Ahmet Saygı
Production Planning Manager at Boyçelik Metal- Claim this Profile
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Türkçe Native or bilingual proficiency
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İngilizce Full professional proficiency
Topline Score
Bio
Credentials
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QlikSense Enduser
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Six Sigma Green Belt
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UiPath Developer
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Experience
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Boyçelik Metal
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Türkiye
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Mining
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1 - 100 Employee
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Production Planning Manager
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Sep 2020 - Present
• Act as the Production Planning Manager of both Boyçelik (Tube & Pipe Factory, Wire & Spring Factory) and Serko (Pocket Spring Factory) companies• Coordinate and implement comprehensive production schedules for the factories, departments, machinery, and workforces to ensure efficient order fulfillment• Collaborate with the Accounting Manager to develop the annual budget plan and determine sales targets, achieving a budget range of $170 - $200 million• Create accurate raw material purchase requests by updating raw material forecasts based on actual data in weekly, monthly, and quarterly periods• Develop and execute alternative scenarios, including new investments, workforce and machine capacity adjustments, and exploring new procurement methods• Lead ERP modernization and Lean/Six Sigma Projects, effectively organizing and guiding cross-functional teams• Supervise and mentor a team of fifteen employees, including six engineers, ensuring their effective performance and development• Manage key master data processes, including Bill of Materials (BOM), work plans, production versions, and work studies• Monitor and analyze various company-wide Key Performance Indicators (KPIs) such as on-time delivery, OEE, TEEP, scrap rate, capacity occupancy/gap levels, stock levels, etc.• Implemented line balancing techniques to increase OEE by 25% and average production per die by 21%; reduced labor costs by 20 K $ annually• Curbed annual idle stock production by 89% from 143 to 15.5 tons using Lean Methodology; established integration between SAP modules to minimize the idle production and excess inventory costs• Collaborated with the Production Manager to develop a comprehensive investment plan; increased production capacity by 27% and generated 8.5M $ in revenue in the first year Show less
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Senior Production Planner
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Sep 2015 - Sep 2020
• Successfully directed SAP R/3 installation and SAP HANA and SAP APO - PP/DS migration projects for two separate companies• Increased the on-time delivery rate from 64% to 91% within one year by providing customer, production, and logistics integration• Utilized ERP algorithms to achieve 99% accuracy in reconstructing scrap rates, even when physical determinations were not feasible due to raw material tolerances and production technology• Redesigned customer product labels, notes, package content quantities, and loading requests on ERP (SD-PP), resulting in a significant reduction in product remaining in stock after loading and prevention of personal errors• Conducted audits to determine actual wall thicknesses of raw materials, resulting in a 1.2% annual cost reduction in purchasing• Improved supplier scorecards by integrating them into the ERP for automated reporting systems Show less
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Production Planner
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Nov 2012 - Sep 2015
• Developed and managed production schedules using MRP based on forecasts, safety, and bufferstocks, inventory levels, and customer orders• Implemented pull systems (Kanban Boards) with demand forecasts and tact time references infinished good stocks• Prepared purchasing requests for consumables needed in production• Innovated a new packaging product that permanently eliminated customer complaints related tothe most exported product packaging• Overhauled warehouse stock layouts according to 5S rules, achieving a 30% reduction in stockspace and a 17% cost reduction• Systematized the empty volume, which is 24% on average, to 3%, and minimized the 160tons/year product remaining after shipment• Generated periodic and Ad-Hoc reports on capacity occupancy, capacity utilization rates, idlestocks, and delivery delays Show less
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İstikbal Mobilya A.Ş.
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Türkiye
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Furniture
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300 - 400 Employee
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Business Analyst
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Nov 2010 - Jul 2011
• Collected field data in the wood-cutting section and transferred it to the ERP - UNITY system • Participated in the Furniture Kaizen project of the continuous improvement department, learning continuous improvement concepts, data collection systems, accurate measurement, and solution tools • Took time and method studies in Morbidelli CNC benches and extracted work samples from machine operators • Collected field data in the wood-cutting section and transferred it to the ERP - UNITY system • Participated in the Furniture Kaizen project of the continuous improvement department, learning continuous improvement concepts, data collection systems, accurate measurement, and solution tools • Took time and method studies in Morbidelli CNC benches and extracted work samples from machine operators
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Education
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2013 - 2019
Erciyes Üniversitesi
Master's degree, Mechanical Engineering -
2007 - 2012
Erciyes Üniversitesi
Bachelor's degree, Mechanical Engineering
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