El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / There is a high margin of informality in small- and medium-sized companies in the bakery sector because of their lack of focus and poor standardization of their activities. Bakery SMEs, the activities of which have not yet been standardized, usually perform activities inefficiently, unnecessarily extending production times. The current average productivity of Lima-based SMEs is 1.7, a figure that, when compared with countries in the Pacific Alliance, is low. In addition, currently no methodologies seek continuous process improvement. Therefore, a Lean Process Management model was established to reduce activities and times. As validation, a production time simulation was performed in a warehouse, increasing the productivity to 2.08, with a percentage variation of 87.39% when compared with the initial productivity.

Currently, there is a large percentage of small and medium-sized enterprises (SMEs) in the Peruvian textile market that show economic loss because of the payment of penalties to customers, which are incurred owing to the delay in the delivery of order batches. This is due to poor production management and a lack of focus. The manufacturing sector is essential because of its high contribution to the country's gross domestic product. Currently, SMEs do not employ methodologies that help improve production and process management as they do not realize how important and necessary the methodologies are, in addition to how complex these may be. Therefore, this paper will propose a production management model designed for SMEs in this sector, based on Lean methodology where the objective is time reductions and production increases as well as exerting changes to the organizational culture. Thus, this model will help organizations to avoid incurring economic losses because of the payment of penalties for orders not delivered on time. To validate the present model, a time simulation was performed in the manufacturing area of a textile company. The result of this project was positive, since there was a 25% increase in productivity and a 20% reduction of takt time with respect to the initial data.

This research study seeks to identify and prioritize the causes of order fulfillment delays in a small wooden furniture manufacturing company. The authors propose a 5-phase Lean Optimization model to address and reduce this problem. Post-implementation results yielded a 54.87% reduction in material search and transportation times, a 32.86% reduction in travel times between stations, and a 19.81% increase in line efficiency. In addition, order fulfillment percentages increased from 12.5% to 60%.

For companies operating within the garment manufacturing industry, having frequent downtimes in their production flows is an extremely common issue. In this context, a balanced production line is required to prevent high waiting times due to limited productive capacity. A well-balanced assembly line allows products to be produced in an optimum time while using less resources, such as machines, materials, or labour, since the right number of products is produced with the exact amount of resources, thus generating savings in production costs. This paper seeks to foster optimum resource allocation through the line balancing tool. Finally, to define a work methodology, best practices were selected, and a procedures manual was developed focusing on Standardization. Both tools were implemented after implementing changes to the company culture by means of the Employee Empowerment tool. As a result of this implementation, workers acquired greater accountability and control over the resources, methods, and equipment of their work areas. After the proposed improvements had been deployed, the company reported an increase of over 20% in production line quality, performance, and efficiency.

El sector gráfico en Perú se encuentra constantemente con la necesidad de reducir tiempos de producción al intentar mantenerse dentro del entorno competitivo porque las entregas tardías al cliente ocasionados por el elevado tiempo de fabricación son problemas críticos. Estudios previos han propuesto utilizar la filosofía de Lean Manufacturing para reducir los tiempos de inactividad mejorando el flujo de información dentro de los procesos de producción. Estos estudios se basan en las grandes empresas manufactureras, pero no en las MYPES del sector gráfico que utilizan un entorno de fabricación bajo pedido. Por lo cual, este documento se centra en el uso de la herramienta Lean Manufacturing ajustada en una empresa MYPE con un entorno de fabricación bajo pedido para reducir sus tiempos de fabricación. Por lo tanto, los procesos Kanban, Single Minute Exchange of Dies (SMED) y Value Stream mapping (VSM) se adaptarán para su implementación en este tipo de empresas. Luego, el modelo se valida mediante su aplicación con el programa ARENA basándose en un caso de estudio. Esta simulación de procesos permitió que los tiempos de producción se redujeran en un 24%, entregando todos los pedidos a tiempo y eliminando el 100% de los costos de penalización por pedidos retrasados. / The printing sector in Peru constantly faces the need to reduce production time because late deliveries to the customer owing to high manufacturing time are critical problems. Previous studies have proposed using the lean manufacturing philosophy to reduce idle times by improving the flow of information within the production processes in large manufacturing companies but not printing SMEs using these tools in a make-to-order environment. This document focuses on implementing an affordable lean manufacturing model in an SME company with a make-to-order environment to reduce its manufacturing times. Therefore, the Kanban, Single Minute Exchange of Dies (SMED), and value stream mapping (VSM) processes will be adapted for implementation in these companies. Then, the model is validated through its application in a case study; through process simulation, production times were reduced by 24% for an SME, delivering all orders on time, and eliminating 100% penalty costs for late orders. / Trabajo de Suficiencia Profesional

En la actualidad, cada vez es mayor la cantidad de personas que opta por alquilar o comprar una vivienda. Junto a esa demanda, se activa el sector mobiliario, el cual es requerido para que gracias a la oferta de sus productos puedan equipar este nuevo espacio. La empresa Decorec SAC se encarga de la fabricación de sillas, muebles, sofás entre otros productos para el hogar, y totalmente personalizados. Actualmente, presenta diversos inconvenientes con los cumplimientos del programa de producción en los tiempos establecidos, que se reflejan en entregas tardías al cliente, generando penalidades y la utilización de recursos extras. El presente proyecto muestra que el modelo de propuesta de mejora basado en la metodología Lean Manufacturing, es capaz de revertir la situación actual. La metodología inicia con el diagnóstico VSM (Value Stream Mapping) con el fin de encontrar el proceso cuello de botella de la situación actual, para ello nos apoyamos en la toma de tiempos de cada proceso relacionado al producto en evaluación. Con el cuello de botella detectado y el análisis del problema, se establece el procedimiento a seguir para lograr la solución. Las etapas de la propuesta de mejora están definidas por: Selección de nuevo proveedor de materia prima, Formación en Lean Manufacturing, Balance de Línea, Aplicación de Sistema 5s, Implementación Andon, Implementación Poka Yoke, Implementación de Priorización de Pedidos y Optimización del Uso de Materia Prima. La metodología fue validada en una simulación empleando el Software Arena. Y gracias a los resultados se pudo comprobar importantes ahorros en tiempos, costos y disminuciones en los envíos tardíos hacia los clientes, además de lograrse la implementación de buenas prácticas en la gestión de los procesos de la empresa. / Today, more and more people are choosing to rent or buy a home. Along with this demand, the furniture sector is activated, which is required to equip this new space thanks to the supply of their products. The company Decorec SAC manufactures chairs, furniture and sofas, among other products for the home, which are totally personalized. Currently, it has several disadvantages with the fulfillment of the production program in the established times, which are reflected in late deliveries to the customer, generating penalties and the use of extra resources. This project shows that the improvement proposal model based on the Lean Manufacturing methodology is capable of reversing the current situation. The methodology starts with the VSM (Value Stream Mapping) diagnosis in order to find the bottleneck process of the current situation. To do this, we rely on the timing of each process related to the product under evaluation. With the bottleneck detected and the analysis of the problem, the procedure to be followed to achieve the solution is established. The stages of the improvement proposal are defined by: Selection of new raw material supplier, Training in Lean Manufacturing, Line Balance, Application of 5s System, Andon Implementation, Poka Yoke Implementation, Implementation of Order Prioritization and Optimization of Raw Material Use. The methodology was validated in a simulation using Arena Software. And thanks to the results, it was possible to verify important savings in time, costs and decreases in late shipments to customers, in addition to achieving the implementation of good practices in the management of business processes. / Trabajo de Suficiencia Profesional

En la actualidad, las industrias textiles presentan frecuentemente problemas en el área de producción, como los elevados tiempos de producción. Este es uno de los principales problemas que se presentan en este tipo de empresas, por la falta de organización de los procesos comprometiendo tanto la productividad como la competitividad de estas. Por ello, para la solución de este problema se propone la implementación de las herramientas del Lean Manufacturing y distribución de planta para reorganizar los procesos de producción, y a su vez, establecer métodos de trabajo adecuados, mediante el diseño de un modelo de optimización de tiempos en la producción, el cual consta en 2 fases enfocadas al proceso productivo y el personal. Como resultado de la implementación se obtendrá una reducción del tiempo de producción del 23.13% y 52.48%. del tiempo actual en el caso de edredones y sábanas, respectivamente. De la misma manera, se mejorará la productividad del operario, aumentando en 54.31% en el caso de edredones y 53.37% en sábanas. / At present, the textile industries frequently present problems in the production area, such as the long production times. This is one of the main problems that arise in this type of company, due to the lack of organization of the processes, compromising both their productivity and their competitiveness. Therefore, for the solution of this problem, the implementation of Lean Manufacturing tools and plant distribution is proposed to reorganize production processes, and in turn, establish appropriate work methods, by designing a time optimization model. in production, which consists of 2 phases focused on the production process and personnel. As a result of the implementation, a reduction in production time of 23.13% and 52.48% will be obtained. of the current time in the case of quilts and sheets, respectively. In the same way, the productivity of the operator will be improved, increasing by 54.31% in the case of quilts and 53.37% in sheets. / Trabajo de investigación

Aplica la metodología Lean Manufacturing para la mejora de la productividad en la empresa manufacturera ABRASIVOS S.A. Obtiene un incremento del 100 % de la productividad al duplicarse el flujo de producción en la fase inicial. En tal sentido concluye que la metodología desarrollada mejora la productividad y convierte en verdaderos agentes del cambio a las organizaciones. / Tesis

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 waste and reprocess problem in Peruvian apparel companies is greater than expected. After reviewing a history of losses and reprocesses, an innovative technical solution based on a combination of Lean Manufacturing and Agile tools is presented herein. This innovative proposal is implemented in the areas of cutting, embossing, and sewing in an apparel company. Value Stream Mapping results before and after implementing the proposed model are compared. The major achievement of this model is the significant reduction in loss percentage after two weeks of implementation.

La presente tesis tiene como finalidad aplicar técnicas y herramientas basadas en los conceptos de Lean Construction para una obra de conjunto residencial destinado a nivel socioeconómico de clase B en el distrito de San Miguel, Lima. Este proyecto nace con la necesidad de reducir el desperdicio generado en la etapa de acabados planteando herramientas específicas para el proyecto análisis de tal forma que se pueda mitigar el impacto por desperdicio en el costo final del proyecto. / Tesis