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Increase of the Service Level in a Textile Company through Planned Maintenance complemented with KARDEX and ABC-XYZ

Torres-Araujo P.; Iza-Rivas M.; Ruiz-Ruiz M.F.; Quiroz-Flores J.C. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2026) · DOI: 10.18687/laccei2026.1.1.245

Resumen

The project addresses the issue of the low service level in a Peruvian textile company dedicated to yarn production. During the review of performance indicators, it was found that its average On Time In Full (OTIF) indicator stands below the national benchmark, which results in additional costs due to storing delayed orders, penalties, and idle time. Based on the diagnostic assessment conducted in the maintenance and warehouse areas, along with the analysis of historical data, several causes were identified that explain the process deficiencies: difficulty locating spare parts, disorganization in the maintenance warehouse, and the absence of an integrated maintenance plan. In response to this situation, a proposal combining three tools was developed. The implementation of a Kardex system helped register and control incoming and outgoing items in a more orderly way, reducing picking errors. The ABC-XYZ analysis made it possible to organize and prioritize spare parts according to their importance and demand patterns. Finally, a planned maintenance program (TPM) was designed, incorporating preventive and predictive tasks to reduce unplanned downtime. The proposal was validated through simulation, comparing the current situation with the improved scenario (AS-IS; TO-BE). The projected results indicate that the OTIF could increase from 68.22% to 77.95%, along with a significant decrease in search times that helped reduce maintenance times by 20.69% and unexpected failures by 80% thanks to planned maintenance. The study shows that integrating these tools generates a strong impact on the company's operations and response capacity, contributing to a more stable and predictable production environment.

Instituciones: Universidad de Lima