Improving the Layout of the Supply Warehouse to the Land Cruiser 70 Series Assembly Line

This paper presents a warehouse layout improvement to supply an assembly line of an automotive company, using Lean methodologies. For the layout change to be efficient, it was first necessary to reorganize the material in the Final Assembly supermarket. Once this task was completed, the racks were reorganized. The implementation of these two improvements resulted in a significant reduction in the number of trips with full dollies. As far as the picking of dollies supplied by the mizusumashi is concerned, a reduction of about 29.02% in the distance traveled by the picking operator was achieved. Regarding the dollies supplied without mizusumashi, it was possible to transform 10.40% of the trips with dolly into trips without a dolly, which reduces the ergonomic risk level of the task. As for the layout of the pre-assembly cell, the workbenches and racks were reorganized, allowing the employee to perform all tasks on time and alone within the stipulated takt time (42.5 min).