quality management - muharrem yaşar
TRANSCRIPT
Integrated Plant Management System
Some examples of
in ZAMAN Newspaper Plants
Prepared by: Muharrem Yaşar Quality and Coord. Manager
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03.09.2015 Wan-Ifra INDIA 2015 Mumbai, India
Istanbul, Turkey
Feza Gazetecilik A.S. known as Zaman
BS Newspaper, in TurkishThe most purchased newspaper, daily circulation > 1millionprinted in 6 printing sites
«in English means TIME »
Printing sites, Distribution areas, % Circulation
own contracted
% 30
% 20
% 20
% 10
% 15
% 5
6 Printing Sites5
1
İSTANBUL
İZMİR
ANTALYA
TRABZON
ANKARA
ADANA
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İSTANBUL
Zaman Head Office İSTANBUL
Zaman Head Office İSTANBUL
Ankara Printing Plant
Printing Plant ANKARA
Zaman (Time) & its weekly sisters Cuma (Friday)
Cumartesi (Saturday) Pazar (Sunday)
1 milli
on
Todays ZAMAN & its Sunday version Sundays Zaman
Daily English newspaper
10. 000 copies
BS size
Weekly periodicals
50. 000 copies
Separately sold
250. 000 copies
magazinsize
Weekly magazine
Weekly news magazine
Newspaper Machines 40 pages, 24p. colorful, 16 p. B&W1x Heidelberg Harris Mercury (1996) 35 000 copies/h. s-s machine 5x KBA Comet (2006 ) 75.000 copies / h., single side-double around
+ Presetting ink keys+ Soft proofing- Automatic register control - Automatic density control- Automatic cut off register
Plate making Rooms 5x 2 Kodak Generation News CTP s( CTP s and P&Bs) in each printing cite
+ Ink saving program + fan out compansation
What we have
General MANAGERVice Manager Responsible for Production
Printing Plant DirectorQuality R.
.Quality R.
.Quality R.
.Quality R.
.Quality R.
Quality and Coordination Dept. DirectorQuality Coord. M.
Technical M.
Planning and Reports M.
Purchasing Dept. Director
Hierarchy
Quality & Coordination Dept. Environment
al Managemen
t Systems (EMS) 14001
Occupational Health and Safety (OHS)
18001 (ISO) 9001
Printing Quality
ISO 12647-3 (IFRA 26)
Main Topics
Integrated Plant Management System
Printing Quality (IFRA26)
Integrated Plant Management(EMS,OHS,ISO)
2010
2012
20142014
Zaman Today's Zaman Zaman Cuma Zaman Cumartesi Zaman Pazar
2010-2012 İstanbul
2012-2014 Ankara İstanbul Trabzon Adana İzmir
2014-2016 İzmir Ankara İstanbul Trabzon Adana
Wan-Ifra INCQC membership certificates
Wan-Ifra invited three times as a speaker
Dates City Platform Subject
10 OCT 2011 - 11 OCT 2011 Vienna - Austria Power of Print Printing Quality Management
07 OCT 2013 - 09 OCT 2013 Berlin - Germany Open 'Media Port' stages 2013 Printing Quality Management
15 OCT 2014 - 16 OCT 2014 Amsterdam - Netherlands
World Printers Forum Conference Printing Quality Management
02 SEP 2015 - 04 SEP 2015 Mumbai - India India 2015, Printing Summit Integrated Quality Management
• How well we are ? How valuable we are to that time did we think?
How much an eye cost?
• If anyone asks you to sell it, will you ? or how much would you ask for?
• What about for both of your eyes?
• Is there any survey about this?
Are you agree with the offer?100 000 $200 000 $500 000 $1 000 000 $ 2 000 000 $ 5 000 000 $10 000 000 $
In a night shift when the machine stoppedA secrewdriver accidently got into his eye He became blind He has a itimation eye instead
A curious and incautious person
Worker consantrated on his work
• badly injured eye
• imitation eye instead
A real story …
in any circumstancein any case
The company(the employer)
is liable, is blameworthy
The companıy have to do :
- Give proper education & training*
- Make the machines safe
- Give Personal Protecteve Materials
- Choose the safe consumables
-etc.
Law says:
E v e r y t h i n k
Oil on the surface
fall off
DANGER If you see: You should think off you can
RİSK
This is
If training was given properly it would have not happen - it is not his work area, nobody ask him to go there - it should notice the danger and have to understand the risk So It should not be so near,
Switched offSwitched on
When the door is opened,
A nylon wrapper machine for bunddles with its mica door
It turns off the power
Cages for safety
A back view of a reel splicer
input of a strapping machine
26
Another real story with photos
27
28
29
30
31
32
33
Max flood level :163 cm = 64.17 inch max
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35
36
37
A Commercial Pirinting Plant Istanbul in 2009 after the water level drops
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The next factory’s watchman has lost in the flood
2 years ago The same place
Max flood level :16 cm = 6,4 inch
just after the flood
Slide, but not fall down
1 30 300
300
fall down, no injury 30
fall off and injure yourself
1
How many times it happens
Slide
Fall down
Injure
Statistic says
Our experiences, laws regulations
Integrated plant management systems ISO 9001, 14001, 18001 ..
Before
After
Before
After
Notice BoardIstanbul Plant INCQC certificates
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Personals work instructions:
printters, production manager, reel operators etc.
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Vision
Mission
Politics
POLITICS & TARGETS
EMERGENCY ACTION PLAN
Emergency Groups, responsible personnel and their telephones
Escape planfor ways and safe area for meeting
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50
Ear plug for guests
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Obligatory signs for workers
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Equipment using instructions
Stacker and counter
53Plate punch and bending
PURPOSE
RESPONSIBLE PERSON
APPLICATION• Turn on the electricity
.
.
.
.
• Turn off the switch
Equipment using instructions
A waste or scrap paper baler
Equipment using instructions
An electricity insulater rug in front of an electrical cabinets
Another exproof lamp inside the printing unit
An exproof ceiling lamp
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Gum section Developer section Preheat section
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MSDS summary for gum section
Blue sings means obligatorywhile you are handlingYou have to use apropriate .. here
glassesglovesworkwear
Green sings means life savings
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If your eyes get contact with chemicals, use this urgently
Cleaner at the wall of the Plate Making Room (CTP room)
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The consumables rooms
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Stock area lines
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Outside of the building
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Speed stopper
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Pede
stria
n
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delineators
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Containers for printing chemicals
and chemical wastes stroge
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HAZARDOUS MATERIAL GETTING CLOSER WITH FIRE PROHIBITED
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Chemical wastes names and codes
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Forced ventilation
MSDS summaries
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Perforated surface
Tank area with sloping surface
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Hose pipe
Tank lid
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Air blow hole for fresh air
Prevents the hazordous chemical to spread around
Izmir Printing Plant
# 2. solution for waste handling and storage
Sloping surface
A tiled wall and surface
Sloping slot
Air blow hole for fresh air
ventilator
Izmir Printing Plant
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Izmir Printing Plant
Izmir Printing Plant
Emptying valfe
TrabzonPrinting Plant
# 3. solution for waste handling and storage
Tank with grilled surface
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Plate making room
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Raised floor panels
Pipe for developer waste
The tank is on the downstairs
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• For summer and winter two different clothes
• Reflector strips
• WAN-IFRA INCQ club membership
• ZAMAN logo
• For technicals and personals different clothes
• Work shoes
85
• for electricians insulated sole• Sure-footed on oily surfaces • steel-toed
steel-toed
Water proof breathableAnti-static
www.ydsshop.com
• We had given a pair of shoes to our workers
• We have make to use work shoes at work obligatory
*Summer
*Winter
Personel had preferred to use them for their special days
When summer comes, personel have made notches on them
• We started to use #Summer&Winter
* Every two years# Every year
OR
ISO 9001 ISO 14001 ISO 18001
Active certificates
Yearly certification existance checks prevents business blindness
If in these checks, there are• 3 Major or 20 minor problems • And not solved in 3 monthscertification will be cancelled
Benefits of to be certified
STARTComfort Comfort
+ no fear
Health ratio
Extra bagback
Benefits of IPMS(Integrated Plant Management System)
Costs Earnings
No earningNo costNo IPMS
Effort
No effort
Loss
less loss
I N P U T O U T P U T
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Our experiences, laws, regulations
Integrated plant management system ISO 9001, 14001, 18001
EFQMEuropean Foundation for Quality Management www.efqm.org
ZAMAN s next target is..
Common properties of the world first 500 biggest companies which make them different and big
Thanks for listening
any questions?
____________________
For communication
Muharrem YAŞAR
ZAMAN NewspaperQuality & Coord. Manager34194 Yenibosna Bahcelievler / Istanbul / Turkey
+90 536 347 91 27 [email protected]