Optimización de procesos operativos basado en herramientas de Lean Manufacturing en industrias de ensamble de bicicletas

Abstract

Manufacturing and assembly industries are constantly searching to optimize their resources and achieve improvements in their production systems. At a time when the differentiating factor is found in efficiency and competitiveness in production, lean manufacturing philosophy contributes to these differentiators, focusing mainly on the elimination of waste to obtain an improvement in the processes, quality and delivery times, being evident the results in a short period of time. This article proposes optimizing processes within a bicycle assembly plant by applying a lean manufacturing tool called Value Stream Map (VSM), which presents the sequence of production processes and requirements of each one, graphically reflecting the current situation and facilitating the identification of waste within the system. For illustrative purposes regarding process mapping, a bicycle model identified as E 26 was selected. Additionally, the tool 5 S that seeks to maintain tidiness and cleanliness within the processes for obtaining an agile production flow is used. The work also includes the balancing of lines, obtaining a reduction of 14% in cycle times and 66% in lead time, generating a mixed production (push and pull). In addition, a warehouse distribution of raw material, obtaining the unification of all the materials involved in the process. Finally, it was verified the validity of the future VSM through software of simulation of discrete events, being an important contribution in the study, obtaining validating the results obtained from the application of tools lean manufacturing.