Congestion is a problem not unfamiliar to any manufacturing plant. This is also the case in the
Body Shop area for the X90 project at Nissan.
Problems that arise from congestion include a longer lead time, safety hazards, over-packing,
over manufacturing, frustrated operators and an overall less productive manufacturing line.
Many tools and techniques are already in place to address congestion, such as Lean
Manufacturing, Methods Engineering, Six Sigma, Kanban pull system, TOC and other industrial
engineering concepts. Some of these will be investigated in-depth in this paper’s Literature
Review to determine ways to improve on the current manufacturing line in the Nissan Body
Shop. To understand the overhead problems, analysis will be done on specific workstations.
Journals and research done by peers in the Industrial Engineering field are reviewed to
determine the best tools for solving issues highlighted in the Problem Statement. An action plan
on how each problem will be addressed is included in the Solutions Methodology chapter of this
Thesis (B Eng. (Industrial and Systems Engineering))--University of Pretoria, 2012.