Order Fulfillment Improvement Model Applying MRP, SLP with Digital Twins and Standardization Integrated with Poka Yoke in a Company in the Metalworking Sector

Abstract

The metalworking industry plays a fundamental role in the global economy. In this context, manufacturing companies in the metalworking sector with the Engineer to Order (ETO) and Make to Order (MTO) strategies have experienced significant growth in the industrial field. However, these companies face considerable challenges, one of them being delays in order delivery. These delays are due to multiple factors, including defective products, material shortages, and excessive travel times due to an inefficient distribution of work areas. In response to this problem, a model is proposed that integrates tools such as MRP (Material Requirements Planning), SLP (Systematic Design Planning) with Digital twins for plant redistribution, and process standardization techniques with Poka Yoke. The implementation of these tools seeks to optimize the production chain, reduce manufacturing times, and improve operational efficiency. The development of this model is measured with the On Time Delivery indicator, which seeks to go from 89% to 96%. This work not only seeks to address the specific challenges of the study company but aspires to become a replicable model to solve production flow difficulties and improve punctuality in the delivery of orders throughout the metalworking industry.