Yalın üretim sistemi ve tekstil sektöründe bir örnek olay çalışması
Küçük Resim Yok
Tarih
2007
Yazarlar
Dergi Başlığı
Dergi ISSN
Cilt Başlığı
Yayıncı
Maltepe Üniversitesi, Sosyal Bilimler Enstitüsü
Erişim Hakkı
info:eu-repo/semantics/openAccess
Özet
Günümüzün hızla gelişen dünyasında şirketler rekabetsel avantajlar yakalamak ve kalıcı başarılar elde etmek için çeşitli yeni üretim ve yönetim teknikleri arayışları içerisindedir. Şirketler; globalleşen dünyada, gerek yönetim anlayışlarını, gerekse buna bağlı olan üretim anlayışlarını, gelişmelere süratle cevap verebilecek, müşteri tatminini en üst seviyede tutacak, tüm gereksiz ve üretime ek bir katkı sağlamayan unsurlardan arınmış, her türlü kaynak israfını engelleyen, verimliliği ve kaliteyi arttıracak bir şekilde organize veya re-organize etmek zorundadırlar. Son yıllarda yeni bir üretim anlayışı, Japonya’dan tüm dünyaya, kuruluşların ihtiyaçlarını en üst düzeyde karşılamak üzere hızla yayılmaktadır. Bu klasik üretim anlayışlarından radikal değişikliklerle farklılıklar gösteren “Yalın üretim sistemi”dir. Yalın üretimin en önemli özelliği, içinde yer alan her kesimi, aktörü yada tarafı aynı anda memnun etmesi, seri üretimin tersine, herkesin kazanmasını sağlayabilecek güçlü bir potansiyele sahip olmasıdır. Seri üretim tarzında hep bir kesimin kazanması, çoğunluğunun kaybetmesiyle sonuçlanmıştır. Yalın üretimi benimsemiş ana sanayi firmaları, üretim, satışlar, ve karlılık açısından dünyada öncü olabilmekte, sistemi adapte eden tüm firmaların rekabet güçleri ve karlılığı giderek artmaktadır. Yalın üretim, seri üretim anlayışına savaş açmış; gerekli miktarda, tam zamanında, hatasız, stoksuz, israfsız ve kaliteli üretimin yapılabilmesini mümkün kılmıştır. Seri üretim anlayışa göre çalışan birçok firmada %1-5 arası ıskarta oranı normal karşılanırken, yalın üretimde ürün kalitesi için saptanan asga¬ri hedef “ppm” (parts per million) noktasına gelinmesi, yani ıskarta oranının yüzdeler (%), bindeler, hatta on binlerle değil, “milyonlar”la ifade edilecek düzeye indirilmesidir. Hatta ppm bile yeterli değildir, nihai hedef “sıfır hata” noktasına gelinmesidir. Yalın üretim Japon Toyota firmasından kaynaklandığı ve çoğunlukla otomobil sanayinden örnekler verildiği için yalın üretim kimi kez otomobil sanayine özgü bir sistemmiş gibi algılanmaktadır. Yalın üretimin en iyi uygulama olarak yorumlanmasında rol oynayan temel etkenlerden biri de sistemin genel olarak üretime bir yaklaşım biçimi, bir üretim felsefesi olması, ve dolayısıyla elektrikten bilgi-iletişim sektörüne ekmek üretiminden tekstile, beyaz eşya üretimine ve hatta servis sektörüne kadar birçok değişik alana adapte edilebilecek, genel-geçer bir sistem konumunda bulunmasıdır. Sonuç olarak yalın üretim sistemi sadece otomotiv sektörüne ve Japonya’ya ait bir takım kurallar olmayıp, tüm endüstrilere genel olarak uygulanabilen ana prensiplerdir. Bu tezin amacı Japon üreticileri dünyada farklı kılan ve rekabette en öne çıkmalarını sağlayan, verimlilik ve maliyetteki ezici üstünlüklerinin kaynağı olan Yalın Üretim Sistemi’nin öğelerini, yöntem ve tekniklerini, seri üretim sistemlerine göre avantajlarını incelemektir. Üretim sistemini sorgulayan ve üretim sürecinde uygulanması gereken araçların incelenmesi hedeflenmiştir. Bu amaçla, birinci bölümde Yalın Üretim Sisteminin öğeleri ve boyutları ana hatlarıyla açıklanılmış, ikinci bölümde Yalın Üretim yöntemleri ve teknikleri incelenmiş, üçüncü bölümde ise Yalın Üretimin Seri Üretim ile karşılaştırmalı olarak, yalın üretimin dünyaya yayılışı ve üstünlükleri açıklanmaya çalışılmış, dördüncü bölümde ise tekstil sektöründe bir örnek olay çalışması olarak Aydın Örmeye yer verilmiştir.
In today's turbulent competitive world, companies more than ever needs a strategy that specifies the kind of competitive advantage that itis seeking in its market place and articulates how that advantage is to be achieved. The onlyquestion is asked by the companies to theirselves is how a company can expect to achieve anysort of competitive advantage if its only goal is to be beter than or at least as good as its thougest competitors.It is obvious that a considerable improvement is necessary. For this century,the nswer is lean production concepts which is here today in the leading automobile companies and will become the norm as it diffuses into other branches of manufacturing. Lean production concepts has been developed over the last 40 years by Toyota in Japan and it is a big revolution in manufacturing as mass production. During the 1980's United Stats of America manufacturing companies rediscovered the powder that comes from superior manufacturing and initiated a variety of activities to improve their competetiveness. In pursing this goal, they have started to visit the Japanese lean production system and started to adopt the principles of the lean production principles.By the utilization of the Universities and their own researchs, the US manufacturers from different branches of industry is now applying the lean production techniques as good as Japanese lean producers. So it improves that lean production concepts are universal which means that they are not only applicable in Japan or in automotive industry. Lean production is lean because it uses less of everything compared with mass production, half of the human effort, half of the engineering hours to develope a new product. Also it requires keeping far less than half the needed inventory on site, results in many fewer defects, and produces a greater and ever growing variety of products. As a consequence, costs come down consistently and continuosly. Mass production are defeated because of their extreme rigidity, equiped as they are with deskilled an dedicated machinery organized in a mechanistic fashion. Such an arrangement may very well function effectively as long as costumers bhave in a stable, homogeneous and foreseeable way. Costumers have become more individualistic in their needs and their prefences are changing all the time. In the first chapter, the elements an dimensions of lean production is explained. In the second chapter, the methods and techniques of lean production are explained. In the third chapter, the advantages of lean production against mass production and the developement of lean production to whole world are explained. In the fourth chapter, the sitution of the Turkish industry against the lean spread is explained and secondly, applicability of lean production concepts to Turkish textile industry supported by a study in a Turkish textile company is discussed in every aspects. Nowadays the big lean producers, Toyota, Honda and Ford are making investments in Turkey. At the first look, this is very crucial for the Turkish Industry in general to learn about lean production. By the adaption of lean production to Turkish industry is so fragile that every step must be taken as it will form a basis to the next one, and it needs time to move in the frame of the lean production.
In today's turbulent competitive world, companies more than ever needs a strategy that specifies the kind of competitive advantage that itis seeking in its market place and articulates how that advantage is to be achieved. The onlyquestion is asked by the companies to theirselves is how a company can expect to achieve anysort of competitive advantage if its only goal is to be beter than or at least as good as its thougest competitors.It is obvious that a considerable improvement is necessary. For this century,the nswer is lean production concepts which is here today in the leading automobile companies and will become the norm as it diffuses into other branches of manufacturing. Lean production concepts has been developed over the last 40 years by Toyota in Japan and it is a big revolution in manufacturing as mass production. During the 1980's United Stats of America manufacturing companies rediscovered the powder that comes from superior manufacturing and initiated a variety of activities to improve their competetiveness. In pursing this goal, they have started to visit the Japanese lean production system and started to adopt the principles of the lean production principles.By the utilization of the Universities and their own researchs, the US manufacturers from different branches of industry is now applying the lean production techniques as good as Japanese lean producers. So it improves that lean production concepts are universal which means that they are not only applicable in Japan or in automotive industry. Lean production is lean because it uses less of everything compared with mass production, half of the human effort, half of the engineering hours to develope a new product. Also it requires keeping far less than half the needed inventory on site, results in many fewer defects, and produces a greater and ever growing variety of products. As a consequence, costs come down consistently and continuosly. Mass production are defeated because of their extreme rigidity, equiped as they are with deskilled an dedicated machinery organized in a mechanistic fashion. Such an arrangement may very well function effectively as long as costumers bhave in a stable, homogeneous and foreseeable way. Costumers have become more individualistic in their needs and their prefences are changing all the time. In the first chapter, the elements an dimensions of lean production is explained. In the second chapter, the methods and techniques of lean production are explained. In the third chapter, the advantages of lean production against mass production and the developement of lean production to whole world are explained. In the fourth chapter, the sitution of the Turkish industry against the lean spread is explained and secondly, applicability of lean production concepts to Turkish textile industry supported by a study in a Turkish textile company is discussed in every aspects. Nowadays the big lean producers, Toyota, Honda and Ford are making investments in Turkey. At the first look, this is very crucial for the Turkish Industry in general to learn about lean production. By the adaption of lean production to Turkish industry is so fragile that every step must be taken as it will form a basis to the next one, and it needs time to move in the frame of the lean production.
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Künye
Belgutay, A. G. (2007). Yalın üretim sistemi ve tekstil sektöründe bir örnek olay çalışması / Lean Production System and an Application in Textile Industry (Yayımlanmamış Yüksek Lisans Tezi). Maltepe Üniversitesi, Sosyal Bilimleri Enstitüsü, İstanbul.
