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.

El proyecto de suficiencia profesional tiene como objetivo principal coadyuvar al descenso del alto índice de reprocesos en las empresas del sector manufacturero. Del estudio se comprueba que este problema se debe a una alta incidencia de paradas de máquinas, tiempos excesivos que conllevan su mantenimiento correctivo y a la inexistencia de procedimientos de actuación en casos de emergencia. Muchos autores han presentado diversas estrategias de mantenimiento, las cuales buscan administrar de manera eficiente las actividades de mantenimiento programado. Sin embargo, estos no son siempre efectivos, ya que no se aplican correctamente, dado a que los recursos no están disponibles o la estrategia no está dirigido a resolver el problema de forma directa. Por tal motivo, este proyecto plantea un modelo de solución, basado en el uso de herramientas lean, tales como 5S, Mantenimiento Productivo Total (TPM) y Single Minute Exchange Die (SMED), con la finalidad de asegurar una mayor confiabilidad de los equipos, reducir sus tiempos de mantenimiento y setup, así como mejorar el índice de reprocesos en una empresa del sector de manufactura no primaria. Tras la ejecución del Plan Piloto en la Planta I de dicha empresa, se obtuvieron resultados favorables que mejoraron los indicadores OEE de los equipos con condición crítica. A modo de ejemplo, se observó que el indicador OEE de la máquina centrífuga mejoró de una 46.84% hasta un 78.71%. Del mismo modo, esta mejora se notó en la máquina mezcladora, en donde el indicador mostró una mejoría de 53.78% a 79.08%. Asimismo, luego de aplicar la herramienta SMED en la Planta I de la empresa, se optimizaron los tiempos de setup de las máquinas centrífuga y mezcladora, los cuales se redujeron en 61.93% y 65.20% respectivamente. En síntesis, el proyecto generó beneficios económicos y productivos en la organización al reducir el índice de reprocesos de un 8.24% a 4.58%. / The project aims to contribute to reducing the high rate of reprocesses in companies in manufacturing sector. The study shows that this problem is due to a high incidence of machine shutdowns, excessive times that lead to corrective maintenance and the lack of action procedures in cases of emergency. Many authors have presented many maintenance strategies, which seek to efficiently manage scheduled maintenance activities. However, these aren’t always effective, since they aren’t applied correctly, given that the resources aren’t available or the strategy is not aimed at solving the problem directly. For this reason, this project proposes a solution model, based on the use of lean tools, such as 5S, Total Productive Maintenance (TPM) and Single Minute Exchange Die (SMED), with the aim of guaranteeing greater reliability of equipments, reduce maintenance and setup times, as well as improve the reprocessing rate in a company in the non-primary manufacturing sector. After the execution of the Pilot Plan in Plant I of this company, favorable results were obtained that improved the OEE indicators of equipments with critical condition. As an example, it was observed that the OEE indicator of the centrifuge machine improved from 46.84% to 78.71%. In the same way, this improvement was noticed in the mixing machine, where the indicator showed an improvement from 53.78% to 79.08%. Likewise, after applying the SMED tool in Plant I of this company, the setup times of the centrifuge and mixer machines were optimized, which were reduced to 61.93% and 65.20% respectively. In summary, the project has generated economic and productive benefits in the organization by reducing the reprocessing rate from 8.24% to 4.58%. / Trabajo de Suficiencia Profesional

Uno de los principales problemas existentes en las empresas manufactureras es el alto índice de reprocesos, debido a la alta frecuencia de averías de máquinas, sus tiempos elevados de reparación y a la inexistencia de un plan de mantenimiento. Con el pasar del tiempo, muchos autores han presentado varias estrategias de mantenimiento que buscan administrar de manera más eficiente los trabajos programados. Sin embargo, estos no siempre son tan efectivos, ya que no se aplican adecuadamente, los recursos no están disponibles o la estrategia no está dirigida a resolver el problema directamente. Esta investigación propone una propuesta de plan de gestión de mantenimiento productivo total basado en las metodologías OEE, 5S, TPM y SMED con el fin de asegurar una mayor confiablidad de las máquinas, reducir el tiempo de configuración y reducir los índices de reprocesos presentados en una empresa del sector de manufactura no primaria. Finalmente, se implementan las herramientas de manera gradual, solucionando el problema principal, a través de la reducción de reprocesos, pérdidas y mejorando así la utilización de máquinas. / One of the main problems in manufacturing companies is the high rate of reprocesses, due to the high frequency of machine breakdowns, their long repair times and the lack of a maintenance plan. Over time, many authors have presented various maintenance strategies that seek to manage scheduled jobs more efficiently. However, these are not always as effective as they are not applied properly, resources are not available, or the strategy is not aimed at solving the problem directly. This research proposes a proposal for a total productive maintenance management plan based on OEE, 5S, TPM and SMED methodologies in order to ensure greater machine reliability, reduce setup time and reduce the reprocessing rates presented in a company in the non-primary manufacturing sector. Finally, the tools are implemented gradually, solving the main problem, through the reduction of reprocesses, losses and thus improving the use of machines. / Trabajo de investigación