Improvement in the sportswear manufacturing process using lean manufacturing tools and mathematical optimization

Carlos L.H.J.; Polo J.E.R. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2021) · DOI: 10.18687/laccei2021.1.1.251

Resumen

The Peruvian textile and clothing sector has been competing with companies from Asia and Central America, which have gained market with their lower-priced products. This market loss is the result of a lack of productivity in the production chain. Lean Manufacturing has several tools for increasing productivity that have produced successful results in multiple organizations. Lean Manufacturing is recognized for its application to production systems and the results obtained after its correct implementation. The aim of this research was to increase the productivity of a small company located in the city of Juliaca dedicated to the manufacture of sportswear through the application of lean manufacturing tools and mathematical optimization. The diagnostic procedure of the current situation includes the elaboration of the value stream mapping, establishment of main indicators, identification of activities that add and do not add value and identification of bottleneck processes. Faced with the main problems, the root cause was found by asking 5 times why; then the problem solving tools were identified. Among the applied tools there are 5S's, Standardization and operations programming. Finally, the results of the implementation of the tools received an improvement in the reduction of the cutting process time (bottleneck) of 50 minutes. This reduction translates into an increase in production capacity of 4 units per day (12% of capacity).

Instituciones: Pontificia Universidad Católica del Perú