Optimización de los indicadores de productividad de los procesos de manufactura de una empresa láctea mediante la simulación con Flexsim integrando la filosofía Lean Manufacturing

Abstract

The objective of this research is to simulate the manufacturing processes of the dairy company Soprab with the integration of the Lean Manufacturing Philosophy. One of the important advantages of simulation is to generate changes in the process without the need to make investments in companies. For the simulation, the data of the manufacturing processes of the yogurt and mozzarella cheese production lines were collected, through an on-site visit of the production plant. During this visit, data was collected on: number of operators, process times, equipment and machinery of the production lines and production batches. The simulation was carried out in the yogurt and mozzarella cheese production lines due to their high demand compared to the other products of the company. For the simulation, the Flexsim program was used, where the data collected in the plant was loaded. The simulation process was validated, with which it is concluded that the simulation carried out reflects the operation of the real process, where the initial productivity indicators were: cycle time equal to 687 min and productivity of 0.88 units / min in the line for making yogurt; while in the mozzarella cheese production line the initial values were: cycle time equal to 2339 min and productivity of 0.427 units / min. Then simulations of the improvement scenarios were carried out, incorporating Lean Manufacturing in the production lines such as: TPM, Poka Yoke, 5 S, elimination of mudas, kaizen and SMED. It was determined that the incorporation of the Lean Manufacturing philosophy did have significant statistical differences in the productivity indicators between the simulated model and the simulated improvement scenarios of the yogurt and mozzarella cheese line. Of the improvement scenarios proposed in the yogurt production line, the incorporation of 5 S is the best scenario because it reduces the cycle time to 620.3 min and productivity of 0.966 units / min. While in the mozzarella cheese production line, the scenario with the standardization of processes was the best with a reduction of the cycle time to 2185 min and a productivity of 0.450 units / min. In the yogurt production line, cycle time was reduced by 9.68% and productivity increased by 10.27%. While in the cheese making line, the cycle time was reduced by 6.58% and productivity increased by 6.79%. In the yogurt production line, the company obtains a daily income of $ 2700 from the sale of 2L yogurt, while with the improvement proposal it could increase production and generate sales of $ 2992, increasing income by 10 , 81%. While in the mozzarella cheese production line, daily income of around $ 375 is obtained from the sale of 250 g mozzarella cheese, and with the improvement proposal it could increase the income to $ 478, increasing the income around 27, 47%.