Process Optimization through the Implementation of SLP, Kanban, Poka-Yoke and TPM to Improve Efficiency in a Metalworking SME

Currently, the metal-mechanic sub-sector faces several challenges in its production processes, such as long lead times, order delays and decreased product quality. These problems have a negative impact on operational efficiency, leading to non-compliance in delivery times and, as a consequence, economic penalties. To address this situation, an exhaustive analysis of historical order records, a time study of each stage of the process, the development of a cause-effect diagram and the application of the Pareto principle (80/20) to identify the most relevant root causes are carried out. Based on this diagnosis, a model i s developed that delves into applying Lean Manufacturing tools adapted to medium-sized companies. The tools used in this study include Line Balancing (LB), Poka-Yoke, Total Productive Maintenance (TPM) and Systematic Layout Planning (SLP). The validation of the model is done through a pilot, prototyping and simulations, achieving an increase of 14.7% in the efficiency of the production process. In summary, this model can be implemented in similar environments, requiring only minimal adjustments for its adaptation.