Research Article
SÜREÇ YETERLİLİK ANALİZİNİN GENİŞLETİLMİŞ KAİZEN YÖNTEMİNE ENTEGRASYONU: OTOMOTİV SEKTÖRÜNDE BİR UYGULAMA
Abstract
İş süreçlerindeki küçük
iyileştirmeler olarak ifade edilen Kaizen uygulamaları kalite iyileştirme
çalışmalarının en etkin olanlarındandır. Bu çalışma kapsamında, tek defada ve
kabul edilebilir bir sürede, doğru iyileştirmeye ulaşmak hedefiyle, bilinen
Kaizen çalışmalarına göre daha kapsamlı ancak Altı Sigma ve benzeri çalışmalara
göre daha kısa sürede gerçekleştirilebilen bir Majör Kaizen uygulaması
gerçekleştirilmiş ve etkinliği incelenmiştir. Bu amaçla, bir otomotiv
firmasında majör Kaizen teknikleri uygulaması ile belirli bir sac parçanın
üretim sürecinde görülen hatalar incelenerek sebepleri belirlenmiş ve bu
hatalar azaltılarak süreç iyileştirmesi gerçekleştirilmiştir. Çalışmanın
amacına uygun olarak ilk önce genel süreç için hata tanımları yapılmış ve bu
hatalar için Pareto analizi gerçekleştirilmiştir. Daha sonra parçanın üretim ve
ölçüm süreçleri detaylı olarak incelenmiş, parçanın tüm kontrol noktaları için
ölçüm sonuçlarına göre süreç yeterlilik indisleri hesaplanmış, kritik öneme
sahip olan kontrol noktaları belirlenerek bu noktalar üzerine odaklanılmıştır.
Mevcut durum analizi sonrası balık kılçığı diyagramı oluşturulmuş, Gemba
analizleri ve hipotez testleri gerçekleştirilmiş, karşı önlemler planlanarak
önceliklendirme matrisi oluşturulmuş ve iyileştirme önerileri sunulmuştur.
İyileştirmeler gerçekleştirilip standart hale getirilmiştir. Sonuç olarak,
belirlenen noktalar için süreç yeterlilik indislerinin iyileştirildiği
görülmüştür. Bu çalışma, literatürdeki Kaizen çalışmaları kapsamında
gerçekleştirilmemiş olan süreç yeterlilik analizini Kaizen uygulamasına başarılı
bir şekilde entegre ederek farklı istatistiksel analizlerle bulguları
desteklemiş ve sonuçları doğrulamıştır.
References
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- Aoki, K. (2008). Transferring Japanese kaizen activities to overseas plants in China. International Journal of Operations & Production Management, 28(6), 518-539.
- Arcidiacono, G., Calabrese, C., & Yang, K. (2012). Leading Processes to Lead Companies: Lean Six Sigma: Kaizen Leader & Green Belt Handbook. Springer Science & Business Media.
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- Berger, A. (1997). Continuous improvement and kaizen: standardization and organizational designs. Integrated Manufacturing Systems, 8(2), 110-117.
- Brooks, R. (1993), Change for the better, The TQM Magazine, 5(4), 51-53.
- Brunet, A.P. and New, S. (2003), Kaizen in Japan: an empirical study, International Journal of Operations & Production Management, 23(12), 1426-1446.
- Charles, A. A., & Chucks, O. K. (2012). Adopting the Kaizen suggestion system in South African Lean automotive components companies. Science Journal of Business Management, 2012.
- Cherrafi, A., Elfezazi, S., Hurley, B., Garza-Reyes, J. A., Kumar, V., Anosike, A., & Batista, L. (2019). Green and Lean: a Gemba–Kaizen model for sustainability enhancement. Production Planning & Control, 30(5-6), 385-399.
- Dave, Y., & Sohani, N. (2015). Solving the issue of electronic breakdown of hobbing machine through Kobetsu Kaizen methodology: A case study. In Applied Mechanics and Materials (Vol. 789, pp. 592-596). Trans Tech Publications.
- Goyal, A., Agrawal, R., Chokhani, R. K., & Saha, C. (2019). Waste reduction through Kaizen approach: A case study of a company in India. Waste Management & Research, 37(1), 102-107.
- Guo, W., Jiang, P., Xu, L., & Peng, G. (2019). Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line. Advances in Mechanical Engineering, 11(2), 1687814019827115.
- Iannettoni, M. D., Lynch, W. R., Parekh, K. R., & McLaughlin, K. A. (2011). Kaizen method for esophagectomy patients: improved quality control, outcomes, and decreased costs. The Annals Of Thoracic Surgery, 91(4), 1011-1018.
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- Junker, B. (2010). Kaizen for improvement of rapid protein production for early reagent protein quantities. Biochemical Engineering Journal, 49(3), 435-444.
- Kumar, S., Dhingra, A. K., & Singh, B. (2018). Process improvement through Lean-Kaizen using value stream map: a case study in India. The International Journal of Advanced Manufacturing Technology, 1-12.
- Kumar, S., Dhingra, A., & Singh, B. (2018). Lean-Kaizen implementation: A roadmap for identifying continuous improvement opportunities in Indian small and medium sized enterprise. Journal of Engineering, Design and Technology, 16(1), 143-160.
- Lyu Jr, J. (1996). Applying Kaizen and automation to process reengineering. Journal of Manufacturing Systems, 15(2), 125-132.
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- Parkhan, A., & Sugarindra, M. (2018). Productivity improvement in the production line with lean manufacturing approach: case study PT. XYZ. In MATEC Web of Conferences (Vol. 154, p. 01093). EDP Sciences.
- Prashar, A. (2014). Redesigning an assembly line through Lean-Kaizen: an Indian case. The TQM Journal, 26(5), 475-498.
- Ramasesh, R. V., and T. R. Browning. 2014. A Conceptual Framework for Tackling Knowable Unknown Unknowns in Project Management. Journal of Operations Management. 32 (4): 190–204. doi:10.1016/j.jom.2014.03.003.
- Reinertsen, D., & Shaeffer, L. (2005). The logic of lean. Research Technology Management, 48(4), 52.
- Sanchez, L., & Blanco, B. (2014). Three decades of continuous improvement. Total Quality Management & Business Excellence, 25(9-10), 986-1001.
- Singh, J., & Singh, H. (2015). Continuous improvement philosophy–literature review and directions. Benchmarking: An International Journal, 22(1), 75-119.
- Singh, J., & Singh, H. (2016). Evaluation of Kaizen Technique Across Manufacturing Unit--A Case Study. Productivity, 57(1).
- Suárez-Barraza, M. F., & Ramis-Pujol, J. (2010). Implementation of Lean-Kaizen in the human resource service process: A case study in a Mexican public service organisation. Journal of Manufacturing Technology Management, 21(3), 388-410.
- Suárez-Barraza, M. F., Ramis-Pujol, J., & Kerbache, L. (2011). Thoughts on kaizen and its evolution: Three different perspectives and guiding principles. International Journal of Lean Six Sigma, 2(4), 288-308.
- Tozawa, B., & Bodek, N. (2001). The Idea Generator: Quick and Easy Kaizen. PCS Inc.
- Vardhan, S., & Gupta, P. (2014). Study on the Implementation of Kobetsu Kaizen (KK) Pillar of TPM in a Process Industry. In Applied Mechanics and Materials (Vol. 592, pp. 2694-2698). Trans Tech Publications.
- Womack, J. P., Jones, D. T., & Roos, D. (1990). Machine That Changed The World. Simon and Schuster.
Year 2019,
Volume: 27 Issue: 3, 165 - 183, 15.12.2019
Abstract
References
- Abdulmouti, H. (2015, March). The role of Kaizen (continuous improvement) in improving companies' performance: A case study. In International Conference on Industrial Engineering and Operations Management (IEOM) (pp. 1-6). IEEE.
- Alukal, G. (2007). Lean kaizen in the 21st century. Quality Progress, 40(8), 69.
- Aoki, K. (2008). Transferring Japanese kaizen activities to overseas plants in China. International Journal of Operations & Production Management, 28(6), 518-539.
- Arcidiacono, G., Calabrese, C., & Yang, K. (2012). Leading Processes to Lead Companies: Lean Six Sigma: Kaizen Leader & Green Belt Handbook. Springer Science & Business Media.
- Aydın, Z. B., ve Kargı, V. S. A. (2018). İstatistiksel Kalite Kontrol Teknikleri İle Otomotiv Sektöründe Bir Uygulama. Yönetim ve Ekonomi Araştırmaları Dergisi, 16(1), 41-63.
- Berger, A. (1997). Continuous improvement and kaizen: standardization and organizational designs. Integrated Manufacturing Systems, 8(2), 110-117.
- Brooks, R. (1993), Change for the better, The TQM Magazine, 5(4), 51-53.
- Brunet, A.P. and New, S. (2003), Kaizen in Japan: an empirical study, International Journal of Operations & Production Management, 23(12), 1426-1446.
- Charles, A. A., & Chucks, O. K. (2012). Adopting the Kaizen suggestion system in South African Lean automotive components companies. Science Journal of Business Management, 2012.
- Cherrafi, A., Elfezazi, S., Hurley, B., Garza-Reyes, J. A., Kumar, V., Anosike, A., & Batista, L. (2019). Green and Lean: a Gemba–Kaizen model for sustainability enhancement. Production Planning & Control, 30(5-6), 385-399.
- Dave, Y., & Sohani, N. (2015). Solving the issue of electronic breakdown of hobbing machine through Kobetsu Kaizen methodology: A case study. In Applied Mechanics and Materials (Vol. 789, pp. 592-596). Trans Tech Publications.
- Goyal, A., Agrawal, R., Chokhani, R. K., & Saha, C. (2019). Waste reduction through Kaizen approach: A case study of a company in India. Waste Management & Research, 37(1), 102-107.
- Guo, W., Jiang, P., Xu, L., & Peng, G. (2019). Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line. Advances in Mechanical Engineering, 11(2), 1687814019827115.
- Iannettoni, M. D., Lynch, W. R., Parekh, K. R., & McLaughlin, K. A. (2011). Kaizen method for esophagectomy patients: improved quality control, outcomes, and decreased costs. The Annals Of Thoracic Surgery, 91(4), 1011-1018.
- Imai, M. (1986), Kaizen: The key to Japan’s Competitive Success, McGraw-Hill, New York, NY.
- Imai, M. (2012), Gemba Kaizen: A Commonsense Approach to a Continuous Improvement Strategy, 2nd ed., McGraw Hill Professional, New York, NY.
- Iwao, S. (2017), Revisiting the existing notion of continuous improvement (Kaizen): literature review and field research of Toyota from a perspective of innovation. Evolutionary and Institutional Economics Review, 14(1), 29-59.
- Junker, B. (2010). Kaizen for improvement of rapid protein production for early reagent protein quantities. Biochemical Engineering Journal, 49(3), 435-444.
- Kumar, S., Dhingra, A. K., & Singh, B. (2018). Process improvement through Lean-Kaizen using value stream map: a case study in India. The International Journal of Advanced Manufacturing Technology, 1-12.
- Kumar, S., Dhingra, A., & Singh, B. (2018). Lean-Kaizen implementation: A roadmap for identifying continuous improvement opportunities in Indian small and medium sized enterprise. Journal of Engineering, Design and Technology, 16(1), 143-160.
- Lyu Jr, J. (1996). Applying Kaizen and automation to process reengineering. Journal of Manufacturing Systems, 15(2), 125-132.
- Ma, J., Lin, Z., & Lau, C. K. (2017). Prioritising the enablers for the successful implementation of Kaizen in China: a Fuzzy AHP study. International Journal of Quality & Reliability Management, 34(4), 549-568.
- Manos, A. (2007). The benefits of Kaizen and Kaizen events. Quality Progress, 40(2), 47.
- Maurer, R. (2012), The Spirit of Kaizen: Creating Lasting Excellence One Small Step at a Time, McGraw Hill Professional, New York, NY.
- Murata, K., & Katayama, H. (2010). A study on construction of a kaizen case-base and its utilisation: a case of visual management in fabrication and assembly shop-floors. International Journal of Production Research, 48(24), 7265-7287.
- Nihon H.R.K. (1995). Improvement Engine: Creativity and Innovation Through Employee Involvement--The Kaizen Teian Approach. CRC Press.
- Parkhan, A., & Sugarindra, M. (2018). Productivity improvement in the production line with lean manufacturing approach: case study PT. XYZ. In MATEC Web of Conferences (Vol. 154, p. 01093). EDP Sciences.
- Prashar, A. (2014). Redesigning an assembly line through Lean-Kaizen: an Indian case. The TQM Journal, 26(5), 475-498.
- Ramasesh, R. V., and T. R. Browning. 2014. A Conceptual Framework for Tackling Knowable Unknown Unknowns in Project Management. Journal of Operations Management. 32 (4): 190–204. doi:10.1016/j.jom.2014.03.003.
- Reinertsen, D., & Shaeffer, L. (2005). The logic of lean. Research Technology Management, 48(4), 52.
- Sanchez, L., & Blanco, B. (2014). Three decades of continuous improvement. Total Quality Management & Business Excellence, 25(9-10), 986-1001.
- Singh, J., & Singh, H. (2015). Continuous improvement philosophy–literature review and directions. Benchmarking: An International Journal, 22(1), 75-119.
- Singh, J., & Singh, H. (2016). Evaluation of Kaizen Technique Across Manufacturing Unit--A Case Study. Productivity, 57(1).
- Suárez-Barraza, M. F., & Ramis-Pujol, J. (2010). Implementation of Lean-Kaizen in the human resource service process: A case study in a Mexican public service organisation. Journal of Manufacturing Technology Management, 21(3), 388-410.
- Suárez-Barraza, M. F., Ramis-Pujol, J., & Kerbache, L. (2011). Thoughts on kaizen and its evolution: Three different perspectives and guiding principles. International Journal of Lean Six Sigma, 2(4), 288-308.
- Tozawa, B., & Bodek, N. (2001). The Idea Generator: Quick and Easy Kaizen. PCS Inc.
- Vardhan, S., & Gupta, P. (2014). Study on the Implementation of Kobetsu Kaizen (KK) Pillar of TPM in a Process Industry. In Applied Mechanics and Materials (Vol. 592, pp. 2694-2698). Trans Tech Publications.
- Womack, J. P., Jones, D. T., & Roos, D. (1990). Machine That Changed The World. Simon and Schuster.
There are 38 citations in total.
Details
| Primary Language | Turkish |
|---|---|
| Subjects | Industrial Engineering |
| Journal Section | Research Articles |
| Authors | |
| Publication Date | December 15, 2019 |
| Acceptance Date | September 2, 2019 |
| Published in Issue | Year 2019 Volume: 27 Issue: 3 |
