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BİSKÜVİ ÜRETİM HATLARINDA HAZIRLIK SÜRELERİNİN AZALTILMASINA YÖNELİK YALIN ÜRETİM VE SMED UYGULAMASI

Yıl 2022, , 413 - 439, 31.08.2022
https://doi.org/10.46465/endustrimuhendisligi.1038736

Öz

Kalıp değişimi, çeşitli ürünler üreten tesislerde verimliliği etkileyen önemli bir faktördür. Kalıp değişim sürelerinin uzaması ve kalıp değişimi sonrasında istenilen kalitenin elde edilememesi büyük bir zaman kaybına neden olabilmektedir. Aynı zamanda, kalıp değişimi için standart olmayan prosedürler, değişim sürecini daha da zorlaştırmaktadır. Bu çalışmada, bir bisküvi üretim tesisinin üretim hatlarındaki kalıp değiştirme sorunları incelenmiştir. Tesiste üretilen her ürün için hamur açma makinesi ve paketleme makinesinde kalıp değişiklikleri yapılmakta ve her değişimde üretim hattı temizlenmektedir. Bu çalışmada, makine kalıp değişimindeki kayıp zamanları azaltmaya yönelik SMED (Single Minute Exchange of Die: Tekli Dakikalarda Kalıp Değişimi) yaklaşımı ve 5S ile mevcut durum analiz edilmiş ve iyileştirmeler yapılmıştır. Bu çalışma sonucunda dış hazırlık süresinde %26,91, iç hazırlık süresinde %20,74 ve toplam hazırlık süresinde %21,05'lik iyileştirme gerçekleştirilmiş, yıllık üretim miktarı ve kârda ise %3,8 oranında artış sağlanmıştır.
Bu çalışmada Kaizen, Poka-yoke ve SMED teknikleriyle 3 aşamalı bir yapı ile bisküvi üretim tesisleri için kalıp değişim süreçlerinde iyileştirmeler yalın üretim teknikleri ve ergonomik değerlendirmeler eşliğinde yapılmıştır.

Destekleyen Kurum

Anadolu Birlik Holding

Kaynakça

  • Agung, D., & Hasbullah, H. (2019). Reducing The Product Changeover Time Using SMED & 5S Methods in The Injection Molding Industry. Sinergi, 23(3), 199-212. doi: 10.22441/sinergi.2019.3.004
  • Akyurt, İ.Z. ve Eren, E. (2019). Hazırlık Süresinin Azaltılmasında SMED Yöntemi Uygulaması. Ekonomik ve Sosyal Araştırmalar Dergisi, 15(3), 315-331.
  • Allahverdi, A., & Soroush, H. M. (2008). The significance of reducing setup times/ setup costs. European Journal of Operational Research, 187, 978–984.
  • Bendall A., Disney J., & Pridmore W.A. (1989). Taguchi Methods: Application in World Industry. IFS Publications, Springer-Verlag, New York, NY.
  • Carrizo Moreira, A., & Campos Silva Pais, G. (2011). Single minute exchange of die: a case study implementation. Journal of technology management & innovation, 6(1), 129-146.
  • Chen L., & Meng B. (2010). The Application of Setup Reduction in Lean Production. Asian Social Science, 6(7). doi: 10.5539/ass.v6n7p108
  • Choomlucksana, J., Ongsaranakorn, M., Suksabai, P. (2015). Improving the Productivity of Sheet Metal Stamping Subassembly Area Using the Application of Lean Manufacturing Principles. Procedia Manufacturing, 2, 102-107. doi: 10.1016/j.promfg.2015.07.090
  • Costa, E., Braganca, S., Sousa, R., & Alves, A. (2013). Benefits from a SMED application in a punching machine. World Academy Of Science, Engineering And Technology International Journal Of Mechanical, Industrial Science And Engineering, 7(5).
  • Çelik, H. (2020). Ayar sürelerinin azaltılmasına yönelik yeni yaklaşım: SMED Taguchi yöntemi. Sakarya Üniversitesi İşletme Enstitüsü Dergisi, 2(1), 13-26.
  • Desai, M. (2012). Productivity Enhancement by Reducing Setup Time -SMED: Case study in the Automobile factory. Global Journal Of Researches In Engineering Mechanical And Mechanics Engineering, 12(5), 15-20.
  • Dillon, A. P., & Shingo, S. (1985). A revolution in manufacturing: the SMED system. CRC Press.
  • Ekincioğlu, C. ve Boran, S. (2018). SMED methodology based on fuzzy Taguchi method. Journal Of Enterprise Information Management, 31(6), 867-878. doi: 10.1108/jeim-01-2017-0019
  • Gadre, A., Cudney, E., & Corns, S. (2011). Model development of a virtual learning environment to enhance lean education. Procedia Computer Science, 6, 100–105.
  • Gung, D., & Studel, F. (1990). A work load balancing model for determining set-up time and batch size reduction in G.T. flow line work cells. International Journal of Production Research, Vol. 28 No. 4, pp. 255-292.
  • Karam, A., Liviu, M., Cristina, V., & Radu, H. (2018). The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project. Procedia Manufacturing, 22, 886-892. doi: 10.1016/j.promfg.2018.03.125
  • Karasu K., Cakmakci M., Cakiroglu M., Ayva E. ve Demirel-Ortabas N. (2014). Improvement of changeover times via Taguchi empowered SMED/case study on injection molding production. Measurement, 47, 741-748. doi: 10.1016/j.measurement.2013.09.035
  • Liker, J.K., & Hoseus, M. (2008) Toyota Culture: The Heart and Soul of the Toyota Way. McGraw-Hill, New York.
  • Lozano, J., Saenz-Díez, J., Martínez, E., Jiménez, E., & Blanco, J. (2016). Methodology to improve machine changeover performance on food industry based on SMED. The International Journal Of Advanced Manufacturing Technology, 90(9-12), 3607-3618. doi: 10.1007/s00170-016-9686-x
  • Mali Y. R., & Inamdar K. H. (2012). Changeover Time Reduction Using SMED Technique of Lean Manufacturing. International Journal of Engineering Research and Applications, 2 (3): 2441-2445.
  • Monteiro, C., Ferreira, L., Fernandes, N., Sá, J., Ribeiro, M., & Silva, F. (2019). Improving the Machining Process of the Metalworking Industry Using the Lean Tool SMED. Procedia Manufacturing, 41, 555-562. doi: 10.1016/j.promfg.2019.09.043
  • Moreira C., A. & Pais, G.C.S. (2011). Single Minute Exchange of Die: A Case Study Implementation. Journal Of Technology Management & Innovation, 6(1), 129-146. doi: 10.4067/s0718-27242011000100011
  • Mulla M. L., Bhatwadekar S. G., & Pandit S. V. (2017). Implementation of Lean Manufacturing Through the Technique of Single Minute Exchange Of Die (SMED) to Reduce Change Over Time. International Journal of Innovative Research in Science, Engineering and Technology, 3(6).
  • Mustafa, K., & Cheng, K. (2016) Managing complexity in manufacturing changeovers: a sustainable manufacturing-oriented approach and the application case study. ASME 11th International Manufacturing Science and Engineering Conference. 2016. Blacksburg, Virginia, USA: ASME.
  • Naboureh, K., & Safari, E. (2016) Integrating the sequence dependent setup time open shop problem and preventive maintenance policies. Decision Science Letters 5(4):535–550. doi: 10.5267/j.dsl.2016.4.002
  • Pellegrini, S., Shetty, D., & Manzione, L. (2012). Study and Implementation of Single Minute Exchange of Die (SMED) Methodology in a Setup Reduction Kaizen. Proceedings Of The 2012 International Conference On Industrial Engineering And Operations Management.
  • Rosa, C., Silva, F., Ferreira, L., & Campilho, R. (2017). SMED methodology: The reduction of setup times for Steel Wire-Rope assembly lines in the automotive industry. Procedia Manufacturing, 13, 1034-1042. doi: 10.1016/j.promfg.2017.09.110
  • Ross, P.J. (1988). The role of Taguchi methods and design of experiments in QFD. Quality Progress, June.
  • Sabadka, D., Molnar, V., & Fedorko, G. (2017). The Use of Lean Manufacturing Techniques – SMED Analysis to Optimization of the Production Process. Advances in Science And Technology Research Journal, 11(3), 187-195. doi: 10.12913/22998624/76067
  • Sarı, E.B. (2018). Yalın Üretim Uygulamaları ve Kazanımları, International Journal of Economic and Administrative Studies, 17, 585-600.
  • Schonberger R. (1982). The Transfer of Japanese Manufacturing Management Approaches to the U. S. Industry. The Academy Of Management Review, 7(3), 479. doi: 10.2307/257340
  • Shingo S. (1985). A revolution in manufacturing, the SMED system. Productivity Press.
  • Simões, A., & Tenera, A. (2010). Improving setup time in a Press Line–Application of the SMED methodology. IFAC Proceedings Volumes, 43(17), 297-302. doi: 10.3182/20100908-3-pt-3007.00065
  • Singh, J.B., & Khanduja, D. (2009). SMED: for quick changeovers in foundry SMEs. International Journal of Productivity and Performance Management, 59(1), 98-116. doi: 10.1108/17410401011006130
  • Sousa, E., Silva, F., Ferreira, L., Pereira, M., Gouveia, R., & Silva, R. (2018). Applying SMED methodology in cork stoppers production. Procedia Manufacturing, 17, 611-622. doi: 10.1016/j.promfg.2018.10.103
  • Taguchi, G. (1990). “Introduction to Quality Engineering”, Asian Productivity Organization, Tokyo.
  • Ulutaş B. (2011). An Application of SMED Methodology. World Academy of Science, Engineering and Technology International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 5(7), 1194-1197.
  • Umap, A., Dhekane, A., Survase, A., Shelke, A., Nigole, S., & Gambhire, G. (2016). Setup time reduction by using SMED and Kaizen approach. Dr. B. R. Ambedkar National Institude Of Technology Jalandhar-144011, India Department Of Industrial And Production Engineering Ivth International Conference on Production and Industrial Engineering.
  • Vieira, T., Sá, J., Lopes, M., Santos, G., Félix, M., & Ferreira, L. et al. (2019). Optimization of the cold profiling process through SMED. Procedia Manufacturing, 38, 892-899. doi: 10.1016/j.promfg.2020.01.171
  • Womack J. P., Jones D. T., & Roos D. (1990), The Machine That Changed the World: The Story of Lean Production- Toyota’s Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry, Free Press, New York.
  • Yalçın S. E., Akın S., Elmas B., Eren M. ve Gündüz T. (2020). Çelik Boru İmalatında Hazırlık Sürelerine Yönelik Yalın Üretim ve SMED Çalışması. Journal Of Industrial Engineering, 31(1), 87-104.
  • Yazıcı, K., Gökler, S., & Boran, S. (2020). An integrated SMED-fuzzy FMEA model for reducing setup time. Journal of Intelligent Manufacturing. doi: 10.1007/s10845-020-01675-x
Yıl 2022, , 413 - 439, 31.08.2022
https://doi.org/10.46465/endustrimuhendisligi.1038736

Öz

Kaynakça

  • Agung, D., & Hasbullah, H. (2019). Reducing The Product Changeover Time Using SMED & 5S Methods in The Injection Molding Industry. Sinergi, 23(3), 199-212. doi: 10.22441/sinergi.2019.3.004
  • Akyurt, İ.Z. ve Eren, E. (2019). Hazırlık Süresinin Azaltılmasında SMED Yöntemi Uygulaması. Ekonomik ve Sosyal Araştırmalar Dergisi, 15(3), 315-331.
  • Allahverdi, A., & Soroush, H. M. (2008). The significance of reducing setup times/ setup costs. European Journal of Operational Research, 187, 978–984.
  • Bendall A., Disney J., & Pridmore W.A. (1989). Taguchi Methods: Application in World Industry. IFS Publications, Springer-Verlag, New York, NY.
  • Carrizo Moreira, A., & Campos Silva Pais, G. (2011). Single minute exchange of die: a case study implementation. Journal of technology management & innovation, 6(1), 129-146.
  • Chen L., & Meng B. (2010). The Application of Setup Reduction in Lean Production. Asian Social Science, 6(7). doi: 10.5539/ass.v6n7p108
  • Choomlucksana, J., Ongsaranakorn, M., Suksabai, P. (2015). Improving the Productivity of Sheet Metal Stamping Subassembly Area Using the Application of Lean Manufacturing Principles. Procedia Manufacturing, 2, 102-107. doi: 10.1016/j.promfg.2015.07.090
  • Costa, E., Braganca, S., Sousa, R., & Alves, A. (2013). Benefits from a SMED application in a punching machine. World Academy Of Science, Engineering And Technology International Journal Of Mechanical, Industrial Science And Engineering, 7(5).
  • Çelik, H. (2020). Ayar sürelerinin azaltılmasına yönelik yeni yaklaşım: SMED Taguchi yöntemi. Sakarya Üniversitesi İşletme Enstitüsü Dergisi, 2(1), 13-26.
  • Desai, M. (2012). Productivity Enhancement by Reducing Setup Time -SMED: Case study in the Automobile factory. Global Journal Of Researches In Engineering Mechanical And Mechanics Engineering, 12(5), 15-20.
  • Dillon, A. P., & Shingo, S. (1985). A revolution in manufacturing: the SMED system. CRC Press.
  • Ekincioğlu, C. ve Boran, S. (2018). SMED methodology based on fuzzy Taguchi method. Journal Of Enterprise Information Management, 31(6), 867-878. doi: 10.1108/jeim-01-2017-0019
  • Gadre, A., Cudney, E., & Corns, S. (2011). Model development of a virtual learning environment to enhance lean education. Procedia Computer Science, 6, 100–105.
  • Gung, D., & Studel, F. (1990). A work load balancing model for determining set-up time and batch size reduction in G.T. flow line work cells. International Journal of Production Research, Vol. 28 No. 4, pp. 255-292.
  • Karam, A., Liviu, M., Cristina, V., & Radu, H. (2018). The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED project. Procedia Manufacturing, 22, 886-892. doi: 10.1016/j.promfg.2018.03.125
  • Karasu K., Cakmakci M., Cakiroglu M., Ayva E. ve Demirel-Ortabas N. (2014). Improvement of changeover times via Taguchi empowered SMED/case study on injection molding production. Measurement, 47, 741-748. doi: 10.1016/j.measurement.2013.09.035
  • Liker, J.K., & Hoseus, M. (2008) Toyota Culture: The Heart and Soul of the Toyota Way. McGraw-Hill, New York.
  • Lozano, J., Saenz-Díez, J., Martínez, E., Jiménez, E., & Blanco, J. (2016). Methodology to improve machine changeover performance on food industry based on SMED. The International Journal Of Advanced Manufacturing Technology, 90(9-12), 3607-3618. doi: 10.1007/s00170-016-9686-x
  • Mali Y. R., & Inamdar K. H. (2012). Changeover Time Reduction Using SMED Technique of Lean Manufacturing. International Journal of Engineering Research and Applications, 2 (3): 2441-2445.
  • Monteiro, C., Ferreira, L., Fernandes, N., Sá, J., Ribeiro, M., & Silva, F. (2019). Improving the Machining Process of the Metalworking Industry Using the Lean Tool SMED. Procedia Manufacturing, 41, 555-562. doi: 10.1016/j.promfg.2019.09.043
  • Moreira C., A. & Pais, G.C.S. (2011). Single Minute Exchange of Die: A Case Study Implementation. Journal Of Technology Management & Innovation, 6(1), 129-146. doi: 10.4067/s0718-27242011000100011
  • Mulla M. L., Bhatwadekar S. G., & Pandit S. V. (2017). Implementation of Lean Manufacturing Through the Technique of Single Minute Exchange Of Die (SMED) to Reduce Change Over Time. International Journal of Innovative Research in Science, Engineering and Technology, 3(6).
  • Mustafa, K., & Cheng, K. (2016) Managing complexity in manufacturing changeovers: a sustainable manufacturing-oriented approach and the application case study. ASME 11th International Manufacturing Science and Engineering Conference. 2016. Blacksburg, Virginia, USA: ASME.
  • Naboureh, K., & Safari, E. (2016) Integrating the sequence dependent setup time open shop problem and preventive maintenance policies. Decision Science Letters 5(4):535–550. doi: 10.5267/j.dsl.2016.4.002
  • Pellegrini, S., Shetty, D., & Manzione, L. (2012). Study and Implementation of Single Minute Exchange of Die (SMED) Methodology in a Setup Reduction Kaizen. Proceedings Of The 2012 International Conference On Industrial Engineering And Operations Management.
  • Rosa, C., Silva, F., Ferreira, L., & Campilho, R. (2017). SMED methodology: The reduction of setup times for Steel Wire-Rope assembly lines in the automotive industry. Procedia Manufacturing, 13, 1034-1042. doi: 10.1016/j.promfg.2017.09.110
  • Ross, P.J. (1988). The role of Taguchi methods and design of experiments in QFD. Quality Progress, June.
  • Sabadka, D., Molnar, V., & Fedorko, G. (2017). The Use of Lean Manufacturing Techniques – SMED Analysis to Optimization of the Production Process. Advances in Science And Technology Research Journal, 11(3), 187-195. doi: 10.12913/22998624/76067
  • Sarı, E.B. (2018). Yalın Üretim Uygulamaları ve Kazanımları, International Journal of Economic and Administrative Studies, 17, 585-600.
  • Schonberger R. (1982). The Transfer of Japanese Manufacturing Management Approaches to the U. S. Industry. The Academy Of Management Review, 7(3), 479. doi: 10.2307/257340
  • Shingo S. (1985). A revolution in manufacturing, the SMED system. Productivity Press.
  • Simões, A., & Tenera, A. (2010). Improving setup time in a Press Line–Application of the SMED methodology. IFAC Proceedings Volumes, 43(17), 297-302. doi: 10.3182/20100908-3-pt-3007.00065
  • Singh, J.B., & Khanduja, D. (2009). SMED: for quick changeovers in foundry SMEs. International Journal of Productivity and Performance Management, 59(1), 98-116. doi: 10.1108/17410401011006130
  • Sousa, E., Silva, F., Ferreira, L., Pereira, M., Gouveia, R., & Silva, R. (2018). Applying SMED methodology in cork stoppers production. Procedia Manufacturing, 17, 611-622. doi: 10.1016/j.promfg.2018.10.103
  • Taguchi, G. (1990). “Introduction to Quality Engineering”, Asian Productivity Organization, Tokyo.
  • Ulutaş B. (2011). An Application of SMED Methodology. World Academy of Science, Engineering and Technology International Journal of Mechanical, Aerospace, Industrial, Mechatronic and Manufacturing Engineering, 5(7), 1194-1197.
  • Umap, A., Dhekane, A., Survase, A., Shelke, A., Nigole, S., & Gambhire, G. (2016). Setup time reduction by using SMED and Kaizen approach. Dr. B. R. Ambedkar National Institude Of Technology Jalandhar-144011, India Department Of Industrial And Production Engineering Ivth International Conference on Production and Industrial Engineering.
  • Vieira, T., Sá, J., Lopes, M., Santos, G., Félix, M., & Ferreira, L. et al. (2019). Optimization of the cold profiling process through SMED. Procedia Manufacturing, 38, 892-899. doi: 10.1016/j.promfg.2020.01.171
  • Womack J. P., Jones D. T., & Roos D. (1990), The Machine That Changed the World: The Story of Lean Production- Toyota’s Secret Weapon in the Global Car Wars That Is Now Revolutionizing World Industry, Free Press, New York.
  • Yalçın S. E., Akın S., Elmas B., Eren M. ve Gündüz T. (2020). Çelik Boru İmalatında Hazırlık Sürelerine Yönelik Yalın Üretim ve SMED Çalışması. Journal Of Industrial Engineering, 31(1), 87-104.
  • Yazıcı, K., Gökler, S., & Boran, S. (2020). An integrated SMED-fuzzy FMEA model for reducing setup time. Journal of Intelligent Manufacturing. doi: 10.1007/s10845-020-01675-x
Toplam 41 adet kaynakça vardır.

Ayrıntılar

Birincil Dil Türkçe
Konular Endüstri Mühendisliği
Bölüm Araştırma Makaleleri
Yazarlar

Hüseyin Ali Sarıkaya 0000-0001-5072-5067

Emine Kübra Soydemir 0000-0001-7535-6261

Beyza Sardaş 0000-0001-9363-3648

Beyza Çayır Ervural 0000-0002-0861-052X

Durrmuş Tayyar Şen 0000-0001-9632-0102

Yayımlanma Tarihi 31 Ağustos 2022
Kabul Tarihi 8 Ağustos 2022
Yayımlandığı Sayı Yıl 2022

Kaynak Göster

APA Sarıkaya, H. A., Soydemir, E. K., Sardaş, B., Çayır Ervural, B., vd. (2022). BİSKÜVİ ÜRETİM HATLARINDA HAZIRLIK SÜRELERİNİN AZALTILMASINA YÖNELİK YALIN ÜRETİM VE SMED UYGULAMASI. Endüstri Mühendisliği, 33(2), 413-439. https://doi.org/10.46465/endustrimuhendisligi.1038736

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