Improvement of Productivity in the Assembly of Industrial Doors Using Lean 4.0 and Automated Picking

Núñez-Rojas M.; Portocarrero-Ruiz C.; Álvarez-Arteaga J.L. · Proceedings of the 2025 IEEE 32nd International Conference on Electronics, Electrical Engineering and Computing, INTERCON 2025 (2025) · DOI: 10.1109/intercon67304.2025.11244665

Resumen

The Peruvian metalworking industry faces productivity limitations, especially in the assembly of industrial hermetic doors, due to its dependence on manual processes and low technological integration. This study proposes an improvement model based on Lean 4.0, applied in a company through an action research approach. The main problems identified were picking delays, lack of traceability and rework due to errors in the installation of the trim and handle, as well as deficiencies in alert communication. The solution included RFID, JIT automated control, Poka-Yoke devices, and an Andon system. The implementation generated a 46.71% increase in productivity, reducing downtime and defective products. From an economic perspective, the results showed a Net Present Value of USD 20,450, an Internal Rate of Return of 77.25%, a benefit/cost ratio of USD 2.28, and a payback period of 0.82 years. The model is replicable and demonstrates how digitalization can improve efficiency and quality in industrial processes.

Instituciones: Universidad Peruana de Ciencias Aplicadas