Lean Manufacturing, Digital Transformation and the Model Factory Methodology

Lean manufacturing consultancy is a transformation programme, structured under 17 topics and applied on the shop floor, that systematically exposes and reduces waste (muda). The Arge Bilişim team measures the starting point with YODA (Lean Maturity Assessment Analysis). It then designs the flow through value stream mapping (VSM), SMED, line balancing, kanban / supermarket, 5S and kaizen work. Targets and success criteria are set per project against the factory's verified baseline KPIs.

YODA is a shop-floor study that assesses your factory's lean maturity on a structured scale. Through observation and interviews it captures the current state under headings such as production flow, visual management, quality, maintenance, material flow, operator competence and leadership behaviour. For each heading it produces a maturity score, concrete findings and an improvement roadmap. The duration of the study and the period of the roadmap are set during discovery according to the facility's scope.

SMED (Single-Minute Exchange of Dies) is a technique used to separate the internal and external set-up steps of a machine or die changeover and to measure the causes of lost time. VSM visualizes the value stream from order entry to shipment and exposes bottlenecks, waiting stock and non-value-adding steps. The improvement target is set from the measured baseline time and the result of a pilot application.

Kaizen is the philosophy of continuous, small-step improvement. On the shop floor it is run through weekly kaizen meetings, A3 reports and short improvement cycles. 5S (Seiri, Seiton, Seiso, Seiketsu, Shitsuke) standardizes the workplace, and visual management makes flow abnormalities visible at a glance; andon boards, shadow boards, color-coded zones and KPI boards are part of this system. Arge Bilişim consultants keep this work integrated with the digital andon and lost-time modules of argemas MES.

The lean transformation programme is planned according to the YODA output and the facility's scope. It starts from a pilot line or product family, and the scope is extended after the results are verified against the baseline KPIs and acceptance criteria. After discovery, a prioritized kaizen calendar, a training plan and, where needed, a digital infrastructure investment are designed. Duration, on-site days and responsibilities should be stated clearly in the proposal.