ATILIM UNIVERSITY
FACULTY OF ENGINEERING
DEPARTMENT OF INDUSTRIAL ENGINEERING
IE 399 SUMMER PRACTICE REPORT
ANADOLU EFES BREWING AND MALT INDUSTRY INC.
Submitted by: Bujen Kutlucan
Submitted to: Kamil Demirberk Ünlü
Ankara/Turkey
2023-2024 Fall Semester
ABSTRACT
This internship report describes the studies and observations made during the 2023
summer internship at Anadolu Efes Brewing and Malt Industry Inc. Anadolu Efes is
a brand that produces a wide variety of beers. In this report, the stages of beer
production, departments at Anadolu Efes and their operations, the work study carried
out during the internship period and its follow-up, Anadolu Efes's general conditions
and productivity over the years are stated, and the importance of industrial engineers
in the workplace is explained.
i
ÖZET
Bu staj raporunda Anadolu Efes Malt San. A.Ş. de 2023 yaz stajında yapılan
çalışmalar ve gözlemler anlatılmaktadır. Anadolu Efes birçok çeşitlilikte bira üreten
bir markadır.Bu raporda bira üretiminin aşamaları Anadolu efesteki departmanlar ve
bunların görevleri,staj sürecinde yapılan iş etüdü ve bunu takibi,Anadolu efesin genel
prensipleri ve yıllar içerisindeki verimin hesaplanması,endüstri mühendislerinin iş
yerindeki yeri ve önemi anlatılmaktadır.
ii
TABLE OF CONTENTS
Page
ABSTRACT .................................................................................................................. i
ÖZET............................................................................................................................ ii
TABLE OF CONTENTS ............................................................................................ iii
LIST OF TABLES ...................................................................................................... iv
LIST OF FIGURES ..................................................................................................... v
1.
INTRODUCTION ................................................................................................ 1
2.
GENERAL OVERVIEW OF THE COMPANY.................................................. 4
3.
COMPUTERS, SOFTWARE AND IT ................................................................ 7
4.
ENGINEERING COST ANALYSIS ................................................................... 8
5.
PRODUCTION ENVIRONMENT ...................................................................... 9
6.
WORK STUDY .................................................................................................. 10
7.
INTERDISCIPLINARY ACTIVITIES AND PROJECT MANAGEMENT .... 13
8.
IMPLICATIONS OF INDUSTRIAL ENGINEERING APPLICATIONS........ 14
9.
CONCLUSIONS AND RECOMMENDATIONS ............................................. 15
REFERENCES........................................................................................................... 16
APPENDIX A ............................................................................................................ 17
iii
LIST OF TABLES
Page
Table 1. Time Study................................................................................................. 10
Table 2. Efficiency Calculations .............................................................................. 10
Table 3. Keg Line Beer Filling Flow Process Chart ............................................... 11
iv
LIST OF FIGURES
Page
Figure 1. The percentage distribution of the number of employees .......................... 5
Figure 2. Demonstration of the Beer Manufacturing Process ................................. 12
v
1. INTRODUCTION
Trade Name and Address of the Organization:
Anadolu Efes Brewing and Malt Industry Inc. Fatih Neighborhood, Turgut Özal
Boulevard No:48 06980 Kazan/Ankara, Turkey
History of the Organization:
Anadolu Efes Brewing and Malt Industry Inc. It offers products and services to a
consumer base exceeding 300 million with nearly 60 brands in a wide geography
consisting of Turkey, Russia, the Commonwealth of Independent States, Central
Asia and the Middle East countries. It extends from Anatolia to the world with 21
breweries, 5 malt facilities and 1 hops facility in 6 countries. In this regard, today
it is the 5th largest beer producer in Europe and the 15th largest beer producer in
the world in terms of sales volume. It has been bringing together our country's
most popular beer brands with its consumers since the day it was founded. It
started its journey with two breweries in Istanbul and Izmir in 1960, and today it
is Turkey's largest brewery with 3 breweries, 2 malt factories, 1 hops processing
facility and 18 brands in its portfolio. continues as a beer producer and market
leader. While achieving many firsts in developing the beer market and culture, it
was the first in Turkey to produce canned beer, low-calorie beer, non-recyclable
bottle, 5 liter keg, embossed box, printed box, transparent label, 1 liter bottle, keg
box, keg bottle packaging products. has been introduced to consumers many
times. The brand continues its investments in line with its excellence strategies
and introduces innovations every year.
The Parent Organization to which the Business is Affiliated and Existing
Facilities:
1
The foundations of Anadolu Group were laid in 1950 by İzzet Özilhan and Kemal Yazıcı.
Anadolu Group is a holding company. Founded by Kamil Yazıcı and İzzet Özilhan, the
group still belongs to two families. 68% of the group is owned by Yazıcılar Holding and
32% by Özilhan Sınai Yatırım.
Areas and operations where Anadolu Group operates;

In the beverage industry: Anadolu Efes (Anadolu Efes and Coca Cola)

In the retail sector: Migros

In the automotive industry: Anadolu Isuzu, Anadolu Landini

In the stationery industry: Adel

Quick Service Restaurant sector: Anatolian Restaurant Enterprises
In addition, social responsibility activities are carried out with Anadolu Foundation,
Anadolu Health Center and Anadolu Efes Sports Club to contribute to the society in the
fields of education, health and sports.
Products Produced By The Company:
Anadolu Efes products, which produces and markets beer, malt and nonalcoholic beverages in a wide range of countries consisting of Turkey, Russia,
Kazakhstan, Georgia, Ukraine, Moldova, the Commonwealth of Independent
States, Europe, Central Asia and the Middle East, are consumed in more than 80
countries in the world.
DOMESTIC

Efes Pilsen,Efes Özel Seri,Efes Pastörsüz,Efes Malt,Efes Light,Efes
Brewmaster,Bomonti Fabrika,Bomonti Filtresiz,Bomonti Red Ale,Bomonti
Black
FOREIGN

Miller Genuine Draft ,Beck’s,Velcopopovicky
Kozel,Grolsch,Bud,Corona,Leffe,Hoegaareden
2
The products produced by the company are not limited to the domestic market. According
to its investor presentation, Anadolu Efes exports its products to over 70 countries,
including Africa, Asia, Europe, North America, and Oceania. in 2010, the export volume
of beer from Turkey was 1.6 million hectoliters, which was 13% of the total production
volume of 12.4 million hectoliters.
The company has the following market shares in its domestic and foreign markets: 52% in
Turkey, 30% in Russia, 28% in Ukraine 47% in Kazakhstan 47% in Georgia 63% in
Moldova.
Some of the constraints that prevent Anadolu Efes to compete with rival companies
offering similar products/services in foreign markets are currency volatility, inflation and
Competitive pressure and consumer preferences.For example, , Anadolu Efes competes
with Turk Tuborg, which has a 48% market share in beer and a strong presence in the ontrade channel. Anadolu Efes needs to adapt to changing consumer preferences and trends,
such as health consciousness, and diversification of tastes.
The company has a quality assurance system certification. Anadolu Efes has obtained
various quality and food safety certifications for its production facilities, such as ISO 9001,
ISO 14001, ISO 22000, HACCP, and OHSAS 18001. These certifications demonstrate the
company’s commitment to ensuring high standards of quality and safety for its products
and processes.
The main industrial engineering activities carried out in Anadolu Efes are planning,
designing, and optimizing the production processes and systems to ensure efficiency,
quality, and safety. Industrial engineers at the factory notice problems during beer
production. For example, line disruption due to bottles falling over for any reason or
malfunction of machines Identifying and implementing improvement projects to reduce
costs, increase productivity, and enhance performance. Industrial engineers eliminates the
noticed problems.They also coordinate with the other departments such as quality or
logistic.
3
Human
Resources
Specialist
Human
Resources
Business
Partner
Administrati
ve Affairs
Manager
Financial
Manager
Manufacturing
Engineer x2
Production
Manager
Factory
director
Quality And
Assurance
Engineer
Quality And
Assurance
Manager
OHS And
Environmental
Manager
Occupational
Health And
Safety
Manager
Administ
irative
Assistant
Filling
Engineer
x2
Filling
Manager
4
Energy
Engineer
Electrical
Meintenance
Engineer
Mechanical
Meintenanc
e Engineer
Assistant
Affairs
Manager
Filling And
Engineering
Manager
Logistics
Field
Manager
Logistics
Specialist
X4
Logistics
manager
(finished
goods
warehouse)
Logistics
Manager
Logistics
Specialist
Logistics
manager
(Central
Warehouse)
2. GENERAL OVERVIEW OF THE COMPANY
As can be seen from the organizational chart, this company consists of HR, finance,
production, quality, filling and logistics departments.
Human Resources: HR is responsible with payroll, administrative duties, and as a liaison
between management and employees.
Finance Deparment: The department controls the income and expenditure in addition to
ensuring effective business running with minimum dearangments.
Production Department: This is the process of transforming raw materials, such as malt,
hops, water, and yeast, into beer. The production department applies a new generation
production technique called +1 RESTING, which allows the beer to rest for an extra day
after fermentation to enhance its flavor and aroma
Quality Control: This is the process of testing the products at every stage of production to
ensure their compliance with the quality standards and specifications. The production
department also implements continuous improvement programs to enhance the quality
performance
Filling: The filling department is responsible for filling the company's different beverage
products into packaging such as bottles, cans or kegs.
Logistics :This is the process of storing and transporting the products from the production
sites to the distribution centers or customers
This organization employs 180 blue-collar personnel and 60 white-collar personnel.
The percentage distribution of the number of employees is represented in Figure 1
White
Collar
Figure 1
5
The main inputs of Anadolu Efes Company's production system are malt, hops, yeast . The
supply of these inputs to the production system is carried out as follows:
Malt: The company supplies approximately 300 thousand tons of barley annually, and
80% of it comes from farmers in Turkey. Barley is sent to malt facilities in Çumra and
Afyon, where it is germinated, dried and turned into malt..
Hops: Hops are a plant used to add aroma and bitterness in beer production. In our
country's only hops processing facility located in Bilecik Pazaryeri, hops are made ready
for use in production.
Yeast: The company keeps the yeast it has been using for 50 years under protection both in
its yeast bank in Germany and in its private laboratories in Turkey. Yeast is combined with
the wort during the fermentation process.
The resources required for Anadolu Efes production activities are raw materials
(malt,hops,yeast),energy (natural gas,fuel oil etc),production facilites and HR.Some of the
resources required for Anadolu Efes production activities can be described as scarce
resources. Anadolu Efes scarce resources are water,hops and energy. Although these are
the main resources for production, they are also scarce resources.The resources necessary
for production activities are land,labor and capital.Land includes the natural resources such
as barley, water ,yeast ,hops ,sugar and other ingredients. Labor includes the human effort
that is applied to production Capital Anadolu Efes uses its capital resources to improve its
production efficiency and innovation.
Company layout plan is represented in the Appendix A
6
3. COMPUTERS, SOFTWARE AND IT
Software used in the factory:
Power BI:
Microsoft Power BI is a business analysis service offered by Microsoft. It provides
interactive visualizations and business intelligence capabilities for users to create their own
reports and dashboards. Power BI provides cloud-based BI (business intelligence) services.
Power BI offers a top-down view of company operations, minimizing possible risks. By
consolidating data in cloud-based application, Excel or open sources; It offers major
features such as interactive dashboards, data analysis and sharing of creative reports with
other users.
SAP:
SAP is one of the world's leading software manufacturers for business process
management, developing solutions that facilitate effective data processing and information
flow between organizations. SAP software centralizes data management, providing
multiple business functions with one accurate view. This helps companies better manage
complex business processes by giving employees in different departments easy access to
real-time insights across the business. As a result, businesses can streamline workflows,
improve operational efficiency, increase productivity, improve customer experiences and
ultimately increase profits
MES:
Production Execution System (MES) is a computer-aided system that collects all methods
and tools used in production and is integrated online. MES performs four basic functions:
Collects real-time data from the Production Site (e.g. machine stops). It organizes the data
and stores it in a central database. It ensures that all data is accessible over the network by
including critical data from other information systems where data is stored, such as
planning and engineering offices. It receives work orders from ERP, organizes them and
transfers them to production units. It also increases efficiency and quality by reacting to
incidents simultaneously with detailed planning. MES is to track all movements in
production, from raw materials to finished products, with the help of informatics tools.
7
4. ENGINEERING COST ANALYSIS
Depreciation Method Of The Company:
The company uses the straight-line method of depreciation for its property, plant and
equipment, except for some buildings and machinery which are depreciated using the
reducing balance method.
Inventory System Of The Company:
The company uses a hybrid inventory system.This system combines the features of
periodic and perpetual inventory systems.A periodic inventory system is a method of
accounting for inventory that records the quantity of items in stock at the end of an
accounting period. A perpetual inventory system is a method of accounting for inventory
that records the quantity of items in stock after every purchase or sale.Anadolu Efes states
that it uses a periodic inventory system for its raw materials and a perpetual inventory
system for its finished goods. This allows the company to optimize its inventory
management and reduce costs.
8
5. PRODUCTION ENVIRONMENT
Anadolu Efes uses mass production as its main type of production. Mass production is a
method of manufacturing large quantities of standardized products using assembly lines or
other efficient means. Mass production allows the company to achieve economies of scale,
lower costs, and meet the high demand for its products in different markets
Anadolu Efes has a product layout, which arranges the resources needed to produce the
product in one line, as per the sequence of operations. For example, the Ankara plant has a
dedicated production line for each brand or market, such as Efes Pilsen, Bomonti, Tuborg,
etc. This type of layout is suitable for mass production with less job variety. The product
layout allows the company plant to achieve high efficiency, quality, and consistency in its
output. However, it also has some challenges, such as flexibility, maintenance, and
inventory management. Therefore, the company plant needs to have a well-designed and
well-managed production system to optimize its performance. Settlement structure suitable
for production volume and diversity
9
6. WORK STUDY
The study on time study within the scope of work study at Anadolu Efes Ankara Factory
was carried out on the kegging line. Table 1 represents the time study.
PROCESSING ELEMENTS
NO
1
2
OBSERVATIONS
PERFORMANCES
TRANSACTIONS AND DURATIONS 1 2 3 4 5 6 7 8 9 10 Tavg Tnormal
PR
Pallet destruction
100 100 100 100 100 100 100 100 100 100 100 322,3
Tobs
330 319 321 328 311 318 314 324 331 327 322,3
Bottle Exterior
Washing
3
Bottle Front Inner
Washing
4
Bottle Final Internal
Washing
5
Bottle Filling
6
Weight Control and
Labeling
7
Palletizing
PR
Tobs
100 100 100 100 100 100 100 100 100 100 100 333,9
340 324 329 332 336 327 329 337 340 345 333,9
PR
Tobs
100 100 100 100 100 100 100 100 100 100 100
393,4
401 398 384 402 374 385 399 408 401 382 393,4
PR
Tobs
PR
Tobs
100 100 100 100 100 100 100 100 100 100 100 270,6
273 278 268 254 271 273 267 274 280 268 270,6
100 100 100 100 100 100 100 100 100 100 100 101,7
101 100 103 104 98 100 106 104 99 102 101,7
PR
Tobs
PR
Tobs
100 100 100 100 100 100 100 100 100 100 100
181,5
182 183 179 176 189 186 181 177 182 180 181,5
100 100 100 100 100 100 100 100 100 100 100 108
106 109 114 101 103 109 111 109 112 106 108
TOTAL
Shares
Total (%)
1711,4/60
=28,5(min)
15%
Table1
Performance Indicator
2018
Annual Goal
Increase in Annual Bottled 13.7
Beer Production (%)
Actual Data in 2018 (First 6
months)
12.9
Performance Indicator
2019 Actual
months)
17.6
2019
Annual Goal
Increase in Annual Bottled 14.8
Beer Production (%)
Table 2
10
Data
(First
6
As can be seen from the calculationss in the table 2when we compare the increases in
annual bottled beer production compared to 2018-2019, the efficiency increased even more
within 1 year due to the greater than expected increase in 2019. The efficiency calculation
formulas used in the page 10 are as follows:
Labor Efficiency = (Production Quantity)/(Labour Quantity)(unit/person – hour or
unit/number of workers)
Capital Efficiency =(Production Value)/(Capital Used in Production) Material Efficiency
=(Production Quantity)/(Material Quantity)(unit/material quantity or production
value/material value)
Keg Line Beer Filling Flow Process Chart:
OP.NO
1
2
3
4
DESCRIPTION DISTANCE
(m)
Separating keg
from pallet
Putting the keg
on the line
Turning the keg
Pressure control
7
External
washing
Washing with
NaOH
Acid washing
8
9
Beer refill
Weight control
10
Labelling
11
Putting the keg
on the pallet
Shipping to
logistics
department
Shipment
5
6
12
13
SYMBOLS
20
Table 3
11
Demonstration of the Beer Manufacturing Process is represented in Figure 2.
Process 1
Process 2
Process 3
Malt
Wort
Filtered beer
180 minutes
Malt grinding
Resting the
wort for 15
minutes
Kieselguhr
filtration
Malt Mash
60 minutes
cooling
PVPP filtration
180 minutes
straining
Fermentation of
wort for 3-5 days
at 9-13 C°
Excessive
filtering
Resting at -1 C°
for 9-21 days
Filling and
bottling
Filtered beer
Pasteurization for
bottles at 62°C for
30 seconds
Boiling at 90 C°
for 60 minutes
Obtaining Must
Figure 2
12
7. INTERDISCIPLINARY ACTIVITIES AND PROJECT MANAGEMENT
Other Disciplines apart from Industrial engineers:
In this factory, there are electrical and mechanical engineers as well as industrial engineers.
In general, industrial engineers are concerned with the design, planning and optimization
of production and production processes. For this purpose, they try to increase the
efficiency and quality of complex systems and processes by combining mathematics,
physical and social sciences with engineering analysis and design principles. At Anadolu
Efest, mechanical engineers deal with the analysis and maintenance of mechanical
systems. Mechanical engineers ensure the functionality of machines and equipment by
using basic physical knowledge such as heat transfer, fluid mechanics and
thermodynamics. Electrical engineers make the necessary calculations and quality controls
of the devices in the factory, vehicles and other equipment used in electricity distribution.
13
8. IMPLICATIONS OF INDUSTRIAL ENGINEERING APPLICATIONS
Anadolu Efes aims to create a safe and healthy working environment for its employees,
suppliers, subcontractors and visitors. Anadolu Efes' principles for this purpose are as
follows:
• To prevent injuries and deterioration of health by providing a safe and harmonious
working environment to its employees.
• To raise awareness of employees, suppliers and subcontractors about occupational safety,
In the decision-making processes different risks are taken into consideration. Some of the
factors
that
affect
the
process
are
level
of
managment,
structure
of
the
problem,interdependence of the problem.Some of the methods that can be used to take
different risks into consideration in the decision-making processes in a factory are risk
analysis and calculating the expected value.Anadolu Efes has a risk management and
mitigation plan that covers various aspects of its operations. Some of the main activities
and responsible departments are:
Integrated Risk Management: Anadolu Efes has established an Integrated Risk
Management System (IRMS) to identify, assess and manage the risks that may affect its
strategic objectives.
Sustainability: Anadolu Efes has integrated sustainability into its business strategy and
operations.
Water Management: The company has implemented a “Zero Waste” program in its
factories to reduce waste and increase recycling.
Anadolu Efes has a change management policy that guides its employees and stakeholders
on how to deal with changes in a systematic and effective way. An example of the
activities performed during a major change in Anadolu Efes is the merger of its beer
operations with SABMiller in 2012. This was a strategic move to create a stronger and
more competitive beer business in Turkey, Russia, Central Asia and the Middle East.
The activities involved in this change were preparation, implementation and evaluation.
In the implementation step Anadolu Efes established a joint venture with SABMiller,
called Anadolu Efes Breweries International (AEBI), to manage the merged operations.
Anadolu Efes has a policy of equality, diversity and inclusion (ED&I) that applies to all its
employees and workers
14
9. CONCLUSIONS AND RECOMMENDATIONS
In this summer practice, we were shown how beer production is. The raw materials in beer,
the production, packaging and distribution of beer were learned with the help of engineers.
The departments and their duties within the company were learned. During this process,
industrial engineers at the company were involved in tasks such as performing quality
control at every stage of the production line, identifying and eliminating inefficiencies in
the production process, performing regular maintenance of the production line, and
increasing the efficiency of the equipment on the production line. As industrial engineers,
they also work on occupational health and safety issues in breweries. For example, they
can focus on issues such as taking the necessary precautions for the safety of workers and
improving the working conditions of workers. Problems experienced in bottles can be
given as examples of problems in the company. Problems such as breakages, cracks,
blemishes and printing errors may occur in the bottles. These problems reduce productivity
and cause the company to make losses. This To prevent this, a personnel can be added to
control the bottles. Damage to the bottle can be prevented, at least within the factory.
While transporting the bottles with a forklift within the factory, driving the forklift at a
certain slowness will minimize the damage. Or, by using high-tech machines, it can be
determined whether the bottle is problematic. These high-tech machines use a photo
system. The photo of the ideal bottle is loaded into the machine from many angles. The
photo of the bottle that arrives in the system is taken and if it looks similar to the photo
loaded in the machine's memory, the system allows it to continue, otherwise it is removed
from the system. In this way, the bottles are removed from the system before reaching the
final stage. If it had reached the final stage, it would have had to be disposed of along with
the other proper bottles in which it was packaged.
15
REFERENCES






Anadolu Efes. [Çevrimiçi].https://anadoluefes.com.tr/67.
Anadolu Efes - Vikipedi (wikipedia.org)
https://www.clawhammersupply.com/blogs/brewing/beer-ingredients
https://www.vectorsolutions.com/resources/blogs/10-daily-workplace-safety-tips-inmanufacturing/
https://www.inorigin.eu/industrial-engineer-roles-and-responsibilities/
https://www.imse.iastate.edu/files/2015/12/Careers-in-Industrial-Engineering.pdf
16
APPENDIX A
17
18