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Bir konfeksiyon işletmesinde bilgisayar destekli üretim planlama ve kontrol

A Computer aided production planning and control model of a ready made clothing sector

  1. Tez No: 22041
  2. Yazar: MÜJDE KOÇER(YAVUZ)
  3. Danışmanlar: DOÇ. DR. MEHMET TANYAŞ
  4. Tez Türü: Yüksek Lisans
  5. Konular: Endüstri ve Endüstri Mühendisliği, Industrial and Industrial Engineering
  6. Anahtar Kelimeler: Belirtilmemiş.
  7. Yıl: 1992
  8. Dil: Türkçe
  9. Üniversite: İstanbul Teknik Üniversitesi
  10. Enstitü: Fen Bilimleri Enstitüsü
  11. Ana Bilim Dalı: Belirtilmemiş.
  12. Bilim Dalı: Belirtilmemiş.
  13. Sayfa Sayısı: 125

Özet

ÖZET Üretim planlaması, endüstriyel işletmelerin varlıklarını sağlıklı bir şekilde sürdürerek ellerindeki mevcut insan gücü, makina ve sermaye gibi kıt kaynakları etkin ve verimli bir şekilde kullanabilmelerini sağlamak tır. Hasır giyim sektörü, günümüzde Türkiye ihracatının en önemli unsurlarından biridir. ülkemiz hasır giyim sanayi, biri nispeten modern teknoloji kullanan orta ve büyük çaplı işletmelerden oluşan, diğeri ise homojen bir teknoloji yapısına sahip olmayan çok sayıdaki atölyeler den oluşan bir yapıya sahiptir. Uygulamanın yapıldığı Sümerbank Bakırköy Konfeksiyon Sanayi ise yukarıda saydığımız birinci grubun içine girmektedir. Bu projede bir konfeksiyon işletmesinde malzeme akışını kontrol etmek,. tahmini üretim samanını bulmak için bilgisayar destekli bir sistem geliştirilmiştir. Hasırlanan program yeni bir siparişin ürün ağacını oluşturup buna göre malzeme ihtiyaçlarını çıkarmakta, ambar stoklarını takip etmekte, her yeni modelin tahmini standart samanını çıkararak siparişlerin üretim samanlarını hesaplamaktadır. Ayrıca malzeme akışını takip etmeyi kolaylaştırmak için bir kodlama sistemi geliştirilmiştir. Kodlama sistemi oluşturulurken malzeme ve hammaddenin çok çeşitli ve karmaşık olması nedeniyle, kullanıcıların bu durum karşısında karşılaşacağı güçlükleri minimize etmek amacıyla bası özellikler mümkün olduğu kadar basite indirgenerek yapılmıştır. Konfeksiyon sanayi, Türkiye gibi gelişmekte olan ülkeler açısından gerek emek yoğun bir sanayi dalı olması ve gerekse üretim ve ihracatta önemli bir paya sahip bulunması nedeniyle büyük bir önem taşımaktadır. Bu nedenle, üretim planlama problemlerini mümkün olduğu kadar bilgisayar destekli çözerek hataları minimize etmeliyiz. - vii -

Özet (Çeviri)

SUMMARY A COMPUTER AIDED PRODUCTION PLANNING AND CONTROL MODEL OF A READY MADE CLOTHING SECTOR Nowadays, textile industry is considered im portant in the devoloping countries. The sector is in a continuous change. The textile sector has an important place in the Turkish economy as well as in other developing countries. Because it provides wide employment, added value and foreign currency flows. Today, the ready made clothing sector is one of the most important elements of Turkey's exports. The“ pret-a-porter ”industry is a labour intensive industry, which is an advantageous factor for the developing countries, like Turkey. This thesis is an application of a computer aided production planning model of a ready made clothing sec tor. In this study a special computer model, which controls the material flow, and finds the forecasting of the production time, is developed and a package program is prepared. The study has five chapters. Chapter one describes the production system and function and its characteristics. The production func tion is that of putting together inputs of men, capital materials, information, and energy; and transforming them into products and services in the quantity, quality, time, and location that will best meet the organisation's objectives. Manufacturing systems can be divided to two basic structures as continuous systems and intermittent systems. In this chapter the differences between these two structures are given. Manufacturing types are as follows: a. Flow shop b. Job shop c. Systems with parallel machines If we consider flow shop structures, the most important attribute of these systems will be one that has multiple resources. - viii -In the job shop models, solving the problems is more difficult than other production systems. Because job routings are different for each order and complicated flows may occur. Scheduling problems with parallel machines con tain both assigment and sequencing decisions. The deter mination of optimal schedules is often returned to diffi cult structures, since both of decisions must be consi dered to solve problems. Chapter two describes the objectives of pro duction planning and control, forecasting demand, master production plan and scheduling. Planning is the activity of determining where a person or organisation wants to be at some time in the future, then developing ways to get there. Types of production planning were divided into three parts as long term, middle term, short term planning. Scheduling and secuencing decisions are the short run planning and control activities. They can be realised in operations level and performed by labour force at the shop. In third chapter, information needs of the management and qualitative characteristics of information such as timeless, relevance and occurancy have been examined. Management Information Systems, its charac teristics has been examined. Levels of decision making can be classified as strategic, tactical and operational levels. Strategic decision making involves the establish ment of objectives for the organisation and the long term plans for attaining these objectives. Tactical decision making is concerned with the implementation of decisions made at the strategic level. Operational decisions are made especially by lower level supervisors. They involve the execution of specific tasks to assure that they are carried out efficiently and effectively. A Management Information System can be defined as a computer information system that can integrate data from various sources to provide the information necessary for management decision making. - ix -Today's managers are forced to be more careful in their field of interests because of changing economic conditions. Especially, the sudden changes of interest rates, the lack of materials, the increase of inventory carrying cost and other similar types of development necessitate, the need for an advanced control mechanism and a faster adaptation rate to these changing condi tions. Nowadays, the actual developments in the computer field and the more frequent use of large scale production planning and control systems. Fourth chapter is reserved to introduce the plant where the production will be implemented.“ Sümerbank Bakırköy Ready-made Clothing Industry Facility ”is established as a textile factory in 1850 with the name of“ Basmahane ve Bes Fabrikası ”. Till 1983, the factory's activity was in the field of fibres and wovening pro duction. That year, the dismounting of the machinery was started and the installation of the plant for ready made clothing began. The new plant started to the production on 1986. There are three seperate workshops in the facility : first is for the production of shirts, second for sport clothing and third for suits. In this study, the shirt producing department is discussed as a pilot workshop. The production is made according to the orders coming from there seperate ways: 1. Directorate of Export of the General Management 2. Directorate of Marketing of the General Management 3. Directorate of Trade of the Facility (for internal market) In a ready made factory, the production starts in the cutting department. Generally, the cutting number is applied 5% excess is a caution against the mistakes on the fabric and the possible loss in the sewing section. All the cut out clothes are transported by the carts to the sewing section. In the facility, there are nine sewing bands; average capacity for shirt production of these nine bands is 550 shirts per day. A shirt is subjected to 50 to 75 different operations depending to its model on the sewing band. In the ready made products, the quality is a selling factor as important as the price. Quality - x -control is performed in every phase of the production. In the cutting department the process controls, at the end of sewing bands 100% controls and before packaging final controls are performed. The shirts succeding to pass over the quality controls are gathered in final proces department, and after the pressing are packaged and submitted to the stores. In the fifth section, a computer program has been developed for the use in the shirt workshop. This computer program produces the bill of the material for every new order and calculates accordingly the ammounts of the needed materials, follows up recordings of the storage, finds approximate standart time for each of the new model and finally calculates production time of the orders. The assumptions of this program are: 1. The ammount of ordes in the order form is fixed. If there will be any addition to the order, a new order form should be opened. 2. Daily working time is 520 minutes. 3. There are nine bands in the sewing department. Average daily output of each band is 550 shirts. 4. The absenteeism rate is 20% in the facility. 5. The facility operates with 85% efficiency rate. 6. The time required in the 100% control for one shirt is two minutes. 7. The labour force is as following: Cutting department = 40 workers Sewing department = 360 workers Quality control department = 40 workers Final process department = 90 workers To facilitate for following the flow of materials, a coding system is developed. Developing this coding system, some properties are as simplified as possible, to minimise the difficulties encountered due to the loose variety and complexity of the materials and raw materials. We can explain the package program as below. When the package is run, first coming is the main menu on the screen. There are four choices in this main menu. In the first choice, there are record add, delete, change and listing choices. xiThe second choice in the mainmenu is a submenu for material management. In this menu, there are forming the bill of material, material requirement planning and storage operations choices. In addition, the list of needed material quantities and storage stocks can be taken from printer. The third choice in the mainmenu is a submenu for calculating the production time of each department (cutting, sewing, quality control and final process). The fourth choice in the mainmenu is for ending the package program. xii

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