Enhancing Space Efficiency Through Improvement Strategies in Industrial Pre-Assembly Lines

Abstract

In today's competitive manufacturing environment, space efficiency has become a critical aspect of operational performance. This study aims to enhance space utilization in industrial pre-assembly lines by applying lean improvement strategies, including 5S and poka-yoke. A case study was conducted in a manufacturing company from March to June 2025. Data were collected through on-site observations, workflow analysis, and staff interviews. The methodology involved assessing the current layout, implementing lean tools, and comparing performance metrics before and after the improvements. The findings indicate substantial advancements in four key areas: material management, layout and flow optimization, inventory and space utilization, and ergonomic design. The most significant gains were observed in material management and spatial optimization. Additionally, ergonomic improvements contributed to worker safety and reduced unnecessary motions. The application of poka-yoke techniques led to the elimination of internal defects, thereby enhancing quality and reliability. This study fills a gap in the existing literature by providing a data-driven, real-world analysis of space efficiency improvements and offers practical insights for industry stakeholders.

Keywords

• case study
• lean practices
• pre-assembly lines
• space efficiency

Endüstriyel Ön Montaj Hatlarında İyileştirme Stratejileriyle Alan Verimliliğinin Artırılması

Öz

Günümüzün rekabetçi üretim ortamında, alan verimliliği operasyonel performansın kritik bir yönü haline gelmiştir. Bu çalışma, 5S ve poka-yoke dahil olmak üzere yalın iyileştirme stratejilerini uygulayarak endüstriyel ön montaj hatlarında alan kullanımını geliştirmeyi amaçlamaktadır. Bir üretim şirketinde Mart-Haziran 2025 arasında bir vaka çalışması yürütülmüştür. Veriler yerinde gözlemler, iş akışı analizi ve personel görüşmeleri yoluyla toplanmıştır. Metodoloji, mevcut düzeni değerlendirmeyi, yalın araçları uygulamayı ve iyileştirmelerden önce ve sonra performans ölçümlerini karşılaştırmayı içermektedir. Bulgular, dört temel alanda önemli ilerlemeler olduğunu göstermektedir: malzeme yönetimi, düzen ve akış optimizasyonu, envanter ve alan kullanımı ve ergonomik tasarım. En önemli kazanımlar malzeme yönetimi ve mekansal optimizasyonda gözlemlenmiştir. Ek olarak, ergonomik iyileştirmeler işçi güvenliğine katkıda bulunmuş ve gereksiz hareketleri azaltmıştır. Poka-yoke tekniklerinin uygulanması, iç kusurların ortadan kaldırılmasına yol açarak kalite ve güvenilirliği artırmıştır. Bu çalışma, alan verimliliği iyileştirmelerinin veri odaklı, gerçek dünya analizini sağlayarak mevcut literatürdeki bir boşluğu dolduruyor ve sektör paydaşları için pratik içgörüler sunmaktadır.

Anahtar Kelimeler

• vaka analizi
• yalın uygulama
• ön montaj hatları
• alan verimliliği

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