Propuesta de mejora en el proceso de extrusión mediante el uso de herramientas Lean Manufacturing en la empresa Avipaz Cía. Ltda.

Abstract

This project presents an improvement in the extrusion process of Avipaz Cía. Ltda., a company dedicated to the production of extruded food. Deficiencies in productivity and quality were identified, especially in the product Dogy Adult 30kg, derived from waste such as waiting, incorrect processing and defects. Through time analysis, flowcharts and value chain mapping (VSM), it was determined that the current cycle time is 211.29 minutes, with the bagging area being the main bottleneck. Based on the weighted factor method, specific Lean Manufacturing tools were selected: SMED to reduce setup times, 5S to improve work order and standardization, Jidoka to stop the process in case of defects, and TPM for efficient equipment maintenance. The theoretical implementation of these tools reduced the cycle time to 166.93 minutes, reducing the total process time by 21% and improving responsiveness to demand. Concrete proposals were developed, such as cleaning manuals, signage, preventive maintenance and compliance records, consolidating a culture of continuous improvement. The new VSM showed an alignment of the process to the takt time, guaranteeing efficiency in the company's production. In conclusion, the proposed application of Lean tools made it possible to optimize the extrusion process performance, increase production and improve the quality of the product.