Improvement Proposal Using Lean Manufacturing Tools to Reduce Operating Costs in a Wood Company, Trujillo 2023

Alza M.A.R.; Cueva R.A.L.T.; Guerrero J.J.V. · CISCI 2023 - Vigesima Segunda Conferencia Iberoamericana en Sistemas, Cibernetica e Informatica, Vigesimo Simposium Iberoamericano en Educacion, Cibernetica e Informatica, SIECI 2023 - Memorias (2023) · DOI: 10.54808/cisci2023.01.204

Resumen

The wood company is currently facing a challenging situation due to issues in the production and maintenance areas, resulting in high operating costs. Therefore, the objective of this project is to reduce operating costs in these areas of a wood company located in Trujillo. To diagnose the situation, a cause-and-effect diagram was used, which allowed identifying and quantifying the following root causes: lack of operator training, lack of preventive maintenance, lack of organization in the workspace, and lack of safety Poka Yoke. These mentioned causes result in a current total loss of S/96,198.92. To address these issues, improvement tools such as Poka Yoke, TPM, and 5S were implemented. Subsequently, the current results were compared with the improved ones thanks to the proposed tools, managing to reduce the loss to S/26,205.05. Then, a cash flow projection was carried out to analyze the investment and operating expenses, resulting in a savings of S/69,993.88 in the company's losses. Furthermore, it was determined that the proposal is viable since it generates a Net Present Value (NPV) of S/55,491.80, an Internal Rate of Return (IRR) of 45.11%, a Payback Period (PRI) of 4.9 years, and a Benefit-Cost Ratio (B/C) of 1.5 in a 10-year projection. This is especially important due to the intense competition in the wood industry.

Instituciones: Universidad Privada del Norte