Modelo de optimización de procesos para la reducción de costos operativos en la empresa Jambi Kiwa

Abstract

This study develops an optimization model aimed at reducing operational costs in the tea production process of the company Jambi Kiwa. The research begins with an assessment of the current production system through direct observation, analytical flowcharts and process diagrams, which enabled the characterization of eleven production stages and the identification of non-productive times, bottlenecks and nonvalue- added activities, particularly in the pre-drying, drying and packaging phases. Subsequently, production costs were identified and classified using the Activity-Based Costing (ABC) method. The results showed that direct labor amounts to USD 2,403 per month, representing the main direct cost, while indirect packaging materials total USD 1,680 per month, making them the most significant component of indirect costs. This cost structure confirms the semi-artisanal nature of the process and its high dependence on manual labor. Based on this information, a linear programming model was developed to minimize the total production cost, yielding a theoretical optimal cost of USD 8,539.32 for a monthly output of 20 batches. This result demonstrates a considerable improvement potential when compared to the actual cost, highlighting the need to optimize resource allocation and enhance operational efficiency. Based on the findings obtained, optimization strategies were established focusing on waste elimination, enhancement of dryer performance, standardization of activities, and control of critical operational parameters. These measures contribute to increasing productivity, reducing operational costs, and strengthening the overall competitiveness of Jambi Kiwa.