Analysis of a Low OTIF Performance in a Footwear Company and an Innovative Proposal Using SMED, Autonomous Maintenance, RFID in a Lean Green Framework

This paper addresses a critical performance gap in a Peruvian footwear SME: the low On-Time In-Full (OTIF) delivery rate, which averaged only 74.26% in 2023. This shortfall led to financial losses equivalent to 9.42% of annual revenue and negatively affected customer satisfaction and operational reliability. To analyze the problem, industrial engineering tools such as Value Stream Mapping (VSM), Pareto Analysis, and ABC Inventory Classification were applied, identifying major inefficiencies including prolonged setup times, frequent unscheduled downtimes, and errors in picking operations. Compared with existing literature, similar issues have been addressed using Lean Manufacturing methodologies in sectors such as metalworking and food processing. However, these approaches often overlook environmental performance. Therefore, this study proposes a Lean Green innovation model tailored to low-automation SMEs. The solution integrates SMED, Autonomous Maintenance, RFID-based inventory tracking, and sustainable practices such as LED lighting and polymer waste reduction in mixing operations. The proposed model is projected to improve OTIF by 15 percentage points, reduce setup time by 50%, cut energy consumption by 35%, and decrease carbon footprint by 77%. The results suggest that Lean Green offers a scalable, cost-effective strategy for achieving both operational excellence and environmental sustainability in the footwear manufacturing sector.