Akademik Veri Yönetim Sistemi
5. INTERNATIONAL ÜSKÜDAR SCIENTIFIC RESEARCH CONGRESS, İstanbul, Türkiye, 22 - 23 Kasım 2025, ss.259-273, (Tam Metin Bildiri)
This study focuses on the application of the Kaizen methodology to reduce scrap levels in an aluminum coil coating facility. In modern manufacturing environments, controlling scrap is crucial not only for cost reduction but also for improving energy efficiency, process stability, and overall sustainability performance. Within this scope, the current scrap structure of the facility was analyzed, and according to ERP system data, “pre-process coil sorting”—the second-highest scrap category—was identified as the primary target for improvement.
Root causes related to this scrap type were examined using a fishbone (Ishikawa) diagram, which revealed that adhesive labels applied to coils prior to the annealing process undergo chemical degradation at elevated temperatures, leading to surface deformation defects. To statistically assess the problem, a p-control chart suitable for the categorical nature of the data was employed. The defect rate was found to exceed control limits, indicating that the process was not statistically stable and that label-induced defects represented a systematic issue.
In line with these findings, an industrial laser marking system was integrated at the mill exit, eliminating the need for heat-sensitive adhesive labels. The QR-based laser marking method prevented surface deformation entirely and removed the necessity for pre-process coil unwinding. Following implementation, the plant achieved monthly savings of 1,593 USD and annual savings of 20,316 USD, demonstrating substantial economic and operational improvement. Overall, the study highlights that the Kaizen philosophy can generate rapid, effective, and sustainable enhancements within industrial production processes.