Increased Productivity in the Garment Manufacturing Process using the SMED Methodology of Lean Manufacturing

Fuentes S.; Torres K.; Cespedes C.; Torres-Sifuentes C.; Cano M.; Raymundo C.; Dominguez F. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2023)

Resumen

Increasing productivity in companies improves operational efficiency and quality. An OEE level below 65% represents low effectiveness and high downtime in the production line. The objective of this article is to increase productivity levels in a Peruvian microenterprise in the textile and garment sector, which achieved an OEE of 31% in its last period compared to an international standard of 75%. Previous studies applied various solutions to increase productivity levels. The main tools used were Single Minute Exchange of Die (SMED), 5S, and Six Sigma from Lean Manufacturing. They managed to increase the productivity index from 0.38 to 1.16 and reduced the defect processes from 13.12% to 4.23%. They decreased downtime that caused significant delays by transforming them into parallel activities, increasing the production capacity from 4 units per day. However, these solutions were implemented in micro-garment manufacturing companies. The motivation was to implement these tools in the production of hand luggage for the armed forces. The SMED tool was applied to eliminate downtime and increase productivity, reducing production costs using minimal resources. The validation was confirmed through a case study, which resulted in a 51% increase in productivity and an OEE of 86%. It was concluded that the implementation of the SMED tool reduces downtime during the garment manufacturing process.

Instituciones: Universidad Peruana de Ciencias Aplicadas