next year. We will gradually carry out repair work and replace equipment at the plant where it is really necessary. After all, the plant is our second home, and keeping it working is a common task to do.
© Beko 2024