Lean Transformation Case Study

Lean transformation and the success

Lutfi Apiliogulları,

General Manager

[email protected] ( 0 532 253 43 36)

mailto:[email protected]

Lutfi Apiliogullari , GM 0 532 253 43 36 [email protected]

What is the goal of the companies ?

3-Cash Flow1-Revenue 2-Profit

The Goal


The Goal

Value Stream Mapping

LEAN Organization

Standard

KAIZEN & TRAINING

Heijunka

The House of VITO The Strategy of VITO

Op

era

tio

na

lExce

llen

ce

The right suppliers

The best people

World Class opr.systems

Performance based management

Cont. Imprmnt & Development Programs

5S Visual Mngmt.

Flow

SMED

PULL

Jidoka

Poka&Yoke

QAN

PDCA

TPM

QRS

P&L

Perf.Mng


The Goal

POPO

POPOPO

RAW Material

Supermarket

Supplier

Supermarket

Finished Goods

Supermarket

Customer

Demand

IRENA

GROUP

IRENA

SUPPLIERSUPPLIERs

SUPPLIERs

IRENA

CUSTOMER


POPO

Min Level

POPO

Min Level

PO

RAW Material

Supermarket

Supplier

Supermarket

Finished Goods

Supermarket

Customer

Demand

IRENA

GROUP

IRENA

SUPPLIERSUPPLIERs

SUPPLIERs

IRENA

CUSTOMER

Immediate Response

Shorter LEAD Time

Immediate Response

Shorter LEAD Time

End to End Pull System


POPO

Min Level

POPO

Min Level

PO

RAW Material

Supermarket

Supplier

Supermarket

Finished Goods

Supermarket

Customer

Demand

IRENA

GROUP

IRENA

SUPPLIERSUPPLIERs

SUPPLIERs

IRENA

CUSTOMER

Immediate Response

Shorter LEAD Time

Immediate Response

Shorter LEAD Time

End to End Pull System

☞ Shortest Lead time between customer order and shipment

☞ Standardized stock level and increased stock turn


The Story and its effect

76% DMC

MSCC81%

TC

90%

SG&A97%

PROFIT100%

REVENUE

BEFORE AFTER

73%DMC

Best in class and limited number of suppliers.

DMC : Direct Material Cost

MSCC 76%

End to End pull system implemented, stock cost reduced / cash

flow increased

MSCC : Material Supply Chain Cost

TC 83%

KAIZEN culture and standardization in al area of business. LEAN

OPERATIONS. Waste elimination.

TC : Transformation Cost

SG&A 90%

Research & 4P

SG&A : Service & General Adm. Cost

PROFIT100%

Profit increased from 3% to 10%

PROFIT


The Goal

We CHALLENGE ourselves to build the highest quality products at the lowest cost thru GENCHI GENBUTSUthe

process by doing KAIZEN with TEAM WORK and mutually TRUST and RESPECT with all parties in order to meet

our Customers Expectations.

Contunial

Imrovement

Challenge

Genchi Gembutsu

KAIZEN

People

Team Works

Mutual trust &

respect

Business Philosophy

Golden Triangles

of customer expectations

Customers Expectations

Quality

Flexibility Competiveness


The Goal

The difference between AIM and DREAM is ;

Dream requires good sleep to see it,

AIM requires SLEEPLESS nights and efforts to

fulfil it.

THANK YOU

Lean Transformation Case Study

Documents

Transcript of Lean Transformation Case Study