Design and implementation of Preventive Maintenance and 5'S tools to reduce costs in a bakery company

Abstract

The present study focused on a baking company, specialized in the production and sale of bakery products. During the investigation, two main problems were identified: The poor maintenance plan of the industrial oven and the lack of order and cleanliness. To carry out these improvements, the implementation of preventive maintenance and the 5S methodology was proposed. Specific action plans were developed using Monte Carlo to simulate various scenarios such as downtime due to unplanned shutdowns and to obtain more realistic estimates of the time required to complete 5S-related tasks. Additionally, a financial evaluation was carried out, projecting a positive cash flow and calculating key indicators. The results revealed a significant reduction of 14.83% and 29% for preventive maintenance and 5S methodology, respectively. In the economic evaluation, a Net Present Value (NPV) of S/. 22,751.99 and an Internal Rate of Return (IRR) of 56.11%. These findings indicate the positive and profitable impact of implementing these improvements on the efficiency and profitability of the baking company.