Este trabalho apresenta a aplicação de uma metodologia para estudos de postos de trabalho com o objetivo de reduzir desperdícios, aplicar melhorias de layout e consequentemente melhora da ergonomia de um posto de trabalho de uma indústria do ramo automotivo, visando o diagnóstico do processo em questão, encontrando assim, oportunidades para melhoria do mesmo. Para realizar este diagnóstico e identificar as melhorias pretendidas foi utilizada a ferramenta de análise de tempo MTM (Methods-Time Measurement), técnicas de balanceamento, ergonomia e estudo de layout. Atualmente há muitas empresas no mundo que utilizam o MTM (Methods-Time Measurement), que é um sistema de tempos pré-determinados. A eliminação dos desperdícios com a finalidade da redução de tempo é necessária para o aumento da produção que será aplicado em 2012, que tem como objetivo a passagem de 29 veículos por hora para 40 veículos por hora na linha de montagem. Para o estudo de caso, foram selecionados três postos, os quais são nomeados segundo suas operações principais. O primeiro deles, Filme CAPOT, compreende a colocação de filme protetor sobre o capot do veículo na saída da linha de montagem. O segundo, Filme TETO, corresponde à colocação do mesmo filme sobre o teto do veículo. Já o Posto ECOM é onde ocorre a liberação do veículo para comercialização. Utilizando a análise de posto com as ferramentas já listadas, foi possível diminuir o tempo necessário ao operador para que mesmo realize suas atividades e assim aumentar a capacidade produtiva da empresa em 48,9%, ou seja, passa-se de 31,1 para 46,3 veículos por hora. A ergonomia do espaço de trabalho teve sua avaliação global modificada nos postos de colocação de filme de proteção no CAPOT e TETO em função da modificação do layout dos postos propiciando aos operadores menores deslocamentos e posturas de trabalho mais ergonômicas que estão abordadas no corpo do trabalho. Temse também o ganho relacionado ao espaço físico, os três postos utilizavam, juntos, 300,9m do prédio da empresa já na situação proposta necessita-se apenas de 142,6m, uma redução de 52,6%. / This paper presents the application of a methodology for studies of work stations in order to reduce waste, implement improvements to layout and consequently improves the ergonomics of a work station at automotive industry, for the diagnosis of the case in question, finding opportunities for improvement. To make this diagnosis and identify the intended improvements was used a toll for analysis of time called MTM (Methods-Time Measurement), balancing techniques, ergonomics and layout study. Currently there are many companies worldwide that use MTM (Methods-Time Measurement), which is a system of predetermined times. The elimination of waste for the purpose of reducing the time is required for the increased production to be applied in 2012, which intends the passage of 29 vehicles per hour for 40 vehicles per hour on the assembly line. For the case study, we selected three stations, which are named according to their main operations. The first, Filme CAPOT, comprising placing protective film on the top of the vehicle off the assembly line. The second Filme TETO corresponds to placing the same film on the ceiling of the vehicle. Finally the station ECOM is where occurs the release of the vehicle for sale. Using the work station analysis with the tools already listed, it was possible to reduce the time required for the operator to perform the same activities and increase the companys production capacity in 48.9%, from 31.1 to 46.3 vehicles per hour. The ergonomics of the workspace had his overall evaluation changed at the placing protective film on CAPOT and TETO stations, because the modifying the layout of the stations enabling operators to smaller displacements and more ergonomic working postures that are addressed in the body of the work. There is also the gain related to the physical space, the three stations used together 300.9 m of the companys building, and after proposed situation they needs only 142.6 m, a decrease of 52.6%.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / This study proposes a production model that increases the manufacturing capacity in a small and medium-sized enterprise (SME) of garments with an aim to reduce the nonfulfillment of order deliveries. An assessment has been done and waiting times between production processes have been identified, along with defective products and inefficient work methods. This study proposes the design of a lean manufacturing model under the change management approach, whose methodology comprises five phases. In phase 0, awareness and training sessions are conducted (change management). Then, phase 1 reorganizes the work area (plant layout re-distribution and 5S) and phase 2 seeks better workload balances (line balance and Heijunka implementation). Later, phase 3 standardizes work methods (standardization). Finally, the proposed model will be validated to determine whether the selected operating tools are supported by the awareness that contributes to increasing production. © 2021, Springer Nature Switzerland AG. / Revisión por pares

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The contribution of the metalworking sector to the gross domestic product is decreased by 8.6% in the 2017–2018 period because of problems such as high rejection rates, lead times, and raw material losses. Consequently, the sector’s production was reduced by PEN 1,200,000 while demand remained flat. Thus, this article proposes a production control model using 5S, Single-Minute Exchange of Dies, and tools such as Kanban and Constant Work-in-Progress (CONWIP) to increase the productivity of a sand casting line in a Peruvian metalworking enterprise that manufactures parts for mining on request. The improvement proposal involves the implementation of lean manufacturing tools and analyzes low productivity effects. The problems identified are typical of the Peruvian metalworking sector; thus, this study may contribute to finding possible solutions for issues faced by other enterprises. / Revisión por pares

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / The Peruvian export supply is primarily based on the segment of dressings and condiments. This paper seeks to adapt lean manufacturing tools using Poka-Yoke techniques and process standardization, which may align with existing processes to prevent production errors. This combination of tools is expected to reduce the percentage of waste generated throughout the condiment production process. Subsequent to an initial evaluation of the current method combined with the application of both the tools, 11.4% waste reduction was ultimately reported. / Revisión por pares

A menudo las pequeñas y medianas empresas dependen en gran medida de su proceso productivo para posicionarse en el mercado. Sin embargo, son escasas las situaciones donde las empresas cuentan con los conocimientos y recursos financieros necesarios para mejorar su desempeño operativo y cumplir con los estándares de productividad. El presente artículo plantea un modelo de producción en la industria de fabricación de muebles metálicos combinando las herramientas de la filosofía Lean Manufacturing (5s, SMED y SLP) para la reducción de mayoría de las actividades que no añadan valor dentro del proceso de producción. El modelo se valida mediante una simulación del proceso de producción con los cambios planteados, en el cual se obtuvo una reducción en el lead time, a causa de la reducción de los tiempos improductivos identificados, de 6.79%. / Small and medium-sized companies often depend to a great extent on their production process to position themselves in the market. However, there are few situations where companies have the knowledge and financial resources necessary to improve their operational performance and meet productivity standards. This article presents a production model in the metal furniture manufacturing industry combining the tools of the Lean Manufacturing philosophy (5s, SMED and SLP) for the reduction of most of the activities that do not add value within the production process. The model is validated through a simulation of the production process with the proposed changes, in which a reduction in lead time was obtained, due to the reduction of identified unproductive times, of 6.79%. / Trabajo de investigación

Aunque la publicación de artículos sobre la adaptabilidad y aplicación de las herramientas lean, en el sector agrícola, en las diferentes plataformas de investigación es poco explorado, en especial si se enfoca en el Perú, algunos autores y profesionales han enfatizado su adaptabilidad a este sector. En ese sentido, este artículo propone un marco para la implementación eficiente de las herramientas lean en el sector agrícola de Perú, abordando los desafíos desde una perspectiva operativa y estratégica. Para ello, el artículo se basa en investigaciones científicos publicadas por algunos expertos en la materia de la filosofía lean, estas investigaciones incluyen revisiones de literatura, modelado y casos de éxito. / Although the publication of articles on the adaptability and application of lean tools, in the agricultural sector, in the different research platforms is little explored, especially if it focuses on Peru, some authors and professionals have emphasized its adaptability to this sector . In that sense, this article proposes a framework for the efficient implementation of lean tools in the agricultural sector of Peru, addressing the challenges from an operational and strategic perspective. For this, the article is based on scientific research published by some experts in the field of lean philosophy, this research includes literature reviews, modeling and success stories. / Trabajo de investigación

La industria gráfica en el Perú ha sufrido un incremento de alrededor un 20% respecto al año anterior. Sin embargo, esta, al estar conformada en su mayoría por micro y pequeñas empresas, presentan problemas de cumplimiento de los pedidos de sus clientes. Alrededor de un 37% de las empresas de la industria gráfica no cumplen con sus pedidos en los plazos fijados. El presente estudio se centra en una empresa que ha sufrido una reducción de sus utilidades de 17% a 5% en dos años, asociado a un incremento de costos operativos causados a su vez por un incumplimiento de pedidos. Los motivos asociados al incumplimiento de pedidos son la presencia de tiempos improductivos y la no disponibilidad de materia prima para iniciar con la producción. La problemática identificada presenta como causas raíz una deficiencia de layout y presencia de demoras por desorden en el área de trabajo. El estudio plantea la implementación de un plan piloto de la metodología 5S y SLP para atacar las causas identificadas. El plan piloto, se centra en la aplicación de Seiri, Seiton y Seiso. Shitsuke y Seiketsu fueron trabajados de manera conceptual. Asimismo, se implementó una nueva distribución de planta y un nuevo flujo de trabajo en forma de U tras la aplicación de SLP. Se concluye que, con la aplicación de este modelo planteado, se logra reducir el tiempo de ciclo en 31.6%, las distancias de traslado en 21.7% y, finalmente, el cumplimiento de pedidos mejora en un 65%. / The graphic industry in Peru grew in a 20% in comparison with the past year. However, since it is composed mostly by small and medium businesses, they have an issue regarding the orders fulfillment. On average a 37% of the companies from the graphic industry fail to deliver their orders on schedule. This study focuses in a company that has been suffering a reduction in their profit margins from 17% to 5% in two years. This was related to an operating cost increase associated with order unfulfillments. The order unfulfillment’s motives are the presence of unproductive time and the unavailability of raw materials to begin with the production. The root causes of the identified problem are a layout deficiency and the presence of delays caused by a disorder in the production area. The study proposes the implementation of a pilot plan for the 5S methodology and SLP for the mentioned causes. The pilot plan applies Seiri, Seiton and Seiso. Shitsuke and Seiketsu were developed in a conceptual level. In addition, a new plan layout and process flow was developed after the implementation of SLP. The study concludes that with the implementation of the proposed model a 31.6% reduction in the cycle time, as well as a 21.7% reduction in moving distances were achieved. Finally, a 65% improvement in the orders fulfillment is accomplished. / Trabajo de Suficiencia Profesional

Debido a la plusvalía del suelo y al incremento poblacional en los distritos Top de Lima, los proyectos inmobiliarios se diseñan con un mayor número de sótanos para poder cubrir la demanda de estacionamientos. Por lo que en la presente investigación vamos a emplear la herramienta Value Stream Mapping para optimizar el proceso de excavación masiva. El Value Stream Mapping es una herramienta empleada en la industria manufacturera que pertenece a la filosofía Lean Manufacturing, esta herramienta consiste en identificar el flujo de la cadena de valor de cierta actividad y mediante un gráfico tener una visión completa del flujo de trabajo y de todos los procesos involucrados. Mediante este mapeo resultará mucho más sencillo identificar los procesos que no aportan valor a la actividad para luego aplicar mejoras y poder optimizar el proceso de excavación masiva. Para analizar el proceso de excavación masiva se utilizaron datos obtenidos de tres proyectos ubicados en Lima cuyas profundidades de excavación fueron de 3 y 4 anillos. El mapeo de estado actual de estos proyectos nos permitió realizar un diagnóstico general e identificar los procesos con mayores tiempos no productivos. Finalmente, se elabora un mapa de estado futuro considerando la propuesta de mejora para el proceso de eliminación con pasamano de dos excavadoras, se implementa la propuesta de mejora en un cuarto proyecto con una profundidad de excavación de 6 anillos, con los resultados obtenidos se justifica que empleando la herramienta de Value Stream Mapping se puede optimizar el proceso de excavación masiva. / Due to the increase in land value and population growth in the top districts of Lima, real estate projects are designed with a greater number of basements to meet the demand for parking. Therefore, in this research we are going to use the Value Stream Mapping tool to optimize the massive excavation process. Value Stream Mapping is a tool used in the manufacturing industry that belongs to the Lean Manufacturing philosophy, this tool consists of identifying the flow of the value chain of a certain activity and by means of a graphic to have a complete vision of the workflow and all the processes involved. Through this mapping it will be much easier to identify the processes that do not add value to the activity and then apply improvements to optimize the mass excavation process. To analyze the mass excavation process, data obtained from three projects located in Lima with excavation depths of 3 and 4 rings were used. The current state mapping of these projects allowed us to make a general diagnosis and identify the processes with the longest non-productive times. Finally, a future state mapping is elaborated considering the improvement proposal for the two-excavator handrail disposal process, the improvement proposal is implemented in a fourth project with an excavation depth of 6 rings, with the results obtained it is justified that using the Value Stream Mapping tool the massive excavation process can be optimized. / Tesis

En los últimos años la demanda de empaques a nivel mundial y nacional se ha ido incrementando y se espera que esta tendencia continúe en los próximos años. Por ello, esta investigación propone mejorar la efectividad global de las impresoras de pliegos en una empresa de impresiones orientada a la elaboración de empaques, ubicada en la ciudad de Lima, Perú. Se buscará incrementar la disponibilidad de los equipos mediante la disminución de los tiempos de Setup y como consecuencia, incrementar los ingresos de la empresa. El capítulo 1 desarrolla el marco teórico en donde se obtienen información científica de las herramientas de ingeniería que utilizan otras empresas, las cuales les ha permitido mejorar sus procesos. En este capítulo se describen la metodología LEAN, las herramientas SMED, TPM, SW. En el capítulo 2, se describe la situación actual de la industria de impresiones y se identifica el problema principal, se analizan las causas y se proponen las herramientas de ingeniería que permitirá solucionar el problema detectado. En el capítulo 3, se validan las herramientas de solución, se describe las etapas de implementación, el cronograma y los indicadores de control. Finalmente, en el capítulo 4 se expone la validación del proyecto, mediante la simulación y el uso del software Arena, donde se calculará el OEE que logre la propuesta. También se realiza la validación económica con el análisis de flujo de caja y los impactos que genere el proyecto mediante la matriz de Leopold; finalmente se presentan las conclusiones y recomendaciones. / In recent years, the global and national demand for packaging has been increasing and this trend is expected to continue in the coming years. For this reason, this research proposes to improve the overall effectiveness of sheetfed printing in a printing company oriented to the production of packaging, located in the city of Lima, Peru. It will seek to increase the availability of the equipment by reducing the configuration times and as a consequence, increasing the company's income. Chapter 1 develops the theoretical framework where scientific information is obtained from the engineering tools used by other companies, which have allowed them to improve their processes. This chapter describes the LEAN methodology, the SMED, TPM, SW tools. In Chapter 2, the current situation of the printing industry is described and the main problem is identified, the causes are analysed and the engineering tools are proposed that will allow to solve the detected problem. In Chapter 3, the solution tools are validated, the implementation stages, the schedule and the control indicators are described. Finally, in chapter 4 the validation of the project is exposed, through simulation and the use of Arena software, where the OEE achieved by the proposal will be calculated. Economic validation is also carried out with the analysis of cash flow and the impacts generated by the project through the Leopold matrix; finally, the conclusions and recommendations are presented. / Trabajo de Suficiencia Profesional

La presente tesis de investigación está orientada en la aplicación de herramientas Lean manufacturing para mejorar los procesos productivos de una empresa que fabrica y comercializa vidrios de seguridad para el rubro de la construcción. Actualmente, la empresa Cánovas S.A.C, require reducir el porcentaje mensual de productos defectuosos que se obtienen del procesamiento en la linea de producción de vidrio templado. El objetivo de la empresa, es disminuir el porcentaje mensual de productos defectuosos a un nivel igual ó menor al 4%, el cual se ha determinado a traves de un desarrollo estadístico, acompañado de artículos de investigación que respaldan dicho nivel porcentual. En el primer capítulo se describió el analisis del sector donde se desarrolla la empresa, es decir, la industria del vidrio, algunos conceptos generales, metodologías, casos de exito aplicando las herramientas de ingenieria, asi como tambien el marco normativo que involucra las operaciones de la empresa. Para el desarrollo del segundo capitulo, se destacan las principales caracteristicas de la organización, la identificación del problema y sus evidencias, analisis de los motivos y las causas que generaron la mayor cantidad de productos defectuosos en la linea de producción de vidrio templado, En el tercer capitulo se procede a evaluar y desarrollar el diseño integral propuesto para la solución. En el cuarto capitulo, este diseño propuesto, se validó en un modelo de simulación mediante el software Arena, el cual nos mostró los analisis de los resultados obtenidos en cada etapa del proceso productivo, del mismo modo, se presento el analisis financiero con los resultados económicos obtenidos para la implementación. Finalmente se muestran las recomendaciones y conclusiones obtenidas del analisis del proyecto de investigación. / This research thesis is focused on the application of Lean manufacturing tools to improve the production processes of a company that manufactures and markets safety glass for the construction industry. Currently, the company Cánovas SAC, requires to reduce the monthly percentage of defective products that are obtained from the processing in the tempered glass production line. The objective of the company is to reduce the monthly percentage of defective products to a level equal to or less than 4%, which has been determined through statistical development, accompanied by research articles that support said percentage level. In the first chapter, the analysis of the sector where the company is developed was described, that is, the glass industry, some general concepts, methodologies, success stories applying engineering tools, as well as the regulatory framework that involves the operations of the company. For the development of the second chapter, the main characteristics of the organization are highlighted, the identification of the problem and its evidences, analysis of the reasons and causes that generated the largest number of defective products in the tempered glass production line. third chapter proceeds to evaluate and develop the integral design proposed for the solution. In the fourth chapter, this proposed design was validated in a simulation model using the Arena software, which showed us the analysis of the results obtained in each stage of the production process, in the same way, the financial analysis was presented with the economic results obtained for the implementation. Finally, the recommendations and conclusions obtained from the analysis of the research project are shown. / Trabajo de Suficiencia Profesional