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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

6

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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

11

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

5S applications5S applications

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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

Value stream mapping workshop Value stream mapping workshop

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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

18

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 : cevdet.dal@leanacademy.com.trWeb: www.leanacademy.com.tr