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Quality is the Norm
Norm Fasteners Group
Izmir
The Norm Fastener Group has demonstrated remarkable growth and technology development since its
establishment in 1973. A leading exporter and domestic supplier of automotive grade fasteners and
special parts from its Norm Civata manufacturing operation – the largest bolt factory in Turkey - it is
also, through its Norm Standard business, one of the country’s biggest traders in an extensive range of
standard products.
Later this year Norm will feature as our Cover Story – when we will identified by bar code – each job card carrying bar codes for each stage
fully explore its history as well as the operations of its four facilities in of production, starting with the code applied to each wire coil as it is
Izmir. Here, we focus on two significant recent developments in Norm’s received. “We carry out all the processes of fastener manufacturing in
continual commitment to enhancing efficiency and quality levels. house,” says Fatih Uysal, “so we maintain complete traceability under
Leading a tour of the Norm operation deputy chairman M. Fatih our own control from beginning to end.”
Uysal quickly points out that the group has adopted lean manufacturing Supervising overall material and product quality control is a large
principles – a process started around six months ago and clearly well- laboratory at the bolt factory – with two satellite laboratories, one at the
established already. Above the rows of cold formers hangs a banner, nut factory, one at the coatings plant, carrying out specific analysis.
signed by every operator, proclaiming Norm’s objectives in ensuring the The good housekeeping evident throughout the Norm operation is
highest standards in quality and productivity. Each of the three buildings also fundamental to the new approach. “We are very sensitive about
in the bolt factory operates as a lean cell, with teams meeting every housekeeping,” says Fatih Uysal. “We recognise very clearly that taking
morning to decide objectives for the day. Display boards provide images pride in the working environment is an important part of taking pride in
of correct operational and safety conditions – these are also to be found the quality of our finished products.”
In-process monitoring at SPC centre
on some machines. Another board provides detailed performance Quality of finished product, or more precisely of its finish, has also
feedback; a third is dedicated to social activities, the highlight of which been the driving force in a recent major investment at Uysal Makina,
is the annual family day. “We invite the families into the factory where Norm’s coating and packaging operation, where the company began
we stage a picnic,” explains Fatih Uysal. “It is very important to bond operating a new Zinc Nickel coating line in February. Norm already
the family to the business.” had MacDermid licenced ZinKlad® 250 Zinc lines as well as a Doerken
Equally visual but focused directly on the key lean tenet of producing MKS licenced Cr-free Delta Protekt Al/Zn operation. The new PLC/
good parts first time every time, each production machine carries a PC controlled line, Turkey’s most advanced barrel-type alkaline Zn/Ni
colour coded record card – a green dot records each customer defect- system, applies Zinklad 1000/1000B. The final coating includes 12-15%
free day for that machine; with a monthly summary on a second card. Nickel delivered as part of a minimum 8 micron coating to ensure the
“A red dot would indicate a customer reported defect related to that best possible corrosion resistance performance. Norm has three salt spray
machine,” says Fatih Uysal. “Central to our lean approach is that each cabinets for carrying out corrosion tests to US and European standards.
operator takes full responsibility for the quality and performance of his The coatings laboratory also houses a recently acquired Schatz torque
machines.” friction tester. “Our previous machine did not have the rotational speed to
In-process quality is monitored personally by each operator who fully simulate assembly,” explains Fatih Uysal. “Particularly important as
carries out regular dimensional checks at computerised SPC centres the friction heats the coating affecting the torque characteristics. The new
located frequently amongst the machines. Each centre comprises a machine operates at 200rpm ensuring full simulation – it is one of only
screen and keyboard, with the relevant gauges linked direct to the two or three similar machines in operation throughout Europe.”
computer system. Out of tolerance readings automatically trigger an It is also just one example of attention to detail characteristic
alert to the screens of both quality and production managers. The job is throughout the Norm operation – of which more later in the year.
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