Propuesta de optimización de procesos operativos basados en herramientas de Lean Manufacturing en industrias de emsamble

Abstract

Competition and economic dynamism force the assembly industries to look for productive philosophies of improvement, optimizing processes, and resources. The challenge in the optimization involves which tools to be applied will grant an optimal process. The present work proposes the optimization of processes, taking as a case study a motorcycle assembly company, through the application of Lean Manufacturing (LM) tools and additional concepts such as: 1.- Plant distribution, which together with the change of the productive system of work cells to assembly line, allows the reduction of distances traveled, elimination of unnecessary movements and reprocessing; 2.- Pull System, which achieves a reduction in stock of both product in process and final product in the warehouse, avoiding the generation of future waste (silent in LM) and expenses for overproduction; and 3.- 5S tool, which entails maintaining order and cleanliness inside the plant to facilitate the management of internal resources. The main results of this study are an average reduction of 40% in assembly time and an average increase in production of 30% of all motorcycle models.