Diseño de un proyecto para el mejoramiento del área de producción usando herramientas Lean Manufacturing en la Empresa GUSTALAC S.A.

Abstract

The objective of this degree work was to design a research project for the improvement of the production area through an analysis of the current model for the production of the milk beverage. For the first step, the Ishikawa diagram was applied to determine the most significant causes that generate the company´s problems and the these causes were identified using the Holmes Matrix, where it was found that very high production cycles, poor personnel management and the lack of indicators are the causes of the greatest impact on the increase in unsatisfied demand. The research focused on the JIT methodology and Lean Manufacturing tools, such as 5S, Value Stream Mapping (VSM), KANBAN and the Pull System to establish the necessary strategies for improvement in the areas of milk storage, ingredient mixing, oat cooling and product packaging. In addition, tools for the analysis of the production process such as the multiple activities diagram and line balancing were used to analyze in depth the aforementioned causes. Posteriorly, a simulation was carried out using the FLEXSIM software, in order to compare the current production model and the design proposal with the corrected problems, obtaining improvements such as compliance with the 5S methodology from 46% to 85%, reducing the time required for shift changes from 43.10 minutes to 12.43 minutes, increasing efficiency from 94.33% to 97.33%, effectiveness from 93.67% to 95.67% and productivity from 88.33% to 93.67%; thus increasing the number of batches produced from 9 to 11 batches per day. In conclusion, the use of control and standardization tools is recommended in order to maintain the improvements obtained.