Positioned as the valve supplier for the world’s leading automobile brands and the largest manufacturer in Turkey, Supsan continued to move forward in the 2019 operating period.
Strategic Positioning
Operating as a Borusan Holding company, Supsan carries out distinctive business processes thanks to the following competitive advantages:
Supsan is Turkey’s largest manufacturer of engine valves,
It is the leader of the domestic Original Equipment Manufacturer (OEM) and spare parts market,
The company’s strategy is focused on expanding its product range and increasing reference units to meet the needs of the automotive spare parts market.
TL 5 Million for R&D
Supsan spent TL 5 million for R&D in 2019. Electric and hybrid cars are on the agenda. The ambition is to have high power output from small engines to match new emissions. Therefore, advances have been achieved in both the engine technology and the use of turbo. However, these changes cause the engine temperature to rise too high because of hollow valves; consequently, sodium valves are considered. Nine internal R&D projects were launched and six internal R&D projects were finalized in 2019. These were about process development, new material development, new product development, digitalization, and Industry 4.0. One of the process development projects was “Direct Quench Process Design for Martensitic Steels,” which aimed to increase Supsan’s heat treatment efficiency.
Supsan is very close to announcing its own engine valve material to reduce the raw material costs. In 2019, Supsan’s material was produced and underwent metallographic and mechanic characterization studies. After successful results in production and engine tests, new material will be ready. Moreover, Supsan started the “Development of Data Collection System” project in 2019. Data analysis and deep learning are the most popular R&D subjects.Supsan started to use different types of sensors to collect data on its own utility services. Supsan can monitor all data 24/7 and predict the next scheduled maintenance. These data will also help to anticipate the root cause of any defect.
Following Digitalization and Industry 4.0 Trends…
Supsan considers the Finite Element Method (FEA) Analysis as important. One of these R&D projects is “Valve Seat Insert Optimization by Finite Element Method (FEA) Model.” The main objectives of this project include creating a Finite Element Method (FEA) Model to define maximum stresses on the surface between the valve seat and valve seat ring and to optimize the match of the valve seat angle with the material. In another R&D project which utilizes Finite Element Method (FEA) modeling, the engine valve is developed and prototyped according to the Original Equipment Manufacturer (OEM) customer’s requirements.
Supsan follows digitalization and Industry 4.0 trends closely. Several examples may be provided for these trends at Supsan. First is the adaption of an industrial robotic arm to allow for automatic visual inspection and avoid the failure of products. This project improves the effectiveness of error detection in the K1 QC line. The other project is the adaptation of sensors for early detection systems to detect problems in all auxiliary facilities and production lines.
Almost ready to supply lightweight, high-strength engines with a hollow valve, Supsan conducts Türkiye Bilimsel ve Teknolojik Araştırma Kurumu (TUBITAK) and internal R&D projects to support characterization of the hollow engine valve. Solid valves and hollow valves are subjected to a thermometric engine test at Supsan’s Dyno Test Room to compare the temperature distribution on the engine valve surface. The thermal stress of a hollow valve is analyzed in comparison with a solid valve by the finite element method (FEM). As a result, the maximum temperature and thermal stress of sodium hollow valve are lower than the solid valve. Turkey often uses regular valves, which cannot be replaced. Supsan is launching a new special valve for LPG. The packaging will be different for easy detection. The most distressing side of the valve is covered with a special material called satellite to increase strength.
Occupational Health and Safety (OHS) is the Top Priority
Occupational health and safety (OHS) has always been the top priority at Supsan. The company has significantly reduced the number of occupational accidents through continuous improvement efforts.
Significant Increase in Productivity with Lean Six Sigma
In 2019, Supsan enjoyed considerable improvements in production and productivity due to its efforts focused on Lean Six Sigma and its philosophy of continuous development.
2019 Business Outcomes
Positioned as the valve supplier for the world’s leading automobile brands and the largest manufacturer in Turkey, Supsan recorded a number of achievements in 2019:
The number of non-valve references increased from 2,534 in 2018 to 3,236 in 2019.
The number of turbocharger references increased to 62.
The share of non-valve products in total turnover corresponded to 25% in 2019.
Some 3,108 people were contacted through 42 customer training & introduction meetings and 48 Apprenticeship Training Center Meetings, in line with the marketing strategy for Turkey.
As a result of productivity studies conducted under Lean Six Sigma and continuous development efforts, 35 projects were developed in order to become a lean manufacturer on a global scale.
Compared to the previous year, the number of projects increased by 17% and the number of Sosyal Destek Programı (Social Support Program - SÖDES) suggestions rose 127%.
Future Outlook of Supsan
Existing performance and future outlook of valve business led to three initiatives to transform Supsan:
Reorganization of Valve Business
Receive more projects from potential players in the Turkish Original Equipment Market (OEM) market
Improve sales channels to get more turnover in foreign markets
Improve the infrastructure to supply large valves to non-automotive sectors (marine, rail system, energy,)
Focus on developing high-technology products such as hollow valves
Aftermarket Transformation
Enhance the distribution network and reach wider areas.
Achieve dominance in selected products in high-potential markets.
Have value-added spare parts (use in electrified transportation standards (xEVs) and electronics).
New Product Development
Work on Original Equipment Manufacturer (OEM) products that will generate turnover in addition to valve business in the short term, replace valves in the long term and also use in electrified transportation standards (xEVs).
Carry out negotiations for candidate/new products, conduct of feasibility studies, establishof market strategies
Execute investment(s) with incentives for candidate/new product(s).
TL 5 million for R&D
Supsan spent TL 5 million for R&D in 2019.
In 2019, Supsan enjoyed considerable improvements in production and productivity due to its efforts focused on Lean Six Sigma and its philosophy of continuous improvement.
COMPANY PROFILE
Operational Information
Total Production: 5.4 million units
Global Sales: 3.56 million units
2019 Valve Sales: 5.5 million units
Exports to Italy: 83%
Corporate Information
Field of Activity
International expertise in the manufacturing and after-sales services of engine parts and other related products in the original equipment and aftermarket.
Valve production for internal combustion engines under the license of Eaton SRL, the leading manufacturer in the global market.
Products and Services
Domestic OEM
Domestic OES
International OEM & OES
Manufacturing Capacity
12 million valves per year
Production capacity of 3 million stellated valves and 3.3 million two-piece valves
Sectors Served
Domestic and international OEM and after-market customers
