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Ar-Ge projelerinde TRIZ yaklaşımı: Teknik çelişkilerin çözümü ve uygulama örnekleri

TRIZ approach in R&D projects: Solving technical contradictions and application examples

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  1. Tez No: 1018246
  2. Yazar: MELİKE SUDE KAZAN
  3. Danışmanlar: DR. ÖĞR. ÜYESİ MEHMET RIZA ADALI
  4. Tez Türü: Yüksek Lisans
  5. Konular: Mühendislik Bilimleri, Engineering Sciences
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 2026
  8. Dil: Türkçe
  9. Üniversite: Sakarya Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Endüstri Mühendisliği Ana Bilim Dalı
  12. Bilim Dalı: Mühendislik Yönetimi Bilim Dalı
  13. Sayfa Sayısı: Belirtilmemiş.

Özet

Bu tez çalışması, endüstriyel üretim ortamlarında karşılaşılan teknik çelişkilerin sistematik olarak analiz edilmesi ve süreç verimliliğinin artırılmasına yönelik yenilikçi çözümler geliştirilmesi amacıyla TRIZ metodolojisini uygulamalı olarak ele almaktadır. Üretim hatlarında süreç karmaşıklığının artması, hata toleransının azalması ve otomasyon seviyesinin yükselmesi, geleneksel problem çözme yaklaşımlarının yetersiz kaldığı alanlarda daha kapsamlı ve yöntemsel bir inovasyon anlayışını gerekli kılmaktadır. Bu bağlamda TRIZ; çelişki analizi, yaratıcı prensipler, fonksiyon-modelleme ve sistem kaynaklarının değerlendirilmesi gibi araçlarla teknik problemlere sistematik çözüm üretme yeteneği sunmaktadır. Tezin kuramsal bölümünde TRIZ'in temel bileşenleri ayrıntılı olarak incelenmiş, yöntemlerin endüstriyel uygulamalardaki başarısını ortaya koyan literatür araştırmasıyla teorik çerçeve güçlendirilmiştir. Uygulama bölümünde TRIZ'in uygulanabilirliği iki gerçek endüstriyel süreç üzerinden test edilmiştir. İlk uygulamada, serigrafi üretim hattındaki pano kontrol sürecinde işlem süresi darboğazı ele alınmıştır. Kontrol süresi ile ölçüm doğruluğu arasındaki teknik çelişki TRIZ 9×28 matrisiyle modellenmiş; çözüm olarak mevcut Flann-based SIFT algoritması, daha hızlı ve doğruluk oranı yüksek XFEAT algoritmasıyla değiştirilmiş ve referans–örnek görüntüleri paralel işleme yöntemiyle eşzamanlı olarak işlenmiştir. Bu yaklaşım sonucunda üç pozisyonlu toplam kontrol süresi %22 oranında azaltılmış, işlem akışı dengelenmiş ve üretim kapasitesinde doğrudan artış elde edilmiştir. İkinci uygulamada ise elektronik kartların lehimlenmesinde kullanılan makinede uç değişimi ve soğutma süreçlerinden kaynaklanan büyük verimsizlikler incelenmiştir. TRIZ 39×36 ve 9×36 çelişki matrisleri aracılığıyla verimlilik–karmaşıklık ve hız–karmaşıklık ilişkileri değerlendirilmiş; özellikle mekanik sistemlerin değiştirilmesi prensibi temel alınarak sistemin tamamen yeniden tasarlanmasına karar verilmiştir. Bu doğrultuda, en küçük komponent geometrisine uygun tek bir sabit uç kullanımı esas alınmış; otomatik dozajlama modülü, servo kontrollü hareket optimizasyonu ve akıllı reçete yönetimi ile yeni bir lehimleme kolu tasarlanmıştır. Uç değişimi, soğutma ve manuel ayarlama adımlarının tamamen ortadan kalkmasıyla toplam çevrim süresi 160–170 saniyeden 35–40 saniyeye düşmüş ve %75–80 düzeyinde iyileşme sağlanmıştır. Sonuç olarak, çalışma TRIZ'in hem yazılım tabanlı kalite kontrol süreçlerinde hem de mekanik sistem tasarımında uygulanabilir, ölçeklenebilir ve yüksek verimlilik sağlayan güçlü bir problem çözme yaklaşımı olduğunu ortaya koymaktadır.

Özet (Çeviri)

This thesis investigates the systematic analysis of technical problems encountered in industrial production environments and the development of innovative and applicable solutions through the TRIZ methodology. In modern manufacturing systems, increasing product variety, rising process complexity, and strict quality–speed expectations create the need for more analytical and scientifically grounded problem-solving approaches. Many of the challenges observed in production lines arise not only from operational inefficiencies but also from inherent structural and systemic contradictions within processes. Consequently, traditional trial-and-error approaches are often insufficient, especially in complex systems where optimization, quality improvement, and productivity enhancement are required. TRIZ, as a structured and research-based methodology, provides a comprehensive framework for identifying contradictions in technical systems and resolving them through inventive principles derived from extensive empirical studies. In this study, TRIZ is examined both theoretically and practically, and the applicability of its principles is tested through two real industrial case studies. The theoretical section of the thesis discusses the historical development of TRIZ, Altshuller's foundational research, the contradiction matrix, the 40 inventive principles, engineering parameters, the ARIZ algorithm, Su-Field modeling, and the laws of technical system evolution. Furthermore, a broad literature review highlights TRIZ applications in various fields such as electronics manufacturing, aviation, mechanical design, energy systems, automotive engineering, and software architecture. The review demonstrates that TRIZ not only provides a theoretical toolset but also offers practical and highly effective solutions to complex engineering problems, making it valuable for industrial R&D environments. The first application presented in the thesis focuses on a bottleneck in the panel inspection process within a screen-printing production line. In this system, 60 cm panels are inspected at three different positions using a camera-based machine-vision setup. Due to the high computational cost of the existing image-processing algorithm, the analysis of each position is performed sequentially, creating delays and significantly reducing the throughput of the entire production line. From a TRIZ perspective, this problem reveals a clear technical contradiction between measurement accuracy and processing speed: enhancements in accuracy lead to increased cycle time, while attempts to reduce cycle time compromise accuracy. This contradiction was mapped using the 9×28 TRIZ matrix, and associated inventive principles were identified as potential solution directions. Guided by matrix results, two complementary solution strategies were developed. The first strategy involved replacing the existing Flann-based SIFT algorithm with a faster and more efficient alternative. Experimental evaluations demonstrated that XFEAT provides superior processing performance while maintaining a high level of matching accuracy. Transitioning to XFEAT yielded an average time reduction of approximately 1.2 seconds per position. The second strategy focused on eliminating unnecessary sequential delays through the introduction of a parallel-processing structure. In the existing system, reference and sample panels were processed in a strictly sequential manner. TRIZ analysis identified this as inefficient use of system resources. To address this, a multi-threaded architecture was implemented, enabling simultaneous processing of reference and sample images along separate execution paths. This parallelization reduced waiting times and provided an additional gain of approximately 8.6 seconds across all three positions. When combined, algorithm optimization and parallel-processing implementation achieved a total cycle-time improvement of 22%. This case study demonstrates that TRIZ contradiction analysis is not limited to mechanical or physical processes but can also be effectively applied to software-based and computational problems. The second industrial application addresses inefficiencies in the soldering machine used for electronic assembly. In the previous system configuration, soldering different component groups required frequent tool-tip changes due to variations in pad size. Before changing the tip, the unit had to be cooled; afterward, the operator performed the manual change, and then the tip had to be reheated. These steps introduced substantial delays and variability. On boards that contained small SMD components, medium-size packages, and larger connectors, multiple tip changes occurred within a single cycle. Measurements revealed that a single tip-change operation required 35–40 seconds, cooling required an additional 20–30 seconds, and reheating further extended the process—resulting in total cycle times of 160–170 seconds. TRIZ analysis identified two major contradictions: the need to increase process efficiency without increasing system complexity, and the need to increase process speed without imposing additional operational constraints. These contradictions were examined through the 39×36 and 9×36 TRIZ matrices. The 39×36 matrix yielded the principles of equipotentiality (12), parameter change/resize (17), mechanics substitution (28), and intermediary (24). The 9×36 matrix similarly suggested preliminary action, asymmetry, mechanics substitution, and elimination of unnecessary components. The common principle across both matrices—mechanical system substitution—was adopted as the foundational direction for redesigning the process. The final solution proposal eliminated the need for tip changes entirely by introducing a new system architecture built around a single universal soldering tip matched to the smallest pad geometry found on the board. To compensate for varying solder requirements, an automatic dosing module was developed. In the new system, solder-wire feed rate is calculated in real time based on pad area, thermal mass of the component, and the required wetting characteristics. A PLC-controlled subsystem ensures that operators only select the appropriate recipe for the target board type, while all process parameters—including feed rate, dwell time, and motion trajectory—are automatically determined. In addition, the servo-based motion system of the soldering arm was redesigned for higher precision. Although servo technology was present in the original system, the new configuration employs recalibrated tolerances and optimized motion paths that yield significantly improved repeatability, particularly in small-pad soldering xxiii applications. This improvement enhances process consistency and reduces defect rates. The redesigned system eliminates all cooling, manual change, and reheating steps. The entire soldering operation for the full set of components is now completed in approximately 15.2 seconds. While the active soldering time slightly exceeds the cumulative time of the previous system's three separate component groups, the removal of all auxiliary steps reduces the total cycle time from 160–170 seconds to only 35–40 seconds. Thus, the redesigned process achieves a remarkable overall improvement of 75–80%. This transformation not only increases production capacity but also ensures consistent quality and reduces dependence on operator skill. When both industrial applications are evaluated together, the findings indicate that TRIZ provides a flexible, powerful, and systematic innovation framework applicable to both software-driven and mechanically intensive production systems. In the panel-inspection case, TRIZ-based analysis yielded a 22% reduction in cycle time through algorithm optimization and parallelization. In the soldering-machine case, comprehensive mechanical and process redesign led to an improvement of up to 80%, demonstrating the transformative potential of TRIZ in manufacturing operations. Overall, this thesis shows that TRIZ is an effective methodological tool for resolving technical contradictions in industrial production processes. Its structured approach enables organizations to convert complex problems into solvable models, identify system resources, and develop sustainable, high-impact innovations. By integrating TRIZ into engineering processes, companies can achieve significant gains in productivity, quality, and operational reliability, while fostering a culture of systematic innovation.

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