Herramientas Lean Manufacturing para la reducción de desperdicios en la empresa de calzado Holger Pilco

Abstract

This research aimed to analyze the manufacturing process of the Clau school shoe model at the company Holger Pilco, with the purpose of identifying the main operational wastes and establishing an improvement plan based on Lean Manufacturing tools. The first stage involved a comprehensive diagnosis of the current production conditions through the development of a Value Stream Map (VSM), workflow analysis, and time measurements for each operational stage. The results revealed a total production time of 104.71 minutes per pair and an operational travel distance of 83.84 meters, as well as the presence of significant waiting times, unnecessary movements, and work-in-progress inventories. Additionally, it was determined that all standard times exceeded the takt time of 6.86 minutes per pair, identifying the Assembly (Montaje) process as the main bottleneck with 37.29 minutes per pair, which disrupts synchronization across the entire production line. In the second stage, a weighted selection method was applied to determine the most appropriate Lean tools, identifying 5S, Poka-Yoke, Standardization, and SMED as the most suitable for addressing the root causes of operational imbalance, task variability, and human errors. Finally, an operational plan was developed, structured with activities, responsible personnel, required resources, and monitoring indicators for each tool, including checklists, diagrams, and control formats that support their implementation. This plan constitutes a practical guideline aimed at reducing waste, improving workflow efficiency, and promoting the gradual adoption of a continuous improvement culture within the company.