1

Geographical Location

Coğrafi Konum

From Istanbul to Sivas approximate 10 hours by the taxi,

one hour by the plane

2

TOTAL LAND/TOPLAM ALAN : 195.500 m²

COVERED AREA/KAPALI ALAN : 62.558 m²

3

MACHINING

NEW FUTURE

FOUNDRY

FUTURE

NEW

SENIOR MANAGERS AND ENGINEERS / ÜST DÜZEY YÖNETECİ VE MÜHENDİSLER : 17

OTHER MANAGERS /DİĞER YÖNETİCİLER : 22

TECHNICIANS /TEKNİKERLER : 16

QUALITY DEPARTMENT PERSONS / KALİTE BÖLÜMÜ PERSONELİ : 24

OTHER WORKERS / DİĞER OPERATÖRLER : 307

TOPLAM / TOTAL : 386

EMPLOYEES / ÇALIŞANLAR

4

5

(% 26) (% 24)

(% 36)

(% 14)

0

20

40

60

80

100

120

140

PRIMARY 5 YEARS -

İLKOKUL 5 YILLIK

PRIMARY 8 YEARS -

İLKOKUL 8 YILLIK

HIGH SCHOOL - LİSE HIGHER EDUCATION -

YÜKSEK OKUL

EMPLOYEES’ EDUCATION ÇALIŞANLARIN EĞİTİM DÜZEYİ

SALES USD

7

R&D CENTER

HAS 6th PLACE

IN TURKEY

IN TERMS OF

PROJECT

CAPABILITY

TO EXPORT TO 42 COUNTRIES IN 6 CONTINENTS

6 KITADA 42 ÜLKEYE İHRACAT

8

PRODUCT RANGE/ ÜRÜN ÇEŞİTLİLİĞİ

INVESTMENT PLAN

YATIRIM PLANI

10

11

ESTAS AWARDED WITH 3 NEW PROJECTS

CREDIT RATING REPORT

EXIMBANK CREDIT LIMIT

13

PRODUCTION METHODS & CAPACITY ÜRETİM YÖNTEMLERİ VE KAPASİTE

3 DIFFERENT PRODUCTION METHODS ARE USED IN ESTAS CAMSHAFT PLANT. CAST IRON METHOD, ASSEMBLED CAMSHAFT METHOD AND STEEL MACHINING METHOD. ESTAŞ KAM MİLİ FABRİKASINDA 3 FARKLI ÜRETİM METODU KULLANILMAKTADIR. DÖKÜM YÖNTEMİ, MONTAJLI KAM MİLİ YÖNTEMİ VE ÇELİK İŞLEME YÖNTEMİ. ABOUT 2.000 DIFFERENT CAMSHAFTS UP TO 3.000 MM LENGTH WITH STEEL AND CHILLED/DUCTILE IRON. YAKLAŞIK 2.000 FARKLI KAM MİLİ 3.000 MM UZUNLUKTA ÇELİK VE CHILL/SFERO DÖKÜM MALZEMEDEN İŞLENEBİLMEKTEDİR.

14

FOUNDRY / DÖKÜM

ESTABLISHMENT YEAR-KURULUŞ YILI : 1991

LAND-ALAN : 15.078 m²

COVERED-KAPALI ALAN : 7.136 m²

CAPACITY-KAPASİTE : 20.000 TONS / YEAR-YILDA 20.000 TON

EMPLOYEES –ÇALIŞAN : 100

PRODUCTS-ÜRÜNLER : CHILLED- DUCTILE- GRAY CASTING /

CHİLL-SFERO-GRİ DÖKÜM

15

THE FOUNDRY HAS WORLD-CLASS EXPERTISE IN PRODUCING CHILL CASTINGS.

A METHOD OF HARDENING WEAR SURFACES DURING THE CASTING PROCESS

CHILL DÖKÜM ÜRETİMİNDE DÜNYA STANDARTLARINDA UZMAN. AŞINMA

YÜZEYLERİNİN DÖKÜM SIRASINDA SOĞUTULARAK SERTLEŞTİRİLDİĞİ BİR METOD 16

PRODUCTION METHOD ÜRETİM METODU

PRODUCTION METHOD ÜRETİM METODU

Classical weight reduction with Quartz tube

17

Samples for Shell core casting

Shell core application has 15 % weight advantage

according to Quartz tube application

CAMSHAFT MACHINING

PLANT

ESTABLISHMENT YEAR / KURULUŞ : 1977

CAPACITY/ KAPASİTE : 3.000.000 PCS / YEAR-YILDA 3.000.000 ADET

EMPLOYEES /ÇALIŞAN : 259

PRODUCTS /ÜRÜNLER : KAMMİLİ / CAMSHAFT,

KÜLBÜTÖR MİLİ / ROCKER SHAFT

BALANS MİLİ / BALANCE SHAFT

MATERIAL USED/KULLANILAN MALZEMELER : CHILLED AND DUCTILE IRON, STEEL /

CHİLL VE SFERO DÖKÜM, ÇELİK

18

19

CAMSHAFT MACHINING

PLANT

CAMSHAFT MACHINING

PLANT

20

Knurling operation is applied on the surface of end

piece by Estaş.

Broaching operation for cams is done in order to

increase strength of the cams on tube by ESTAŞ.

ASSEMBLED PRODUCTION

Each tube has a hexagonal section formed by

cold-pressing technique and Knurling

operation is applied by ESTAŞ.

21

ASSEMBLED PRODUCTION

Cam and journal ring parts assembled to tube by broaching..

Sprocket tube will be assembled by close fit.

22

PRODUCTS / ÜRÜNLER

Steel Camshaft / Çelik Kam Mili

SAE 8620H, SAE 1050, 16MnCr5

The Estas machining plant includes the latest automated equipments in use

today - multi-axis mills, drills, lathes, grinders, and super-finishers with

inspection and quality-control check-stations throughout the plant.

23

ENGINEERS / MÜHENDİSLER : 2

TECHNICIANS /TEKNİKERLER : 1

QUALITY DEPARTMENT PERSONS / KALİTE BÖLÜMÜ PERSONELİ : 1

OTHER WORKERS / DİĞER OPERATÖRLER : 9

TOPLAM / TOTAL : 13

HEAT TREATMENT

EMPLOYEES

24

HEAT TREATMENT CAPACITY

MAX. CEMENTATION CAPACITY DIA.150 mm LENGTH 1200 mm MAX. INDUCTION HARDENING CAPACITY DIA.150 mm LENGTH 1800 mm

GAS CARBURAZING FURNACE : 7

DEEP FREEZING : 3

INDUCTION HARDENING FURNACE : 3

TEMPERING FURNACE : 1

ANNEALING FURNACE : 1

MANGANESE PHOSPHATE BATH : 1

COPPER PLATING BATH : 1

CRACK CONTROL STATION : 1

TOPLAM / TOTAL : 18

25

RESEARCH AND DEVELOPMENT

SECTION

OPENING OF : 11.08.2011

TOTAL AREA : 1540 m²

RESEARCHER : 16

TECHNICIAN : 40

SUPPORT STUFF : 6

TOPLAM / TOTAL : 62

26

DEPARTMENT OF EDUCATION

EĞİTİM BÖLÜMÜ

27

QUALITY CONTROL DEVICES

28

STOCK AREA

29

LEAN PRODUCTION SYSTEM

30

CERTIFICATES

31

CERTIFICATES

32

CERTIFICATES

33

UNIVERCITY EDUCATION PARTNERSHIP PROGRAM

34

AWARDS / ÖDÜLLER

35

AWARDS / ÖDÜLLER

36

37

O.E.M. CUSTOMERS

O.E.M. MÜŞTERİLERİMİZ

DENMARK/DANİMARKA BUKH DIESEL

ENGLAND/İNGİLTERE RICARDO

GERMANY/ALMANYA AUDI /BOSCH

GERMANY/ALMANYA JENBACHER

AUSTRIA BOSCH

FRANCE/FRANSA PSA/RENAULT

RUSSIA AVTOVAZ

INDIA TATA/RENAULT/MAHABAL/MAHINDRA

TURKEY/TÜRKİYE OYAK-RENAULT

TURKEY/TÜRKİYE TÜMOSAN (FIAT)

TURKEY/TÜRKİYE TÜRK TRAKTÖR (FIAT)

TURKEY/TÜRKİYE FORD

SWEDEN/İSVEÇ SCANIA

USA/ABD CUMMINS-WOODWARD-CATERPILLAR

USA/ABD GE-WAUKESHA

POLLAND FIAT

ITALY FIAT

ROMANIA DACIA

BRASIL IVECO LATIN

ARGENTINA PSA

O.E.M. CUSTOMERS

O.E.M. MÜŞTERİLERİMİZ

1977- Establishment of Estas camshafts / Estaş Kam mili fabrikasının kuruluşu

1991- Opening of casting plant / Döküm Fabrikasının açılışı

1997- Receipt of first Quality Document (ISO 9001) / İlk Kalite Belgesinin alınması (ISO 9001)

2004- ISO/TS 16949 certification

2005- First Fuel Pump Camshafts production to original producer / Orijinal üreticiye ilk yakıt

pompa millerinin üretimi

2011- Opening of inhouse gas carburizing units / Gaz karbürizasyon ünitelerinin açılışı

2011 - Establishment of R&D Center certification by Goverment incentive program

2012 – Starting of INOTECH 12K Lean Production studies / INOTECH 12K Yalın Üretim

Çalışmalarına başlanması

2012- ISO 14001 Environmental Management Systems / Çevre Yönetim Sistemi

2012 - OHSAS 18001 - Health & Safety Certification / OHSAS 18001 İş Sağlığı ve Güvenliği

MILESTONES

39

XPI PROJECT PERFORMANCE

40

DELIVERY PERFORMANCE

41

42