Founded in 1995 as a small furniture shop in İnegöl/Bursa, Çilek now conducts its production activities in an indoor space of 33.000 sqm and a total space of 212.000 sqm by using high-tech German machines and employing the Japanese Lean Manufacturing philosophy.
Çilek is capable of manufacturing 20 different products in a day in two shifts with a daily product capacity of 1.200 items.
In its production process, Çilek uses state-of-the-art technology computer-controlled CNC machines.
Lean Manufacturing System
Lean manufacturing activities were commenced in April 2008 by the project team organized under the consultancy of Professor Bülent Durmuşoğlu from Istanbul Technical University.
Lean manufacturing system, at least the source of customer demand, as soon as targets are met cheaply and be without a fault. Lean manufacturing system aims at fulfilling customer needs with minimum resources, in the shortest time possible, at the lowest cost, and free of fault. In other words, it means just-in-time manufacturing in smaller batches and in a broad array with zero error.
As a result of lean manufacturing principles:
- All production processes were reviewed by the lean manufacturing team. Value stream maps were prepared; product families were identified; a drawer cell was established as the first production cell.
- In order to increase production flow rate in main production lines, machine layouts works were performed; in 2009, 28 main manufacturing machines were relocated.
- As the flow rate increased, product cycle times decreased by 65% from 187 hours to 65 hours. Thus, demands started to be satisfied in a shorter time.
- Internal stocks decreased proportionately.
- As the flow rate increased, 10% (1.300 m2) indoor space was saved.
- In consequence of SMED (Single-Minute Exchange of Die), lot sizes were reduced by 50%. So, without any loss, product range was increased.
- For the purpose of ensuring, controlling and managing internal workflow, KANBAN was commenced in April 2011.
- Continuous improvement is guaranteed with 487 Kaizens in a month.
- Thanks to Total Productive Maintenance and 5S practices, the rate of downtimes decreased from 7% to 2%.
- Product quality was improved by 65%.
- Blue-collar workers were offered Lean Manufacturing training for 70 hours/person in the first year and for 20 hours/person in the following years by Çilek Academy. The objective for 2013 was 30 hours/person (10.500 hours in total) training.
- Each worker performs minimum 1 “applied improvement” (Kaizen) regarding his/her duty.
- In Çilek Teens Room, MilkRun was commenced for generalizing lean manufacturing practices. The suppliers in İnegöl and Bursa (pilot area) were chosen and daily planned shipments were launched.