Improvement of productivity by applying 5S, Work Standardization, Ergonomic Analysis and Poka Yoke in Metalworking Company

Abstract

This company manufactures faucets and sanitary ware in Lima, Peru. This study will focus on the faucet product line. This research focuses on studying a company within the metal-mechanic sector that faces productivity issues, negatively impacting its competitiveness. Periodic visits to the company were conducted to collect data. Various tools, such as “5 Whys”, Ishikawa diagram and Pareto diagram, were employed to identify the main issues, revealing significant problems such as poorly optimized workstations, low-quality parts, high unproductive times and improper machine usage, among others. The root causes were identified to address them using Lean Manufacturing tools, including 5S, Work Standardization, ergonomic analysis and Poka-Yoke. Improvements were simulated using Arena software, yielding remarkable results, such as a 24% reduction in human errors per quarter, an 11.11% increase in productivity, and a 5% reduction in non-productive times. Finally, the profitability of the proposal was evaluated through a Net Present Value (NPV) of 1,792,845.45 USD, an Internal Rate of Return (IRR) of 66.56%, and a return on investment within less than 1.5 years.