Propuesta de mejora de la productividad de una línea de producción de galletas para perros mediante herramientas de manufactura ajustada

Abstract

The purpose of this project was to optimize the productivity of the dog biscuit production line at Soguar S.A. through the implementation of Lean Manufacturing tools. The initial diagnosis, based on a time study and Value Stream Mapping (VSM), revealed critical deficiencies in the manual rolling and baking process (53 minutes), which prevented the company from meeting market demand and increased operating costs. The proposal was based on four pillars: the application of the 5S methodology to standardize the work environment, achieving a compliance level of 90%; the implementation of a Total Productive Maintenance (TPM) plan in the oven to reduce its operating cycle to 38 minutes; the adoption of the Jidoka principle by incorporating a semi-automatic extruder to eliminate the bottleneck in rolling; and the redesign of the operational flow towards a more synchronized model. The quantitative results show a substantial improvement in the production process: production capacity increased by 76%, from 80000 g to 140800 g per shift. Likewise, lead time was reduced by 47.91% (from 4.3 to 2.24 days). From a financial perspective, the proposal demonstrated high viability with a 27.45% reduction in production costs and an investment recovery period of approximately three months. This allows the organization not only to stabilize its operation, but also to project a competitive and sustainable commercial expansion.