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

Öz

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.

Anahtar Kelimeler

• Lean production
• Corporate performance
• Yarn industry

Geri Çekildi: Yalın Üretime Geçiş: İplik Sektöründe Bir Uygulama

Öz

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.

Anahtar Kelimeler

• Yalın üretim
• Kurumsal Performans
• İplik sektörü

Kaynakça

1. Baysal, M. E., Canıyılmaz, E. ve Eren, T. (2002). Otomotiv yan sanayinde hata türü ve etkileri analizi. Teknoloji Dergisi, 5(1-2), 83-90. Erişim adresi: https://jestech.karabuk.edu.tr/arsiv/1302-0056/2002/Cilt(5)/Sayi(1-2)/83-90.pdf
2. Benjamin, S.J., Murugaiah, U. ve Marathamuthu, M.S. (2013). The use of SMED to eliminate small stops in a manufacturing firm. Journal of Manufacturing Technology Management, 24(5), 792-807. Erişim adresi: https://doi.org/10.1108/17410381311328016
3. Bukhsh, M., Khan, M.A., Zaidi, I.H., Yaseen, R., Khalid, A., Razzaque, A. ve Ali, M. (2021). Productivity improvement in textile industry using lean manufacturing practices of 5s & single minute die exchange (SMED). 11th Annual International Conference on Industrial Engineering and Operations Management Singapore. Erişim adresi: http://www.ieomsociety.org/singapore2021/papers/1282.pdf
4. Choudhary, S., Nayak, R., Dora, M., Mishra, N. ve Ghadge A. (2019). An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the UK. Production Planning and Control. Erişim adresi: http://dx.doi.org/10.1080/09537287.2018.1501811
5. Comm, C.L. ve Mathaisel, D.F. (2005). An exploratory analysis in applying lean manufacturing to a labor‐intensive industry in China. Asia Pacific Journal of Marketing and Logistics, 17(4), 63-80. Erişim adresi: https://www.emerald.com/insight/content/10.1108/13555850510672430/full/html
6. Cortez, J. (2021). Just In Time. Investing Answers. Erişim adresi: https://investinganswers.com/dictionary/j/just-time-jit
7. Costa, L.B.M., Filho, M.G., Fredendall, L.D. ve Ganga, G.M.D. (2020). The effect of lean six sigma practices on food industry performance: implications of the sector's experience and typical characteristics. Food Control, 112. Erişim adresi: https://doi.org/10.1016/j.foodcont.2020.107110
8. Çilhoroz, Y. ve Arslan, İ. (2018). Yalın yönetim yaklaşımı ve sağlık hizmetlerinde uygulamaları. Süleyman Demirel Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, 1(32), 156-185. Erişim adresi: https://dergipark.org.tr/tr/download/article-file/559204

9. Eser, S. ve Yıldız, M.S. (2017). Denim pantolonu üretiminde değer akış haritalandırma yönteminin uygulaması. Sakarya Üniversitesi İşletme Bilimi Dergisi, 5(3), 1 – 23. Erişim adresi: doi: 10.22139/jobs.315916
10. Goforth, K.A. (2007). Adapting lean manufacturing principles to the textile industry (Yayımlanmamış yüksek lisans tezi). North Carolina State University, USA. Erişim adresi: https://repository.lib.ncsu.edu/bitstream/handle/1840.16/2865/etd.pdf?sequence=1
11. Goshime, Y., Kitaw, D. ve Jilcha, K. (2018). Lean manufacturing as a vehicle for improving productivity and customer satisfaction A literature review on metals and engineering industries. International Journal of Lean Six Sigma, 9(4). Erişim adresi: http://dx.doi.org/10.1108/IJLSS-06-2017-0063
12. Gökçe İ. (2006). Mevcut üretim sürecinin yalın üretim yaklaşımıyla yeniden yapılandırılması ve bir uygulama (Yayımlanmamış yüksek lisans tezi). Dokuz Eylül Üniversitesi Sosyal Bilimler Enstitüsü, İzmir.
13. Guleria, P., Pathania, A., Shukla, R.K. ve Sharma, S. (2021). Lean six-sigma: Panacea to reduce rejection in gear manufacturing industry. Materials Today: Proceedings, 46(9), 4040-4046. Erişim adresi: https://doi.org/10.1016/j.matpr.2021.02.559
14. Gupta, V., Narayanamurthy, G. ve Acharya, P. (2018). Can lean lead to green? Assessment of radial tyre manufacturing processes using system dynamics modelling. Computers & Operations Research, 89, 284-306. Erişim adresi: https://doi.org/10.1016/j.cor.2017.03.015
15. Güner, E. ve Karaca, M.E. (2004). Tam zamanında üretim sisteminde tedarikçi ilişkileri ve en iyi parti büyüklüğü üzerine bir uygulama. Gazi Üniversitesi, Mühendislik Mimarlık Fakültesi Dergisi, 19(4), 443–454. Erişim adresi: https://dergipark.org.tr/tr/download/article-file/76189
16. Halton, C. (2021). What is Kanban. Erişim adresi: https://www.investopedia.com/terms/k/kanban.asp
17. Hargrave, M. (2021). Kaizen. Bussiness Essentials. Erişim adresi: https://www.investopedia.com/terms/k/kaizen.asp
18. Hodge, G.L., Ross, K.G., Joines, J.A. ve Thoney, K. (2011). Adapting lean manufacturing principles to the textile industry. Production Planning & Control, 22(3), 237-247. Erişim adresi: https://www.tandfonline.com/doi/full/10.1080/09537287.2010.498577
19. Korkut, D.S. ve Küçük, B.B. (2016). Orman ürünleri endüstrisinde toplam verimli bakım faaliyetlerinin incelenmesi; İnegöl örneği. Kastamonu Üniversitesi Orman Fakültesi Dergisi, 16 (2) , 401-411. doi: 10.17475/kastorman.289750
20. Kulaç, Ü. (2012). Yalın Üretim Felsefesi. Erişim adresi: https://lean.org.tr/yalin-uretim-felsefesi/
21. Liker, J.K. ve Morgan, J.M. (2006). The Toyota way in services: The case of lean product development. Academy of Management Perspectives, 20(2), 5-20. doi: 10.5465/AMP.2006.20591002
22. Lu, J.C., Yang, T., ve Wang, C.Y. (2011). A lean pull system design analysed by value stream mapping and multiple criteria decision-making method under demand uncertainty. International Journal of Computer Integrated Manufacturing, 24(3), 211–228. Erişim adresi: https://doi.org/10.1080/0951192X.2010.551283
23. Macsay, V. ve Banyai, T. (2017). Toyota production system in milkrun based in-plant supply. Journal of Production Engineering, 20(1), 141-146. Erişim adresi: http://dx.doi.org/10.24867/JPE-2017-01-141
24. Mahmood, A. (2020). Smart lean in ring spinning—a case study to improve performance of yarn manufacturing process. The Journal of The Textile Institute, 111:11, 1681-1696. doi: 10.1080/00405000.2020.1724461
25. Maware, C. ve Adetunji, O. (2019). Lean manufacturing implementation in Zimbabwean industries: Impact on operational performance. International Journal of Engineering Business Management. Erişim adresi: https://journals.sagepub.com/doi/pdf/10.1177/1847979019859790
26. Mo, J.P.T. (2009). The role of lean in the application of information technology to manufacturing. Computers in Industry, 60, 266–276. Erişim adresi: https://doi.org/10.1016/j.compind.2009.01.002 Nagaraj, T.S., Jeyapaul, R., Vimal, K.E.K. ve Mathiyazhagan, K. (2019). Integration of human factors and ergonomics into lean implementation: ergonomic-value stream map approach in the textile industry. Production Planning & Control, 30:15, 1265-1282, doi:10.1080/09537287.2019.1612109
27. Neves, P., Silva, F. J. G., Ferreira, L. P., Pereira, T., Gouveia, A. ve Pimentel, C. (2018). Implementing lean tools in the manufacturing process of trimmings products. Procedia Manufacturing, 17, 696–704. Erişim adresi: https://doi.org/10.1016/j.promfg.2018.10.119
28. Prasad, M.M., Dhiyaneswari, J.M., Jamaan, J.R., Mythreyan, S. ve Sutharsan, S.M. (2020). A framework for lean manufacturing implementation in Indian textile industry. Materials today: proceedings, 33, 2986-2995. Erişim adresi: https://www.sciencedirect.com/science/article/pii/S2214785320317727
29. Ramos, N.B., Cayetano, L.T., Tuesta, F.M. ve Raymundo C. (2020). Lean manufacturing model of waste reduction using standardized work to reduce the defect rate in textile mses. 18 th LACCEI International Multi-Conference for Engineering, Education, and Technology: “Engineering, Integration, and Alliances for a Sustainable Development” “Hemispheric Cooperation for Competitiveness and Prosperity on a Knowledge-Based Economy”, 29-31 July 2020, Buenos Aires, Argentina. Erişim adresi: http://dx.doi.org/10.18687/LACCEI2020.1.1.356
30. Robinson, H. (1997). Using Poka-Yoke techniques for early defect detection. In Sixth International Conference on Software Testing Analysis and Review (pp. 134-145). Erişim adresi: http://faculty.washington.edu/apurva/502/Readings/Lean/pokasoft.pdf
31. Roser, C. (2018). What exactly is Jidoka? Erişim adresi: https://www.allaboutlean.com/jidoka-1/
32. Sabadka, D., Molnar, V., Fedorko, G. ve Jachowicz, T. (2017). Optimization of production processes using the yamazumi method. Advances in Science and Technology Research Journal, 11(4), 175-182. Erişim adresi: https://doi.org/10.12913/22998624/80921
33. Shortell, S.M., Blodgett, J.C., Rundall, T.G. ve Kralovec, P. (2018). Use of lean and related transformational performance ımprovement systems in hospitals in the United States: Results from a national survey. The Joint Commission Journal on Quality and Patient Safety, 44(10), 574-582. Erişim adresi: https://doi.org/10.1016/j.jcjq.2018.03.002
34. Sotelo, L.D., Moreno, M.M., Soriano, P.C., Ibanez, C.R. ve Dominguez, F. (2020). Lean production management model under the change management approach to reduce order fulfillment times for Peruvian textile SMEs. IOP Conf. Series: Materials Science and Engineering 796 (2020). doi:10.1088/1757-899X/796/1/012023
35. TDK, 2021. Erişim adresi: https://sozluk.gov.tr/
36. Tortorella, G., Ninob, J.C., Buelvasb, J.M., Pachecob, L.V. ve Fontalvo, Z.H. (2020). Design of a methodology to incorporate lean manufacturing tools in risk management, to reduce work accidents at service companies. Procedia Computer Science, 177, 276-283. Erişim adresi: https://doi.org/10.1016/j.procs.2020.10.038 Veres, C., Marian, L., Moica, S. ve Al-Akel, K. (2018). Case study concerning 5S method impact in an automotive company. Procedia Manufacturing, 22, 900-905. Erişim adresi: https://doi.org/10.1016/j.promfg.2018.03.127
37. Ward, Y. ve Graves, A. (2004). A new cost management and accounting approach for lean enterprises. University of Bath School Of Management, Working Paper Series, 5. Erişim adresi: https://scholar.google.com.tr/scholar_url?url=https://www.academia.edu/download/34201695/2004-05.pdf&hl=tr&sa=X&ei=vGxMYbmuKMKfmAGin5aIBw&scisig=AAGBfm3vf-7N8L28dtNmwgb256AujlM6CA&oi=scholarr
38. Wickramasinghe, G.L.D. ve Perera, A. (2016). Effect of total productive maintenance practices on manufacturing performance: Investigation of textile and apparel manufacturing firms. Journal of Manufacturing Technology Management, 27(5), 713-729. Erişim adresi: https://www.emerald.com/insight/content/doi/10.1108/JMTM-09-2015-0074/full/html
39. Womack, J.P. ve Jones, D.T. (1996). Lean thinking: Banish waste and create wealth in your corporation. Journal of the Operational Research Society 48(11). Erişim adresi: http://dx.doi.org/10.1057/palgrave.jors.2600967 Yalın Kavramlar Sözlüğü, (2016). Erişim adresi: https://lean.org.tr/heijunka-nedir/
40. Zerenler, M. ve İraz, R. (2006). Japon yönetim anlayışı ve şirket ağları keiretsu analizi. Selçuk Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, (16), 757-776. Erişim adresi: https://dergipark.org.tr/en/download/article-file/1723856