Calculation of Efficiency Rate of Lean Manufacturing Techniques in a Casting Factory with Fuzzy Logic Approach

Sectoral growth is increasing day by day and the competition market is growing with it. At the same time, customer awareness is also increasing. As customer awareness increases, the quality of service provided should also increase. One of the ways that companies will apply in order to maintain their existence in this competitive environment and to prevent customer loss is to make the lean manufacturing philosophy a corporate culture. It is a production approach that does not contain any unnecessary elements in the lean manufacturing structure, minimizes waste and aims to increase efficiency in production. When moving to the lean manufacturing philosophy, it is of great importance for companies to draw a correct road map. This study was applied to the product/product group produced in a foundry. Value stream mapping (VSM), which is one of the lean manufacturing techniques for the determined product/product group, was made and the current situation value stream map was created. With value stream mapping, bottlenecks and losses in the process were determined and a future situation value stream map was created. Lean manufacturing techniques were applied at these determined points, problems were eliminated and productivity increase was achieved in production. Fuzzy logic was used to clearly determine the productivity increase. Fuzzy logic creates numerical models by imitating the human mind many vague, non-numerically expressed terms that we use daily. With fuzzy logic, the efficiency rate was modeled numerically and the contribution of the lean manufacturing techniques applied to productivity was determined.