Productivity Improvement Based on 5S and Systematic Layout Planning in Wooden Pallet Production

Albarracin-Reategu C.M.; Gaviria-Salcedo A.L.; Yacono-Llanos J.C. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260709

Resumen

The pallet manufacturing sector in Peru faces operational limitations associated with non-productive times, excessive material handling, and variability in task execution. At Royal Corp, the initial diagnosis revealed low productivity per operator, prolonged cycle times, and a physical layout that generated unnecessary movements and imbalances in workload distribution. To address these issues, an integrated improvement model based on the Systematic Layout Planning methodology and the 5S system was proposed, aimed at enhancing workflow efficiency and standardizing the work environment. The methodology included time studies, process mapping, cause-effect analysis, and prioritization, as well as validation through discrete-event simulation to compare the current state with the improved scenario. The results showed a significant reduction in cycle times, an increase in operator productivity, a decrease in internal travel distances, and an improvement in the final product quality. These findings confirm that the integration of Systematic Layout Planning and 5S represents a low-cost, high-impact alternative for improving operational efficiency in pallet manufacturing processes.

Instituciones: Universidad de Lima