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<p>This article presents the application of Lean manufacturing principles, supported by digital tools, to optimize the support areas of an automotive parts supplier. The study aims to reduce work‑in‑process inventory and eliminate operational waste through a two‑phase improvement strategy. The first phase consists of a comprehensive analysis of existing processes to identify inefficiencies and sources of waste. The second phase involves the design and implementation of a dedicated software system for traceability and control of reworked materials. The proposed digital system provides precise monitoring of material flows and enables real‑time data collection to support informed decision‑making. The results demonstrate substantial gains in operational performance: work‑in‑process inventory was reduced by 40%, and the incidence of defective parts decreased by 60%. The results confirm that the integration of Lean methodologies with digital solutions significantly improves efficiency, productivity, and quality in support operations. Furthermore, the implemented improvements establish foundational capabilities for the organization’s transition toward a smart-industry framework.</p>

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Integrating Lean and Digital Traceability to Reduce Work-in-Process Inventory and Defects in Automotive Support Operations

  • 期刊论文

  • 发表日期：

    2026年6月2日

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  • Jesús del Carmen Peralta-Abarca,
  • Pedro Moreno,
  • Sergio Nesmachnow,
  • Diego Rossit

摘要

This article presents the application of Lean manufacturing principles, supported by digital tools, to optimize the support areas of an automotive parts supplier. The study aims to reduce work‑in‑process inventory and eliminate operational waste through a two‑phase improvement strategy. The first phase consists of a comprehensive analysis of existing processes to identify inefficiencies and sources of waste. The second phase involves the design and implementation of a dedicated software system for traceability and control of reworked materials. The proposed digital system provides precise monitoring of material flows and enables real‑time data collection to support informed decision‑making. The results demonstrate substantial gains in operational performance: work‑in‑process inventory was reduced by 40%, and the incidence of defective parts decreased by 60%. The results confirm that the integration of Lean methodologies with digital solutions significantly improves efficiency, productivity, and quality in support operations. Furthermore, the implemented improvements establish foundational capabilities for the organization’s transition toward a smart-industry framework.