The main focus of this project is to investigate the energy consumption of the manufacturing lines in the car industry and look for the potential methods regarding energy saving. Special emphasis is put on the lighting technologies that can be used in the manufacturing processes. Two lighting technologies are tested in order to see which one has better performance and lower energy consumption. Fluorescent tube and LED tube are compared concerning illuminance, UV irradiance and power consumption. Economic evaluation is also conducted to exam the feasibilities replacing fluorescent tubes with LED tubes. Results of the study show that the LED tubes have much lower energy consumption than fluorescent tubes, produce more direct and „colder“ light, and have much lower UV irradiance. However, the payback period of LED is relatively long at current price situation. Since it is expected that the price of LED tubes will decrease in future, it is reasonable to predict that the LED technology will change the fluorescent one in many applications. The energy consumption has been estimated for two manufacturing lines which use different technologies to produce car underbodies. In order to identify the differences from the energy consumption point of view, some measurements are conducted, such as the consumption of electricity, compressed air, air for ventilation and cooling water. The measured results show a disproportion in the power consumption when the lines are in stand-by mode. This affects the energy consumption per produced unit significantly. The line that has a higher capacity and a lower power consumption in the stand-by mode has a lower energy consumption per produced unit when it is operating with lower production loading. So, in order to improve the energy efficiency, it is necessary that it works at as high volume as possible and to have the stand-by power consumption as low as possible.

There are manufacturing systems all over the world and all of them present dif- ferent characteristics. To get close to those manufacturing systems and aid them to analyze data and improve their efficiency, it arises FACTS Analyzer®. The present project concerns the development of a bottleneck analysis using REVERSE- SCORE (Simulation based COnstraint REmoval), feature included in FACTS Ana- lyzer. It is used Simulation-based Multi-Objective Optimization (SMO) to ana- lyze the different variables of a production line and investigate how to best extend previous application of SMO for bottleneck detection to not only consider im- provements of system parameters but also degradations of them. Degrading some system parameters can have many hidden advantages such as reduce power con- sumption, increase material efficiency or lengthen the useful life of the machines or tools, advantages that can draw near sustainability.

This thesis deals with the current state of assembly workplace for prefabrication in selected company. Using lean manufacturing principles it describes and subsequently eliminating all forms of waste that occur in the workplace. Part of the project is to design a new layout of the manufacturing cell, operation balancing and standardize the work of operators in the process. The project aims to achieve the planned production volumes at the same or lower operating costs.