Application of Standardization Methods and Quality Control to Reduce the Defect Rate in a Footwear SME

Abstract

This research paper addresses the critical issue of the high rate of defective products in a footwear SME located in Lima, Peru. In a demanding market environment, operational inefficiency hinders growth; the initial diagnosis revealed that the company operated with a defective rate of 10%, generating significant cost overruns and material losses. The root causes, identified through preliminary analyses, included the lack of standardization in manufacturing processes, marked deficiencies in the quality control system, and the negative effects of high operational personnel turnover. With the strategic objective of reducing the defect rate to an acceptable limit of 3%, a continuous improvement methodology based on the PDCA cycle was deployed. The intervention integrated methods of engineering tools for work standardization and Statistical Process Control (SPC) techniques to mitigate production variability. The implementation phase encompassed the rigorous documentation of Standard Operating Procedures (SOPs), the design of visual manuals to accelerate learning, the introduction of inspection sheets at critical points, and technical training programs. The results project a substantial reduction in rework and waste, achieving the optimization of cycle times and fostering a preventive quality culture. This study demonstrates technical feasibility in SME environments. It is concluded that standardization and statistical control are low-cost, high-impact strategies, fundamental to guaranteeing financial sustainability, operational competitiveness, and end-customer satisfaction, validating the effectiveness of the proposed engineering solutions. Keywords-- standardization, quality control, continuous improvement, SME, footwear.