Fiziksel test sonuçlarının kök sebep çalışması ile ürün iyileştirme süreçlerine etkisi (İTÜ-GTTM'de yapılmış bir uygulama)
The effects of physical test results with root cause study on product improvement processes (An application in ITU-GTTM)
Yazar: MUSTAFA BABAOĞLU
Danışman: YRD. DOÇ. İSMAİL ÇİÇEK
İstanbul Teknik Üniversitesi / Fen Bilimleri Enstitüsü / Deniz Ulaştırma Mühendisliği Ana Bilim Dalı / Deniz Ulaştırma Mühendisliği Bilim Dalı
Derece: Yüksek Lisans, 2017
Konu: Denizcilik = Marine

Özet:
Bu çalışmanın amacı, GTTM(Gemi Teçhizatı Test Merkezi)'de yapılan gemi teçhizatlarına ve taşımacılıkta kullanılan ambalajlara yönelik yapılan testlerde, ürünlerin başarı oranlarını incelemek, ayrıca ilk testte başarısız olup ürün iyileştirme uygulandıktan sonra tekrar testlerinden başarı ile geçen ürünlerde, yapılan iyileştirmeleri belirleyerek gelecekte benzer ürünlerin testlerde daha yüksek oranda başarı elde edebilmelerine katkı sağlayacak tavsiyelerde bulunabilmektir.
Deniz taşımacılığı ve ekonomisi, Dünya ticaretinde önemli bir role sahip olmakla birlikte, Dünya ekonomisi açısından da stratejik öneme sahip sektörlerden birisidir. Birçok sektörde olduğu gibi denizcilik sektörü de, bazı kurallara bağlı şekilde dizayn edilmiştir.
Deniz, hava ve karayolları taşımacılığında kullanılan ambalajlar, kullanım amaçlarına göre çeşitlilik göstermektedir. Çeşitli ebatlarda üretilen bu ambalajlar, kullanım amaçlarına göre farklı üretim tekniği, malzeme seçimi ve tasarım detayları gibi disiplinler ile üretilmektedir. Bununla birlikte deniz taşımacılığının yapılmasını sağlayan gemilerinde çeşitli teçhizatlara sahip olduğu bilinmektedir. Sektörel riskler sebebiyle bu teçhizatlar ilgili kurallara bağlı olarak test edilmektedir. Gemi teçhizatlarının yanı sıra deniz, karayolları ve hava taşımacılığında kullanılan ambalajların da ilgili kurallara bağlı olarak test edilmeleri gerekmektedir.
Son yıllarda gittikçe artan konteynerizasyon eğilimi ile deniz taşımacılığında da çeşitli boyutlarda ambalajların kullanımı artmıştır. Dökme yük gemileri yada tankerlerle taşınan birçok yük, günümüzde konteyner gemileri ile taşınmaktadır. Bu eğilim beraberinde küçük ve orta boyutlardaki ambalajlara ihtiyacı artırmıştır. Ambalaj üreticileri bu talebi karşılayabilmek için bu tip ambalajların üretimine yönelmektedir. Bu ambalajların ve gemi teçhizatlarının testlerinin yapılabilmesi için 2014 yılında GTTM, İTÜ bünyesinde kurulmuştur. Bugüne kadar, GTTM testleri ile ilgili herhangi bir akademik çalışma yapılmaması nedeniyle, bu testlerin sonuçları ile ilgili yeterli bilgi ve istatistiksel veri bulunmamaktadır. GTTM bünyesinde yapılan testlerde, sayısal verileri anlamlı sonuçlar verebilecek düzeyde bulunması nedeniyle ambalaj testlerinin başarı oranlarının incelenmesine ağırlık verilmiştir. 
Türkiye'de ilk ve tek olan GTTM merkezinde teste giren ürünlerin, başarı oranlarının yanı sıra gerekli test performansını ilk testte gösteremeyip, tekrar testleriyle başarıya ulaşan ürünlerde uygulanan ürün iyileştirme işlemleri, beş farklı kategoride sınıflandırılmıştır. Üreticilerle ve test merkezi çalışanlarıyla, bilgi paylaşımı yapılarak ürünlerin genel test başarı performanslarının tablosu oluşturulmuştur.

Abstract:
The aim of this study is to examine the success rates of the products in the tests made for the ship equipment and transportation packages used in the GTTM(Ship Equipment Test Center) and also to determine the improvements made in the products which have failed successively in the first test, to be able to find recommendations that will contribute to the success of similar products in the future in tests.
Maritime transport and economy, have an important role in World Trade, but also in terms of the world economy is one of the sectors of strategic importance. As is the case in many sectors in the maritime sector to cover all branches of many have been designed in such a way, depending on the rule. 
The packaging used for sea, air and road transport varies according to the usage purposes. These packages, which are produced in various sizes, are produced with different disciplines such as different production technique, material selection and design details according to usage purposes. Along with this, it is known that the ships have various equipments to provide the sea transportation. Due to sectoral risks, these equipments are tested according to the relevant rules. Packages used for sea, highways and air transport as well as ship equipment must also be tested in accordance with the relevant rules.
With the increasing tendency of containerization in recent years, the use of packaging has increased in various dimensions in maritime transport. Many cargoes carried by bulk carriers and tankers are now being carried by container ships. This trend has increased the need for small and medium sized packages. Packaging    manufacturers tend to produce such packages in order to meet this demand. GTTM was established in ITU in 2014 for testing of these packages and ship equipment. To date, due to the lack of any academic work on GTTM tests, there is not enough information and statistical data on the results of these tests. In the GTTM tests, the emphasis was placed on examining the success rates of packaging tests at levels where numerical data can yield meaningful results.
The fact that the manufacturers involved in this study make applications to identify problems on a sectoral basis ensures that they get important feedback on the operational performance of the manufacturers, but it is costly both in terms of resources and time. The packaging manufacturers demonstrate by physical tests that they can achieve their objectives. It leads to actions that will increase the high quality level. Manufacturers are basically responsible for two types of testing. The first consists of tests for quality control of production. Tests for the product's technical specifications such as pressure and strength, and tests for hazardous materials to be placed in the material. The testing of these tests required by the ADR directive may be provided by the firm providing the appropriate conditions or outsourced by an appropriate testing organization with authority such as GTTM. Physical tests are an important test in many research and development studies on product development as well as in documenting conformity-compliance as there are no alternatives. No other test method is accepted except for the physical test method in the test orientations specified in the ADR, which is referred to as the legal obligation for the product tests applied in the GTTM. The packaging manufacturers demonstrate by physical tests that they can achieve their objectives. It leads to actions that will increase the quality level. Physical tests are an important test in many research and development studies on product development as well as in documenting conformity-compliance as there are no alternatives. No other test method is accepted except for the physical test method in the test orientations specified in the ADR, which is referred to as the legal obligation for the product tests applied in the GTTM.
Some tests applied to products in GTTM fail. This leads to the need to apply the product improvement process to the products. For this reason, producers have to go through a process similar to the roadmap of a new product development process. This study covers the products of 33 different companies that have been tested in GTTM. Test procedures applied to 171 different products between 2014 and 2017 have been examined. For the 11 different types of products described in the second part of the thesis and without any classification, a performance test was performed for the criteria determined by the producers. In addition, statistical data on the test results applied to the packaging of 160 different hazardous substances referred to ADR have been obtained. 
In GTTM center, which is the first and only in Turkey, the products that have been tested, the success rates, as well as the improvements in the products which can not show the required test performance in the first test and succeeded by the retest tests are separated in five different categories. A general performance chart was created by sharing information with producers and test center employees.
The methods of product improvement to be applied to unsuccessful products can occur in many disciplines in subcategories. Due to the limited data environment, product improvement actions are divided into different main categories to obtain meaningful findings. Product improvement processes are similar to the stages of developing a new product. Research has been carried out on the application of product improvement methods, which are classified under design, production technique, production equipment, material metallurgy selection and quality control.
Together with the collected data, data were obtained and compared to provide information on the significance of deficiencies in the production process identified as the 'root cause'. It is also considered that they are effective in this process either singly or in combination with other processes. The primary aim in this study is; it is not a detailed analysis of the production processes that determine the root cause of the products encountering unsuccessful results in the physical tests applied in the GTTM. The results of the graphical analysis were examined whether there were any significant differences between the root causes examined.
In the conclusion part, it is investigated whether GTTM test results can be used to determine reliability levels at a meaningful level. Bayes Success-Run theorems are used as the formula for the reliability of product performance. In addition, it has been examined how many successful test results should be obtained under the same conditions so that the products entering the test can reach certain reliability levels in terms of quality control. In the test results based on the total number of products, the success rate of the products in the first test is high. The retest rates are also found to be higher than the complete failure rate of the products. It can be predicted that more meaningful statistical results can be achieved by carrying out promotional activities for GTTM and by matured test results in digital terms in the following years. As a result of this study, a significant statistical inference could not be obtained due to the inadequacy of the data. With this thesis, in the next years, it has been presented as a study which can be useful for parallel studies.