Recent Submissions

  • A validation model to reduce non-contributory time based on Lean tools: Case of a construction company in Perú

    Cabrera, Olenka; Tejeda, Joselyn; Llontop, José; Mendoza, Pablo; Alvarez, José C.; Demirkesen, Sevilay (Cogent OA, 2023-01-01)
    The construction industry has long been suffering from high rates of non-contributory time. Construction processes are likely to include time, which is sometimes lost for non-value-adding operations resulting in time waste. Considering the large percentage of lost time in all operations, this study aims to reduce the high rate of non-contributory time (NCT) in construction services. To test the management model, a Peruvian company was selected as a study case. In this respect, a management model based on mostly implemented Lean tools such as Kanban, 5S, and TPM was utilized. It is of utmost importance to emphasize that this proposal aims to reduce the NCT by up to 25%, as well as reduce the number of orders generated with delay, and eventually reduce the loss or damage of materials and equipment stoppages.
    Acceso abierto
  • Lean Service-inventory Management Integrated Model to Improve the Service Level in a Metalworking Company

    Alfaro, F. G.; Jacinto, D. V.; Flores, A. E.; Alvarez, J. C.; Trianni, A. (IEEE Computer Society, 2022-01-01)
    The importance of the metalworking sector in Peru is reflected in the high demand for machinery, equipment and structures in various economic sectors such as industry, construction, mining, transportation, among others. This makes it a generator of large productive links and employment. Today, the struggle to follow a quality standard that guarantees the production of these goods persists, as well as the effort to improve the customer's perception of the service offered. This study proposes an integrated model to increase the service level of a metalworking company through the use of Lean Service and Inventory Management tools. The results show a 10.13% increase in the service level, thanks to the implementation of engineering concepts such as 5s, Kaizen and Inventory Management.
    Acceso restringido temporalmente
  • Model based on the Lean Manufacturing methodology to increase the OTIF of a MYPE company in the textile sector

    Bryan, Anzualdo; Christian, Malpartida; Iliana, Macassi (Latin American and Caribbean Consortium of Engineering Institutions, 2023-01-01)
    Textile companies in Peru are currently facing problems of low productivity and exports, caused by the COVID-19 pandemic, generating a deficit in the trade balance and forcing producers to be more competitive. Reason why the national industry seeks to raise the standards of delivering products on time and fully delivering orders, increasing the level of service offered. For this reason, an improvement model is proposed for its application in the printing area of a Peruvian MYPE textile company, which will seek to improve production times and reduce reprocessing in order to increase the company's OTIF. Finally, the validation will be carried out through simulation to rein in the viability of the improvement model in the textile company and to validate the effectiveness of the proposed tools to solve the existing problems in the printing area.
    Acceso abierto
  • Proposal for optimization of inspections of electric poles using Lean tools and Last Planner System. An empirical research in Peru

    Salazar, Brayan Avilés; Ormeño-Soto, Blanca; Flores-Perez, Alberto (Latin American and Caribbean Consortium of Engineering Institutions, 2023-01-01)
    The efficiency of the public lighting system in electrical maintenance services is essential and aims to ensure compliance with quality in established times. Currently, the company only achieves 59% of work in a period of 6 months, being the minimum set by the case study of 97% of the total work. This study proposes using Lean tools such as Standardized Work, Line Balance and Last Planner System. For this purpose, the process and the times required for the development of activities in different areas will be standardized. The next step will be to calculate the resources needed to start activities, culminating with planning and continuous improvement. The results were validated in the Arena software, one of the critical indicators being the planning effectiveness index (PEI), which is to be increased by 27% concerning the initial scenario.
    Acceso abierto
  • Analysis of the water-food nexus for food security in a high Andean Community

    Fiestas, M. A.; Gonzalez, S. N.; Gomez-Cunya, L. A. (Institute of Physics, 2022-01-01)
    Water and food are facing increasing demand worldwide. This increase is significant in mountainous regions where glaciers are melting, and water availability is in danger. Food demand has also increased with the population growth. This study sought to evaluate relationships between water supply and food demand in a community located in the Peruvian Andes mountainous region. The developed methodology reveals a practical way to identify future problems with food availability. Water supply was evaluated using historical precipitation data. On the other hand, water demand was estimated using meteorological data. Irrigated areas were determined using 2019 agricultural data from the local government. Food consumption was evaluated using a 2019 per capita regional consumption. Results show a water deficit for the current agricultural demand for ten out of the twelve months. The potato was the main crop being produced in the community, among sixteen studied crops. A high percentage of the time, many products were found do not satisfy local demand. For example, the potato was found to secure only fifty-five percent of the total local-demand fifty percent of the time. Current results can help the management of food security.
    Acceso abierto
  • A framework for design lean supply chain: a case study in a Peruvian concrete company

    Arauco, Ivan; Ramos, Edgar; Mesia, Ron; Coles, Phillip S. (Inderscience Publishers, 2022-01-01)
    This paper seeks to demonstrate the positive effects of a lean supply chain at a concrete company. Management of this lean SC illustrates a new lean SC approach in the Peruvian construction industry. This case study provides a lean SC framework. The proposed methodology is introduced step-by-step according to lean management concepts; each step uses lean tools: visual management, 5S methodology, and standardised work. The findings demonstrate the viability of the methodology. We summarise the results and conclusions obtained in the research. These specific tools improved metrics in each SC process studied: source, make, and deliver. Delivery times were improved by 20%, and SC costs were reduced by 8%. This case study shows the benefits of costs and time. It demonstrates that the lean SC framework and tools applied to an integrated SC achieved exceptional operational results.
    Acceso restringido temporalmente
  • Incremento del nivel de servicio en un clúster ferretero a través de la aplicación de metodologías mixtas

    Quiroz-Flores, Juan Carlos; Campos-Sonco, Jakeline; Saavedra-Velasco, Valeria (Associacao Iberica de Sistemas e Tecnologias de Informacao, 2022-01-01)
    The problem identified in hardware SMEs engaged in the marketing and distribution of various products is the poor management of their warehouses because they use long times to carry out the processes of receiving products, storage and picking. In addition, they are unaware of the inventory accuracy, which causes stock ruptures and does not allow in many cases the complete delivery of orders. All this causes the company’s service level to be below standard. The proposal designed consists of the application of the 5S, ABC, System Layout Planning and Work Standardization tools to improve warehouse management. Among the main results of the research, the service level was increased to 95%, the picking process time was reduced by 55%, the storage time by 57% and the product reception time by 63%.
    Acceso abierto
  • Conceptual model to reduce non-contributory time based on Lean tools in the construction industry in Peru

    Cabrera, Olenka; Tejeda, Joselyn; Llontop, Jose; Alvarez, Jose C.; Demirkesen, Sevilay (Institute of Electrical and Electronics Engineers Inc., 2022-01-01)
    The construction sector in Peru is growing and is one of the most important, representing 19% of GDP. However, currently, in the construction industry, there is a high rate of non-contributory time, that is, the activities carried out during the construction process have a large percentage of time dedicated to activities that do not add value and lead to losses. This research attempts to reduce the high rate of non-contributory time (NCT) in building maintenance services in a Peruvian company in the construction sector. To achieve this, a conceptual model at the managerial level based on Lean tools such as Kanban, 5S, TPM was proposed.
    Acceso restringido temporalmente
  • Model based on TPM and Standardization for the maximization of efficiency in an SME in the plastics sector

    Aguilar-Schlaefli, Jhonatan; Campos-Campos, Zuyeiry; Leon-Chavarri, Claudia; Saenz-Moron, Martin (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The plastics industry is important in the world due to its recurrent use in daily life and the supply it provides to other sectors such as medicine, transportation, health. Previous studies show that the average difference in global efficiency between the manufacturing industry and the World Class ranges between 15 to 25 percentage points, also affecting the plastics sector. The case study presents a gap of 17% regarding this metric in the thermoforming line. This efficiency gap has had an impact on cancelled orders, which generate 18.8% of annual sales losses. During the analysis it was determined that availability losses are generated by constant machinery breakdowns and quality losses are caused by the high rate of nonconforming products. Thus, in view of the scarcity of efforts in the sector, an efficiency maximization model is proposed that combines the management of time and machinery with the quality associated with the process. To this end, the integration of tools such as 5S, autonomous and planned maintenance to reduce unscheduled stops and standardization under a continuous improvement framework to reduce the sources of quality loss is proposed. In this way, an improvement of 12.15% in the efficiency of the line is achieved, increasing by 3.36% and 10.96% in the Availability and Quality indicators respectively for the M4 thermoforming machine.
    Acceso abierto
  • BPM and cycle counting in the design of a model to increase the perfect order: a case study in a company in the commercial sector

    Fernandez Lopez, Kevin Scott; Monte Barahona, Karim; Altamirano Flores, Ernesto (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    This paper aims to evaluate the level of delivery compliance in an industrial tools trading company in Metropolitan Lima, based on the decrease in sales observed in the year 2020. For this reason, a quantitative and qualitative diagnosis of the company was carried out, where a low level of delivery compliance was observed, which is generating an economic impact of about 15% of the company's annual income. Furthermore, this problem is measured through the technical gap of the percentage of perfect deliveries, which is currently 64.5%, below the current market. In this sense, a model was proposed to increase the percentage of perfect orders through the implementation of Cyclic Counting, 5S, AHP and BPM in order to increase the Inventory Record Accuracy (IRA), avoid confusion in the selection of products, make an adequate selection and evaluation of suppliers and identify those activities that do not add value. In this way, the simulation of the model will be carried out and a decrease in late and incomplete deliveries will be observed, obtaining a value of 74.3% of perfect orders and a 25% increase in sales.
    Acceso abierto
  • Production management model to reduce late deliveries in a metal-mechanical SME using lean tools

    Orellana-Nuñez, Nicole; Puerta-Girón, Miguel; León-Chavarri, Claudia (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The metal-mechanic industry is indispensable for the economic growth of a country since it generates capital goods for industrial sectors at a national and international level. Currently, metal-mechanic SMEs face different challenges to meet their customers' demand at the right time and with quality products. The article studies a medium-sized metal-mechanic company with an on-time delivery percentage of 66.94%, generating dissatisfaction in its customers and economic losses close to 50 thousand dollars. To solve the problem, a production management model is proposed exclusively for SMEs with MTO production systems that includes 4 Lean tools. To validate the model, a pilot program was chosen, and an adequate production rate was achieved to meet the required production demand, thus validating the efficiency of lean techniques to solve problems in a scenario of medium-sized manufacturing companies.
    Acceso abierto
  • Production optimization model to increase order fulfillment by applying tools under the Lean Green philosophy and TPM in plastic manufacturing SMEs

    Garrido-Silva, Ricardo; Marquezado-Yamunaque, Katherine; Quiroz-Flores, Juan Carlos (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The plastic sector sustains an important growth based on production worldwide and nationally during the last years. However, this growth in production can be affected by the various problems that the sector sustains, harming the availability of plastic products and thereby affecting customers, this impact is reflected in customer losses due to the non-fulfillment of orders or additional payments for penalties imposed by them. In this context, companies in the plastic sector aim to reduce machine downtime rates to increase availability and thereby maintain smooth production and thus increase the order fulfillment rate. After the above, in the research, the problem that generates a low rate of order fulfillment is due to the constant blowing machine shutdowns in the plant. Therefore, it is proposed to design a model based on the Lean Manufacturing philosophy, using tools such as 5S, SW, TPM and SMED, based on applications of the Lean Green philosophy; with the aim of reducing stops in the blowing machine making it more efficient and environmentally friendly. This research emphasizes the most representative product of the company, the drums, developing the diagnosis in the blowing process, which, the root causes were quantified with respect to the main problem, through the tools of the Lean Manufacturing philosophy it is proposed to address each cause and mitigate them. Finally, the model that has been proposed manages to reduce the rate of machine shutdowns by 55.48%, giving greater availability to the blowing machine and with it a better production flow, which generates an increase in the order fulfillment rate by 74.59%. In this way, a precedent is achieved in the plastic sector regarding the improvement of blowing processes.
    Acceso abierto
  • Maintenance management model to increase availably in a metalworking SME applying TPM, SMED and PDCA

    Espinoza-Huamash, Mirella; Arana-Hurtado, Irvin; León-Chavarri, Claudia (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The variability of demand has led metalworking SMEs to develop more efficient processes. Therefore, increasing availability is a necessity to maintain competitiveness in the market. The main problem of the sector is the deficient maintenance system that involves machine and operator performance, causing losses in 8% of profit. Therefore, a maintenance management model is implemented, where the basis consists of improving the work environment and operator performance through 5S and TPM (Safety, Health and Environment). Subsequently, the disuse and setup time of each machine is reduced through the application of SMED, autonomous and preventive maintenance. The level of availability was increased by 4% and continuous improvement was applied to the indicators, which further increased availability by 2%. In summary, the successful implementation of the model depends not only on the diagnosis of the machines, but also on the commitment of the operator and management.
    Acceso abierto
  • Implementation of engineering techniques for reducing waste in Warehousing: A case study in a Peruvian Food Company

    Chumpitaz-Martínez, Enzo; Sanchez-Sotelo, Alonso; León-Chavarri, Claudia (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    ompanies belonging to the food sector are exposed to a problem related to the loss of products during the production and commercialization processes, which mainly causes an increase in the amount of waste generated. The objective of this research is the reduction of waste generated during warehouse operations in a food company, which presents an increase in its waste ratio equivalent to 233% compared to previous years. The implementation of Lean Warehousing tools was developed, specifically Kaizen Teian and Kanban Pull, together with the Slotting warehouse strategy considering the useful life of the products as a criterion. With the development of these tools, the food waste ratio is expected to be reduced to a value close to the industry standard, corresponding to 0.25%.
    Acceso abierto
  • Lean Service management model to reduce canceled orders in a fast-food company

    Avalos-Maldonado, Jazmin; Mezarina-Azaña, Elizabeth; Quiroz-Flores, Juan Carlos (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The restaurant subsector is of great importance in the country's economy, generating a contribution of 2.8% of the national GDP. However, based on the research carried out, some problems that afflict the industry were identified, being the high rates of canceled orders the main problem that affects the study company. This problem results in customer dissatisfaction, so it is vitally important to reduce the causes that generate the cancellation of the client's orders. In relation to the above, the case study presents a high rate of returns surpassing the sector by 13.46% negatively impacting the profitability of the company. Therefore, a model based on the PDCA cycle was used, implementing Lean, BPM and FEFO Inventory Management tools with the aim of reducing canceled orders in the company. The implementation of these tools was carried out in different stages, taking as baseline the following indicators: percentage of overdue supplies, distance traveled, occupancy rate and level of satisfaction. At the end of the implementation, the % of cancelled orders was reduced by 9.7% and the percentage of overdue supplies decreased to 7.71%. In this way the distances traveled were reduced to 2255.6 meters improving the gross margin of the company. The result will be used as a reference and example for future implementations to the rest of the companies in the sector.
    Acceso abierto
  • Applying Lean Manufacturing tools to minimize waste in a mass consumption food company

    Lagos, Maricielo; Luis, Katsuhiro Nishizawa; Ramos, Edgar (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The Bakery and Confectionery industry has expanded over the years and the products that make it up have taken an established place in people's diets. Many companies today seek to increase their market share while adding value to their products using fewer resources through process optimization, waste elimination, increased performance and productivity. Because of that the purpose of this research work is to provide the concepts of the Lean Manufacturing methodology and its Kaizen, Total Productive Maintenance (TPM) and Centerline tools, an example of its application in mass food consumption companies. Likewise, the application of the Lean methodology and its tools is carried out to a case study developed in a transnational cookie company with the purpose of guaranteeing the achievement of the internal objectives of the company, evaluating the processes and identifying the waste that is generated. in the production process to propose possible solutions.
    Acceso abierto
  • Lean Manufacturing Model to improve the order fulfillment in a company in the wine sector

    Diaz, Maria Isabel; Dioses, Giancarlo; Ramos, Edgar (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    The wine industry has grown in recent years causing many of the companies in the sector to improve their processes. When it comes to medium and large industrial facilities, there are always some well-known methodologies that are adopted to boost their growth and minimize logistics costs. While, in the case of PYMEs, there is no provision as such to apply any Lean Manufacturing or process management technique. The case study is Bodega Peru SAC, which presents difficulties in fulfilling the perfect order due to deficiencies in its logistics processes. The purpose of this study is based on properly managing the Supply Chain to increase its performance and reduce logistic costs. The processes that cause bottlenecks or have high error rates have been identified in the case study. Likewise, the study is based on information from researchers for the analysis of supply chain processes related to the industry.
    Acceso abierto
  • Model to increase the use of production capacity using Lean tools in the paint subsector

    Allison Lizeth, Garcia Contreras; Ronaldinho Joel, Leon Janampa; Fernando, Maradiegue Tuesta (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    Currently, the contribution to the PBI of the construction sector has increased, which generates a greater demand for its products. Also, the production of paints fails to meet the demand generated, so the problem to be addressed in this article is the use of production capacity in a manufacturer of industrial paints with an annual turnover of approximately 80 million soles, which currently uses an average of 53.29% of its installed capacity, below the 69.7% average of the sector, generating large losses of money for the company. The case study was carried out so that it can be replicated with other companies with a similar context and generate added value to the sector, therefore an improvement model is proposed by applying the tools and methodology of Aggregate Planning, Autonomous TPM and SRM through the integrated application of the above mentioned providing an efficient production planning, an improved maintenance plan and the approval of suppliers. Validation of the tools was performed with case studies that presented similar problems. The proposed model implements and integrates the main techniques, managing to increase mill availability to 93%, reduce reprocesses and the percentage of error in the demand forecast by up to 1% and eliminate the stock-out of raw material, thereby increasing the use of production capacity. Finally, an increase of 16% is obtained for the use of production capacity, with an NPV of $68,732 and IRR of 45.54%, which indicate that the project is profitable and optimal for the company.
    Acceso abierto
  • Production management model to reduce non-fulfillment of orders in Peruvian garment SMEs through 5S, SMED and standardization tools

    Silva-Castro, Daniela; Campoblanco-Carhuachin, Rafael; León-Chavarri, Claudia (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    Currently, formal SMEs in the textile sector represent 16.4% of Peru's manufacturing SMEs, in other words, there are approximately 32,137 companies in this sector. The textile industry is the third largest contributor to manufacturing and is intensive in the generation of approximately 400,000 direct jobs. However, one of the main problems that prevents it from competing effectively with other countries in the region is related to non-fulfillment of orders. Also, lack of communication in the organization, inadequate operator training and employee resistance to new changes are the main barriers faced by companies in the sector during lean implementation. This research study will focus on reducing order non-compliance in an SME in the apparel sector using 5s techniques, SMED and standardization. An improvement is expected in relation to the problem, in addition, it is intended to develop a framework of lean practices that will serve companies in the sector. In this way, it contributes to the existing literature.
    Acceso abierto
  • Increased efficiency of a metalworking SME through process redesign using SMED, Poka Yoke and Work Standardization

    Huertas-Reyes, Anell; Quispe-Huerta, Stefany; Leon-Chavarri, Claudia; Velasquez-Costa, José (Latin American and Caribbean Consortium of Engineering Institutions, 2022-01-01)
    After the difficult period during the year 2020, the metal-mechanic sector has been characterized by its high participation in the Peruvian GDP. However, by not having established working methods, productivity in the production process is affected and in comparison, at national level, companies in other sectors have an efficiency greater than 80% in their processes, which generates an increase in competition. This article intends to incorporate to the literature through the combination of Lean Manufacturing tools: The SMED tool will be used for the reduction of Set Up times; Poka Yoke, to avoid human errors through a mold that will prevent defects in the bending machine and through the standardization of work, to establish best practices in the various manufacturing processes of metal racks. The main result of this proposal is the reduction of man-hours lost in non-value generating activities to increase efficiency in the analyzed processes of the organization.
    Acceso abierto

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