@rgeMAS System With The Eyes of Engineers

Could you briefly introduce your company and yourself?

My name is Sinan Çalışır. I work in Ünlü Tekstil. Ünlü Tekstil has been around for over 30 years.Provides service in the ready-to-wear garment industry and continues its work mostly in the field of weaving. I worked as a manager in the production engineering department for about 8 years.Then, I continued in the field of production planning for 2 years in the’production planning and control manager’ position.Currently, I continue my career in Ünlü Tekstil, with a managerial position in the productivity department.

You are a company with approximately 1300 employees in two locations. How do you keep track of this?

Honestly, it is a very difficult process to keep track of 1300 employees in productivity and other areas.You definitely need to manage a system that will not allow any coincidence and black order to work.In that sense, we ensure the follow-up of internal employees on various issues with the @rgeMAS system.

Who are your customers? Can you give some information about your supplier position according to your customer?

We serve very big brands such as H&M, Tommy Hilfeger, Lacoste. We also have a very valuable position with our customers.In particular, we are a ‘key supplier’ on the side of H&M. In other words, we have passed to an organization where the responsibility is left entirely to us. The customer just places the order and does not interfere with anything else.

What are your views about production management? How do you think production management should be?

People can have very different ideas about production management. There is a point here. There is an old-style organization in production, which we call the black order and you cannot go much further in this order. Because your internal control mechanisms are reduced.You can keep numbers on paper, it is not known how right they are. In production management, some managements should be made more data-oriented. I believe that systems must be included in management.

How many years have you been using @rgeMAS as a production management system? Can you give some information about this system?

Of course… As Ünlü Tekstil, we have been using the @rgeMAS system for 11 years. This system is a barcode and RFID based system.It uses both technologies. In addition, it is a system that allows you to access all types of data in production.In other words, we use it in terms of both efficiency and quality, machine maintenance, etc. In addition, it is a system we use in our social responsibility projects.

As you stated, you receive a lot of data from @rgeMAS such as efficiency, quality and performance, and you get many reports. How do you use these reports?

Today, management with data is an inevitable issue.You also need to be able to evaluate these datas very well.While these datas are being collected, it should be collected by a reliable system in the same way.In that sense, we can get all kinds of reports from @rgeMAS.And we use these reports in our internal works as well.It is very important to evaluate the reports after they come to us.Since these reports show us the lowest quality points, for example, in terms of quality, we can increase our quality rate to much higher levels with point interventions to these poor quality points.We receive support from @rgeMAS in order to reveal the reasons of inefficiency of the inefficient personnel in the productivity studies. And we continue to work on their elimination in the same way.

Also, in production, you use the bundle system, unlike the classical methods. Why do you prefer the bundle system and what are its advantages?

First of all, I would like to say that organization is a very important concept in every aspect of life.The bundle system, on the other hand, allows the production to continue by dividing the work into certain bundles and groups rather than carrying out the work one by one.Due to the nature of textile, we cannot divide the operations into equal periods in the productions you make one by one. And for this reason, it causes delays in the line.With the bundle system we have developed, we can prevent very small waits in production. We can minimize this internal source of inefficiency. And we ensure that employees continue to work more regularly.At the same time, dividing the internal work into bundles, means some groups, also helps to measure the amount of work done on a personal basis. In addition, we have the opportunity to receive and evaluate our datas much more accurately.

How has productivity and quality changed since you started using @rgeMAS?

Honestly, it is very difficult for us to identify the source of inefficiency in the works in the old layout. In the studies carried out in the old organizations, we find it difficult to determine at what points the internal employees were unproductive.Employees at which points, there may be work waiting behind, the machine may be malfunctioning, or there may be lost times due to a repair they have made, when we do not see such disruptions, when we cannot get it in terms of data, we have difficulties in managing them.For this reason, after the new layout we had great gains in identifying the sources of inefficiency. And we started to have quality data that we could not normally keep on paper and on other systems.In this way, @rgeMAS actually enabled us to do our main job, as we were able to research the operations that made the most mistakes and the methods for their elimination, and focus on them, means, we spend more of our time not on collecting data, but on correctly evaluating the data presented to us by @rgeMAS.

What is your quality control and assurance system like? What do your customers think of your quality control and quality assurance system?

Honestly, I can say this.When we told our customers that we have such a system when we presented our quality assurance system and what we did inside, we were met with great admiration.At the point we have reached, poor quality has been a coincidental result for us, since quality works according to a system.In other words, since it is now a system to ensure quality, it has definitely reached the levels where it should be.Of course, there may be points where we have problems in terms of quality.But at least, by detecting them much earlier, we have reached the level of detecting and eliminating them thanks to this system ,@rgeMAS system.

What is the line balancing optimization among the modules developed by @rgeMAS? And how do you evaluate such a development in terms of production future?

I can explain it this way.As a matter of fact, in textile, the most important issue in manufacturing is to give the right operation to the right person.When you solve this, you can solve about 70% of the job.Giving the right operation to the right person, especially in the current textile life, I do not say this with underestimating , of course, they do very valuable work, it is a process that is done based on the experience of the foreman of the line chief.At this point, what data will provide us is far beyond human memory.I believe that it will bring a great benefit in assigning the right person to the right operation based on the operations performed by an employee in the past years, the efficiencies they perform in this operation, the efficiencies it provides, how often and how efficiently it performs this operation, as well as the quality performances of even the quality data in this operation. In this sense, I can say the following.Because now, when you reach very large number of people in very large productions, you can no longer recognize people. Or, after seeing the operations of a newcomer to your factory, you can add it to the pool very quickly.Therefore, I can easily say that; Now,in the future of textile, there will definitely be data about assigning the right operation to the right person.Those who evaluate this data correctly will be able to win.We can definitely get this in perfect condition by the way of software.I believe that @rgeMAS has provided this very well.

You give bonus to your employees. How do you pay the bonus? How does the bonus affect the productivity and motivation of the employees?

At this point, of course, employee compensation and its management in business life has become a very important issue.You can try to increase productivity with many different methods inside, but I believe that the most positive and necessary and the only indispensable one is the bonus system.Because if employees can be paid at the same time in proportion to their contribution when they are productive, their belonging to their work will increase and you can always have a certain efficiency inside.I consider the bonus system as a gain-gain system.Also,the company gains a profit from its overproduction due to the work done inside.And the purposes of the establishment are this way.And when it is evaluated with these bonus rates, which are reflected in the wages as a result of the productivity work done by the employee in the same way, the employee is also satisfied with this.His work affiliation has increased, and he is seeing to be more productive by eliminating internal sources of inefficiency. In this sense, we can reward quality work in the same way by linking the bonus system with quality data. To work more efficiently ,the employee does not miss the quality as well as  quality in this way.

How do you ensure product traceability?

As a result of my studies in terms of planning, I realized that traceability is very important. Because, like other companies, we are a company that competes with time.Especially in this sense, it is very important to see the data instantly at what stage the product is at, when it is finished on the production lines, how much of it is processed in which processes in the finish.It is also very important to evaluate them. In that sense, we provide internal traceability with the @rgeMAS system.In production, we follow up with bundles, means with the basket system, as 20.In addition, we have a data matrix system in which we follow the products one by one in the finishing part, i want to say, in the final ironing quality control and other stages. And we provide follow-up of the products one by one.

Do you do kaizen studies on efficiency and quality? How do you do this?

Of course.Honestly,we evaluate the data recieved from the system we use here, periodically in terms of quantity and on a daily basis in terms of quality.We identify the worst 5 operations on a daily basis and work on them.We are thinking about how we can prevent them.And we share them daily with the friends responsible for this work.And thus, we have been able to provide this on-site and solve it before any poor quality occurs.Besides, I can easily say this. As a matter of fact, let’s say there are 50 or 40 different operations that create a product inside the line.In this, the source of poor quality can be detected very easily, 50% – 60% of the top five.In other words, when we eliminate the poor quality in 5 operations, we can actually ensure the quality of the product at the rate of 70% – 80% in a very strong way. As I said, as a result of the reports we received from @rgeMAS, we focus on them and eliminate their poor quality.

I would also like to ask a question in terms of social compliance. Does the working operator have easy access to a senior management?

We receive special support from the @rgeMAS system in this regard. Thanks to a barcode available in the @rgeMAS system, employees can read this barcode whenever they want and automatically send an e-mail to the top management.In fact, we established this system using the module where we measure efficiency, quality and traceability.Thanks to this e-mail sent, the senior management can call the relevant friend and listen to the dissatisfaction or satisfaction of the employee about the job or other issues.This also provides:When he has a problem with the line chief, the foreman and the production manager,can easily convey it to the top management.Since it is an independent system from them, we see it as a system that increases the satisfaction of the employees in terms of social compliance in the same way.In addition, we have inquiry studies in general. We are also considering getting support from @rgeMAS in these inquiry studies.If I talk about this very briefly, we organize some surveys on paper for the employees in certain periods.In the same way, we have a system idea that if we want daily on the system, they accumulate in the system via the terminals in front of them on a weekly basis and then they are reported from there.I believe that @rgeMAS again will solve this very well.

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

In fact, the concept we call industry 4.0 has just entered our lives now. I can easily say that since the beginning of @rgeMAS, we have already been using the system, whose name is not industry 4.0, by collecting and evaluating internal data for 11 years.Industry 4.0 is important in this aspect, we no longer waste time in collecting data. @rgeMAS enables us to access these data easily and by pressing a single button on the computer.At this point, we will be in a position to benefit from all the blessings of industry 4.0 with the automatic line installation project in the same way at the point of evaluation of this data.In other words, it is very easy to collect this data and with one click, it is now on our computer, in front of us.We now spend most of our time evaluating and improving data.And I think that we will come across a @rgeMAS system that is included in the decision structure that evaluates this data with projects such as automatic line installation.

There are some applications in the form of data collection directly from machines in a sector such as apparel where manual labor is intense. What do you think about this subject ?

Honestly, collecting data from machines is a very valuable concept, but in a way, it’s a bit of a half. Because there are still handicraft operations in the confection industry. I also think that they should be measured very easily in the same way.Because, sometimes, a regulation process we do inside or a boot process we do in manufacturing connect the next machinists.It can also cause them to wait.I also think it is very important to measure them again.Because these are also a part of production and at the same time, they constitute a cost in terms of labor costs.Of course, collecting data from machines can be useful areas, but I think it is not right. Because in the confection industry, it is seen that 50% of the operation is done by hand, 50% of it is done by machine, including the operation of wearing a collar or a sleeve on the forehead. Collecting data from the machine at these rates may not always give right results. My opinion is that in case of a malfunction that may occur during the operation, such as leaving it unfinished, the bobbin ended or the machine malfunctioning in a different way, the data received will not give right results.That’s why I think that this data should be collected in a much suitable way.In other words, I think that this data should be collected with a much suitable system, rather than a half system, even if it is implemented completely correctly.

Supposing that in a Ünlü Tekstil there is no like  @rgeMAS production management system datas, what would be a change for both you and your employees? Could you do your job comfortably?

Honestly, I can say this. Together with the @rgeMAS system, we have gained a management approach in our lives, not to collect data but to evaluate them. If the @rgeMAS system had not been included, we, as the management, would have spent more time collecting data and evaluating some unhealthy results.In that sense, @rgeMAS has been of great help to us. Without @rgeMAS I think a factory of this size is absolutely unmanageable.

Would you recommend @rgeMAS?

Of course, I recommend @rgeMAS to all other businesses.

Is there anything you want to add?

Finally, I would like to add: Today, without data, unfortunately, there is no production understanding either in the production area or in all other business areas.That’s why I would like to express my gratitude to @rgeMAS, who provided us with this data in the most accurate way.And when we look at the benefits it provides to us at the point of evaluation of this data, I would like to thank the @rgeMAS team, who have supported us in every project until today, opened our horizons in these projects, and completed the missing parts.

We also thank you.