Evaluation of Performance by Operating Process Improvement Modeling On A Company With Pump Manufacturing

Yıl 2019, Cilt: 31 Sayı: 4, 305 - 315, 01.11.2019

Ahmet Talat İnan Mehmet Akif Kartal

https://doi.org/10.7240/jeps.554409

Öz

There may be more than one element affecting quality and efficiency in
the manufacturing organizations. As a result of multiple elements occurring at
the same time, permanent losses occur in final production and quality. Both the
customer sense of trust and their satisfaction are negatively affected because
of those problems.

Failure to achieve targeted levels of quality and productivity in the
organization reduces customer satisfaction. Quality and productivity in the
organization are affected by inefficiency in resource utilization, bottlenecks
in the production and inefficient workflow design within the organization.

This study aims to improve production process in a manufacturer of air
operated diaphragm pumps by simulation analysis. Most efficient way of
utilizing raw materials, manpower, vehicles and equipment is sought by
simulation based process improvement. Discrete-event simulation software
(Arena) is used to detect problems in the production process such as:
transportation, blockage and/or layout. Simulation is used to experiment with
process improvement approaches without making changes in the real-world
production system.

Simulation models of the current state and the proposed future state with
improvements to the layout of the production system are created. The results
from the models were compared with each other and evaluations were made. The
future state simulation model utilizes existing resources for process
improvement, without the requirement for additional resource acquisition.
Comparison of current state model and future state model simulation output
data, suggests a 67% increase in the number of products produced per month. It
is foreseen that this increase can greatly affect the operational efficiency and
future managerial decisions, and suggestions are made for future works.

Anahtar Kelimeler

Assembly Line, Process Improvement Simulation, Pump, pump process improvement

Kaynakça

• [1] Monks, J., G. (1996) “İşlemler Yönetimi” S. Üreten (2.Bas. Çev.), İstanbul, Nobel Yayıncılık.
• [2] Bozkurt, R. (2003) “Süreç İyileştirme” 3. Basım, An¬kara, MPM.
• [3] Takcı, E.:’Bir İmalat İşletmesinde Simülasyon Yardımıyla Süreç İyileştirme Uygulaması Kayseri Gürkar Tekstil Örneği’, Yüksek Lisans Tezi, Nevşehir Hacı Bektaş Veli Üniversitesi Sosyal Bilimler Enstitüsü, Nevşehir, Türkiye, (2013).
• [4] Yurdakul, M.;Eşkin, S.;İç, Yusuf T.İ.:’ Bir İmalat Sisteminin Yerleşim Düzeninin İyileştirilmesi’, Gazi Üniversitesi Mühendislik Fakültesi, Başkent Üniversitesi Mühendislik Fakültesi,Ankara, Türkiye, (2009).
• [5] Özateş, M.;Şahin, M.; Şenol, S.; Terzi, F.; Yörükoğlu, S.; Köksal, G.; Serin, Y.:’ Düşük Hacimli Üretim İçin Kalite Kontrol Sistemi Tasarımı’, Orta Doğu Teknik Üniversitesi Mühendislik Fakültesi, Ankara, Türkiye, (2012).
• [6] Yurdakul, M.;Türkbaş, S.; Altınova, S.: ’ Bir İmalat Tesisinde Toplam Verimli Bakım (TVB) Uygulaması’, Gazi Üniversitesi Mühendislik-Mimarlık Fakültesi, Ankara, Mercedes-Benz Türk A.Ş. Aksaray Fabrikası, Aksaray, (2008).
• [7] Oran, A.:’ Talaşlı İmalat Optimizasyonunda Metodik Yaklaşım ve Sektörel Bir Altı Sigma Proje Uygulaması’, BOSCH San. ve Tic. A.Ş. Teknik Fonksiyonlar 1 Departmanı, Bursa, Türkiye, (2012).
• [8] Şahin, Ş.; Öztürk, F.:’ İmalat Süreçlerindeki Problemlere Optimum Çözüm Arama Ve Bir Uygulama’, Uludağ Üniversitesi Mühendislik-Mimarlık Fakültesi, Bursa, (2009).
• [9] Görener, A.:’ Toplam Verimli Bakım ve Ekipman Etkinliği: Bir İmalat İşletmesinde Uygulama’, Electronic Journal of Vocational Colleges, İstanbul, (2012).
• [10] Kathiriya1, J. J.; Amareliya2, V.D.; Kapadiya3, S.H.:’ Production Process Analysis On Manufacturing of Hydraulic Gear Pump’, 1Department of Mechanical, Shantilal Shah Engineering College, Bhavnagar, Gujarat, INDIA2 Department of Mechanical, Mahatma Gandhi Institute of Technical Education and Research Centre, Navsari, Gujarat, INDIA3 Department of Mechanical, Mahatma Gandhi Institute of Technical Education and Research Centre, Navsari, Gujarat, INDIA, (2014).
• [11] Kaljahi, B.Z.:’ Reverse Engineering of Pump Impeller Utilizing Rapid Prototyping Technology’, Eastern Mediterranean University the Institute of Graduate Studies and Research, Gazimağusa, North Cyprus, (2015).
• [12] Tamlander, J.:’Defining a Manufacturing Planning and Control Model For a Lean Manufacturing Company’, Bachelor’s Thesis, JAMK University of Applied Sciences, Technology Degree Programme in Logistics Engineering, Jyväskylä, Finland, (2016).
• [13] Chan, K., K. ve Spedding T., A. (2003). An Integrated Multidimensional Process Improvement Methodology for Manufacturing Systems. Computers & Industrial Engineering, 44(4): 673-693.
• [14] Schiefer, G. (2002). Environmental Control for Process Improvement and Process Efficiency in Supply Chain Management- the Case of the Meat Chain. International Journal of Production Economics, 78(2): 197-206.
• [15] Freire, J. ve Alarcon, L. (2002). Achieving Lean Design Process: Improvement Methodology. Journal of Construction Engineering and Management, 128(3): 248-256.
• [16] Rohleder, T., R. ve Silver, E., A. (1997). A Tutorial on Business Process Improvement. Journal of Operations Management, 15(2): 139-154.
• [17] Özveri, O. ve Kayışkan, D. (2016). Bir Gıda İşletmesinde Süreç Yönetimi Ve Süreç İyileştirme Uygulaması, s. 12-25.
• [18] Er, Ö. (2016). Process Improvement And An Industrıal Example Over Company BSH, Bahçeşehir University, Master Thesis, İstanbul.
• [19] Karaman U. (2017). Bir Finans Şirketinde Kurumsal Süreç İyileştirme ve Uygulaması, Maltepe Üniversitesi, Yüksek Lisans Tezi, İstanbul.
• [20] Etleç, B. (2017). Yalın Üretim Tekniklerine Bağlı Süreç İyileştirmelerinin Bir Kozmetik Firmasında Uygulanması, Arel Üniversitesi, Sosyal Bilimler Üniversitesi, Yüksek Lisans Tezi, İstanbul.
• [21] Berber, G. (2017). Bir Gıda İşletmesinde Süreç İyileştirme Uygulaması: Dondurma Fabrikası Örneği, İnönü Üniversitesi, Sosyal Bilimler Enstitüsü, Yüksek Lisans Tezi, Malatya.
• [22] Sönmez, Y. (2017). Otomotiv Sektörü Süreç İyileştirmede Jishuken Uygulamaları, Sakarya Üniversitesi, Fen Bilimleri Enstitüsü, Yüksek lisans Tezi, Sakarya.
• [23] Özbilgin, O. (2017). Sirkülasyon Pompası Tasarımı ve HAD Yöntemi İle Performans Analizi, Gazi Üniversitesi, Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi, Ankara.
• [24] Karaca, G. (2017). Güneş Enerjisi Destekli Isı Pompası Sistemlerinin Performansının İncelenmesi: Muğla Örneği, Muğla Sıtkı Koçman Üniversitesi, Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi. Muğla.
• [25] Şenol, G. K. (2017). Pompa Sistemlerinde Enerji Tasarrufu ve Demir Çelik Sektöründe Örnek Bir Uygulama, İskenderun Teknik Üniversitesi, Mühendislik ve Fen Bilimleri Enstitüsü, Yüksek Lisans Tezi, Hatay.
• [26] Alpaslan, İ. (2018). Otomotiv Yetkili Servisinde Müşteri Memnuniyeti Odaklı Süreç İyileştirme Çalışması: Bir Uygulama Örneği, İstanbul Medeniyet Üniversitesi / Sosyal Bilimler Enstitüsü, Yüksek Lisans Tezi, İstanbul.
• [27] Sarıaslan, H. (1986) “Sıra Bekleme Sistemlerinde Si¬mülasyon Tekniği” 1. Basım, Ankara, Ankara Üniversitesi Siyasal Bilgiler Fakültesi Yayınları.
• [28] Prasad M. M., Aravindh A., Baskar R. and Kannan S. D.:’ Implementation of Lean Manufacturing in Centrifugal Pump Assembly’, Sri Krishna College of Engineering & Technology, Kuniamuthur, Coimbatore-641008, Tamilnadu, India, (2017) 134-140. http://www.ijirset.com/upload/2017/tapsa/17_mech_017.PDF.
• [29] Aravinth K. A., Dr. Rajenthirakumar D.:’ Lean Implementation through Enhancing Productivity in a Pump Industry’, Department of Mechanical Engineering, United Institute of Technology, Coimbatore, TN India, (2016) 430-433. http://ijer.in/publication/v5/097.pdf.
• [30] Kumar D.K.R., Shivashankar G.S. and Rajeshwar S.K.:’ Application of Value Stream Mapping in Pump Assembly Process: A Case Study’, Industrial Engineering & Management, Barcelona, Spain (2015) 1-11. DOI: 10.4172/2169-0316.1000162.
• [31] Parthiban M., Perumalsamy M. and Aravinddinesh G.:’ Manufacturing Lead Time Reduction in Monoblock (SWJ) Pump Industry’, International Research Journal of Engineering and Technology (IRJET), Tamilnadu, India, (2017) 1801-1807. https://www.irjet.net/archives/V4/i12/IRJET-V4I12331.pdf
• [32] Prabhu C. and Aravindha B. S.:’ Product and Process Improvement Using Simulation Based Value Stream Mapping: An Case Study’, International Journal of Innovative Research in Science, Engineering and Technology, Tamilnadu, India, (2014) 1186-1190. http://www.rroij.com/open-access/product-and-process-improvement-usingsimulation-based-value-stream-mapping-ancase-study.pdf.