Análisis de los niveles de desperdicio desde la perspectiva de lean manufacturing en la empresa Renova

Abstract

This research project is based on classic Lean Manufacturing wastes analysis that are present in production processes at RENOVA Company and is focused on proposing an action plan through Lean Manufacturing philosophy tools and methodologies application contemplated in a manual that allows the resources optimization, achieving a better productive flow and greater efficiency in the products delivery to final customer. From sales history between January and October of 2022 and through an ABC analysis the most profitable product was known, on which the information gathering of existing processes was carried out and later a time study was developed for the current VSM trace that allowed to determine initial production plant situation, where the present wastes were known as: defects of which 44% were associated to the machine factor and 56% to the human factor; reprocesses with a higher incidence of stitch jumps with 23.44% compared to the other causes; unnecessary movements by the warehouse and docking operator adding a total of 52.53% of unproductive time; waits mostly in the warehouse for finished product with 67.25% and inventory where a total of 240 garments were detected in season at the end of November. Through a cause analysis, improvement opportunities were established for each identified waste, which were complemented by a literature review of the advantages and contributions of each tool for its subsequent selection, resulting in the following methodologies: JIDOKA, TPM, APU and HEIJUNKA. By tools applying, a reduction in defects per unit percentage is established, an increase in the overall efficiency index of the equipment of 40.94%, a reduction of displaced meters of 72.86%, and finally, the elimination of waits and inventories by producing what is necessary in required time which brings an improvement of 77.27% in product delivery days to the final customer.