Implementation of Lean Manufacturing Tools to Improve the Fulfillment of Orders in a Footwear Company in Peru

EasyChair Preprint 9210

Abstract

The objective of this article is to reduce nonfulfillment of orders in a line of footwear that, in the last 03 years, has tripled to 20%, which generates economic losses for the company. There are two main factors that affect the problem: On the one hand, the loss of availability of the compressor machine that provides compressed air throughout the production process and, on the other hand, the inadequate spare parts warehouse, which generates disorder and delay in the search for spare parts. Based on the above, this document proposes a maintenance management model based on 3 tools of the Lean Manufacturing philosophy: Total Productive Maintenance (TPM), 5S and Visual Management as support for the standardization of the location of items in the warehouse. The validation method is a simulation in ARENA of the repair of the critical machine. After the simulation, the MTTR was lowered and the MTBF increased, so the availability increased by 10.96% and consequently the non-fulfillment rate was reduced by 12%. Likewise, there was additional income of S /. 189,275.72 annually. With a VAN of S /.175,518.33, the project is viable.

Keyphrases: 5S, Footwear, Lean Manufacturing, TPM, Visual Management

@booklet{EasyChair:9210,
  author    = {Jeyson Paniagua Pinto and Roberto Tarazona Peche and Victor Nuñez Ponce and Cesar Nunura Nunura},
  title     = {Implementation of Lean Manufacturing Tools to Improve the Fulfillment of Orders in a Footwear Company in Peru},
  howpublished = {EasyChair Preprint 9210},
  year      = {EasyChair, 2022}}