Improving Production Process Efficiencies at a Peruvian Company through a Lean Manufacturing Implementation Model

One of the most important Peruvian manufacturing industries is footwear since it generates a large contribution to GDP. In fact, this industry is very competitive since customers commonly demand higher quality products at lower prices. Hence, companies must constantly improve their processes to be able to produce more units in less time with better finishes. It has also been reported that one of the most prominent issues facing Small and Medium Enterprises in Perú are poor production processes since their nationwide efficiency rate is set at 46%. This research study focuses on improving a Lean Manufacturing implementation through the application of 5S, Work Standardization, Kanban and TPM (Total Productive Maintenance) at a micro footwear company located in Lima whose main problem is poor production processes. This model will be validated using the Arena Simulation software. The results are an improvement in production efficiency of 55% to 87%. In addition, cycle times were reduced by 68%. and on-time order deliveries increased from 65% to 98%.