Process analysis and process improvement in a furniture factory

Providing customer satisfaction by fulfilling customer demands and expectations in a changing and developing world is one of the most important goals of companies, and customer satisfaction is one of the most important tools that can bring companies to success. In a competitive market where competition conditions are constantly changing and competitors are constantly increasing, companies must keep their processes dynamic in order to ensure their sustainability and achieve success. In order to improve a process, that process needs to be analyzed, and at this point, lean manufacturing techniques are used to determine and eliminate the factors affecting the performance of the process. In this study, process analysis and process improvement studies were carried out in a furniture company in the light of process analysis and process improvement methods found in the literature. 8-month failure notifications from customers were examined, and work was started in the packaging department to solve the errors. 9-month errors detected by the final quality control department were reported and pareto analysis was used to choose which error type to focus on first. The current situation of the identified faults was analyzed with the A3 method, and root cause analyzes were made with the fishbone diagram and the 5N1K method. 5S studies were carried out in theprimary material warehouse and other warehouses during the planned renovation and development works at the primary material warehouse. Warehouse processes were analyzed and process improvement studies were carried out in order to reduce the duration of processes such as addressing and kanban preparation.. As a result, it was determined that the error of using different materials (61 pieces) detected in the final quality control section was caused by human, machine, material and method by fishbone diagram method; using missing material (62 pieces) error from the before packaging processes with the 5N1K root cause analysis method; It has been determined that the material warehouse consists of preparing the module kanban and mixing the stacks of spider-man. first material warehouse was completely renewed and the number of addresses from 4600 tripled and reached approximately 14000. In terms of surface area, the warehouse area has been increased from 875 m² to 1650 m². The materials were grouped according to various criteria and their addresses were determined. Thanks to this addressing, a 33% improvement in kanban preparation time has been achieved. In the metal profile warehouse, 6% improvements were made in the storage area by switching from the car transport system to the conveyor system.