METU

Mechanical Engineering Department

ME 300
SUMMER PRACTICE REPORT
2004
idem KARACA
1345313

TABLE OF CONTENTS
Description Of The Company.. 3
Introduction.. 5
Report
-Manufacturing Processes Used In Machine
Workshop..7
-Processes Used in Tank Factory Machine
Workshop:
Power Transformers Tanks.....10
Distribution Transformers Tanks.14
-The Machine Tools In The Machine Workshop.18
-Manufacturing Systems Used In Machine
Workshop...............................................................24
-Production of 5 Sample Parts25
-Cost Analyses........................................................27
Conclusion.................................................................28
Appendix
-Organisation Chart................................................ 29
-Flange Cost Analysis............................................ 30
-Lifting Lug Cost Analysis....................................... 31
-Radiator Bondage................................................. 32
-Lifting Lug............................................................. 33
-Storage Unit Flange.............................................. 34
-Distribution Transformer Cover Base.................... 35
-Pipes..................................................................... 36

DESCRIPTION OF THE COMPANY

AREVA T&D Enerji Endustrisi A..
Bar Mah. 1801 Sok. No:104 41410 Gebze/KOCAEL
Organisation chart of the company can be found on
appendix page number 29
AREVA is employing 1068 workers.
Engineers: 123
Workers: 737
Executive: 45
Employee: 163
Engineers in AREVA work in
-Design and Construction dept.
-Production dept
-Production Planning dept.
-Sales dept.
-Purchase dept.
-R&D dept.
-As Welding Engineers in Machine Workshop
Company mainly works on:
-Power Transformers
-Distribution Transformers
-Medium and Low Voltage Switchboards
-Protection and Control Systems
-Dimensional Transformers
AREVA uses newest technologies on their modern
establishments on 88.218m2 area, 48.736m2 of which is
indoors.
AREVA Enerji Endstrisi A.. is founded by AEG AG and
Etibank, a Turkish-German partnership in 1966 under the
name of AEG ET and began production in 1967.

Firm was renamed GEC ALSTOM in 1997 and ALSTOM

in 1998. It was finally renamed AREVA Enerji Endstrisi
A.., as ALSTOM group was sold to AREVA group on
10.02.2004
AREVA T&D Enerji Endustrisi A.., who has the level of
selling technological license and know-how also has a
good competitive nature in world market.
Since 1992 the company successfully applies ISO 9001,
which is a quality guarantee model which includes all the
activities from determining the wishes of the customer, to
execution of planning and production, technical support
and service during use. AREVA is one of the first
transformer companies to get an ISO 9001 certificate in
Europe. The company is inspected every year by TSE and
DQS.
Not only AREVA T&D Enerji Endustrisi A.. has the
large market share in Turkey, it also exports more than
half of its production to Europe, Far East, Australia,
Canada, South America, Africa and Middle East.

INTRODUCTION
In universities generally students have many classes
about their field of study, but none could ever get them
ready for working conditions. Likewise students in
Mechanical Engineering department of Middle East
Technical University have all the necessary theoretical
information they need to be mechanical engineers. They
also have classes which are more frequently in use in
working conditions. They have technical drawing in ME113
and 114, and manufacturing technologies in ME202.
But are these lessons enough to get a student ready for
working as mechanical engineers? The answer is
obviously no. Students of now and the engineers of the
future need practical knowledge as well as theoretical.
To ensure this, students in Middle East Technical
University have ME300 Summer Practice Program, in
which they have to work in a company as interns for a
period of at least 20 days.
The summer practice has many advantages for a
student. First, a practical knowledge and a good exercise
of the theoretical knowledge from the lessons are
obtained. Students see manufacturing processes in
working conditions. They are able to identify the
techniques and see the advantages and disadvantages of
the techniques for some particular products. To see the
processes that they saw in theory in real life, improves the
knowledge of that processes in students memories.
Second great advantage of the summer practice is that
students get used to the working conditions, which may be
called here the working routine. To have prespecified

working hours and general working rules to obey, helps

the students get used to the working routine.
And the third advantage of the summer practice is of
course the experience. Nowadays employers put a great
importance to experience and a summer practice, though
limited, is a great way of getting experienced in the
university years.
As a result of all these conditions, summer practice is
very important for an engineering student, both in studying
and in business life.

REPORT
Manufacturing Techniques Used in Tank Factory
Machine Workshop
1) Cold Working Processes:
a) Bending:
- Angle Bending:
Bending is the plastic deformation of metals about a
linear axis with little or no change in the surface area.
Machine workshop uses press brakes to bend thin sheets
of material. The metal is bent between interchangeable
dies and is fed inward between successive strokes to
produce repeated bends. Tank Factory machine workshop
uses angle bending for producing corrugated walls for
Distribution Transformers Tanks.
b) Shearing:
- Basic Shearing:
Shearing is the mechanical cutting of sheet or plate
materials without formation of chips. Machine workshop
uses guillotine cutters, Peddinghaus machine and
Kaltenbach saw for shearing of steel sheets into desired
dimensions, if the sheet cannot be cut by flame cutters.
- Piercing and Blanking:
Piercing and blanking are shearing operations, in which
the blade takes curved form. In blanking, the piece
punched out is the desired work piece; whereas in
piercing, piece punched out is the scrap. Tank Factory
machine workshop uses Trumpf 235, Trumpf 260, Trumpf
7

300 CNC Punching machines and sometimes

Peddinghaus machine to form flanges or to cut out desired
shapes on tank covers.
2) Chip-Type Machining Processes:
a) Drilling:
Drilling is the process of producing internal cylindrical
surfaces. Drilling is a simple process, but because of the
friction between the body of the drill and the wall of the
work piece, heating of the parts occur as well as chip
formation. This poor heat removal results in difficulties in
this very simple process. Machine workshop uses a radial
drill to drill various holes on tanks and accessories.
b)

Turning:

Turning process enables to machine external cylindrical

and conical surfaces. In turning, the work piece rotates
and a longitudinally fed, single-point tool does the cutting.
If the tool is fed at an angle to the axis of rotation, an
external conical surface results. This is called taper
turning. If the tool is fed at 90o to the axis of rotation, a flat
surface is produced and the operation is called facing.
Tank Factory machine workshop uses a vertical turning
lathe to machine cylindrical parts like flanges.
c) Abrasive Machining Processes:
- Blasting:
This is a process where small abrasive particles are
blasted with pressure on the surface of the material to
clean the material from dirt and rust or to polish the
material after machining. Machine workshop uses a sand
blasting facility to clean the sheets before machining and
to polish them to make them finished products.

3) Joining Processes:
a) Welding:
Welding is the process of permanently joining two
materials through localized coalescence, resulting from a
suitable combination of temperature, pressure and
metallurgical conditions. Because the combination of
temperature and pressure can vary from high temperature
and low pressure to low temperature and high pressure,
welding can be done under a lot of different conditions and
numerous welding processes have been developed to be
used in manufacturing. Tank Factory Machine Workshop
uses MIG/MAG Shielded Gas Welding methods to
assembly the different parts and accessories of the tanks
together.

Processes Used in Tank Factory Machine Workshop

Tank factory machine workshop makes two kinds of
tanks. One is Power Transformers tanks, and the other is
distribution transformers tanks. Production processes of
these two kinds are basically similar but have some
differences in detail. Here are the processes which the
tanks overgo during production:
Power Transformers Tanks:
Flat-wall tanks which are used for medium or large
power transformers are built in various geometrical
shapes. They are built according to the dimensional
tolerances set by DIN ISO 2768, medium. Is it extremely
important to be unleakage and durable properties for the
tanks. Power transformers tanks and accessories pass
through following paces to be a finished product:
1) Pre-Blasting:
Steel sheets in the open area warehouse are
transported to pre-blasting facility. Sheets get into the
machine in vertical position. Rust, dirt and mud are
removed from the material by sand blasting. After cleaning
process sheet comes to the exit of the machine. By lift updown apparatus the sheet position change vertical to
horizontal in order to realise an easy transportation.
2) Flame Cutting:
After removal of rust, dirt and mud in order to prepare
surface for cutting process, sheet is lifted by cranes from
the lift up-down apparatus to table of cutting machines. In
Tank Factory there are two CNC flame cutting machines.

10

Stainless Cr-Ni austenitic sheets can be formed by special

plasma cutting unit. Drawings transmitted from
programming center to CNC cutting machine are seen in
the screen of the machine operators. Operators can make
manual changes, new drawings and change template
drawings. Parts cut by drawings of the projects are
stacked to transfer pre-assembly unit .
3) Pre-Assembly:
Forming of pipes, angle irons, chennels and steel parts
are performed in pre-assembly process. Saw machines,
peddinghaus, CNC punching machines, guillotines,
bending machines etc. are operated to form steel parts.
Formed materials according to drawings are transferred to
assembly unit by carrier on rail.
4) Assembly:
Walls of the tanks, bottom parts, covers, conservators,
cable boxes and other accesories are assembled
according to drawings and norms in medium power and
power transformers tanks assembly unit. On the 30 m
plates marking mounting and spotting processes are
realised in very high sensitiveness.
5) Adaptation:
After welding process, assembled tank, cover,
conservator, cable box and other accesories are ready for
the adaptation. All parts are adapted to each other and
piping system is set by experienced workers. Before
welding and surface treatment, fitting of the parts are
controlled finally. Following the Quality Contollers
approval, tank and tank components are relocated to
prepare for shot blasting and painting.

11

6) Welding:
Welding is performed by modern welding machines,
spotting and welding plates of 30 m applying generally
MIG/MAG Shielded Gas Welding methods, because such
methods are superior to arc welding with covered
electrode in terms of simplicity and cost efficiency. The flat
walls are built in a modular system. Seperately
manufactured base, front and side walls and upper frame
are welded together to form the tank. All the welders in the
welding facility are experienced and are certified
according to EN 287-1 standard by the international and
european welding engineers. In tank factory MIG/MAG
shielded gas welding, e-hand electricarc welding and TIG
welding is applied at world standards.
7) Testing:
Tightness of all welding seams of the tanks are
controlled by penetration tests and checked with ultraviolet
lamps.
8) Shot Blasting:
Sheet surfaces of the flat-wall tanks are cleaned by shot
blasting till the degree of SA 2 in the shot-blasting
facility with modern machines and robots. Depending on
customer request, sheet surfaces are shot-blasted up to
degree SA 3 before zinc spraying applied. The new shot
blasting facility is equipped with robots.
9) Zinc spraying:
Subsequently, tank surfaces after being completely
cleared of sand, minimum zinc coat of 100 micron is
plated. Zinc material is sprayed homogeneously with
spray guns to all surfaces of the parts. During the zinc

12

spraying process workers use every means of protection

for their health and easy working, and these equipments
are controlled periodically.
10) Painting:
By assesment of transformers environment, all surfaces
are painted with appropriate paint systems. Internal
surfaces and all the sealed surfaces on the flat-walled
tanks are painted with special oil-resistant paint. External
surfaces are painted with air-dried paints by airless
pistons. The paint dry film thickness of the three coatings
is minimum 145 micron. Besides, that may be increades
upon request, according to various strain levels, for
example, under chemical environments of tropical
climates.
Water based paints, solvent based paints can be used in
painting operations according to customer requirements.
All paints applied for flat-walled tanks are air-dried paints.
In power transformers tanks unit there are two seperate
modern facilities for painting, primer coat painting cabin
and finished coat painting cabin. These covered cabins
have their own digitally controlled crying unit up to 90oC
and cold air flowing for water based paints.
On account of water based paints being environment
and health friendly, in tank factory paintshops waterbased
paints are applied since 2002. To increase surface qualiy
and painting process, machine workshop cooperates with
international paint and chemical material suppliers.

13

Distribution Transformers Tanks:

Distribution transformers tanks are similar to power
transformers tanks but are smaller and have one major
difference, corrugated walls. Distribution transformers
tanks and accesories pass through following paces to be a
finished product:
1) Pre-Blasting:
Steel sheets in the open area warehouse are
transported to pre-blasting facility. Sheets get into the
machine in vertical position. Rust, dirt and mud are
removed from the material by sand blasting. After cleaning
process sheet comes to the exit of the machine. By lift updown apparatus the sheet position change vertical to
horizontal in order to realise an easy transportation.
Removed rust, dirt and mud are filtered in machines own
filtering system out of the plant and sent to scrap storage
under control.
2) Flame Cutting:
After removal of rust, dirt and mud in order to prepare
surface for cutting process, sheet is lifted by cranes from
the lift up-down apparatus to table of cutting machines. In
Tank Factory there are two CNC flame cutting machines.
Stainless Cr-Ni austenitic sheets can be formed by special
plasma cutting unit. Drawings transmitted from
programming center to CNC cutting machine are seen in
the screen of the machine operators. Operators can make
manual changes, new drawings and change template
drawings. Parts cut by drawings of the projects are
stacked to transfer pre-assembly unit .

14

3) Pre-Assembly:
Forming of pipes, angle irons, chennels and steel parts
are performed in pre-assembly process. Saw machines,
peddinghaus, CNC punching machines, guillotines,
bending machines etc. are operated to form steel parts.
Formed materials according to drawings are transferred to
assembly unit by carrier on rail.
CNC punching machines can punch the steel sheets up
to 8 mm, stainless steel up to 3 mm, copper steel up to 12
mm. All the covers of tanks with corrugated walls can be
punched by CNC punching machines. All punching
machines are computer controlled and operated according
to drawings transmitted from the programming center.
Punching machines have a safety area prevented by
photocells.
4) Corrugated Wall Production:
Corrugated wall production semi-automatic production
line includes folding, crushing, spot welding and welding
unit. corrugated walls are manufactured in various widths
from 500 mm to 1400 mm at 100 mm increments. Slice
depths may be 50, 100, 125, 160, 200, 240, 280, 320 and
360 mm. Slices from 200 to 260 mm in depth feature oval
links which are spot welded. The distance between slices
is 45 mm, the width of oil grooves on the slice is 8 mm and
the thickness of the used sheet is 1-1,2-1,5 mm. The
corrugated walls are reinforced at both ends by internal
braces with 8mm in diameter.
5) Assembly:
Tank factory machine workshop utilises manipulators for
economic and better quality welding and assembly. For
this purpose, tanks with corrugated walls are assembled

15

and welded with their upper and lower part joined together
on manipulators. These 360o rotating all-position
manipulators ensure regular welding in horizontal position
and continuous, uniform, made to freseen quality,
appearing smoother and error-free welding seams and
easy assembling.
6) Welding:
Welding is performed by modern welding machines and
manipulators, generally MIG/MAG Shielded Gas Welding
methods, because such methods are superior to arc
welding with covered electrode in terms of simplicity and
cost efficiency. All the welders in the welding facility are
experienced and are certified according to EN 287-1
standard by the international and european welding
engineers. In tank factory MIG/MAG shielded gas welding,
e-hand electricarc welding and TIG welding is applied at
world standards.
7) Testing:
Tightness of all welding seams of the tanks are
controlled by penetration tests and checked with ultraviolet
lamps.
8) Sand Blasting:
Sand blasting facility is designed to work automatically.
Sand blasting operation is applied to distribution
transformers tanks and accessories in degree SA 2 and
to surfaces which will be galvanized in degree SA 3. All
the tanks and components remain for a definite time in the
sand blasting facility to obtain homogeneous surfaces.
After sand blasting process, all parts are ready to
phosphating with iron-phosphate or galvanizing.

16

9) Galvanizing:
Depending on customer request, tanks and components
can be galvanized between 55-85 microns according to
DIN EN ISO 1461.
10) Iron-Phosphating:
In order to remove oily and greasy substances from the
surface of sand blasted tanks and accessories, ironphosphate is applied to all external surfaces and they are
rinsed with water by using pressured equipments.
11) Painting:
Tanks with corrugated walls are painted by flow painting
method and dried through an oven heated up to 160 o and
Flat wall distribution transformers tanks and
components are painted by spraying method with air-dried
paints. Movements of the tanks in the painting unit are
ensured by automatic conveyors. Solvent based and
water based paints, air dried or oven dried paints can be
used in painting operations.
On account of water based paints being environment
and health friendly, in tank factory paintshops waterbased
paints are applied since 2002. To increase surface qualiy
and painting process, machine workshop cooperates with
international paint and chemical material suppliers.

17

The Machine Tools In The Machine Workshop

Here are the various machine tools that the machine
workshop uses:
Flame Cutters (ESAB (1) AND SATO (1)):
They are used for cutting sheets before being punched
and drilled.
ESAB:
Maximum cutting area: 183 cm x 366 cm
Maximum cutting thickness: 2.5 cm
Maximum speed: 0.04 m/s
SATO:
Maximum cutting area: 365.7 cm x 609.6 cm
Maximum cutting thickness: 3.05 cm
Manual Plasma Cutters (4):
For processes that cannot be done on flame cutters.
Maximum cutting thickness: 3.2 mm
Weight: 27.2 kg
Kaltenbach saw (2):
It is a manual saw used for cutting thicker sheets.
Saw blade diameter: 400 mm
Weight: 816,48 kg
Power: 1,72 kW - 2,61 kW
Cutting speeds: 0.2/0.4 m/s to 0.3/0.6 m/s

18

Pedinghouse (1):
It is a multi-functional manual machine tool. Used for
cutting plain and angled frets on one side and on the other
side drilling with the help of a a small press by adjusting
proper sets of tools.
Flat shear: 15.8 mm x 508 mm
Angled shear: 152.4 mm x 152.4 mm x 12.7 mm
Rated punching capacity: 110 tons (punch)
140 tons (shear)
Trumpf 260 (1):
A CNC. For cutting and drilling according to the desired
work or drawing. This machine is half hydrolic-half
pnomatic. Work is programmed from the programming
center and transmitted to the machine. Templates can be
changed manually if desired.
Number of tools: 10
Blade force: 250 kN
Maximum sheet metal area: 2.5 m x 1.6 m
Speed: 108 m/min
Maximum sheet thickness: 6.4 mm
General dimensions: 7.35 m x 6.7 m x 2.47 m
Weight: 16500 kg

Abkant Press (Hydrolic) (2):

Used for bending of the pre-worked sheet materials. It
can bend up to 30 mm thickness. Material is adjusted and
the machine is set manually.

19

Working thrust: 1600 kN

Bending distance: 4200 mm
Stroke: 200 mm
Maximum space: 440 mm
Table height: 900 mm
Slide speed: 80 mm/s
Pressing speed: 8 mm/s
Lifting speed: 50 mm/s
Motor power: 15 kW.
Abkant Press (Mechanic) (3):
They are used for bending and cutting materials by
adjusting different patterns on the machines.
Nominal power: 1000Kn.
Strokes per minute: 25
Stroke: 50 mm
Ram adjustment distance: 50 mm
Main motor power: 3.7 kW.
Distance from BDC: 200 mm.
Weight: 25000 kg.
General dimensions: 2.3 m x 1.2 m x 2.1 m

Guillotine machines (2):

They are manual cutters in which sheet material is cut to
desired dimensions before going to Trumpf machines to

20

be worked. Guillotine cutters can cut up to 12 mm

thickness and they are also hydrolic.
Blade length: 1600 mm
Adjustable angle: 0.5-3o
Pressing force: 11200
Backwards motion: 800 mm
Motor power: 15 kW
Weight: 5700 kg
General dimensions: 2.2 m x 2.3 m x 2.2 m

Trumpf 235 (1):

It is a CNC machine. Most simple of the trumpf
machines in the workshop. Used in simple cutting, drilling,
embossing etc.
Punching capacity: 250 kN
Maximum sheet metal area: 2 m x 1 m
Maximum sheet thickness: 6.4 mm
Maximum punching diameter: 105 mm
Maximum stroke length: 45 mm
Number of tools: 5
General dimensions: 3.8 m x 4.68 m x 2.3 m
Weight: 8000 kg

21

Trumpf 300 (1):

It is an NC machine. Cuts and drills the materials that
has been pre-cut in ADH or ATM cutters. It is half hydrolichalf pnomatic. Programs about the work which are written
in the main central are transferred onto a special paper
ribbon to be used by the Trumpf 300 NC.
Punching capacity: 30 tons
Maximum sheet metal area: 1.6 m x 2.25 m
Maximum sheet thickness: 8 mm
Number of tools: 20
Radial drill (3):
A manual drill used for drilling holes of any diameter and
period, cutting grooves etc. by the 360 degree turning
head.
Drilling capacity: 40 mm
Rotation speed: 90-1000 rot/min
Feeding speed: 0.2-0.1 mm/rot
Drilling radius: 505-1125 mm
Spindle-column distance: 400-1020 mm
Spindle-base distance: 380-1180 mm
Motor power: 1.5 kW
Weight: 1500 kg
General dimensions: 1.7 m x 1 m x 2 m
Vertical turning lathe (1):
It is a manual turning machine used for shaping
cylindrical parts like flanges.

22

Welding (65-70):
MIG/MAG Welders are used to permanently assembly
the components and accessories of transformers tanks
together.
Input voltage: 220 V
Output current: 30/140 A
Duty cycle: 120 A / 20%
Thickness of material: 0.5 mm / 4 mm
Weight: 30 kg

23

Manufacturing Systems Used In Machine Workshop

a) Job Shop Manufacturing:
In this system, units for different orders follow different
paths through processes or machines. The characteristics
of this kind of production are its flexibility, wide variety of
product design or customer service, and the need for
many highly skilled people, much indirect labor, and a
great deal of manual material handling. General-purpose
machines are grouped by function and adapted to specia
requirements of different orders. The price for this
flexibility is long in-process times, large in-process
inventories of components and materials, and the
formidable task of scheduling different orders through the
functional centers in which machines and people must be
shared.
b) Project Shop Manufacturing:
This system is directed toward creating a product or
service which is either very large (This is the case here,
for large Power Transformers Tanks), or one-of-a-kind,
with a set of well-defined tasks, which typically must be
accomplished in some specified sequence. The men,
materials and machines all come to the project site for
assembly and processing. The project shop is generally
backed up by a job shop or a flow shop operation to
supply component parts.

24

Production of 5 Sample Parts

Radiator Bondage:
Stainless sheet metals of 40x60 mm dimensions are first
pre-blasted to remove rust dirt and mud that could arise
from storing in open air. It is then cut to 2320 mm length
bars by flame cutters or saw whichever is not used at that
moment. With saw you get relatively clean edges but with
flame cutter you must do grinding after cutting. Four holes
of 15 mm diameter are then drilled on the bar with periods
of 620 mm by radial drill. The now ready bandage is then
sent to painting. Because the material is stainless sheet
blasting is not done after shaping. A technical drawing of
the bondage can be seen in Appendix page number 32.
Lifting Lug:
Lifting lug is composed of four parts. All sheets are preblasted. For the first part 30 mm thick sheet metal is cut to
desired dimensions by flame cutter and sent to grinding. It
is then bent by 125 degree by abkant bending press.
Second part is again cut by flame cutter into a 90 mm high
20 mm thick hollow cylinder. It is again sent to grinding.
Third part is cut from 10 mm thick sheet and fourth part is
cut from 30 mm sheet by flame cutter and grinded. Then
all parts are welded together and sent to assemblying to
the tanks. A technical drawing of the lifting lug can be seen
in Appendix page number 33.
Storage Unit Flange:
ST 37-2 metal with 15 mm width is first pre-blasted then
sent to a flame cutter. Cutter first cuts a circle of 990 mm

25

diameter and then turns it into a hollow circle by cutting a

890 mm diameter hole in it. The ring is then sent to turning
machine which cuts a groove of 4.9 mm on it. 36 holes of
15 mm diameter are drilled on the ring on a circle of 950
mm diameter by radial drill. Shot blasting and painting is
done to the whole assembly after the flange is fixed on the
storage unit. A technical drawing of the flange can be seen
in Appendix page number 34.
Distribution Transformer Cover Base:
The base of the cover is made of 6 mm pre-blasted
sheet metal and it is cut to appropriate dimensions by
guillotine cutter. Then 14 mm diameter holes and the 25
mm diameter hole are drilled by one of the trumpf
machines whichever is not on work. The piece then is sent
to one of the flame cutters for the other big holes and the
220x810 mm rectangle to be cut. It is then sent to shot
blasting and painting. A technical drawing of the cover can
be seen in Appendix page number 35.
Pipes:
88.9 mm diameter and 3.2 mm thick pipes are cut to
1300 mm and 800 mm by kaltenbach saw. Appropriate
flanges of 180 x 180 x 30 are cut by flame cutters and
sent to turning machine for final shaping. It is important to
consider 1-2mm of welding tolerance when shaping the
flanges. The flanges and small connecter parts are fitted
on the pipes by welding. Lastly shot blasting and if needed
galvanizing is done and the pipe is sent to painting. A
technical drawing of the pipes can be seen in Appendix
page number 36.

26

Cost Analyses
Storage Unit Flange:
We multiply the weight 15kg with the unit cost 0,55
euro/kg to get material cost 8,25 euro and we take labor
hour as 1,5 hours. Rest of the calculations are done on
the table which can be found in Appendix page number
30.
Lifting Lug
We take the weight of the lug as 53 kg and multiply it
with the unit material cost 0,55 euro/kg to get material cost
and we take the lug can be done on 2 hours which is a
rounded time but suitable. Rest of the calculations are
done on the table which can be found in Appendix page
number 31.

27

CONCLUSION
ME 300 Summer Practice in AREVA is a very useful
experience for a Mechanical Engineering student. The
student gets used to the working life and working
conditions, facing real problems in manufacturing
processes. He observes the various production
techniques and also learns how an engineer and a worker
is related to each other.
Tank Factory has a highly developed, orderly and
suprisingly fast Machine Workshop. Despite using
relatively slow manufacturing systems like Job Shop and
Project Shop Manufacturing, the Machine Workshop is
very quick in satisfying the customers demands using
appropriate machines and highly skilled workers. AREVA
also supplies technical support and service during use and
Tank Factory Machine Workshop is also very effective in
repairing and updating the tanks that are in use.
One problem of AREVA Tank Factory Machine
Workshop could be not checking up the machines they are
using periodically. Machine Workshop works by orders
and these orders can be variable. So every machine in the
workshop is used many times within a short period, which
may result in more rapid breakdowns in machines.
Machine Workshop needs to check the machines
periodically and repair the needed ones.
To sum up, the Summer Practice is very useful for future
engineers. It improves theoretical and practical knowledge
and also the student gets experience in working conditions
and bussiness life.

28

APPENDIX
Organization Chart

29

Storage Unit Flange Cost Analysis

Cost Type

Overheads
Rate

Material Costs
Import Overheads
Small Material
Material Overheads
Engineering
Eng.Overheads
Labour Hours (Active)
Labour Hours (Tank)
Production Overheads
(Active)
Production Overheads (Tank)
R&D Overheads
Sales Overheads
Admin. Overheads
Total

1,0
2,0
0
0
1,5
255
185,0
2,2
6,0
8,5

30

Cost Price
8,250
0,000
0,083
0,167
0,000
0,000
0,000
9,750
0,000
18,038
0,798
2,225
3,341
42,651

Lifting Lug Cost Analysis

Cost Type

Overheads
Rate

Material Costs
Import Overheads
Small Material
Material Overheads
Engineering
Eng.Overheads
Labour Hours (Active)
Labour Hours (Tank)
Production Overheads
(Active)
Production Overheads (Tank)
R&D Overheads
Sales Overheads
Admin. Overheads
Total

1,0
2,0
0
0
2
255
185,0
2,2
6,0
8,5

31

Cost Price
29,150
0,000
0,292
0,589
0,000
0,000
0,000
13,000
0,000
24,050
1,476
4,113
6,177
78,846

Radiator Bondage

32

Lifting Lug

33

Storage Unit Flange

34

Distribution Transformer Cover Base

35

Pipes

36