Improving Productivity in a Metalworking SME Through an Integrated Lean Model: A 5S, SMED, Poka Yoke Approach

Bayona-Sojo L.K.; Guevara-Lucio C.J.; Leon-Chavarri C.C.; Ávalos-Ortecho E. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260685

Resumen

Low productivity remains a persistent challenge for metal-mechanical small and medium-sized enterprises, largely driven by excessive non-productive time associated with poor workplace organization, long machine setup times, and manual errors during assembly processes. These inefficiencies directly limit operational performance and competitiveness, particularly in labor-intensive manufacturing environments.To address this problem, this study proposes and evaluates an integrated and sequential Lean model that combines workplace organization, setup-time reduction, and error prevention through the coordinated application of 5S, SMED, and Poka Yoke. The model was applied to the junction-box manufacturing process of a metal-mechanical SME and validated through a pilot implementation that measured productivity, tool-searching time, machine setup time, and downtime due to manual errors.The results show significant improvements: productivity increased by 28.97%, tool-searching time decreased by 53.23%, machine setup time was reduced by 47.81%, and downtime caused by manual errors decreased by 50.99%. These findings demonstrate that applying Lean tools within a structured and sequential framework effectively reduces non-productive activities and enhances operational efficiency.Overall, the study provides empirical evidence that an integrated Lean model offers a practical and scalable approach for improving productivity in metal-mechanical SMEs facing organizational, procedural, and human-related inefficiencies.

Instituciones: Universidad de Lima