| Summary: | In this study, an intermediate product manufactured in an automotive supplier plantis addressed through an integrativeapproach including Kaizen method and facility layout design technique, which are among the process improvement techniques, and the errors in the process are examined. In addition,REBA analysis is conducted for the process. As a result of this study, the prevention and improvement activities for an error that significantly affect customer satisfaction were presented and the expected returns of these activities were determined. While improving the quality of the process with the Kaizen method, suggestions for facility layout have been presented by considering the ergonomic aspects and cost analyzes have been carried out in terms of applicability. In terms of occupational health and safety, when the layout design improvement proposed in this study is realized, 13%to 18% of the insecure conditions, one of the main causes of occupational accidents, will be eliminated and a safer workshop environment will be achieved. In addition, with the design and improvement suggestions presented in this study, the errors that negatively affect customer satisfaction will be reduced, and related financial losses will be prevented, cycle time will be approximately reduced by 25%and a yield of 22% will be obtained from the area utilized and the cost will be reduced.
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