Thesis advisor: Assoc. Prof. Dr. İkilem Göcek
Student's name/surname: Işıl Yıldız
Supporting organization / Project information: Arçelik
In this respect, the aim of this study was determined as suggesting a road map for the implementation of lean applications and proposing a comparison tool for lean performance evaluation in the apparel industry.
Toward this aim, the road map was suggested to help the companies in determination of which processes should be accomplished. Moreover, a comparison tool was developed, which enabled the companies to assess their current and future position within the lean production implementation in comparison to their previous performances or the other counterparts. In this way, the needs of both the apparel companies dealing with their own performances and the apparel retailers working with many suppliers after a burdensome supplier selection and assessment procedures was tried to be satisfied. Considering these points, the comparison tool was developed in modular structure enabling to make a detailed assessment in terms of many performance indicators and relevant performance metrics generally used in apparel production. Moreover, in case that it facilitated the positioning of the companies, the performance evaluations were made in comparison to the industry standards for the attainable performance levels with the usage of fuzzy logic and fuzzy numbers. The modular structure revealed four different performance evaluation by calculating primary performance score, relative performance score, average performance score and the overall performance score. Thus, the comparison tool allowed to make one general evaluation based on overall performance scores on one hand and it allowed to go into detail in absolute and relative performance evaluation in terms of performance metrics, performance indicators on the other hand.
The verification and the validation of the comparison tool was shown with an application in real case. In parallel with this, the road map planned was executed for the selected apparel retail company. The current and future position of the company evaluated with the employment of value stream mapping, spaghetti diagrams and value analysis. Moreover, line balancing technique and the other lean practices were employed to decrease the wastes in production processes was established. The findings showed that the improvement in the lean performance can be obtained with the implementation of the carefully planned road map. The initial performance and the future performance scores were calculated using the data from the real case and the lean comparison tool.