Hello, could you briefly introduce yourself and your company?
Hello, my name is Engin Kaya. I am the General Director of Görkem Giyim Sinop Factory.Established in 1977, our company manufactures women’s outerwear for customers around the world. Our production adventure, which started in a small workshop in Istanbul, continues today at our headquarters in Ataşehir and at our production factory in Sinop. Together with our production partners in Istanbul and Anatolia, we produce approximately 600 thousand pieces per month.
Who are your customers?
Our customers are international brands such as H&M and Zara, which have a large number of customers all over the world.
What are your visions on production management? You have been practicing management for many years.How do you think production management should be?
In our opinion, production management should definitely be easy and understandable. We think that each section should be at a measurable level without any blind spots.And at the same time, we think that production management should be strictly and definitely kept with real-time instant data.And in line with our requests in this direction, we found @rgeMAS by researching. We are currently running a project together.
What did you consider when deciding on the @rgeMAS system? For how you think it should be,did you prefer @rgeMAS?
We had a productivity program that we used before @rgeMAS.However, the productivity program we used was a non-real-time productivity program such as collecting barcodes from the field and reading these barcodes, means that, we accessed today’s data at 11:00 am at 12:00 am the next day. And now, in an environment where competition is heating up and pricing is so heavy, this system did not seem sustainable to us.That’s why we wanted a system that is more suitable for real-time technology, which can give us instant data and where we can go instantly and interpret and interfere in production, so we agreed with @rgeMAS.
You started this project about 7 months ago. With the @rgeMAS system, you receive software, hardware and consultancy services. Can you briefly describe this process?
First of all, we looked at how many years Arge Bilişim company is. Because something like this, you buy software, but after you get this software, you can’t see the continuation of this software.Unfortunately, we have experienced these in the productivity software we used before. It was not a system that lived with us.But when we look at the companies that @rgeMAS provides consultancy on production, we see that they are famous companies and it is a company that has been in this business for 30 years and constantly improving itself. And that’s why we started working with @rgeMAS.
Currently the project is not completed but can you give some information about @rgeMAS system? What data does it provide you?
@rgeMAS definitely gives us instant data from the field.It provides real-time data at any time of the day. It also provides real-time quality reports from inside the factory and production.It provides quality traceability. At the same time, we have a very serious remaining traceability within the factory. In every sense. We are able to track each product and every one of it in the factory.
You said you received many reports from @rgeMAS. Which reports do you use, especially as an administrator?
First of all, after starting to get real-time reports, we lived some troubles,we immediately interfere in bottlenecks with our production team.We can analyze what the problem is, what kind of problem there is with the personnel, whether there is a problem with the equipment, or if there is a problem with the work being done, and we can interfere immediately.If there is a problem, we can see it instantly, not after a day ,or 2 hours and 3 hours, and we can interfere. Both in terms of efficiency and quality.
Could you also tell us about your efficiency measurement and improvement mechanism? There is an inefficient operator, what kind of works do you do about it?
After @rgeMAS, we are having a meeting around 9 means with our engineer staff about what to do about the inefficient operator, that is, after we go back to work.Each engineer carries out follow-up studies on the personnel with the lowest productivity in his area of responsibility.If we do not get results in short follow-up studies, then we do long follow-up studies.In the long followup, our engineer friend follows our staff for about an hour.Is he having a problem with the machine? Having trouble with general business? Or if there is a problem that affects his efficiency, if there is a problem that disrupts his method, we see it there instantly and go there and describe it again as a result of a long follow-up. We interfere again. This is how the process works.
You are using a bundle system, different from the one by one mooving production. Why do you prefer it and what its advantages?
One of the biggest reasons why we prefer the bundle system in production is that we do a fast fashion. In other words, we enter 2 thousand, 3 thousand, and 5 thousand jobs.If there are about 6-7 sections at the stage of layout building, such as collar, pocket, sleeve, front size, back size, etc., you need to install each section at the same time when installing it in a non-bundle system.And it has to be finished at the same time. In the old system, we need too many experts, too many technicians, too many organizations. But the bundle system has a big advantage that it provides us.Since all parts of a product are placed in a single car in the bundle system, line entries are now entered from a single point. Since it is entered from a single point, we gain enough time to line preparation.And thanks to this, our lines do not break, I want to say in the transition between two models, which is one of the situations where we have the most problems.We are now able to make our new model come out within an hour, behind an old model, without any break in model transitions.In the past, it used to take a day and a half to come out the new model without @rgeMAS.Now we can connect and release our models fluently, regardless of their number.
How has productivity and quality changed since you started using @rgeMAS?
There have been some changes in efficiency.Since we have switched to the bundle system, the waits that we could not see in the system that was operating one by one, means the waits when people are working by hand, have now completely emerged with the bundle (car) system.In other words, we have prevented unnecessary stocks for those who have a short period of time and make too many pieces.From stocks, I am giving an example in a part of the line, while a part of the product did not reach, on the other hand, we prevented the accumulation of 1000 or 500 stocks from another part with the bundle system.Now we are establishing a more fluid, more balanced line. At the same time, this system allows us to take not necessary operators from the line.
How did the presence of @rgeMAS system in your factory affect your organizational structure and supply chain?
There are some obligations that @rgeMAS has brought to us with the bundle system. What are they?We have now started to query our Istanbul-based fabric supply.We started to work with our center about the need to do the model phase more quickly and to get the manufacturing approval faster.@rgeMAS disciplines us in every way. At the moment, together with @rgeMAS, we will eliminate situations such as the timely arrival of the fabrics and the timely arrival of the accessories so that the back of the line will not break.
The installation has not been completed yet, but after the system is installed, how much of an efficiency increase do you expect in quality and efficiency?
We are very new to the project, but according to our studies, we expect a 15% increase in productivity and a 25% increase in quality. And we will definitely provide that.
How do you evaluate the ‘assignment optimization’, which is among the latest modules developed by @rgeMAS, especially considering the future of production?
There is an elegance in assignment optimization.Of course, due to human nature, we cannot keep a very serious amount of data about what operations an employee has done before, or what his efficiency is in operations, or what my quality efficiency is in the operation.But in assignment optimization, we can now go back and see how efficient that operator was in that operation and how much he did. We can automatically install and view our lines without the need of human intervention.This is a revolutionary module for us, not just for us, but really for manufacturers.Of course, as data entry increases in the system, I think it will become more efficient. The more data it collects, the more efficient it will become. Today, our data is incomplete because our project is new. We are maybe at the 60% level in assignment optimization, but as our data increases, this will increase to 80-90% in the future.
How do you ensure traceability? Could you tell us specifically about the 2D barcode you have applied?
With the 2D barcode application that @rgeMAS brought to us, we have now given each product an identity.In other words, when we open any paket from our packaging department and look at any work today, when we look at any work, from which lot this product was cut, by which cutter, by which labler has processed labbeling , by which classification worker it passed, by which operation in the production and on which day and at what time, who carried out the quality control. , information about who did the last ironing is currently being reported.And that provides us traceability.This made us earn fairness among the employees. Before applying the 2D barcode system of @rgeMAS, for example, if 5-6 people were doing the same job in the line, if there was a repair before, for example, if 10 came, we would distribute it in twos.And thanks to this 2D barcode application, we can now see who did the repair and who did it by point shooting in heavy operations that we had 4-5 people do in the line, on which day and at what time.This time, the person who hasn’t really done the wrong operation will be unfairly affected by this work. But now, whoever made this mistake with the 2D barcode application, it goes to him with a point shot and the one who makes the mistake fixes it.And if a training is required for this error, we provide training to the operator. This also significantly affects our quality.
You are making an application about making the used machines ready for use in model transitions. Can you explain this a little bit?
In layout setups, we can describe jobs to approximately 15-20 people in a day in the bundle system. Among these 15-20 people, the average time for a new job from one operator to another operator is between 20 and 30 minutes.We position their machines, prepare their equipment and adjust their settings just to describe the job to the operator during this time.Since we intend to spend this 20-30 minutes as much as possible by describing the job to the operator and checking the work done here, we enter into a serious machine preparation before.And we number them. During the operation, we try to remove the old machine and place the prepared machine and perform the layout preparation as soon as possible.
In the confection industry, there is data collection from machines, it is counter application. Is it a suitable method for this sector where manual labor is intense? What are your thoughts about this?
First of all, we do not find the counters on the machine absolutely right. Already before @rgeMAS, many companies came to us and presented us projects on installing counters in machines.But we don’t think it has much functionality.First of all, we do not think that the lost time periods taken from the counters are correct.When you look at it logically, it is requested to calculate this over a given time to the counter.We think that this is very true, especially in labor-intensive industries like ours, which will not reflect the truth, as many problems will arise.Therefore, we certainly did not enter such a process. We don’t think this is right. I would not recommend the counter to anyone.
Considering if Görkem Giyim didnt have a production management system like @rgeMAS, what would change for both the employees and you. Could you do your managerial duties comfortably?
We entered such a project with @rgeMAS because we could not do our managerial duty comfortably before that.Because @rgeMAS make us earn that. First of all, it promises to come to the workplace in the morning with your employees for the same purpose.How is this achieved? This is provided by the bonus system. Now, sometimes we cannot get enough efficiency from our employees in today’s customer requests. We are now trying to take it in a more functional and scientific way together with @rgeMAS. And it made us earn it.
Is it possible to manage your company without data? Is this sustainable?
Absolutely not. Especially in large-scale factories employing 500-1000 people, it is up to your chance to be successful in this business without the data that you can access instantly,and i dont think it can be possible to give the right price and the right time to the customer in the newly emerging competitive environment.
What kind of consultancy support did you receive from Arge Bilişim?
We have received very serious consultancy support from Mr. Hulisi since the beginning of the project. From the stage of establishing of cutting to preperation, from preparation to the establishment of my bundle system in production, to the establishment of quality systems.Well, we are people who have been in the kitchen of this business for years, by nature. But together with Arge Bilişim, we got at least as much knowledge about efficiency as an industrial engineer.We received and continue to receive serious consultancy support from Arge Bilişim about how a business should work, how to minimize lost time, how to improve quality at quality control points, and how this data should be collected.And my favorite feature of Arge Bilişim, @rgeMAS is definitely not a software program but a living productivity program.living with you ,adapting to your problems immediately with the software team,a software system that adapts to your company.We are coming to the end of our project, but I am sure that our relations and working principles will continue for years, as for the previous customers of Arge Bilişim.Because we, together with our team, are truly amazed by the traceability that this system brings to our factory.That’s why we would like to thank Mr. Hulisi first and then you.
Would you recommend @rgeMAS?
To everyone who really produces on this scale, to managers who are not at the head of their factories, if you want to see your entire factory in a computer, wherever you are even from afar , you definitely and definitely need to buy and implement it. We recommend it to everyone we know, as it has been done to us. We met with Arge Bilişim on recommendation. Its a good thing that we found it and now we continue. We are very happy about this now.
Is there anything you want to add?
Now, in today’s customer demands and difficult market conditions, and now the customer says, in cases where he/she says, “I’m costing this job for this minute in Bangladesh. In Turkey, I have to cost accordingly and I have to give my price accordingly.”You no longer have a chance to provide them without using a productivity system, without using a productivity system like @rgeMAS.That’s why, no matter what, large factories of this size definitely and definitely need to have an efficiency system.If they want a real-time system, if they want to follow the quality, efficiency, internal mooving, and the sustainability of the products, I can say with peace of mind that they should definitely work with Arge Bilişim.