Orta ölçekli bir konfeksiyon atölyesinde üretim planlama ve uygulama

Abstract

V. ÖZET Bu tezin Giriş Bölümü' nde konfeksiyon sektörünün Türkiye ekonomisindeki önemi ve belirgin sorunları ile teorik çalış malar için kullanılacak dataların elde edildiği Sümerbank Konfeksiyon isletmeleri hakkında bilgiler verilmiştir. Materyal ve Metod Bölümü' nde ise üretim sistemleri ve ü- retim yönetimi kavramları incelenerek, üretim planlamanın ya pılabilmesi için gerekli ön planlama konuları ve bunlardan a- na üretim planlama aşamasında nasıl yararlanılacağı ele alın mıştır. Kontrol kavramının açıklanmasından sonra yönetim bi lişim sistemleri ve veri tabanı kavramı, hazırlanan bilgisa yar programının daha iyi anlaşılabilmesi için incelenmiştir. Tezin Bulgular Bölümü 'nde ise bir konfeksiyon işletme sinde malzeme akısını kontrol etmek, tahmini üretim zamanını bulmak için bilgisayar destekli bir sistem geliştirilmiştir. Ayrıca, tasarlanan sistemdeki malzeme kodlama sistemi, prog ramın veri tabanı ve kullanımı bu bölümde mevcuttur. Kodlama sistemi, malzeme ve hammadde çok çeşitli ve karmaşık olduğun dan kullanıcıların karşılaşacağı güçlükleri minimize etmek a- macıyla mümkün olduğu kadar basite indirgenerek yapılmıştır. Hazırlanan program yeni bir siparişin ürün ağacını oluş turup buna göre malzeme ihtiyaçlarını çıkarmakta, ambar stok larını takip etmekte, her yeni modelin tahmini standart zama nını çıkarıp siparişlerin üretim zamanlarını hesaplamaktadır.

SUMMARY A COMPUTER ADDED PRODUCTION PLANNING AND CONTROL MODEL OF A READY MADE CLOTHING SECTOR Nowadays, textile industry is considered important in the devoloping countries. The sector is in a continuous change. The textil sector has an important place in the Turkish economy as well as in other developing countries. Because it provides wide employment, added value and foreign currency flows. Today, the ready made clotting sector is one of the most impotant elements of Turke's exports. The `pret-a- porter` industry is a labour intensive industry, which is an advatageous factor for the developing coountries, like Turkey. This thasis is an application of a ready made clothing sector. In this study a special computer model, which controls the materyal flow, and find the forecasting of the production time, is developed and a package program is prepared. The study has five chapters. Chapter one describes the production system and function is that of putting together input of men, capital materyals, information, and energy; and transforming them into products and and services in the quantity, quality time, and location that will best meet the orgniztion's objectives. Mnufcturing systems en be divided to two basic structures as continuous systems and intermittent systems. In this chapter the differences between these two structures are given. -103-Manufacturing types are as follows: a. Flow shop b. Job shop c. Systems with parallel machines If we considerr flow shop structuures, the most important attribute of these systems will be one that has multiple resources. In the shop models, solving the problems is more diffucult than other production systems. Because job routings are different for each order and complicated flows may occur. Scheduling problems with parallel machines countain both assigment and sequencing decisions. The determination of optimal shedules is often returned to diffucult structures, since both of decisions must be considered to solve problems. Chapter two describes the objectives of production planning and control, forecasting demand, muster production plan and scheduling. Planning is the activity of determining where a person or organization wants to be at some time in the future, then developing ways to get there. Types of productions planning were divided into three parts as long term, middle term, short term planning. Scheduling and secuencing decisions are the short run planning and control activities. They can be realised in operations level and performed by labour force at the shop. In third chapter, information needs of the management and qualitative caracteristics of information such as timeless, relevance and occurancy have been examined. Management Information Systems, its characteristics has been -104-examined. Level of decisions making çan be classified as strategic, tactical and operational levels. Strategic decisions making involves the establishment of objectives for the organization and the long term plans for attaining these objectives. Tactical decision making in concerned with the implemention of decisions made at the strategic level. Operational decisions are made especially by lower level supervisors. They involve execution of spesific tasks to assure that they are carried out efficiently and effectively. A Management Ii formation System can be defined as a computer information system that can integrate data from various sources to provide the information necessery for management decision making. Today's manager are forced to be more careful 1 in their field of interests because of changing economic condintions. Espacially» the sudden changes of interest rates, the lack of materials, the increase of invertory carriying cost and other similar types of development necssitate, the need for an advanced control mechanism and a faster adaptaion rate to these changig conditions. Nowadays, the actual developments in the computer field an the more frequent use of large scale production planning and control systems. Fourth chapter is reserved to introduce the plant where the production will be implemented. `Sümerbank Bakırköy Ready-made Clothing Industry Facility` is established as a textile factory in 1850 with the name of `Basmane ve Bez Fabrikası` Till 1983, the factory's activity was in the field -105-of fibres and wovening production. That year, the dis mounting of the machinery was strated and installation of the plant for ready made clothing begun. The new plant started to the production on 1986. There are three seperate workshops in the facility: first is for the producrion of shirts, second for sport clothing and third for suits. In this study, the shirt producing department is discussed as a pilot workshop. The production is made accourding to the orders coming from there seperate ways: 1. Directorate of Export of the General Management 2. Directorate of Marketing of the General Management 3 Directorate of Trade of the Facility (for internal market) In, a ready made factory» the production starts in the cutting department. Generally the cutting number is applied 5% excess is a caution against the mistake on the fabric and the posible loss in the siwing section. All the cut out clothes are transported buy the cards to the sewing section. In the facility, there are nine sewing bands; avarage capacity for shirt production of these nine bands is 550 shirts per day. A shirt is subjected to 50 to 75 different operations depending to its model on the sewing band. In the ready products, the quality is a selling factor as important as the price. Quality control is performed in every phase of the production. In the cutting department the process controls, at the end of sewing bands 100% controls and before packaging final controls are performed. The shirts succeding to pass over the quality controls are gathered in final process department, and after the pressing -106-are packaged and submitted to the stores. In the fifth section, a computer program has been developed for the use in the short workshop. These every new order and calculates accordingly the ammounts of the needed materials, follows up recordings of the storage, finds approximate standart time for each of the new model and finaly calculates productions time of the orders. The assumptions of these proogram are: 1. The ammount of order, in the order from is fixed. If there will be any addition to the order, a new order from should be openned. 2. Daily working time is 520 minites. 3. There nine bands in the sewing department. Avarage daily output of each band is 550 shirts. 4. The absenteeism rate is 20% in the facility. 5. The facility operates with 85% efficiense rate. 6. The time required in the 100% control for one shirt is two minutes. 7. The labour force is as following: Cutting department = 40 workers Sewing department =360 workers Quality control department = 40 workers Final process department = 90 workers To facilitate for following the flow of materials, a coding system is developed. Developing this coding system, some proporties are as simplified as possible, to minimize the difficulties ancountered due to the loose variety and complexity of the materials and raw materials. -107-We can explain the package program as below. When the package is run. first coming is the mainmenu on the screen. There are four choices in this mainmenu. In the first choices, there record add, delete, change and listing choices. The second choices in the mainmenu is a submenu for material management. In this menu, there are forming the bill of material, material requirement planning and storage operations choices.. In addition, the list of needed material quantities and storage stocks can be taken from printer. The third choice in the main menu is a submenu for calculating the production time of each department (cutting, sewing, quality control and final process). The fourth choice in the mainmenu is for ending the package program. -108-