Diseño e implementación de herramientas lean y de mejora continua en el área de producción de una empresa de manufactura

Abstract

The Ecuadorian manufacturing industry, which is mostly made up of MSMEs, faces challenges such as resource waste, lack of standardization, and resistance to change. These factors affect its competitiveness, efficiency, and sustainability. In response to this situation, the application of Lean and continuous improvement tools was proposed as an alternative to improve operational indicators of companies in this sector. The objective of this thesis project was to design, implement, and evaluate these tools in a company that produces products based on non-metallic minerals. The methodology was developed in three stages. First, the organizational context was analyzed through a Value Stream Mapping (VSM) to identify the main wastes. Then, Lean and continuous improvement tools were selected based on a systematic review using the Fink methodology and a PICK matrix, prioritizing 5S and the PDCA cycle. Finally, these tools were implemented in the packaging area, documenting the processes and monitoring key performance indicators (KPIs). The results showed an improvement of over 30% in monthly production after implementing 5S, in addition to a reduction in operational downtime linked to disorganization. More than 80 non-conformities were identified and resolved through internal audits. The PDCA cycle made it possible to close the improvement process by standardizing activities, optimizing the layout, and monitoring indicators. In conclusion, the structured application of Lean and continuous improvement tools enhances efficiency, fosters a culture of continuous improvement, and can be replicated in other manufacturing companies in the sector.