Lean Manufacturing Analysis

Lean manufacturing or lean production, which has become widespread all over the world since the 1980s, is a production system aimed at excellence in production and continuous improvement. For lean manufacturing, it can also be said that the lean thinking is applied to the production systems with various tools and techniques. In today’s world, companies in the manufacturing sector are tried to deal with reducing the cost effectiveness, lead time of the process, idle time and waiting time, wastes and unnecessary works in the production system. Trying to solve this confusion problems, the most importing point is that to find the best methods for the reaching the company ' goals, which are without reducing the production quality.

In the development

Lean manufacturing methods and improvements have been used widely in manufacturing systems.

The aim of this study is to make lean manufacturing techniques of the applicability in the company, the mapping of the flow of all processes, the determination of wastes (idle times, waiting times, etc.) and the proposals for reducing these wastes by using the Value Stream Mapping and if necessary Line Balancing techniques. This work was carried out at Kale Kilit-Çerkezköy production factory. The value flow mapping technique will be used to determine what step in production is needed. Subsequently, the part to be improved will contribute to the development of production using the line balancing technique.

In Section 2, some articles about lean manufacturing and value stream mapping are researched. Then, literature review is performed and the lean management and manufacturing and also its tool 's importance are explained for companies.

In the third section of the project, the short and briefly information of the company and the problem definition about the factory 's

LITERATURE REVIEW

2.1. Lean Manufacturing

Toyota Motor Corporation is known as the first and most successful practitioner of lean manufacturing practice. For 50 years, Toyota has constantly improved its lean practices under the name Toyota Production System (TPS). The performance of the TPS has allowed Daimler, Chrysler, Ford and General Motors to be left behind on the market. Toyota 's financial and market success is a result of lean manufacturing practices.

Ohno 's ideas are applied to many companies in the world under the names Lean Enterprise, Just in Time (JIT) or World Class Manufacturing. In recent years, different methodologies have been developed based on the fundamental process analysis, productivity, statistical process control and problem-solving techniques. Total quality management, six sigma, process management and lean six sigma are some of these methodologies and also lean manufacturing can work in harmony with these methodologies. In the past, the term of “Made in Japan" refers to the cheap and bad quality goods. However, nowadays, high price is associated with good quality and reliability. After the Second World War, Japan has suffered from the economic crisis. Thus, Japan has got through this economic crisis with using the lean production and similar