Metodología Lean Manufacturing en los procesos productivos de la empresa Discoint

Abstract

This research project focused on analyzing and reducing Lean waste in the production processes of DISCOINT, a food machinery manufacturing company. Relevant inefficiencies were identified in critical areas such as Design and Development, Production and Assembly, which affected the timely delivery of products and increased operating costs. To address this problem, the 1-liter oil sleeving machine was selected as the reference product, identified through an ABC analysis of sales for the year 2024 as the one with the highest demand. A detailed survey of the processes was carried out, applying the back-to-zero timing method to measure times and build the Current Value Flow Map, in order to visualize the activities that do not add value. The results showed that the most frequent wastes correspond to waiting times with 46% of occurrence, rework with 31% and unnecessary movements with 8%, totaling 14 hours and 41 unproductive minutes. The main causes of these inefficiencies were identified through Ishikawa diagrams, showing delays in the delivery of materials, multiple revisions of drawings and disorder in the work environment. Through a technical literature review using the PRISMA methodology, Lean Manufacturing tools adapted to the company's context were selected: KANBAN to reduce waiting times through visual control of inputs, process standardization to reduce rework by establishing clear and documented methods, and 5S to eliminate unnecessary movements by organizing and cleaning the work area. To facilitate their application, specific manuals were prepared for each tool, aligned with DISCOINT's operational needs, with the aim of optimizing processes, improving coordination between areas and fostering a culture of continuous improvement oriented towards efficiency and quality.