Providing Business Package Services to SMES Using Lean Manufacturing and Digital Technologies

Document Type : SEMIT 2024

Authors

1 Ankara Yıldırım Beyazıt University

2 15 Temmuz Şehitleri Yerleşkesi, Ayvalı Mah., Gazze Cad., 150. Sokak, Antares AVM

Abstract

This study investigates the effect of lean production systems on the performance of businesses. Lean manufacturing is a production philosophy that aims to reduce waste, increase efficiency and maximize customer satisfaction. The aim of the research is to evaluate the contribution of lean production principles to business performance and to understand the impact of these system applications on business processes. This study was carried out in cooperation with the Ankara model factory affiliated with the Ministry of Industry. It includes improvements that can be made in the application areas used within the Model Factory, based on the lean production principles of this organization for small and medium-sized (SME’s) enterprises. Lean manufacturing principles were extensively researched using current literature sources and their potential benefits were determined through practical training within the Model Factory. In this study, by creating four work packages, the benefits they provide and their contribution to the Model Factory will be examined. The Standard Operation Combination Table (SOCT) study showed that a 200% increase in profitability was achieved by reducing the number of workers from three to one in the first work package. The regression analysis of the milling machine's sensor data revealed strong correlations between various variables. High R-squared values between current and voltage pairs and between noise and temperature indicate robust relationships in the second work package. Sensor technology, IoT, cloud computing, and tools like Node-RED have been studied, their output are extracted and used for anomaly detection for third work package. Based on the survey results, the current digital maturity levels of SMEs will be determined and areas that need improvement will be identified and digital transformation strategies are proposed as the fourth work package.

Keywords


Sütçü, A., Karşıyaka, O., & Burhan, M. E. (2019). Bir mobilya üretim tesisinde iş analizi ve benzetim uygulaması ile süreç verimliliğinin artırılması. Avrupa Bilim ve Teknoloji Dergisi, 17, 45–57.
Sarıkaya, H. A., Soydemir, E. K., Sardaş, B., Çayır Ervural, B., & Şen, D. T. (2022). Bisküvi üretim hatlarında hazırlık sürelerinin azaltılmasına yönelik yalın üretim ve SMED uygulaması. Journal of Industrial Engineering, 33(2), 413–439.
Reçel, S., Balcı, N., Çetin, B., Öztürk, N., Özalp, T., & Özbey, H. (2010). Bir otomotiv yan sanayi firmasında kesici takımlar için çekme ve MILKRUN sisteminin uygulanması. Endüstri Mühendisliği Dergisi, 22(3), 71–87.
Esin, F. (2004). Tam zamanında üretim sisteminin bir işletmede uygulanması. Tam Zamanında Üretim Sistemleri Dergisi, 11(2).
Kahraman, Ö., & Demirer, A. (2010). In the OHSAS 18001 contents FMEA application. Electronic Journal of Machine Technologies, 7(1), 53–68.
Birgün, S., & Gülen, K. G. (2006). Yalın üretime geçiş sürecinde değer akışı haritalama tekniğinin kullanılması: İmalat sektöründe bir uygulama. İstanbul Ticaret Üniversitesi Fen Bilimleri Dergisi, 5(9), 47–59.
Akyurt, İ., & Eren, Z. (2019). Application of SMED method to reduce the setup time. The International Journal of Economic and Social Research, 15(3).
Özçakar, N. (2010). Yalın tedarik zincirinde optimizasyon. Yalın Üretim Dergisi, 6(2).
Erozan, İ. (2019). Çekme sistemleri için karşılaştırmalı bir analiz ve bir karar destek sistemi önerisi. GU Journal of Science, Part C, 7(3), 523–539.
Keleş, A. E., Gürsoy, G., & Çelik, G. (2013). 5S sistematiği aşamaları ve örnek bir uygulama. Çukurova University Journal of the Faculty of Engineering and Architecture, 28(2), 51–60.
Aksoy, A. S. (2019). İleri üretim teknolojileri ve Andon uyarı sistemleri. Journal of Academic Value Studies, 5(3), 352–366.
İşler, M., & Güner, M. (2014). Yalın üretim araçlarından Heijunka ve konfeksiyon uygulamaları. XIII. Uluslararası İzmir Tekstil ve Hazır Giyim Sempozyumu.
Öztürk, H. (2023). İki aşamalı yeşil bir tedarik zincirinde stok kontrolü. Doğuş Üniversitesi Dergisi, 24(2), 411–433.
Kökten, E. S., & Çağrı, S. (2020). Ahşap makara üretiminde kereste boyutlarının belirlenmesi: Hammadde kaybını azaltan bir karar destek modeli. Verimlilik Dergisi, 2.
Bozdemir, E., & Orhan, M. S. (2011). Üretim maliyetlerinin düşürülmesinde Kaizen maliyetleme yönteminin rolü ve uygulanabilirliğine yönelik bir araştırma. Atatürk Üniversitesi Sosyal Bilimler Enstitüsü Dergisi, 15(2), 463–480.
Çelik, H., & Taşkın, K. (2019). Examination of the effect of SMED methodology on the setup time and unit cost: Application in the steel bar peeling production line. The Journal of Business Science, Sakarya University, 7(1), 77–103.
El-Namrouty, K. A., & AbuShaaban, M. S. (2013). Seven wastes elimination targeted by lean manufacturing: Case study Gaza Strip manufacturing firms. International Journal of Economics, Finance and Management Sciences, 1(2), 68–80.
Salleh, N. A. M., Kasolang, S., & Jaffar, A. (2012). Simulation of integrated total quality management (TQM) with lean manufacturing (LM) practices in forming process using Delmia Quest. Procedia Engineering, 41, 1702–1707.
Naufal, A. A., Nurul Ain, A., & Azianti, I. (2016). Improvement of overall efficiency of production line by using line balancing. ARPN Journal of Engineering and Applied Sciences, 11(12).
Rathod, B., Shinde, P., Raut, D., & Waghmare, G. (2016). Optimization of cycle time by lean manufacturing techniques-line balancing approach. International Journal for Research in Applied Science & Engineering Technology (IJRASET, 4(5).
Ingaldi, M., & Jagusiak-Kocik, M. (2014). Lean tool used in the automotive industry. International Journal of Industrial Engineering and Management, 4(3).
Breznik, M., Buchmeister, B., & Vujica Herzog, N. (2023). Assembly line optimization using MTM time standard and simulation modeling: A case study. Applied Sciences, 13(10), 1–15.
Klimecka-Tatar, D., & Ingaldi, M. (2022). Digitization of processes in manufacturing SMEs: Value stream mapping and OEE analysis. Procedia Computer Science, 200, 1–12.
Siti, A., Purva, H. H., & Setiaji, S. D. (2020). Analysis work standardization using the standardized work combination table on CNC of mission case line process at PT Astra Otoparts, Tbk - Nusametal Division. IOP Conference Series: Materials Science and Engineering.
Bragança, S., & Costa, E. (2015). An application of the lean production tool standard work. Jurnal Teknologi, 76(1).
Berber, G., & Deste, M. (2021). Bir gıda işletmesinde süreç iyileştirme uygulaması: Dondurma fabrikası örneği. Anadolu Üniversitesi İktisadi ve İdari Bilimler Fakültesi Dergisi, 22(3), 53–72.
Kwoka, P. K., Yan, M., Chan, B. K. P., & Lau, H. Y. K. (2019). Crisis management training using discrete-event simulation and virtual reality techniques. Simulation and Training Review, 135, 711–722.
Özcan, E., & Sonuç, E. (2022). Prediction of amount of material used in desulfurization process using machine learning techniques. Zeki Sistemler Teori ve Uygulamaları Dergisi, 5(1), 57–63.
Ardatürk, A. Ş. (2022). Tasarımcı zihninin bir yansıması olarak; yapay zeka. Online Journal of Art and Design, 10(4).
Çelebi, A., & Koda, D. Y. (2021). Endüstri 4.0 çerçevesinde katmanlı imalatta sensör uygulamaları. International Journal of 3D Printing Technology and Digital Industry, 5(1), 85–97.
Dündar, M. M. (2020). KOBİ'lerin dijital dönüşümü. KOBİ Yönetim Dergisi.
Jindal, P., et al. (2024). Mediating role of psychological safety on support at the workplace and its association with organization performance: Context of Indian IT sector. The Open Psychology Journal, 17(1).
Tian, Y., et al. (2023). Strategies for sustainable production of hydrogen peroxide via oxygen reduction reaction: From catalyst design to device setup. Nano-Micro Letters, 15(1), 122.
Habib, M. A., Rizvan, R., & Ahmed, S. (2023). Implementing lean manufacturing for improvement of operational performance in a labeling and packaging plant: A case study in Bangladesh. Results in Engineering, 17, 100818.
Du, J., et al. (2023). Lean manufacturing applications in prefabricated construction projects. Automation in Construction, 150, 104790.
Rasheed, K., et al. (2023). Integrating sustainability management and lean practices for enhanced supply chain performance: Exploring the role of process optimization in SMEs. Engineering Proceedings, 56(1), 154.
Singh, S. P., Mehta, A., & Vasudev, H. (2024). Application of sensitivity analysis for multiple attribute decision making in lean production system. Engineering Management Journal, 17(1), 1–24.
Pozzi, R., Cannas, V. G., & Rossi, T. (2024). Data science supporting lean production: Evidence from manufacturing companies. Systems, 12(3), 100.
Kassem, B., et al. (2024). Lean 4.0: A systematic literature review on the interaction between lean production and Industry 4.0 pillars. Journal of Manufacturing Technology Management.