Optimización de procesos en el área de fabricación de armas de fuego de la Empresa Santa Bárbara EP mediante herramientas de manufactura esbelta

Abstract

ABSTRACT The study presents a proposal to optimize the manufacturing process of weapons by means of lean manufacturing tools at the Santa Barbara EP company. It begins with the analysis of alternatives and is structured in three phases: information gathering on the process, diagnosis of the current situation and design of the proposal. The product studied is the .38 caliber revolver. It is analyzed in material flow in the Job shop by means of a time study, process diagrams and the PFA method. The VSM of the current situation identifies the waste and the bottleneck according to the Takt Time. The optimization proposal attacks four detected opportunity areas: system restriction, change sequence, workload balancing and lead time reduction. Regarding the system restriction (CNC machining center), the cycle time is optimized by 12 percent reducing non-value added activities, and the set up time by 55.4 percent applying the SMED methodology. The optimal sequence for the manufacturing of the parts was obtained by solving the JSSP problem in the Lekin software. A multi-criteria AHP analysis is applied with the help of the Expert Choice software for the selection of the best algorithm. The workload balancing in the assembly area achieves a reduction of 75.4 percent in the idle time, achieving a 32 percent increase in efficiency. The balancing rules in the POM-QM software are compared. Finally, a VSM of the future state is designed to allow the continuous flow of materials by improving the current system of supermarkets and Kanban. The proposal achieves a 46.5 percent reduction in process lead time and a 55 percent increase in labor productivity.