Arçelik A.Ş. Refrigerator Plant – Lean Assembly Line and Transportation Systems Design

Group: Semih Barutçu, Onur Güneş, Salih Burak Karatopan, Ali Serkan Nuhoğlu, Ege Naz Özer

Arçelik’s Eskişehir refrigerator plant’s 6th production line’s material handling is operated via forklift trucks from ASRS storage system and general storage area. In the current system, the utilization of workstation storage areas is not efficient and using forklift trucks cause material damage and lost material cases. The plant is to double the production capacity of the line, use supermarket storage system instead of ASRS and use AGVs instead of forklift trucks. Therefore, a transportation scheduling plan that provides the materials at the right place at the right time is required. To achieve that, at first the mathematical model is used to have initial solutions, and then the system is represented with the simulation model. The simulation model is run for various numbers of AGVs, dispatching rules and maintenance policies and the results are analyzed. As a result, configurations for different priorities of the firm are determined.