Trip report

Name: …

Faculty: IMiR – mechatronics

Subject: fundamentals of material science

Date: 14^th May 2013

On May 14, 2013 we visited the brewery and Fiat Auto Poland car factory in Tychy. We left AGH at 9 am and arrived in Tychy about hour and a half later. The trip was very interesting and gave us an opportunity to see how the work at big companies really looks.

The first point of the trip was the brewery. Unfortunately, we did not have enough time to see all the Tyskie Browarium so we were given only the essential information about it. At the beginning we were divided into two groups. During the visit we learned that it has a long history – it was established in 1629. The guide told us also that Poland is one of the top countries in beer production – it is on the fourth position in this ranking. She told us a lot about beer ingredients (hop, yeast, water and barley malt) and said that hop is responsible for the proper aroma and bitterness of the beer.

We saw huge fermentation containers and learned that fermentation is the first process in beer production and that it is a totally isolated process. It takes from ten to twelve days. Beer made in this process is called green/yellow beer and it is not good to drink. After that, it comes a time seven days of conditioning

We noticed a lot of safety signs and chemical rescue equipment so the place was properly secured. As far as statistics are considered:

• There are 160 containers in the brewery area.

• The average Pole drinks 88 l of beer per year.

• Workers are traditionally paid with money and beer as well. In the past It was about 60 l per month but now beer produced is much stronger so the workers are given 12 l of beer per month.

• Bottled beer is more popular then beer in cans.

• We call the beer strong if it contains more than 7% of pure alcohol

After the visit at Tyskie Browarium we returned to the bus and headed to Fiat factory. There, we were also divided into two groups. At the beginning the guides gave us reflective vests. During the trip we were given an interesting statistics about the factory:

• The area of the factory is equals 230 ha. Halls’ area is equal 50 ha.

• The factory produces about 1400 cars a day.

• It imports cars to 68 countries including Japan.

• In the previous year the factory produced 350.000 cars. It is planned to produce 300.000 cars this year. 2009 was the best year in the company’s history – they produced 605.000 cars. Surprisingly, in this year there was a recession in other parts of Europe.

• 3 out of 100 car produced have some small defects like a burned out bulb.

• Employees work in 2 shifts system. One shift lasts 7 hours, 5 minutes and 55 minutes of a break. In the past the company was working in a 3 shifts system.

• 3.200 people are employed in the company in Tychy. There are also 5.000 people from external companies.

• At the beginning of 2013 about 1500 employees were fired out due to decrease in sales.

• Each worker have the possibility to buy car 15% cheaper - even the Ferrari, Maseratti and Jeep.

The floor in the factory was divided into special parts. Yellow path was for the visitors and other walking people, blue one was designed for forklifts, bikes etc. and the red area was the place where people were working. We noticed a lot of safety signs that allow a quick evacuation. Also many coffee and snacks machines were presents to allow employees a short and good break.

We learned that the factory produces both Fiat and Lancia cars. Some of the employees work at the stations were parts two both of these car types are produced. This includes a lot of focus and responsibility. Actually, responsibility is one of the most important things at this factory. If one person has some problems when adding some parts to the car, all the production line can be stopped and cause a great money loss. Each of the working stations was numbered ant properly described.

We were impressed by many different robots which were working with an amazing precision. Every robot works in seven axis and for each axis there is a different motor to power the movement. Also every robot designed for spot welding is steered by small box programmed by human; a few of them are hanging from the ceiling. All the robots can work at 360°. There are 931 robots, each of them cost about 150.000 PLN if we consider also the controllers. The process of changing the car model at production line is very easy. It is sufficient to change just the steering firmware of the robot. 5 robots are required for Fiat 500 to receive widescreen and rear window.

We visited the painting area where, initially, chassis is being cleaned from corrosion substance which was applied at ironworks. First operation is phosphating bath, also anodizing is happening there which causes the phosphorans to stick to the chassis. This protect the car from corrosion. Then, the car is sprayed by the special painting robots. Next step is putting the layer of enamel, then – pastel and metallic base. The last layer is transparent. All the 6 layers have the thickness of 106 microns. There are 10 pastel and 21 metallic colours to choose from. After applying the paint we seal the body car with yellowish glue.

Everything is carefully segregated. There are plenty of boxes and shelves with many different parts and all of them have to be properly described. There are also scrap and waste baskets – nothing can be wasted in such a place.

Each worker occupy his position on the production line just for 2 to 3 days and then he or she is shifted to a different position at the construction process. The whole process takes even about 3 years. To assembly the Fiat 500 we need to perform actions at 850 different stationary points and all of them are equally important because even a little thing can cause the accident. After the work day each of the workers made a special stamp on the car card which is stored for 15 years. Every car has its own card so in case of an accident it can be checked if everything was done well during the process of production. If not, the employee responsible for a part that caused the accident could be even held criminally liable. There are always new trainings for all the employees, also for the management. Each year the workers are assessed. They can get grades from 2 to 5. Mark 3 does not guarantee the job at Fiat company. 14.5 mln PLN is spent a year for sport and recreation.

The workers applied an easy technique to check whether machines work properly. It is very loud in the hall so it is impossible to hear whether the fans in some devices are working properly. Folic strips are attached to the fans so it is possible to notice that the wind is blowing from the fan (so the device works as it should).

After the car is produced, it is put to the test – workers drive each car for 2.5 km. For the testing car is filled with 5.5 l of petrol. The testing person has a special computer with all testing procedures listed. If the car fails at some point, the car is sent to high-qualified car mechanic in Fiat service.

As many of us are very interested in cars, this trip is a very valuable experience. We found out a lot of great information and we were glad that it was possible to see such a factory.