A solution approach to a synchronisation problem in a JIT production system

Delivering of orders on time, increasing productivity and reducing costs are all challenges that companies have to cope with on a regular basis. Making production lines compatible solves these problems and means a reduction in line stoppages and cycle time. In continuous production systems in which production is carried out in lots, the main ways to ensure an uninterrupted and smooth flow and have a high production rate, are line balancing and synchronising work stations. In this paper, a line stoppage and productivity problem at an automotive factory (Toyota Turkey plant, Sakarya city) is solved by root-cause analysis. Cycle time and in-process inventory inconsistency causes the problem between paint and assembly lines. Different solutions are researched and the most appropriate one is selected and implemented.

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