Manufactura esbelta para reducir los desperdicios en un taller de matricería

Abstract

EXECUTIVE SUMMARY The present project proposes the GEMBA P2CH model, which refers to the fact that improvements are made in the gemba through four pillars: programming, process, quality and skills. A survey of the current situation of a tooling workshop is carried out in which preventive maintenance 8000 H is identified as the activity that covers the largest number of processes within the area, it is found that the main wastes are waiting for materials, imbalance in the distribution of activities and the breach of the standard time. Subsequently, the improvements are proposed through a structural system with results in the gemba, the application of the model is progressive and systemic. The tools make the process more efficient, in terms of programming, maintenance prioritization rules and the information flow are integrated in which kick off and heijunka are used so that the communication of requirements is adequate. In the process, the mapping of the current and future value flow is applied, which allows the identification of the sequence of activities with better productivity. In quality and skills, audits are structured in the gemba with critical control points and the ILU system respectively. The results show the successful application of the model with a 5.3 percent decrease in delivery time for maintenance, a 3 percent average increase in service level and an overall reduction of 42.45 percent in cost.