Increase of the Service Level in a Textile Company through Planned Maintenance complemented with KARDEX and ABC-XYZ

Abstract

The project addresses the issue of the low service level in a Peruvian textile company dedicated to yarn production. During the review of performance indicators, it was found that its average OTIF stands at 68.22%, a value below the national benchmark, which results in additional costs due to storing delayed orders, penalties, and idle time. Based on the diagnostic assessment conducted in the maintenance and warehouse areas, along with the analysis of historical data, several causes were identified that explain the process deficiencies: difficulty locating spare parts, disorganization in the maintenance warehouse, and the absence of an integrated maintenance plan. In response to this situation, a proposal combining three tools was developed. The ABC-XYZ analysis made it possible to organize and prioritize spare parts according to their importance and demand patterns. The implementation of a Kardex system helped register and control incoming and outgoing items in a more orderly way, reducing picking errors. Finally, a planned maintenance program (TPM) was designed, incorporating preventive and predictive tasks to reduce unplanned downtime. The proposal was validated through simulation, comparing the current situation with the improved scenario (AS-IS; TO-BE). The projected results indicate that the OTIF could increase to 77.95%, along with a significant reduction in search times, unexpected failures, and operational overcosts. The study shows that integrating these tools generates a strong impact on the company’s operations and response capacity, contributing to a more stable and predictable production environment.