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Model Factory Development Projects

 

The Model Factory can be defined as a tool (a competency center for common use) that enables enterprises to disseminate operational excellence principles in a scalable manner by using experiential learning techniques.

The most basic feature that distinguishes Model Factories from other centers established to increase the efficiency and competitiveness of enterprises is the use of experiential learning techniques. As a result of combining theory and experiential curriculum, it is aimed to make competence gains permanent.

Model factories have been established by us in Bursa, Gaziantep, Kayseri, and Mersin, where the Ministry of Industry and Technology- General Directorate of Industry and Efficiency, the United Nations Development Programme, and the Chambers of Commerce and Industry are partners. The execution of Turkey's original, local and national Competence and Transformation Centers (Model Factory) projects were carried out under the leadership of UnoPro.

Model factories involve experiential learning, unlike other consulting models and theorical trainings. As the famous philosopher, Confucius said, "If you say, I forget, if you teach, I remember, if you include me, I learn" which supports the holistic applied teaching methodology in the model factory. Participants of the workshops become capable to apply the tools they have learned in the workshops immediately after learning them. They become competent individuals by applying lean manufacturing tools or operational efficiency tools in their businesses under the supervision of model factory mentors. The model factory, which is based on experiential learning principles, will make people's experiential learning competencies permanent and increase their competencies and achievements in the long term.

Within the scope of this program, you can start the lean transformation process by applying the training curriculum (roadmap) in your own business that we have prepared especially for the lean and digital transformation of the industry.

With this roadmap, you can eliminate waste by first simplifying your processes and then digitalizing your system according to Industry 4.0. Going digital without simplification means having an inefficient, wasteful expensive digital system.

In short, we can realize the simplest and most efficient manufacturing most economically and establish a production and management system. You can gain flexibility, cost, production rate, and delivery time advantage over your competitors and gain priority in the eyes of your customers.

Phases of the Model Factory project are handled in 4 stages as explained below;

  • The preparation and identification phase begins with product selection. After product selection, prototype product trees and workflows are created so that the machines and technology required to produce the product are determined.
  • CAD designs are made by customizing the selected product.
  • Prototype of the product is produced according to CAD designs.
  • After the prototype production, offers are received for the necessary machinery, equipment, and assembly stations.
  • Traditional production scenarios, traditional state factory layout, and prototype value stream map are created.
  • The machines are commissioned, the facility is established, and prototype and pre-mass productions are carried out.

According to the production system, the training curriculum and the applications of the subjects in this curriculum in the Model Factory production area are developed.

  • Theoretical trainings are given to Model Factory trainers in classrooms, and their applications are made in groups at the production site.
  • The transition process from the current state to the lean state is experienced with scenarios, and the trainers are allowed to learn about the transformation.
  • The most basic feature that distinguishes these trainings from the trainings of other centers established to increase the productivity and competitiveness of the enterprises is that they combine theory and practice by using experiential learning techniques and thanks to making their competence gains permanent

  • Identification of the enterprises where the project will be implemented is carried out and a list of factories is created according to the determined criteria.
  • The companies that will start the work are selected from this list.
  • Groups of trainers and business employees are created to carry out lean transformation studies in selected companies.
  • Groups start their work in companies.

  • The digital transformation maturity level of the company is determined to construct digital transformation studies in the selected companies within the scope of the project.
  • As a result of the maturity level determination, the points that are open to improvement are determined in order of priority.
  • Value Chain Optimization through VSM 4.0 – Value Stream Analysis and Design for Industry 4.0
  • In addition to the Model Factory lean manufacturing training curriculum, special applications including the following topics prepared to support the digital transformation of these trainings, are given to the companies selected within the scope of this program.
  • MES (Manufacturing Execution System)
  • Pick By Light Application
  • Material Flow and RFID Application
  • Kanban Card / Shelves
  • Smart Wristband App
 

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