A3 raporlama yöntemi ile israfın yok edilmesi: Fren sistemleri üreten bir işletmede uygulama

In today's competitive business environment, there is an increasing need of businesses who aim to make a difference in order to maintain the existence and growth of their companies. For this reason, continuous improvement activities are emerged against to increasing number of actors in the market prices. By eliminating wastes, businesses can reduce their costs which are directly effective on value-adding process and profit. In this case, lean philosophy creates a solution to identify necessary activities and then eliminate unnecessary actions that cannot be evaluated as value-added. Furthermore, companies can increase the qualification of the use of labors and technological equipment to cause to make mistakes during production. Lean philosophy, which is described as "Lean Manufacturing System", achieves the whole emphasized continuous improvement actions by producing highest yield of product with minimum input. At this point, the A3 approach is one of the core methods involved under the lean philosophy followed by the Plan-Do-Check-Act (PDCA) cycle which allows continuous healing. This study performs in a company that produces brake systems and approaches Muda elimination covered by A3 method. This method has been selected to reduce rework losses in the company. At the first step of the study, literature research was made on lean manufacturing system and experimental design methodology. In case of initial experimentation of the analysis, one of the problem-solving techniques called fishbone were applied. After, Pareto analysis was performed to understand the main root-causes of reworks on the surface roughness. The processing parameters providing the minimum surface roughness value were obtained by using the Full Factorial Experimental Design Method in addition to methodology part of this study. Keywords: A3 thinking, lean philosophy, Toyota production system, muda elimination, full factorial experimental design, problem solving, PDCA.