@rgeMAS System in the Eyes of Manufacturing Managers

Fatih Yurdadon (Görkem Giyim -Sinop- Manufacturing Manager)

Hello, could you briefly introduce yourself and your company?

Hello, I’m Fatih Yurdadön. I have 22 years of textile experience. I have been working as a manufacturing manager at Görkem Giyim’s Sinop factory for 2.5 years. We have been trying to do good work since we came.

Unlike conventional methods, Arge Bilişim recommends bundle system in product movement. Did you have any question marks when the bundle system started to be installed?

We had a similar system. But when the bundle system was first installed, we had a prejudice.After we started using the bundle system, we saw how useful it started to be for us.It has been about 8 months since we started using this system. We have seen a lot of changes in this 8-month period.We found that some of our way of working is reversed, that the new working order is a more accurate way of working.Our project with Arge Bilişim is also going very well. We plan to do better with the @rgeMAS system.

How did the product work in the past, how does it work now? Can you explain this a little bit?

In the past, we used to have our product prepared separately from four arms, namely front, collar and back.Waiting rates were too high. In addition, there were cases where the supervisor was requested in 4 different areas at the same time. And there were a lot of waitings.Now we have allocated enough time to our supervisor in the bundle system. After entering the product from the back, there is a lot of time left until the front. Almost half an hour to describe a job to an operator.We are making good use of this time.At least, we establish and continue it with everything, with its quantity, quality, efficiency.I think this system is very beneficial for us.Compared to the old system, we see that the current system has great benefits.

You listed its benefits, but how did it benefit especially in bottleneck management?

For example, we used a method like this before. We could not measure the competence of the employee. We were looking at this person with the eye of being able to complete the job we gave.With the bundle system, we can see more easily what the operator cannot achieve. And we can balance the line by making moves accordingly. This has been one of the biggest advantages for us.When we work with the bundle system, there is no condition that it will work in a certain place. We can change the locations of the operators. This has been a plus for us.The new bundle system had advantages in seeing the bottlenecks in the same way.We can track it with the car numbers on it. This is a huge gain for us.

Did the bundle system also help in raising jokers?

Sure. We have now reduced the number of jokers (people who perform multiple operations). We used to run 7-8 jokers in the past, but now we can use jokers better with the car (bundle) system.Because we say you’re going to take car number 13 or car number 20 and do it. You will work here between the first hour and the second hour.Or we inform the joker that you will do this job. Plus, something like this happened. For example, if our joker is sewing a bordure, three cars before or after next job, for example, the collar or the cuff, can be sew in the same place.This facility also helped us a lot in solving the bottleneck. We are very happy with that too.The decrease in the number of jokers has also increased our production.

Can you compare your old system with the one after @rgeMAS, especially considering the time losses?

For example, we used to track people’s time loss through their master and it was an extra waste of time for the master.In the current system, we can capture time losses as data. Previously, we could not see time losses as data. In other words, we couldn’t see it properly.Now that people see their working minutes, production minutes, lost time, late card printing, we can track them better.At least we can minimize these time losses. It has now shown an improvement of 30-40% by my calculations. This is an extra production gain for us. Frankly, we’re happy that people are being followed in this way.

You just said that one of your important duties is to describe a job to the operator. How has the bundle system been useful here?

The benefit of the bundle system here is that one product is prepared before the other product is finished.It creates the potential for a wider scope of work when production starts. Since we have more time, we can easily describe the job to the operator and concentrate it.It allows us to explain the job to the operator without panicking. This is a very good thing, I think. That’s why I think we got used to the bundle system fast.I think this positive thing reflects on us very well. Currently, there is a 40% improvement in our line installations compared to the old one. The bundle system has been really helpful to us.

You used to use operators to match parts. Are you using it now? Do you experience parts loss compared to the past?

Let me summerize it up for you. Before the bundle system, we used 8-9 people for matching in the line. But now we only use one or two unless there are very critical points.This is a huge gain for us.We do not think of it as a day or two, and when we spread it over the years, the cost of 6 or 7 employees is a significant amount.At least that’s what we could see.When we use the bundle system correctly, we never use null matchers. We saw that we would add these to production. This is a huge gain for us. It’s actually one of the biggest gain.It’s actually one of the biggest gains. Previously, when a matchmaker could not find a part of the product, he says, ‘I couldn’t find a part of it, my chief’, and we were cutting a new part instead.This resulted loss of production. But not so now. In the bundle system, when the operator buys a bundle, for example, if there are 25 bundles, the employee knows this and it is easy to follow.We reduced the part losses from 70% to 30%. When a piece is missing inside the car, we know where it is.

How do you find that piece?

We use the 2D barcode system as follows. 2D barcode is a system we created with @rgeMAS. When Mr Hulisi came to meet us for the first time, we had conveyed this problem. Mr. Hulisi said that there is a way to solve this and that losses will be prevented.We said yes its possible.Now, the product is identified to the car by attaching a data 2D barcode before it goes into production while it is in form of parts. We can reach the parts inside this car with the 2D barcode.We can easily find out which car the missing piece belongs to. Now our losses have been prevented and it has been a great gain for us.

Do you use the vehicle to transport products?

No, we do not use it. We no longer use the vehicle with the bundle system. For example, as in the past, the situation where “go get me a job from the cutting-house, the back, the iron or that machine shop” has definitely disappeared. This is one of the very good developments for us.Maybe we could be wasting people’s time here. Not so now, everyone knows the car they will work on. He can also see the next car. If I’m doing car number one, I know I’ll get car number two after I finish car number one.Now we sort the cars by numbers. People have become much more conscious now, I think much better things have emerged.I found it very useful for myself. The workload has definitely taken off and that was a huge load.

How do you track the quality?

We draw reports such as quality, quantity tracking, effiency tracking from @rgeMAS. We can also reach the person by scanning the 2D barcode.When an error is out of quality control or final control, for example, three people in the line are doing the same job, the 2D barcode system and the @rgemas system is really very efficient to see who do the work or which error.Two people are doing the same operation and who makes more mistakes we can concentrate on that person.If one made 1 and other 5 mistakes, we concentrate on Ayşe that made 5 mistakes .We can say that this error is made mostly by Ayşe. This also added very nice things to us in terms of justice. Because we couldn’t see it in the past.Ayşe is doing the same job Fatma is also doing the same job.The error comes 6 times we were saying “you make 3 you make 3”.This was not fair.Among the employees consisted of a contradiction.’Yeah I’m doing this job, but this mistake was not mine ‘when we said this question , question marks were created in our minds.With the @rgemas system 2D barcode application, we can stream more comfortably datas, as we can see the mistakes more comfortably, we can give Ayşe’s error to Ayşe or Fatma’s one to Fatma.This is a really nice system because we think it is very useful in terms of traceability.

What reports do you receive in @rgeMAS system and how do you use these reports?

In the @rgeMAS system, we can easily draw reports such as quantity tracking, yield tracking and quality tracking.

Among these reports, we follow mostly quantity  and effiency tracking. This strengthen our one-to-one communication with the employee.Because we can see more easily what people can do at the end of the day and report them more easily. These reports are important for us why they are important for the following reason.We can see our end-of-day targets more easily and faster with the number of tracking and quality tracking reports.

Would you recommend @rgeMAS?

For sure. It is really positive for such large organizations to establish and work with successful systems like @rgeMAS.I think this system is a very successful system for people to really adopt and use this system seriously, to increase their one-to-one dialogue with people and to make them have a trackable system. I would definitely recommend using them.

Is there anything else you want to add?

The @rgeMAS system really has features that can increase the success of a factory management.We would definitely like to hear from you when there is an innovation in the @rgeMAS system. We would be very happy if you share this information with us.We believe that the @rgeMAS system has added a lot to us.