Operational Improvement Model Based on Lean Manufacturing Tools to Enhance Productivity in a Textile Company

Ballón A.; Pereira C.; Villanueva R. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260681

Resumen

The Peruvian textile industry exhibits persistent productivity gaps compared to international benchmarks, particularly among medium-sized yarn manufacturers. In the company analyzed, economic productivity reaches 0.0239 kg/PEN, below the sectoral benchmark of 0.0325 kg/PEN, revealing a technical gap of 35.98% mainly driven by unplanned machine downtime, lengthy setup times, and rework in the dyeing laboratory. This study proposes an integrated Lean model composed of two complementary components: (1) the joint application of SMED and Preventive Maintenance on critical equipment to reduce operational unavailability, and (2) the combined implementation of 5S and Standardized Work in the dyeing laboratory to minimize variability and reprocessing. Validation followed a hybrid approach using discrete-event simulation in Arena and pilot testing on the shop floor. Results show reductions of 23.6% in critical internal activities, 19.3% in total setup time, 19.7% in the frequency of unplanned downtime, and a decrease in the rework rate from 7.05% to 5.4%. Under a conservative scenario, these improvements translate into approximately one million PEN in additional annual value added, demonstrating the effectiveness of the proposed model in closing productivity gaps within industrial spinning operations.

Instituciones: Universidad de Lima