Cevdet Dal LeanACADEMY® www.leanacademy.com.tr Right implemented lean system makes your company excellent.
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LeanACADEMY®www.leanacademy.com.tr
Right implemented lean system makes your company excellent.
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About
LeanACADEMY®www.leanacademy.com.tr
Our partnerships
Lean Academy is founded in 2009. As soon as it was founded has been able to serve automotive, white good, furniture, textile and other industries.
Since December 2009, Lean Academy is partner of Leonardo Group A.G and LeanFactory Group in Turkey
LeanACADEMY is a registered brand of us
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About
Aydın University
Aydın University
MarmaraUniversityMarmaraUniversity
LeanACADEMY Partnerships
Leon
ardo
Gro
up A
G
Collaborations
Middle East University
Middle East University
Süleyman DemirelUniversity
Süleyman DemirelUniversity
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Our Services
Supplier Manufacturing facilities Distributions Customers
II II II
PlanlamaPlanlama
Inventory InventoryProduction Inventory
Our improvement and consulting services through supply chain.
• Supply chain management (SCM)
• Purchasing Management
• Supplier development
• Lean Manufacturing Implementation (lean transformation)
• TPM (Total productive management) system implementation
• Production management consulting• Advanced product quality planning (APQP)
• Inventory management & lean logistic
• Order management & Heijunka system
• Milk run to customer
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Our Services
• JIDOKA – production with zero scrap
• 5S – Order, self discipline and cleanliness
• A3 – Failure management
• KAIZEN – Continuous improvement
• APQP – Advanced product quality planning
• POKA YOKE, FMEA, MSA, CPK – Failure proofing
• JIDOKA – production with zero scrap
• 5S – Order, self discipline and cleanliness
• A3 – Failure management
• KAIZEN – Continuous improvement
• APQP – Advanced product quality planning
• POKA YOKE, FMEA, MSA, CPK – Failure proofing
QUALITYQUALITY
• SMED – Changeover in single minute
• PULL SYSYEM, KANBAN – Demand production (JIT)
• HEIJUNKA – Production leveling
• MILK RUN
• LEAN LOGISTIC
• SMED – Changeover in single minute
• PULL SYSYEM, KANBAN – Demand production (JIT)
• HEIJUNKA – Production leveling
• MILK RUN
• LEAN LOGISTIC
DELIVERYDELIVERY• VSM – Value stream
mapping
• SHOJINKA – workforce leveling
• HOSHIN KANRI – Strategic planning
• TPM – Total productive maintenance
• LAY-OUT, ANDON
• STANDARDIZED WORK
• VSM – Value stream mapping
• SHOJINKA – workforce leveling
• HOSHIN KANRI – Strategic planning
• TPM – Total productive maintenance
• LAY-OUT, ANDON
• STANDARDIZED WORK
COSTCOST
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Principles Content Tools
1) Process and customer focus Product flows in customer cycle – analysing and improving all processes in terms of customer demand and "world-class" standards
Value stream analysis
2) Pull Production in line with customer demandReduction of high inventory costs and long lead times Kanban, supermarket, routing
3) Quality & avoiding defectsAvoiding defects through prevention and in-process quality controls, creating higher quality rates, reducing waste and unnecessary work (waiting, looking for things) through order and cleanliness
5 S, Poka Yoke, Jidoka
4) Flexibility Ensuring flexibility in relation to quantity, variance, capacity and time Mixed Model Line, fast tooling changes (SMED), flexible staff/training
5) CIP/Kaizen Avoiding waste and anchoring the idea of continuous improvement in the business culture, building up staff motivation
Training, workshops and kaizen organisation
6) Visualisation/transparency Making statuses and discrepancies identifiable at all times through visual systems
IPC, information boards for performance indicators, traffic light control, andon
7) Personal responsibility Encouraging staff by increasing responsibility-> appropriate system support and common sense Cell formation and self-monitoring
8) Holistic integration Eliminating unnecessary interfaces throughout the organisation and supply chain
Organisational developmentShop floor managementPerformance indicator system
Principles and implementation tools from Toyota
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GoalSavings with advanced technics
Applications• PULL SYSYEM• HEIJUNKA• KANBAN• MILK RUN• JIDOKA• VISUAL
MANAGEMENT• ANDON
GoalSavings with advanced technics
Applications• PULL SYSYEM• HEIJUNKA• KANBAN• MILK RUN• JIDOKA• VISUAL
MANAGEMENT• ANDON
GoalImplementation of applications in the field
Applications• 5S• SMED• TPM• LAY-OUT• SHOJINKA• MILK RUN (in
production)
GoalImplementation of applications in the field
Applications• 5S• SMED• TPM• LAY-OUT• SHOJINKA• MILK RUN (in
production)
GoalOrganize of necessary team and road map
Organization• Lean office• Logistic team• Process team• Kaizen plan
GoalOrganize of necessary team and road map
Organization• Lean office• Logistic team• Process team• Kaizen plan
GoalTo make white cooler persons to understand the system
Trainnings• Lean thinking• Production
according to Toyota
• VSM • Kaizen• Hoshin kanri
GoalTo make white cooler persons to understand the system
Trainnings• Lean thinking• Production
according to Toyota
• VSM • Kaizen• Hoshin kanri
Planning & Reorganization
Planning & Reorganization
Road Map
Start up trainingsStart up trainings Pilot applicationsPilot applications Advanced technicsAdvanced technics
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Results
50% - 90% Inventory reduction
50% - 90% Inventory reduction Improved cash flowImproved cash flow Reduction in short-term
account payableReduction in short-term
account payable
30 – 50% productivity increasing per person 30 – 50% productivity increasing per person
Increased productivity(OEE 90%)
Increased productivity(OEE 90%)
Increased profitability and market share
Increased profitability and market share
30-50% space reduction
30-50% space reduction
Reduction in capital requirement
Reduction in capital requirement
Decreasing of none value added worksDecreasing of none value added works
90% Decreasing of scraps and failures90% Decreasing of scraps and failures
Reduction in customer complaints
Reduction in customer complaints
Release of the new production area
Release of the new production area
Application results Management results Financial results
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Examples
Connection of 7 machineries in LAF
line.
Decreasing of change over time from 420 min to
7.5 min
Connection of 7 machineries in LAF
line.
Decreasing of change over time from 420 min to
7.5 min
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Examples
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22
33
44
55
Implementation at plastic folder line
• New packaging system
• Poka yoke • Decreasing of change
over time
Result• Scrap 0,5%. • Decreasing of change
over time from 420 min to 2 min.
Implementation at plastic folder line
• New packaging system
• Poka yoke • Decreasing of change
over time
Result• Scrap 0,5%. • Decreasing of change
over time from 420 min to 2 min.
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Examples
Milk run application: no need unpacking of part by operatorsResult: Production per hour is increased from 120 pcs to 180 pcsMilk run application: no need unpacking of part by operatorsResult: Production per hour is increased from 120 pcs to 180 pcs
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Examples
Kanban for cable harness line
Result
Easy planning.
Reduction of inventory days to 9
days
Kanban for cable harness line
Result
Easy planning.
Reduction of inventory days to 9
days
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Examples
SMED application at injection
molding line
Result
Change over time of mold from 4 hours to 20 min
SMED application at injection
molding line
Result
Change over time of mold from 4 hours to 20 min
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Examples
Kanban workshop for injection molding lines
Result• Reduction of
inventory from 10 days to 2 days
• Service level (delivery rate) for Bosch & Siemens 99%
Kanban workshop for injection molding lines
Result• Reduction of
inventory from 10 days to 2 days
• Service level (delivery rate) for Bosch & Siemens 99%
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Examples
5S and one piece flow implementation for test system assembly line.
5S and one piece flow implementation for test system assembly line.
BEFORE AFTER
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Referances
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Foker ElmoFoker Elmo
ArçelikArçelik
Mekra LangMekra Lang
British American Tobaco
British American Tobaco
Scheider Electric
Scheider Electric
SeçilSeçil
AldoraAldora
Ege IndustryEge Industry
PAS South East PAS South East
TrelleborgTrelleborgAk OfficeAk Office
PrettlPrettl
TSK Test SystemsTSK Test Systems
KadifeteksKadifeteks
PakpenPakpen
BekaertBekaert
UrtimUrtimMorgan CarbonMorgan Carbon
TRW DireksiyonTRW DireksiyonB/S/H Ev Aletleri
B/S/H Ev Aletleri
MVD MakinaMVD Makina
SimferSimfer
Hema Endüstri
Hema Endüstri
Dicle edaşDicle edaş
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Contact Information
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Person : Cevdet DalMobile : +90 533 256 2019e-mail : [email protected]: www.leanacademy.com.tr