Increasing productivity by layout improvement of factory production area

In this study, which includes the efficiency increase of the production line, initially the current situation of bus seat layout and its problems are presented. End-product, which is composed of products from several production lines, has to be produced with requested quality, quantity and on time. For planning this production line flexible production systems, Kaizen, logistics conditions and occupational health and safety standards are considered and more efficient production line is generated. In this study firstly the current situation is analyzed by drawing the current layout. Furthermore the workflow on the layout, which includes the situation of the current operator, machines, materials and devices, is presented. In this scope, the current workflows and the production time analyzing for the chosen end-product is performed. All of these analyzes will be used for planning and increasing productivity. After scrutinizing the manual transportation problem of the materials, several methods are thought for solution of the problem. While choosing this equipment, initially the automatic and semi-automatic systems are evaluated and the using of semi-automatic conveyor, which is most suitable, is decided. The next step of this study was the design of the new layout. For this design several alternatives are considered and the most suitable one is chosen and the structure and system of new conveyor are determined according to the new layout. Alternative solutions for the problems, which appeared because of new layout, are considered. For this study the other production centers and production facilities in Germany are inspected. In this section, different design ideas are thought, and their advantages and disadvantages are compared. In the end the best solution suggestion is chosen. After constitution of production line the results of the project are presented in details. The new layout is designed and as a result of this new design costs are calculated and a feasibility study is done. Consequently the production time is reduced and production efficiency is increased. By decreasing the production time of the vehicle the capacity is increased.