Kaizen is an improvement activity based on feedback. It means gradual, continuous change, change for the better as a result of small investments, open-shared knowledge and long-term effects. Kaizen efforts focus mainly on the elimination of non-value-added activities (muda). It can consist of individual improvements, or it can be carried out as a team and in a planned workshop environment to achieve effective results.
Kobetsu kaizen (focused kaizen) is a team-based problem solving and decision-making effort related to the problem identified as a result of loss analysis to increase productivity. Kobetsu kaizen involves support teams and requires time and cash resources.
The kaizen process was commissioned in our business at the end of 2021. Its content consists of kaizen proposal, kobetsu kaizen, A3 problem solving activity and 8D problem solving activities.
The process, which is open to the participation of all our employees, is managed by the lean production team in a hybrid way with both kaizen suggestion forms in production areas and the continuous improvement module in the electronic environment. As our employees make kaizen, they receive points and are rewarded in return for points. In 2022, a total of 287 kaizen and kobetsu kaizen and 43 A3 problem solving activities were carried out, and this number is 91 kaizen and kobetsu kaizen and 3 A3 problem solving activities as of April 2023.
The increasing interest of our employees in the kaizen process every day creates satisfaction for us. We would like to thank all our employees who participate in our kaizen process and support the process through you. We would like to take this opportunity to present a few examples of the kaizens we have realized.
• RISKY SITUATION: Possibility of deformation of the impeller parts during transportation in the crate.
Since the impeller parts are not fixed inside the case while being transported in their own special case, an apparatus was made to fix the part inside the cases in order to prevent deformations due to transportation. Thus, the movement of the part during transportation and deformation due to transportation were eliminated. In addition, thanks to this system, there is no need to use sponge.
• SUBJECT: In order to facilitate the spiral pipe deburring process, the use of a deburring trolley suitable for spiral pipes.
Previously, the manual operation of the auger pipes was carried out by rotating 3 turns with auxiliary materials on the V pallet. With Kaizen intervention, the operation time was shortened and OHS risk was prevented by making a trolley suitable for all spiral pipes.
• RISKY SITUATION: Material lifting apparatus used in machining poses an OHS risk.
The current state of the lifting apparatus posed a threat to our employees in terms of Occupational Health and Safety. For this reason, a new apparatus was designed to improve its strength and facilitate transportation by crane.
• SUBJECT: Changing the apparatus used as a center support while machining Spiral Tube on DMF machine, shortening the end change time and improving the setup time.
The design of the center support, which consists of three parts, was changed to coincide exactly with the center of the workpiece to be processed on the machine, thus preventing time loss.
• SUBJECT: Prevention of misaligned machining of motor plate holes (poka-yoke)
A misalignment could occur when the part was connected to the workbench and as a result of the misalignment, re-processing was wasted due to dimensional problems. By making Poka Yoke, the part was prevented from running away after it was connected to the workbench.
• SUBJECT: Ø660 Flat drum was started to be processed on HM-1000 machine due to the long processing time on HUT-183 Okuma Double machine.
V-bearing was made in order to shorten the machining time. In this way, the operation time of the Ø660 Flat drum, which was started to be processed on the HM-1000 machine, was shortened by 58%.
• SUBJECT: Reducing transportation waste in malaxator boiler manufacturing.
2 stations were relocated, eliminating the waste of transportation and crane waiting.
• SUBJECT: Improvement of the welding process on the engine consoles by using a mirror.
A clamping apparatus was made for the welding operation, saving pre-operation preparation time.
