Impacto en la productividad de una empresa de manufactura usando la propuesta de la metodología 5S: caso de estudio fabricación de muebles

Abstract

This thesis addresses improving performance in the foam bonding area of a furniture manufacturing company through the application of a Lean Manufacturing tool: the 5S methodology, validated using discrete event simulation in FlexSim. First, data on the current situation was collected through time studies and analytical tools such as process flow diagrams, Ishikawa diagrams, and Value Stream Mapping (VSM), which allowed for the identification of the bottleneck in the study area. The methodology was developed in four phases: (i) diagnosis of the current situation, (ii) proposal of the 5S methodology, (iii) design of improvement alternatives, and (iv) evaluation of results using performance indicators. As a result, three proposals were formulated to improve the workspace, reduce travel distances, and optimize workflow. These alternatives were evaluated using FlexSim results tables to compare each proposal with the current situation. The results showed that Proposal 1 was the best alternative, achieving a productivity of 2.7 units per hour and reducing delivery time per model: Type 1 from 323.03 min to 251.91 min and Type 2 from 563.52 min to 358.04 min, reflecting a more stable flow and less accumulated waiting time. Finally, recommendations were established to ensure sustainability through training, 5S audits, and standardization.