Mejoramiento productivo en el área de soldadura para camioneta Wingle aplicando herramientas lean: VSM, 9’S, KAIZEN en la Empresa CIAUTO

Abstract

The present research links theoretical knowledge with manufacturing processes in the industry, with the objective of achieving a productive improvement in the welding line of the company CIAUTO, in the Ambato canton. For this purpose, Value Stream Mapping (VSM), 9'S and Kaizen methodologies were applied, as well as the tools of the Lean Manufacturing philosophy. Production data were analyzed in the welding line of the WINGLE pickup truck model, then, the production line balance and study of methods and times were carried out, with the collection of data from the workstations, determining the takt, normal, standard, and slack times, to understand the welding process in a general way. With the CAD tool (Computer Aided Drawing) for the elaboration of the current VSM, the processes were analyzed and the sources of direct affectation to the productive process were determined, through the application of Kaizen action plans, such as: the implementation of a new workstation SR-2, exclusively destined to the cleaning of welding points; the redesign of the workstation ADJ-0 to shorten the distance between the component raks and the operators; keyboards were installed in the station ADJ-1,2 for the elevation of doors and their installation in the cabins. These improvements were used for the development of the future VSM, 9'S were implemented in certain stations that were not complying with the philosophy. The result was a significant improvement in the production process of the welding line, since, when evaluating the improvement achieved, an increase in productivity was obtained from 27 units produced with a takt time of 15:40 min with 19 workers, to 34 units with a takt time of 12:30 min with the same number of workers. In this way, a higher production was achieved with the same workers.