STARGRUP

Sipopo Congress Center

2015

PRESENTATION OUTLINE

• StarGrup at Glance

• StarGrup Mission & Vision & Values

• Capabilities & Capacities & Flexibility

• Order Management System

• Production Planning System

• Shop Floor Management

• Quality Management System

SECTOR INVOLVED Glass Processing

ANNUAL TURNOVER 30 million Euros

BASIC PRODUCT GROUPS Insulated glass,Tempered glass,Laminated glass,Edge processed glass,Cutted glass

MARKETS 50% export, 50% local market

MANPOWER 325 workers

STARGRUP AT GLANCE

Four Winds Project

Mission• With the target to excellence;• To have delighted customers by creative solutions,• To develop continuously the manpower,• To satisfy all stakeholders’ expectations,• To respect the nature and the environment.

VisionTo be a leader and always preferred in priority company in local and near geographical target markets for internal and external architectural glass applications by creating a difference with its multifunctional products, contemporary management understanding and practices.

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MISSION & VISION

•Heat control• Solar control,• Noise control,• Safety and security

MAIN MARKET SEGMENTS

Building Façades Interior Glass Applications

•Glass doors, •Stair railings,•Shower cabins, •Blind Systems,

OUR SUPPLIERS

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STARGRUP VALUES

Our employees are our most valuable asset; We give priority to our employees’ wealth and safety conditions and the needs to increase their job capabilities.

Our customers are our future; We believe that a sustainable success in the market could be realized by pursuing our customers’ expectations on time and satisfying them beyond their expectations continuously

Waste elimination is a must; We know that our customers do not pay the cost of activities which do not create a value for them. We eliminate all kind of waste such as customer claims, breakages, excess stocks, etc.

Continuous improvement is waiting's the road to excellence; We relentlessly promote the search to excellence by continuous improvement programs and we believe that this is the most valid way to manage the change.

Use systematic approach and take decisions based on data; We evaluate all of our processes with system view and solve our problems with a systematic approach and take decisions based on data analysis.

Internalize the proactive approach and right questioning; We encourage all employees to take preventive actions in order to eliminate the problems and in case of a problem occurrence to ask the right question: instead of ” who did it?” ask ” why was it happen and what was the source of it?”

Work as a team; We develop a working environment generating mutual benefits for all employees instead of interpersonal competition. We always share the success as well as the difficulties.

Code of ethics are our guides; We generate trust and behavioral consistency within the company through our code of ethics which are valid in all of our activities.

STARGRUP TEAM

White Collar:

Blue Collar:

Total Employess:

Engineers:

Total Manpower: 325

Blue Collar - 270White Collar - 55

Engineers - 30Proportion - 9,2 %

STARGRUP FIRST PRIORITY: CUSTOMER SATISFACTION

StarGrup’s priority is to increase his customers satisfaction by improving his performance about below parameters;

• Capability, Capacity and Flexibility• High performance products• High quality products• On time delivery • Effective communication• Competitive price

In order to realise that StarGrup;

• Follows techological developments closely and invest for needed machinery • Build effectively working systems• Train his employees continously

Customers focus is beyond manufacturer’ machinery infrastructure. Quality is created troughout the company. For consistent succesful results effective company management system is a must.

MANAGEMENT SYSTEM SOFTWARE – ( ERP)

ORDER MANAGEMENT SYSTEM

• Product type, quantity, shape, etc

• BOM materials one by one (glass, spacer, sealant, fiiling gas, etc )

• Special customer requests (tolerances, logo, packing etc)

PRODUCT CONFIGURATION

• Process to be executed to each glass ( cutting, grinding, printing, tempering etc)

• Details of each process (type of grinding, type of printing, print drawing, tempering standart, etc)

OPERATIONS TO BE EXECUTED

• Supplier name and lot number of glass used, machine and operator names for each operation are recorded in the system.

• Starting from final product barecode number it is possible to determine the history of any product.

PRODUCT FOLLOW UP

AWARD

In 2014 at 34.National Operations Research and Industrial Engineering Congress our system “ Integrated Real Time Production Management System” is nominated as second successful project among nine industrial application projects.

As concept and the content StarGrup Production Management System is the first system developed from zero in Turkey’s flat glass business.

MAIN PROCESSES IN PLANT

In total there are 50 different work stations

CAPABİLİTY & CAPACİTY & FLEXIBILITY - I

• 3 cutting tables and manuel cutting

• All type & size raw glass

• Rectengular & shaped cutting

• Capacity: 2.000.000 M2/year

• Max Size (mm): 3210*6000

• New investment: no need

CUTTING

• Horizantal grinding for high volume orders

• Vertical grinding for shaped glasses and small volume orders.

• All type of grinding (C, flat, seamed / polished & mat)

• Capacity: 1.800.000 M27year

• Max Size(mm): 3200*6000

GRINDING

• Horizantal drilling: 3 machines

• All type of glass and drilling configuration

• Capacity: 150.000 m2

• New investment: Vertical drilling, grinding & CNC machine (September 2015)

DRILLING

CAPABİLİTY & CAPACİTY & FLEXIBILITY - II

• Screen printing: 1 machine

• Roller printing: 1 machine & manuel printing

• Digital printing: 1 machine

• All type and size printing. Max Size(mm): 2580*6000

• Capacity: 700.000 M2/year

• New investment: no need

PRINTING

• Flat tempering: 2 tempering furnaces

• Full & semi tempering

• All type of glasses. Max size: 3300*6000 mm

• Capacity: 1.500.000 M2/year

• New investment: no need

TEMPERING

• 3 furnace

• All type & size glass. Max size: 3300 * 6000 mm

• Capacity: 180.000 M2/year

• New investment: May 2015

HEAT SOAK

• PVB, Vacum, EVA, Sentry Glass

• 1 PVB Laying&heating line, 1 Vacum production unit

• 3 Autoclaves

• All glass & PVB types. Max Size (mm): 2800*5000

• Capacity: 350.000 M2/year

• New investment: Vacum lamination Unit ( September 2015)

LAMINATION

• Double & Triple Insulation Units

• All type of glass combinations & shapes

• All type of spacer & sealant

• 1 IG Line for regular sizes

• Capacity: 650.000 M2/year

• Max Size (mm): 2500*5000

• New investment: 1 IG Line for big sizes & low volume orders

INSULATING GLASS

CAPABİLİTY & CAPACİTY & FLEXIBILITY - III

PRODUCTION PLANNING SYSTEM

• Read order data (Customer, Project, Product, BOM, Route, Quantity, requested delivery date) ,

• Define shift program of work stations

• Eliminate bottlenecks

• Calculate expected delivery dates of the orders in terms of week.

CAPACITY PLANNING

( CP )

• Read final order data ( product, final dimensions, revised delivery dates etc )

• Finalize cutting optimization

• Schedule the orders ( machine by machine job orders sequences & productionstart /finish times )

• Calculate expected delivery times of orders in terms of days.

FINITE SCHEDULING

( APS )

• Calculate material needs for each order according to CP and APS results.

• Taking into account actual inventory level and open purchase orders data generate new purchase orders.

MATERIAL REQUIREMENT

PLANNING ( MRP )

SHOP FLOOR MANAGEMENT

•Job orders, their sequences, start-finish times which are generated by Finite Scheduling (APS) are shown as a list on each work station screen.

•At cutting work stations all cutted glasses are labeled with a barcode on it and the pallets on which those glasses are put are specified in the system.

•At each work center job orders are started and finished in the system and new pallets are declared.

•All data are updated in computer system every 3 minutes

•Each work center declares in the system when a pallet is received or a pallet becomes empty.

•Each work center declares the glass breakages and machine stoppages in the system when it happens.

RESULT: Orders production are followed up on real time basis and the information about «status of an order» is openly shared within the company.

QUALITY: MANAGEMENT & PRODUCT CERTIFICATES

Management Certificates

•ISO 9001:2008 – Quality Managent System•ISO 14001 – Environmental Management System•OHSAS 18001 - Occupational Health & Safety Management System

Product Quality Standarts

• EN 572 Float Glass Standard• EN 1096 Coated Glass Standard• EN 12150 Tempered Glass Standard• EN 11502 Tempered Glass (for use in domestic appliances) Standard• EN 1863 Heat Strengthened Soda Lime Silicate Glass Standard• EN 14179 Heat Soak Standard• EN 1279 Insulating Glass Standard• EN 12543 Laminated Glass Standard• CEKAL Insulated Glass – France• GOST Insulated, Tempered, Miror and Laminated Glass – Russia• BENOR Contruction Certificate - Belgium• SEPRO Insulated, Tempered, Miror and Laminated Glass – Ukraine• CE Insulated, Tempered and Laminated Glasses

QUALITY MANAGEMENT SYSTEM

• Quality policy

• Occupational Health & Safety Policy

• Environmental Policy

• Management Certificates

• Quality Targets

• Continous improvement & corrective actions

QUALITY ASSURANCE

• EN Quality Standarts

• Input Control

• Process Control

• Final Product Control

• QC Laboratories

QUALITY CONTROL

QUALITY CONTROL SYSTEM

• All BOM materials ( glass, spacer, peint, sealant, PVB etc) are controlled visually

• Samples are examined in QA Laboratory

• Unconvenient materials are rejected immediately

• All precautions are taken to eliminate usage risk of rejected materials.

INPUT CONTROL

• At each work station glass coming from previous work station are controlled visually according to quality standarts and unconvenient ones are rejected

• Auxiliary materials ( water etc) affecting the quality of an operation are controlled

• Environmental conditions (temperature, humidity etc) affecting quality of an operation are measured

• Outgoing semi product quality is inspected before delivery to next working station

PROCESS CONTROL

• Quality standarts for Insulated Glass, Laminated Glass, Tempered Glass and Edge Processed Glass are clearly defined

• 100% final product quality control is done at each final work station.

FINAL PRODUCT CONTROL

STAR GRUP QUALITY MANAGEMENT SYSTEM

REFERENCES

http://www.stargrup.com.tr/project.asp

CONTACT

Stargrup Cam A.S.

Address: Hadimkoy Mah. Prof. Mustafa Inan Cad. No:17,TR-34960, Hadimkoy / Arnavutkoy / Istanbul - TURKEY

Tel: + 90 212 771 38 18

Fax: + 90 212 771 38 28

E-mail: info@stargrup.com.tr

Web: www.stargrup.com.tr

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