Enhancing Space Efficiency Through Improvement Strategies in Industrial Pre-Assembly Lines

In today's competitive manufacturing environment, space efficiency has become a critical aspect of operational performance. This study aims to enhance space utilization in industrial pre-assembly lines by applying lean improvement strategies, including 5S and poka-yoke. A case study was conducted in a manufacturing company from March to June 2025. Data were collected through on-site observations, workflow analysis, and staff interviews. The methodology involved assessing the current layout, implementing lean tools, and comparing performance metrics before and after the improvements. The findings indicate substantial advancements in four key areas: material management, layout and flow optimization, inventory and space utilization, and ergonomic design. The most significant gains were observed in material management and spatial optimization. Additionally, ergonomic improvements contributed to worker safety and reduced unnecessary motions. The application of poka-yoke techniques led to the elimination of internal defects, thereby enhancing quality and reliability. This study fills a gap in the existing literature by providing a data-driven, real-world analysis of space efficiency improvements and offers practical insights for industry stakeholders.