Project Success Story Erak Giyim @rgeMAS MES (Production Management System)

Could you briefly introduce your company and yourself?

Of course, our company was founded in 1984 by Sait Akarlılar. We have been producing denim since that year. We are the main manufacturer and besides, we have many big overseas brands in our Çerkezköy factory situated in Turkey and we continue our production in many subcontracting points in Turkey, as well as in our factories in Egypt .Our annual production is around 7 million.

How many workers do you have in production?

 In production, 1200 people work in our own locations of Turkey. 900 people work in our factory of Egypt.

You are using @rgeMAS as production management system. How many years have you been using this system? What kind of system is it? Can you give some information about the system?

We started working with @rgeMAS 8 years ago. Before we started working, we were making our productivity measurements via the production program we are actually using.Of course, this was returning to us with a loss of one day. This is ,as we have observed, a critical issue for us . That’s why we decided to work with @rgeMAS.

In which departments do you use it?

We use it in the cutting, sewing, washing and packaging sections of production. At the end of each point, we evaluate it at the quality control stages.

What did @rgeMAS add to your company?

 When we first started with @rgeMAS 8 years ago, one of the most important contributions to us is the timely evaluation of data. Precautions were taken on time. Previously, we were performing our productivity measurements in our old system, and we were recording a day later. This made us lose the following issues.The low productivity of the person while making a transaction reduced our number of that day, our quality that day, and our productivity that day. @rgeMAS has added a great value to us at this point. Because we can measure efficiency in a short time and interfere in our personnel and production stages in a short time.We can see the number of operations based on the two sections and make an evaluation according to it. In the next stages, the biggest factor was in terms of personnel motivation.It was in two quality stages. And at the end of the day, of course, the cost that will keep all companies afloat. It was helpful in seeing our costs and measuring our operations.

Which changes has been lived in the development by evaluating the  human resources ?

Now we have thousands of employees related to human resources. One of the most important issue in the departments where we measure in these production departments is to reward the personnel who work well.

Here too, the bonus stepped in , so after we made our productivity measurements with @rgeMAS, we made our evaluations and rewarded our employees who worked well with a bonus. This motivated other employees.It enabled us to better motivate our employees with poor productivity by showing them efficiency measures.  Then, with the suggestion of our boss, we first evaluated our personnel who performed a single operation. We have taken their efficiency to very high levels. What did this make us win? In total, it caused an increase in operating efficiency.This reflected to us as quantity, this reflected to us as quality. Because the quality of those who performed a single operation was higher.We also made an application like this. In our company, a certain amount of workers from İŞKUR was provided within the scope of a project. We included these colleagues in productivity. During this period of six-month ,we offered employees with good Productivity to stay in our company. The ones who accepted stayed with our company and continued.

You said you’ve boosted your productivity. Can you talk a little bit about quality? Because you said that you also follow the quality with the @rgeMAS system..  

Now, the personnel know that their productivity is followed in a short time by number. For this reason, they are trying to increase their numbers. Of course, increasing the number means reviewing the quality. At the end of each section, in the quality control, how many products that person made that day were stuck on that quality, the number of people who stuck to the quality decreased from the person’s efficiency. This has provided us with a resource for the personnel to do the job properly from the  beginning, to do it in a shorter time and to do it with quality.

What looks your quality control and assurance system like? What do you think of your quality control and quality assurance system?

Inside of @rgeMAS software there is a quality control module at the end of the chapters. In other words, so that the quality of people can be measured not by the pieces they make, but by the pieces they do right. When all the other customers working with us come and visit our company, the fact that they see the productivity measurements of the personnel within the company and the evaluation of the bonuses given to the personnel at the end of this efficiency provides a positive aspect for us to choose us.

You’ve been using @rgeMAS for a long time. Can you get technical support?

Yes we can and they are sincere about this topic.

When you have a new request. Because it is a local company. How is this evaluated by the company?

They analyze more than we do. One has to do with their suitability for their infrastructure. The two are related to what they will add to us in the future. We can make an example like this. There is an automatic integration between our current production module and @rgeMAS. In other words, the systems work integrated without the intervention of the users. Information flows integrated. It is transferred integrated, including the information that will create many official records. This is a building with collaborative work.

You are not using it yet, but automatic band installation, which is among the modules developed by @rgeMAS. How do you evaluate this in terms of the future of production?

The world is going to smart systems. By looking at more statistical data before you, it goes to more accurate structures, autonomous structures. We can also look more warmly to this type of structure. It may be more positive for our personnel to evaluate the statistical data of the systems on a person-to-operation basis over a long period of time and to make comments before us, rather than the emotional or previous experiences of our personnel.

How do you ensure product traceability?

Of course, we provide product traceability through barcodes on bundle bundles.

Thus, We can provide tracking of pieces   in production such as :at what stage, which bundle, on what date, who made it, where did it go from where?

Do you do kaizen work on productivity and quality improvement? And how you do it?

we do. Because we have a historical data with the software. We analyze and evaluate this data. We make other comments on that evaluation.

Could you share your experiences about Industry 4.0 and lean production?

As I mentioned before, this structure that we started with @rgeMAS, which we started 8 years ago, means that we have already established industry 4.0 8 years ago. Of course, at this stage, there were many innovations that we carried out together.

We have done our measurements and evaluations very well here. Plus, we have done something that is not available in any other industry. First, we automated the washing sections. In other words, we are getting the duration of the washing tubs. We have been measuring the productivity of the personnel in sewing. With Industry 4.0, we were able to better position and analyze them.

There are a number of applications in the garment industry to collect data from machines. What do you think about this subject? Do you think it is suitable for the nature of production?

Yes, it is a method suitable for the nature of production. Just like my example. There are concepts such as the chemical puttings into the washing tubs, the temperature of the water in the tub, the speed of the tub spinning, and how long that operation should stay in the tub. This is definitely important for us to collect and evaluate information from the machines with the system. Let me share with you one of the most stable examples we have experienced. We have hundreds of washing tubs at our disposal. We measure the efficiency of these washing tubs. Its productivity is also roughly how many hours a day it worked, when it stopped, when it started, how many hours it worked. Thus, we can warn and inform our workers and department managers about this issue.

Would you recommend @rgeMAS?

Yes, I recommend @rgeMAS.