Digitalization in the lean production system and process improvement analysis with industry 4.0 applications: An application in a manufacturing company

The term Industry 4.0 is to improve all business processes by digitizing both the global language and every stage of production. The concept of lean production is the elimination of all waste at all operational levels, from the way the product is created to the product delivery process. Applications of Industry 4.0 and lean manufacturing techniques, which are the reflection of digitalization on production systems, together as an integrated system constitutes the basic basis of the thesis work. In order to achieve functional excellence in processes and unlock success in digital transformation, two philosophies need to be carried out together. These advantages can be listed as minimizing costs, increasing customer satisfaction, increasing efficiency by improving processes and meeting customer demands very quickly. In the lean manufacturing system, digitization of production lines and Industry 4.0 applications focus on improving all production processes. In this study, it is aimed to increase the competitiveness in global production and sales by adopting these philosophies. In this self-optimizing project called "Production Data Collection and Barcode Product Tracking Automation", the source of the problems arising in the processes has been identified and compared the targeted efficiency values of the production lines with the instant data collected from the business centers. It is also focused on tracking information about quantity, duration, scrap, downtime and failure. By transferring this information to ERP system at all levels, it is aimed to prevent all problems that occur and may occur with the ability to perform real-time product and stock tracking, with these data, to improve production processes by doing productivity enhancing, cost-reducing activities, to be monitored and reported instantly throughout the entire phase. In the thesis study, the digitalization processes of lean production stations in the enterprise, which implements the lean manufacturing system and are active in the automotive sub-industry sector in Aydın, province are discussed. In this context, using the digital production management system called MAS (Manufacturing Execution System), the Total Equipment Effectiveness (OEE) method was applied through instant data entry, analysis, tracking, analysis and correct interpretation of the data. Applications focused on increasing OEE values and improving processes more positively. Also, process improvement studies covering different digital lean manufacturing techniques in the business, different from MAS, are included with the data in the reports taken from the MAS system, which supports and will support. At the application station selected as a pilot line; OEE averages of August-September-October 2019, which is analyzed through data from past system with entered data manually, OEE averages of November-December / January 2020, calculated directly by the system, obtained through instant data from MAS and compared to the ideal OEE average in the world. OEE is the universal criterion of Industry 4.0 The numerical results obtained from the research alone do not show the effect of digitalization on efficiency. In order for the ideas to be transformed into actions for intended activities, the university-industry-state triangle should act together to form a durable and sustainable picture is important. In this context, the fact that all organizations support each other in order to increase the efficiency of the businesses in the digital transformation journey will be the key to success in the Industry 4.0 journey. The aim of this thesis study is to increase the level of digital literacy by creating awareness in many people in circles such as growth, employment, investment, business world, academy world and government institutions and organizations. By this way, it is aimed to help the adaptation of this new level to be achieved in a successful, easy process to increase the level of digital literacy and to contribute positively to the future of our country. KEYWORDS: Lean Manufacturing, Digitalization, Digital Manufacturing, Industry 4.0, Process Improvement