At Toyota, having engineers or managers stand inside a circle drawn with chalk for a long time is one of the most famous learning practices of TPS. Because this method was often applied by Taiichi Ohno, it is known as the “Ohno Circle”. 🎯 Core Purpose:🟢 To see reality (Genchi Genbutsu)🟢 To understand processes from […]
Let’s set up a suggestion system; let’s have boxes on the wall, cute suggestion forms, and rewards… Let the suggestions pour in, let the money roll in! 📦 Box on the wall📃 Suggestion forms exist💶 Even rewards exist❌ No suggestions, no results ⚠️ IN REALITYSuggestions go unanswered. After a while, the employee stops writing suggestions […]
The Name of Chaos is Always a Planning Problem…Production Planning ➡️ Material Planning ➡️ Purchasing In TPS (Toyota Production System), chaos is not a lack of planning, but the loss or confusion of process ownership. When these three departments are not clearly separated, what emerges is: A systematic failure disguised as a planning problem. In […]
04
Mar
Mar
We set up a board and hold stand-up meetings every morning. But in reality: 🔴 Behavior doesn’t change. 🔴 Decision-making speed doesn’t increase. 🔴 Problems aren’t voiced, or simply cannot be. Meaning, there is a ritual, but no system. In many companies, even the ritual is missing. Why is Asakai Important in Lean Manufacturing? 1️⃣ […]
01
Nov
Nov
Lean projects without value stream-based organization fail to maintain the initial excitement. In this article I explain why and how to fix it. I have witnessed many projects related to lean transformation. You know the initial excitement; kaizen workshops are established, teams are motivated, measurements are made. The place is filled with energy for a […]
13
May
May
A few years ago, I visited a factory and observed workers racing against time on the production line. The strange thing was that sometimes they had to wait idly, while at other times they were working excessively hard. This inconsistency affected the entire production process. The management team was unhappy with productivity, employees were constantly […]
BEGINNING: RECOGNIZING THE NEED FOR CHANGE In July 2023, SAG Gılamları embarked on a lean transformation journey to gain deeper insights into the challenges faced in production efficiency and to develop lasting solutions. This decision was driven not only by the need for operational improvements but also by the desire for a mindset shift. The […]
04
Mar
Mar
2022… It was the beginning of a challenging year for AYVEN Group. Our warehouses were overflowing, customers constantly complained about delayed orders, and our operations were becoming increasingly costly. To be honest, even we didn’t know where we were heading. That’s when we came across the concept of lean transformation. At first, we wondered, “Does […]
21
Feb
Feb
Lean Production Techniques and Application Examples In the first part, we looked at the basics of lean production and Toyota’s JIT system. Now let’s take a closer look at lean production techniques, ERP integration, real-life examples and other important topics. Lean Production Techniques: SMED, Poka-Yoke and Kaizen Lean manufacturing involves many techniques and methods to […]
10
Feb
Feb
In today’s competitive business world, companies need to increase efficiency, reduce costs and increase productivity. This is exactly where Lean Manufacturing comes into play. This powerful method, which enables companies to gain a competitive advantage by optimizing production processes and eliminating waste, offers great opportunities, especially for production managers and engineers: Creating more value with […]
