Retraction: Transition to Lean Manufacturing: An Application in the Yarn Industry

Abstract

In these days, when classical production methods are not enough for changing consumer demands, continuous improvements and developments are needed for companies to survive in markets where there is intense competition. In terms of sustainability, it has become a necessity for businesses to prefer more flexible and faster production systems that can meet instantaneously changing demands, and at this point, lean production comes into play. This study aims to determine the transition process of a synthetic yarn manufacturer operating in Gaziantep Organized Industrial Zone to the lean production system and the advantages obtained as a result of the process. According to the pilot region and product selected in the enterprise, the current system was analyzed and the operation was determined. The work done in each process is standardized. VSM application was made to detect the disruptions in the operation and the activities that do not add value. Accordingly, the problems in the processes were tried to be eliminated by using lean tools such as Kaizen, TPM, OEE, 5S according to the jobs in the departments. In the department, where the lean production system was implemented, a decrease in the energy consumption and the number of personnel and an increase in the amount of production were achieved.

Keywords

• Lean production
• Corporate performance
• Yarn industry

Geri Çekildi: Yalın Üretime Geçiş: İplik Sektöründe Bir Uygulama

Abstract

Değişen tüketici taleplerine klasik üretim metotlarının yetmemeye başladığı şu günlerde, firmaların yoğun rekabetlerin yaşandığı pazarlarda varlığını sürdürebilmesi için sürekli iyileştirmelere ve gelişmelere ihtiyaç duyulmaktadır. Sürdürülebilirlik açısından işletmelerin anlık değişen talepleri karşılayabilecek daha esnek ve daha hızlı üretim sistemlerini tercih etmeleri bir zorunluluk olmuştur ve bu noktada yalın üretim devreye girmektedir. Bu çalışma Gaziantep Organize Sanayi Bölgesinde faaliyet gösteren bir sentetik iplik üreticisinin, yalın üretim sistemine geçiş sürecini ve süreç sonucunda elde edilen avantajların tespit edilmesini amaçlamaktadır. İşletme içinde seçilen pilot bölge ve ürüne göre mevcut sistem analiz edilerek işleyiş belirlenmiştir. Her bir proseste yapılan işler standart hale getirilmiştir. İşleyiş içerisindeki aksaklıklar ve değer katmayan faaliyetleri tespit etmek için VSM uygulaması yapılmıştır. Buna bağlı olarak bölümlerdeki işlere göre Kaizen, TPM, OEE, 5S gibi yalın araçları kullanılarak süreçlerdeki aksaklılar giderilmeye çalışılmıştır. Yalın üretim sistemi ile uygulama yapılan departmanda enerji sarfiyatında ve personel sayısında azalış ve üretim miktarında artış elde edilmiştir.

Keywords

• Yalın üretim
• Kurumsal Performans
• İplik sektörü

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