Hazır giyim üretim işletmesinde simülasyon kullanımı ve hata oranlarının azaltılması: Gömlek üretimi örneği

Errors, quality problems, time losses, and cost increases in production processes of the ready-made garment sector adversely affect the competitiveness of enterprises. This study aims to develop solution proposals to reduce the errors occurring in the shirt production process of a ready-made garment company. In the research, the company’s data were modelled using the Arena Simulation Program, and operational observation data were utilised. The current state simulation prepared in this context achieved an overall similarity of 97.5% and a conformity of 99.1% specifically for shirt production. The sources of errors were identified as material selection and usage, machine failures, insufficient maintenance, human-related negligence and lack of training, weaknesses in method planning, environmental factors, as well as supply chain and logistics problems. Within this scope, solutions such as preparing digital models and marker plans, as well as printing labels/barcodes on product parts, were proposed. In the improvement scenario, applications such as digital marker cutting and labelling of parts were simulated, resulting in a reduction of the defective shirt production rate from 17% to 0,4%. The findings indicate that simulation-based process improvement provides significant contributions to enterprises in reducing costs, improving quality, optimising resource utilisation, and increasing customer satisfaction.