Improvement of Gembas in the Wood Industry: Integration of Lean Manufacturing and Ergonomics

Abstract

The timber sector in Cartagena is essential for the economic development of the city, significantly contributing to job creation and industrial growth. However, the sector faces challenges related to operational efficiency due to high levels of waste and non-value-added activities that impact its competitiveness. In this context, the present research project uses a representative company from the timber sector of Cartagena as a Case Study, which is engaged in the artisanal and semi-industrialized manufacturing of high-quality wooden products, operating in a limited space where cutting, assembly, painting, and storage activities are performed. This study analyzes the ergonomic conditions of the workshop, evaluating the physical and cognitive activities of the staff to identify improvements in processes, work postures, and the design of tools and workstations. The project aimed to improve the ergonomic and safety conditions of the gembas by implementing methodologies such as the 5S, enhancing the use of personal protective equipment (PPE), improving lighting and organization, in order to reduce the risks of injuries and accidents, promoting a safer and more productive work environment. The strategic implementation of Lean Manufacturing principles and ergonomics was essential in designing improvement proposals that increased efficiency in the gembas. This integrated approach not only improved the well-being of the workers but also increased productivity, reduced unproductive times, improved product quality, and ensured the sustainability of the business.