Improvement model to reduce internal lead time trough SLP, slotting and MRP in a metalworking plant

Abstract

This research was conducted in a micro-enterprise (MSME) in the metalworking sector, which, like other similar companies, faces logistical problems in its warehouse management. In this case, the Internal Lead Time (ILT) of the order preparation process was 4.74 hours, impacting the achievement of the internal customer service level and causing delays in the timely supply of materials to the production area. The diagnosis revealed unnecessary travel distances and disorganized storage of supplies as the root cause, associated with a layout that does not favor material flow, as well as frequent stockouts due to poor planning. An improvement model was proposed that integrates Systematic Planning (SLP), Slotting, and Material Requirements Planning (MRP). SLP reduces internal travel time, Slotting reduces search time on shelves, and MRP reduces stockouts. The Arena simulation, modeled with data from a pilot project, validates that the ILT was reduced by 18.6%, thus validating the effectiveness of the proposed model.