Applying Lean Manufacturing Technologies for Productivity Improvement in an Industrial Glue SME

Abstract

The research utilizes Lean Manufacturing tools to enhance productivity in a small company that specializes in the production of industrial glue. For this purpose, we conducted a methodological process to diagnose the industrial glue production activities through direct observation and interviews. We quantified this data in a time study and constructed a Process Operations Diagram (POD). Over-processing waste was identified in the cleaning and drying stages, resulting in waiting times in the shelling and milling sub-processes. Kanban cards and a visual control board (Andon) were implemented, in addition to standardizing activities in the cleaning and drying subprocesses at the simulation level using the FlexSim tool. As a result, the times of the cleaning and drying subprocesses were improved, in addition to a reduction in reprocessing during the production of industrial glue. Likewise, an increase in raw material, labor, and energy productivity of 29.8%, 17.1%, and 33.4%, respectively, is projected. This results in a 16.67% increase in total productivity, due to improved resource management and the minimization of waste in the production process. From the economic perspective, the use of Lean Manufacturing tools results in a positive NPV of S/94,829.56 and a Cost Benefit Index of 3.43, demonstrating the significant economic benefits of the proposal