Propuesta de mejora mediante la aplicación de Lean Manufacturing para incrementar la productividad en una empresa de fabricación

This study was carried out in a company dedicated to the manufacture and commercialisation of industrial products, such as heat exchangers and coolers, its main product being Mesabi tubes. The aim of the research was to apply engineering methodologies and tools to address the low productivity in the production processes. Among the main problems identified were the defective output of mesabi tubes and the disorder and inadequate control of materials, caused by the inadequate layout of the machinery, which generated prolonged movements of operators between processes. In addition, a lack of a culture of order and cleanliness was detected. Two alternative solutions were evaluated for each problem, considering realistic constraints such as complexity of implementation, flexibility, adaptability, cost and the necessary tools. After a detailed analysis, layout redesign and implementation of the 5S methodology were selected as the most suitable options. The simulation of these solutions showed a significant improvement. The simulation of these solutions showed a significant improvement for the company as the first problem related to a poor layout reduced unproductive activities from 70.69% to 48.5%. On the other hand, the 5S compliance increased from 42% to 76% showing that the tools were viable. Finally, the economic analysis showed a total profit of S/ 37,244.09, an IRR of 44%, an NPV of S/ 21,495.06 and a B/C ratio of 2.36, confirming the profitability of the proposed solutions in an effective way.