Hybrid Model of Digital Transformation and Lean Manufacturing to Increase Operational Efficiency in the Footwear Sector in Peru

Huaroto J.; Raymundo J.; Hurtado A. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260728

Resumen

The purpose of this research is to optimize processes and increase operational efficiency in a Peruvian SME in the footwear sector that faces high levels of order non-compliance, defects, and unnecessary movement - common problems in this industry. Its objective is to propose and validate a Hybrid Model of Digital Transformation (Lean 4.0) and Lean Manufacturing that sequentially integrates Lean tools and low-cost digital technologies. Using a case study design, a comprehensive diagnosis of the production process is conducted to identify sources of inefficiency. Subsequently, a Lean-Digital model is designed to strengthen operational maturity prior to digitalization, and its impact is validated through Discrete Event Simulation. The results show improvements of 38% in operational efficiency, as well as reductions of more than 50% in setup times and defects, confirming that Lean maturity is a key prerequisite for effective digitalization and improved organizational performance. This research was applied only to one SME in the footwear sector. However, the study provides an accessible and adaptable model for SMEs, highlighting the incorporation of the Set-up Saving Deployment (SSD) as a complement to SMED to guide the prioritization of investments and reduce the financial barriers that limit a sustainable digital transformation.

Instituciones: Universidad Peruana de Ciencias Aplicadas