Defective Product Reduction Model for a Bakery Using Standardized Work, TPM and Poka-Yoke

Caque A.; Leon M.; Cabrera E.; Chavez R. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260718

Resumen

In the Peruvian food industry, approximately 15% of raw materials are wasted exclusively during the processing and packaging stages due to non-compliance with established quality standards. This study aims to reduce the percentage of defective hamburger buns in a bakery production line that currently reports 2.75% of defects, exceeding the sector benchmark (1.71%). The main causes identified were insufficient time during rounding and fermentation, operational errors in dough rounding and cutting, and thermal failures associated with oven component malfunctions. To address these issues, an integrated improvement model was developed using the Lean tools Standardized Work, Poka-Yoke, and a TPM-based preventive maintenance program. Validation through pilot testing, physical prototypes fabricated via 3D printing, and simulation in Arena demonstrated significant improvements: reductions in cycle times for dough rounding and cutting (4.02% and 3.76%), fewer operational errors (2.09% and 1.41%), full compliance with fermentation time, and a 14.32% increase in the oven's MTBF. Overall, the model enhanced process stability and reduced defective products to 1.64%, reducing the environmental impact by 4,318.47 kg CO2-eq per year.

Instituciones: Universidad de Lima