Publication: Orta ölçekli basım işletmelerinde üretimi aksatan nedenlerin belirlenmesi
Abstract
ORTA ÖLÇEKLİ BASIM İŞLETMELERİNDE ÜRETİMİ AKSATAN NEDENLERİN BELİRLENMESİ Orta Ölçekli Basım işletmelerinin seçiminde KOSGEB kriterleri baz alınmıştır. Yaptığı üretim itibari ile yüksek sayıda işlere sahip olan ambalaj sektörü araştırma dışı bırakılmıştır. Gün içerisinde ürün çeşitliliği olan, düşük ve orta baskı sayısı özelliğinde işler üreten, ve üretim problemlerini yoğun yaşayan basım işletmeleri anket uygulamasının ve tez çalışmasının kitlesini oluşturmaktadır. Orta Ölçekli Basım İşletmelerinde karşılaşılan üretim problemlerinin tespit edilmesi çalışmasında, ürünün tasarımı, film alınması ve montaj yapılması aşamaları araştırma dışı bırakılmıştır. Tezde Orta Ölçekli İşlemelerin üretimde karşılaştıkları problemlerin tespiti ve bu problemlerin üretimi ne ölçüde etkilediğinin belirlenmesi hedeflenmiştir. Problemler tespit edilmiş, karşılaşılma sıklıklarına göre sıralanmış ve çözüm aşaması sonrası gelişmelerin grafiklere yansımaları gözlenmiştir. Uygulama, yaşanan sorunların genellenmesi amacı ile sektör problemlerini yansıtacak anket uygulaması ile başlatılmıştır. Bu anketler değerlendirilerek sıralama pareto analizi yardımı ile yapılmış, daha sonra genellemelerden elde edilen problemleri bire bir yaşayan model işletme seçilmiştir. Model basım işletmesinde makine parkı tablo içinde gösterilmiş ve iş akış diyagramı verilmiştir. Anketlerde çıkan sonuçlarla paralellik gösteren model işletmede, problemlerin detaylandırılması ve çözüm süreci; grup çalışmaları, problem ve hedef ağaçları yöntemleri, mantıksal çerçeve yaklaşımı ve SWOT aracı ile sağlanmıştır. Yapılan çalışmalarda şu sonuçlar elde edilmiştir. a-)Anket çalışmalarına katılan orta ölçekli basım işletmeleri arasında öncelikli üretim problemleri; ani ve önemli siparişlerin program arasına sıkıştırılması, bilgi eksikliği, müşteri onayının gecikmesi, makine arızaları, iletişim eksikliği, olarak tespit edilmiştir. b-)Ankete katılan ve sektörde 20 yıl ve üzeri faaliyet gösteren Basım İşletmelerinde, iş teslim zamanlarının gün farkıyla aşılma oranının daha sık gerçekleştiği tespit edilmiştir. c-)Ankete katılan ve sektörde 20 yıl ve üzeri faaliyet gösteren firmaların üretim programlamada paket bilgisayar kullanma oranının, diğer gruplardan fazla olduğu tespit edilmiştir. d-)Gün farkıyla gecikmelerin 11-19 çeşit üreten Basım İşletmelerinde arttığı, 20 çeşit ve üzeri ürün üreten işletmelerde azaldığı görülmektedir. e-)20 çeşit ve üzeri iş üreten Basım İşletmelerinde üretimin programlanmasında, firma için hazırlanan paket bilgisayar programları kullanma yüzdesinin diğer gruplardan daha fazla olduğu görülmektedir. f-)İşletme organizasyon yapısını yatay şemaya dönüştürecek çalışmalar yapılmış ve bu yapının üretime etkilerinin pozitif olduğu gözlenmiştir. g-)Firmaya sürekli iş getiren müşteriler, müşteri ilişkileri sorumluları arasında paylaştırılmış, uygulamanın etkileri olumlu olmuştur. h-)Kesim Makinesinde Düşük gramajlı kâğıt gruplarında, genel programlamanın uygun olmasının getireceği ılımlı yükselme ya da düşmeler yerine, radikal değişimler gözlenmiştir. i-)2 ve 3 kırım işlerin 2510–5000 Tabaka Kırım Sayılarında Üretim Sürelerinde artış görülmüştür. Veriler incelenerek artış nedeninin; farklı zamanlarda toplanan verilerde kırım makinesinin 2 ve 3 kırım grupları arasında veri sayısı olarak aşırı dengesizlik olmasından kaynaklandığı düşünülmektedir. j-)İletişim ağının kurulması ve üretimi programlama için kullanılan bilgisayar paket programın siparişe ait tüm bilgilerin kayıt altına alındığı, hata kodlarının işlenerek rapor alabildiği firmaya özel paket program olması sağlanmıştır. k-)İletişim, iyi bilgi tanımı ve kullanım alanları, geri bildirim, insan kaynakları ve yönetim önerileri, problem çözme adımları konulu sunumlar hazırlanmış ve etkili iletişimde görsel öğelere yönelik anlatımlarla zenginleştirilen sunumların dikkat çektiği gözlenmiş ve üretime etkileri olumlu olmuştur. l-)Üretimi Programlarken baskı makinelerindeki işlerin kâğıt gramaj geçişlerine bakılarak köklü yanlışlar saptanmış, çalışma süreci içerisinde gramaj geçişlerinin daha uygun olmasına dikkat edilmiştir. m-)Firma planlamalarında yer alan atölye düzenlemesi, konu etrafında planlama olarak öne alınmış ve üretim için daha uygun makine parkı yerleşimi gerçekleşmiştir.
THE DETERMINATION OF CAUSES WHICH AFFECT THE PRODUCTION PERFORMANCE IN MIDDLE LEVEL PRINTING PLANTS In the selection of middle level printing plants, the KOSGEB criteria are taken as a base consideration. The packaging sector which has a great number of work in terms of production are left out of this present investigation. The printing plants having product diversity in a day, producing a number of work in the property of low and middle printing number and facing product problems heavily are the main body of the present work. In the study of determining printing problems encountered in the middle level printing plants, the steps on product design, film preparation and montage preparation are left out of the present investigation. The aim of the present thesis is to determine the problems which the middle level printing plants encounter in the production and also to establish how much of these problems affect the production. The problems were fixed and rated according to their frequency. Then, the improvements observed after solution steps were graphically determined. The present investigation was started with the application of a questionaire to reflect the sectoral problems by the purpose of generalisation of problems faced. The questionaire was evaluated and the rating was carried out with Pareto Analysis, then the model printing plant which has the problems obtained from generalisations was selected. In the model plant which shows a linearity with the results of questionaire, the convertion of problems in a detailed form and the process for solving these problems were obtained by a team work, a method of problem and target trees, a logical frame approach and a means of SWOT. The following results were obtained with the present study: a-) The major production problems in between the middle level printing plants attented to the questionaire were found to be instant and important orders squeezed in a program, lack of information, delay of the customer confirmation, machine problems and lack of communication. b-) In the printing plants which is in operation for at least 20 years, it was found out that the rate of exceeding work submission times via a day difference was more frequent. c-) In the companies attending in the questionaire, the rate for using computer program was higher than other groups. d-) The delays with the day difference was observed to increase in the printing plants producing 11-19 different types of work; but a decrease was observed in the printing plants producing 20 and more. e-) In the programming of the production in the printing plants producing 20 and more different types of work, the percentage of packet computer program usage prepared for the company was higher than other groups. f-) Following a work which converts the structure of organisation into the horizontal scheme, it was observed that this structure had a positive effect to the production. g-) The customers bringing continuous work to the company were shared in between the responsible people for customer relations and the effects of this structure to the production were found to be positive. h-) In the paper groups with the lower grammage in the cutting machine, radical changes were observed instead of moderate increases or decreases because of the proper general programming. i-) An increase was observed in the production time at the 2510-5000 sheet folding numbers of 2 and 3 folding work. By the evaluation of data, it was thought that the reason for the increase was originated from the excess unbalance in data number in between 2 and 3 folding groups of folding machine in the data obtained in the different times. j-) The computer package program used for fixing the communication network and for programming the production was to be a program specific to the company in which the all information related to the order and the fault codes were recorded to be obtained for a later use. k-) A number of presentations regarding communication, good description of information and usage areas, re-decleration, human resources and management suggestions, problem solving steps were prepared and it was observed that the prersentations enriched with the visual objects were attracted in an effective communication and their effects in the production was positive. l-) In the programming stage of the production, the radical faults were determined by evaluating the paper grammage passings of the work in the printing presses and the attention was paid to get more proper grammage passings during the working period. m-) The design of workshop in the company planning was considered to be the first factor in the subject and the better machine park placement were planned for the production.
THE DETERMINATION OF CAUSES WHICH AFFECT THE PRODUCTION PERFORMANCE IN MIDDLE LEVEL PRINTING PLANTS In the selection of middle level printing plants, the KOSGEB criteria are taken as a base consideration. The packaging sector which has a great number of work in terms of production are left out of this present investigation. The printing plants having product diversity in a day, producing a number of work in the property of low and middle printing number and facing product problems heavily are the main body of the present work. In the study of determining printing problems encountered in the middle level printing plants, the steps on product design, film preparation and montage preparation are left out of the present investigation. The aim of the present thesis is to determine the problems which the middle level printing plants encounter in the production and also to establish how much of these problems affect the production. The problems were fixed and rated according to their frequency. Then, the improvements observed after solution steps were graphically determined. The present investigation was started with the application of a questionaire to reflect the sectoral problems by the purpose of generalisation of problems faced. The questionaire was evaluated and the rating was carried out with Pareto Analysis, then the model printing plant which has the problems obtained from generalisations was selected. In the model plant which shows a linearity with the results of questionaire, the convertion of problems in a detailed form and the process for solving these problems were obtained by a team work, a method of problem and target trees, a logical frame approach and a means of SWOT. The following results were obtained with the present study: a-) The major production problems in between the middle level printing plants attented to the questionaire were found to be instant and important orders squeezed in a program, lack of information, delay of the customer confirmation, machine problems and lack of communication. b-) In the printing plants which is in operation for at least 20 years, it was found out that the rate of exceeding work submission times via a day difference was more frequent. c-) In the companies attending in the questionaire, the rate for using computer program was higher than other groups. d-) The delays with the day difference was observed to increase in the printing plants producing 11-19 different types of work; but a decrease was observed in the printing plants producing 20 and more. e-) In the programming of the production in the printing plants producing 20 and more different types of work, the percentage of packet computer program usage prepared for the company was higher than other groups. f-) Following a work which converts the structure of organisation into the horizontal scheme, it was observed that this structure had a positive effect to the production. g-) The customers bringing continuous work to the company were shared in between the responsible people for customer relations and the effects of this structure to the production were found to be positive. h-) In the paper groups with the lower grammage in the cutting machine, radical changes were observed instead of moderate increases or decreases because of the proper general programming. i-) An increase was observed in the production time at the 2510-5000 sheet folding numbers of 2 and 3 folding work. By the evaluation of data, it was thought that the reason for the increase was originated from the excess unbalance in data number in between 2 and 3 folding groups of folding machine in the data obtained in the different times. j-) The computer package program used for fixing the communication network and for programming the production was to be a program specific to the company in which the all information related to the order and the fault codes were recorded to be obtained for a later use. k-) A number of presentations regarding communication, good description of information and usage areas, re-decleration, human resources and management suggestions, problem solving steps were prepared and it was observed that the prersentations enriched with the visual objects were attracted in an effective communication and their effects in the production was positive. l-) In the programming stage of the production, the radical faults were determined by evaluating the paper grammage passings of the work in the printing presses and the attention was paid to get more proper grammage passings during the working period. m-) The design of workshop in the company planning was considered to be the first factor in the subject and the better machine park placement were planned for the production.