Publication: A systematic perspective on supply chain improvement by using lean six sigma and an implementation at a fertilizer company
Abstract
Rekabetçiliğin giderek arttığı günümüz iş dünyasında işletmeler ayakta kalabilmek içinsüreçlerini durmaksızın gözden geçirmektedir. Süreçlerde gerçekleştirilen küçükiyileştirmeler kimi zaman büyük maliyetleri ortadan kaldırırken kimi zamanda kaliteyi yada müşteri memnuniyetini artırmaktadır. Süreçlerdeki iyileştirmeyi işletme kültürü halinedönüştürebilenlerin rakiplerine açık ara fark attıkları gözlenmektedir. Yalın Altı Sigmayaklaşımı ise sürekli iyileştirme felsefesini disiplinize ederek birçok başarılı projeninhayata geçirilmesini sağlamıştır.Bu tez çalışmasının amacı, Yalın Altı Sigma araçlarını kullanarak işletmenin tedarikzinciri süreçlerini gözden geçirmek ve mevcut durumun yeterliliğini sorgulamaktır.Şirketin Türkiye genelinde 5 farklı lojistik merkezi ve 2 üretim merkezi ile yüzlerce bayisibulunmaktadır. İşletmenin tedarik zincirindeki maliyet kalemleri finans sorumluları ilegörüşülerek sigorta gideri, depo kirası, finansman gideri ve evsafı bozulan ürünlerinmaliyeti olarak sıralanmıştır.Uygulama bölümünde stokta kalma süresini ve stok miktarını azaltmak için TÖAİK(Tanımla, Ölç, Analiz Et, İyileştir, Kontrol) tekniği kullanılmıştır. Tanımla aşamasındasistemin mevcut durumu ortaya çıkarılarak SIPOC aracı ile süreç analiz edilmiş ve CTQdiyagramı çıkarılarak projenin metrikleri belirlenmiştir. Analiz aşamasında Kanbanyöntemi kullanılarak ortalama stok miktarı hesaplanmıştır.Projenin uygulanmasıyla 503.858 ton olan ortalama stok miktarı 320.721 tonadüşürülerek 80 gün olan stokta kalma süresi 52 güne indirilmiştir. Stok miktarınınazaltılmasıyla 22.4 Milyon TL tasarruf sağlanmıştır.
In today's business world where competitiveness is increasing steadily, businessescontinuously review their processes in order to survive. Small improvements in processessometimes eliminate large costs while at the same time increasing quality or customersatisfaction. It is observed that those who convert the improvement of the processes intobusiness culture make a difference to their competitors. The Lean Six Sigma approachhas led to the realization of many successful projects by discipline the philosophy ofcontinuous improvement.The purpose of this study is to review the supply chain processes of an enterprise usingLean Six Sigma tools and question the adequacy of the existing situation. The companyhas hundreds of distributors throughout Turkey with 5 different logistic centers and twoproduction centers. The cost items in the supply chain of the company are discussed withthe finance officers and listed as insurance expense, warehouse rent, financial expenseand the cost of spoiled goods.In the application section; The DMAIC (Define, Measure, Analyze, Improve, Control)techniques was used to decrease inventory time and inventory amount. By defining thecurrent situation of the system in the Define phase, the process is analyzed with theSIPOC tool and a CTQ diagram is created to determine the project metrics. In the Analyzephase, the average inventory amount is calculated using the Kanban method.The average inventory amount which is 503,858 tons has been decreased to 320,721 tonsand the waiting time of the inventory which is 80 days has been reduced to 52 days withthe implementation of the project. 22,4 million TRY is saved with the decrease in amountof inventory.
In today's business world where competitiveness is increasing steadily, businessescontinuously review their processes in order to survive. Small improvements in processessometimes eliminate large costs while at the same time increasing quality or customersatisfaction. It is observed that those who convert the improvement of the processes intobusiness culture make a difference to their competitors. The Lean Six Sigma approachhas led to the realization of many successful projects by discipline the philosophy ofcontinuous improvement.The purpose of this study is to review the supply chain processes of an enterprise usingLean Six Sigma tools and question the adequacy of the existing situation. The companyhas hundreds of distributors throughout Turkey with 5 different logistic centers and twoproduction centers. The cost items in the supply chain of the company are discussed withthe finance officers and listed as insurance expense, warehouse rent, financial expenseand the cost of spoiled goods.In the application section; The DMAIC (Define, Measure, Analyze, Improve, Control)techniques was used to decrease inventory time and inventory amount. By defining thecurrent situation of the system in the Define phase, the process is analyzed with theSIPOC tool and a CTQ diagram is created to determine the project metrics. In the Analyzephase, the average inventory amount is calculated using the Kanban method.The average inventory amount which is 503,858 tons has been decreased to 320,721 tonsand the waiting time of the inventory which is 80 days has been reduced to 52 days withthe implementation of the project. 22,4 million TRY is saved with the decrease in amountof inventory.