Textile Industry Digital Transformation Story | Timay Tempo Succeeded
About the Company
Founded in 1987 with the philosophy that “details matter,” Timay & Tempo operates today as Turkey’s largest button manufacturer and one of the top five brands in Europe in its sector, with modern facilities spanning 29,200 m². Serving 10 different sectors with product groups such as buttons, snaps, rivets, clickers, metal accessories, buckles, eyelets, zamak labels, and leather/jacron, the company carries out production in 16 different product categories. Integrating its sustainable production approach with its corporate values, Timay & Tempo chose ProManage in 2013 in order to transform its strong production infrastructure into a data-driven, traceable, and manageable structure.
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Reasons for Need
Timay & Tempo’s need for digitalization arose from the goal of managing its growing production volume in a more traceable, controlled, and efficient manner. The company aimed to ensure quality assurance, reduce losses, and make production processes more transparent by monitoring data coming from the field in real time.
Key Needs Driving Digitalization:
- Global Traceability Standards: While working with major brands worldwide, minimizing the margin of error to zero and transparently documenting production processes were the most critical needs.
- Managing High-Volume Production: It became clear that monthly production of millions of units could not be managed sustainably through manual records or Excel spreadsheets.
- Reducing Field Losses: The goal was to make downtime, waste, and efficiency losses occurring on the production floor visible; analyze these losses and improve them.
- Data-Driven Decision Making: The aim was to establish a system that moves decision-making processes away from personal estimates and bases them on the interpretation of real-time data collected from the field.
- Centralized Management Need: It was anticipated that such a large and complex production structure could not be effectively managed from a single point without digital systems.
Motivation for Choosing and Important Details
Timay & Tempo realized through its first field trials that digitalization could solve problems in production. However, to ensure that this transformation would be sustainable, it chose to move forward with a professional solution partner that is independent of individuals and has proven itself in the industry.
- Technical Insight and Initial Trials: The first prototypes developed with a computer engineering-based approach demonstrated that collecting data from the field could contribute to production processes.
- Person-Independent Sustainability: To avoid the risks that systems dependent on the knowledge of a single individual could create, a corporate and sustainable infrastructure was preferred.
- Strong References and Industry Expertise: During the selection process, moving forward with a professional solution partner that had proven itself in the industry and possessed strong references became a primary criterion.
- Strategic Investment and Management Approval: The concrete efficiency improvements achieved through the initial technical trials were shared with the board of directors, ensuring that digitalization was evaluated not as an expense, but as a strategic investment supporting the company’s growth.
- Need for a Scalable Infrastructure: The success of the initial trials revealed that the solution needed to have a strong and scalable structure capable of being expanded across the entire production site.
Personal Experiences
The experiences Timay & Tempo encountered during its digital transformation process and the key highlights of its transformation journey are as follows:
- Facing Field Resistance: During the transition to digital systems, employees’ perception that they were being monitored created resistance in the early stages of the transformation process.
- Communicating the Change Correctly: Adaptation to the transformation was supported by explaining to employees that the purpose of the system was not to control them, but to improve the process.
- Increasing Participation Through Rewards: Rewarding employees who entered accurate and timely data encouraged system usage and created positive competition among teams.
- Prioritizing Data Recording: For digital transformation to progress successfully, regularly recording production data from the field in an accurate and interpretable manner became a fundamental step.
- The Impact of Transparency on Corporate Culture: With production data becoming visible, downtime, losses, and performance indicators began to be monitored more clearly.
- The Importance of Management Support: The commitment of senior management to the project played a decisive role in overcoming field resistance and making the transformation permanent.
- A Mutual Benefit Approach: Through digitalization, while the company gained efficiency, employees also became involved in the process through more visible performance, reward, and recognition mechanisms.
What Has ProManage Brought?
ProManage has provided Timay Tempo with multidimensional benefits:
- Record Increase in Production Volume: By reducing losses by 99% and eliminating inefficiencies on the shop floor, the monthly production capacity has increased from 110 million to 190 million with the same number of employees.
- Fast Return on Investment (ROI): Thanks to the right digitalization steps, the ProManage investment has fully paid for itself within a short period of 6 to 12 months.
- Prevention of Excess Inventory and Overproduction: Through real-time digital monitoring of production and ERP integration, the overproduction issue has been resolved, resulting in a direct 15% cost saving.
- Predictive Maintenance and Mold Management: By assigning an identification number to each mold and tracking the number of cycles, autonomous alerts are generated before failures occur, ensuring production continuity.
- Customer Trust and Fast Planning: Simulating the delivery time of massive orders within 30 minutes and providing responses to customers has reinforced the company’s position as an “indispensable supplier” in partnerships with global brands.
- Autonomous Control and Continuous Improvement: Thanks to autonomous data from the system, master data errors are detected instantly, and a structure has been established where processes are continuously improved through “mini Kaizens.”
- Transparent and Accountable Corporate Culture: Recording every second of production facilitates audits while creating a data-driven and transparent working environment for both blue-collar and white-collar employees.
- Operational Efficiency and Scalability: The 100-fold increase in turnover while the number of employees grew 10 times has become the most concrete indicator of the efficiency multiplier provided by digitalization.
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