Bir mobilya fabrikasında süreç analizi ve süreç iyileştirme
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Dosyalar
Tarih
2023
Yazarlar
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Yayıncı
Bursa Teknik Üniversitesi, Lisansüstü Eğitim Enstitüsü
Erişim Hakkı
info:eu-repo/semantics/openAccess
Özet
Değişen ve her geçen gün gelişen dünyada müşteri talep ve beklentilerini yerine getirerek müşteri memnuniyetini sağlamak firmaların en önemli amaçlarından bir tanesi, müşteri memnuniyeti ise firmaları başarıya ulaştırabilecek en önemli araçlardan biridir. Rekabet koşullarının sürekli değiştiği ve rakiplerin sürekli arttığı rekabetçi piyasada, firmalar sürdürülebilirliğini sağlamak ve başarıya ulaşabilmek için süreçlerini dinamik tutmalıdır. Bir sürecin iyileştirilebilmesi için o sürecin analiz edilmesi gerekmektedir. Bu noktada ise sürecin performansını etkileyen etmenlerin belirlenmesinde ve ortadan kaldırılmasında yalın üretim tekniklerinden faydalanılmaktadır. Bu çalışmada; literatürde bulunan süreç analizi ve süreç iyileştirme yöntemlerinin ışığında, bir mobilya firmasında süreç analizi ve süreç iyileştirme çalışmaları gerçekleştirilmiştir. Müşterilerden gelen 8 aylık arıza bildirimleri incelenmiş, hataların çözümü için çalışmaya paketleme bölümünden başlanılmıştır. Final kalite kontrol bölümünün tespit ettiği 9 aylık hatalar raporlanmış ve hangi hata türüne öncelikle yoğunlaşılması seçiminde pareto analizi kullanılmıştır. Belirlenen hataların A3 yöntemiyle mevcut durumu analiz edilerek, balık kılçığı diyagramı ve 5N1K yöntemiyle hataların kök nedeni analizleri yapılmıştır. İMM (ilk madde ve malzeme) deposunda planlanan yenileme ve geliştirme çalışmalarında İMM depo ve diğer depolarda 5S çalışmaları yapılmıştır. Depo süreçleri analiz edilerek adresleme, kanban hazırlama gibi proseslerin sürelerinin azaltılması amacıyla süreç iyileştirme çalışmaları gerçekleştirilmiştir. Sonuçta, final kalite kontrol bölümünde tespit edilen farklı malzeme kullanılması hatası (61 adet) balık kılçığı diyagramı yöntemiyle insan, makine, malzeme ve metot kaynaklı meydana geldiği, eksik malzeme kullanılması hatası (62 adet) 5N1K kök neden analizi yöntemiyle paketleme öncesi proseslerden, malzeme deponun modül kanban hazırlamasından ve örümcek adamın istifleri karıştırmasından meydana geldiği tespit edilmiştir. İMM depo tamamen yenilenerek 4600 olan adres sayısı 3 katına çıkarak yaklaşık olarak 14000'e ulaşmıştır. Yüz ölçümü olarak depo alanı 875 m²'den, 1650 m²'ye çıkartılmıştır. Malzemeler çeşitli kriterlere göre gruplanarak adresleri belirlenmiştir. Bu adresleme sayesinde kanban hazırlama süresinde %33 oranında iyileştirme sağlanmıştır. Metal profil deposunda arabalı sistemden konveyörlü sisteme geçilerek depolama alanında %6 oranında iyileştirmeler gerçekleştirilmiştir. Sonuç olarak, paketleme bölümünde meydana gelen hataların diğer proseslerden süregeldiği saptanmıştır.
Providing customer satisfaction by fulfilling customer demands and expectations in a changing and developing world is one of the most important goals of companies, and customer satisfaction is one of the most important tools that can bring companies to success. In a competitive market where competition conditions are constantly changing and competitors are constantly increasing, companies must keep their processes dynamic in order to ensure their sustainability and achieve success. In order to improve a process, that process needs to be analyzed, and at this point, lean manufacturing techniques are used to determine and eliminate the factors affecting the performance of the process. In this study, process analysis and process improvement studies were carried out in a furniture company in the light of process analysis and process improvement methods found in the literature. 8-month failure notifications from customers were examined, and work was started in the packaging department to solve the errors. 9-month errors detected by the final quality control department were reported and pareto analysis was used to choose which error type to focus on first. The current situation of the identified faults was analyzed with the A3 method, and root cause analyzes were made with the fishbone diagram and the 5N1K method. 5S studies were carried out in theprimary material warehouse and other warehouses during the planned renovation and development works at the primary material warehouse. Warehouse processes were analyzed and process improvement studies were carried out in order to reduce the duration of processes such as addressing and kanban preparation.. As a result, it was determined that the error of using different materials (61 pieces) detected in the final quality control section was caused by human, machine, material and method by fishbone diagram method; using missing material (62 pieces) error from the before packaging processes with the 5N1K root cause analysis method; It has been determined that the material warehouse consists of preparing the module kanban and mixing the stacks of spider-man. first material warehouse was completely renewed and the number of addresses from 4600 tripled and reached approximately 14000. In terms of surface area, the warehouse area has been increased from 875 m² to 1650 m². The materials were grouped according to various criteria and their addresses were determined. Thanks to this addressing, a 33% improvement in kanban preparation time has been achieved. In the metal profile warehouse, 6% improvements were made in the storage area by switching from the car transport system to the conveyor system.
Providing customer satisfaction by fulfilling customer demands and expectations in a changing and developing world is one of the most important goals of companies, and customer satisfaction is one of the most important tools that can bring companies to success. In a competitive market where competition conditions are constantly changing and competitors are constantly increasing, companies must keep their processes dynamic in order to ensure their sustainability and achieve success. In order to improve a process, that process needs to be analyzed, and at this point, lean manufacturing techniques are used to determine and eliminate the factors affecting the performance of the process. In this study, process analysis and process improvement studies were carried out in a furniture company in the light of process analysis and process improvement methods found in the literature. 8-month failure notifications from customers were examined, and work was started in the packaging department to solve the errors. 9-month errors detected by the final quality control department were reported and pareto analysis was used to choose which error type to focus on first. The current situation of the identified faults was analyzed with the A3 method, and root cause analyzes were made with the fishbone diagram and the 5N1K method. 5S studies were carried out in theprimary material warehouse and other warehouses during the planned renovation and development works at the primary material warehouse. Warehouse processes were analyzed and process improvement studies were carried out in order to reduce the duration of processes such as addressing and kanban preparation.. As a result, it was determined that the error of using different materials (61 pieces) detected in the final quality control section was caused by human, machine, material and method by fishbone diagram method; using missing material (62 pieces) error from the before packaging processes with the 5N1K root cause analysis method; It has been determined that the material warehouse consists of preparing the module kanban and mixing the stacks of spider-man. first material warehouse was completely renewed and the number of addresses from 4600 tripled and reached approximately 14000. In terms of surface area, the warehouse area has been increased from 875 m² to 1650 m². The materials were grouped according to various criteria and their addresses were determined. Thanks to this addressing, a 33% improvement in kanban preparation time has been achieved. In the metal profile warehouse, 6% improvements were made in the storage area by switching from the car transport system to the conveyor system.
Açıklama
Anahtar Kelimeler
Ağaç İşleri, Endüstri ve Endüstri Mühendisliği, Ormancılık ve Orman Mühendisliği, Ahşap endüstrisi, Wood Products, Industrial and Industrial Engineering, Forestry and Forest Engineering, Wood industry, Forest industry
