Design of an improvement plan applying Lean Tools in a baking company in Trujillo, 2024

Flavio H.; Pamela N.; Teodoro G.-M. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2024) · DOI: 10.18687/leird2024.1.1.236

Resumen

The main objective of the project is to develop an improvement plan in the baking company using lean manufacturing tools to reduce operating costs based on a pre-experimental design where a pretest and posttest were used to later compare these data and determine the impact. The company, which specializes in the production of bread, faces several challenges that affect its profitability such as: costs due to shrinkage, loss due to nonproductive time, costs associated with absence from work due to paid medical leave due to accidents at work, cost overruns. for raw materials, costs for unnecessary movements and costs for disorder in the warehouse. These problems were quantified, resulting in an annual loss of S/ 45,632. For each problem found, two alternative solutions were presented, choosing alternative 2 after carrying out an exhaustive analysis of limitations, where tools were incorporated such as: a time study, staff training, 5S Methodology, supplier control and a security system. and workers' health (SGSST). After investigating the engineering standards, a simulation was carried out with Monte Carlo and ProModel, reducing the annual losses to S/ 19,541.59, therefore, the choice of the tools supported by this research generated a benefit of S/ 26,090.41 and a decrease in the initial cost. loss of 57.18%. The 12-month economic evaluation confirmed the viability and profitability of the proposal, with an NPV of S/ 50,451, an IRR of 44% and a B/C of S/ 1.50. Additionally, continuous monitoring was planned to ensure effective implementation of improvements and key performance indicators were defined to monitor the progress of each tool.

Instituciones: Universidad Privada del Norte