Project
X-Frost Line
My first exposure to high-volume manufacturing at scale. BSH's Çerkezköy plant is the largest factory in the group: 550,000 m², nearly 7 million appliances per year, exports to 90+ countries. I analysed the X-Frost refrigerator/freezer line to identify throughput bottlenecks and propose practical flow improvements.
Cycle-Time & Bottleneck Analysis
Mapped cycle times station by station across the X-Frost line to identify the actual throughput constraints. On a high-volume line, the bottleneck is rarely where you first expect it: stations interact, local delays cascade, and the real constraint often sits upstream of the obvious symptom.
Layout & Process Recommendations
Translated observations into practical improvement proposals for workstation layout, task sequencing, and process flow. The key constraint: this was a running production line making millions of units, so recommendations had to be implementable without shutting down the line or requiring major capital investment.
~7M / yr
Units Produced
550,000 m²
Factory Floor
90+
Export Countries
Challenges
- On a line producing ~7 million units per year, even a 1% throughput improvement is significant, but the analysis had to distinguish real constraints from noise in a complex, interacting system.
- Any recommendation had to be implementable on a running line. A theoretically optimal change that requires a two-week shutdown is not a real option.
Outcomes
- Delivered a bottleneck analysis and layout recommendations for the X-Frost line.
- Recommendations scoped for incremental rollout: workstation layout, task sequencing, and process-flow changes implementable without line shutdown.