Lean tools are a set of methods and techniques that allow the elimination of waste, that is, everything that does not generate value, in order to achieve excellence. In this sense, the present article aims to increase productivity in a textile manufacturing workshop, reducing waste through the application of Value Chain Mapping (VSM), Waste Assessment Model Analysis (WAM) and the implementation of 9S. In this sense, the objective of this research is to increase productivity in a textile manufacturing workshop, identifying waste within the production process in order to reduce waste and residues with greater severity such as inventory, defects and overproduction. After applying these methodologies, the main types of waste were identified: inventory (21.82%), defects (20.50%) and overproduction (17.44%). The lead time was reduced from 8.63 days to 2.65 days, the search times in the cutting process were reduced by 75%, sewing by 28%, finishing by 97% and warehouse by 52%; the number of defective products from internal production by 4% and from third-party production by 37%; which led to an increase in productivity for shorts by 26%, leggings by 22% and sports polo shirts by 49%. Finally, the motivation of workers, the feeling of well-being, internal communication and making 9S a new work culture were increased.

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Application of Lean Tools to Increase Productivity in a Textile Workshop

  • Quicaño Jara Nory Judith,
  • Castro Blancas Fiorella Denisse,
  • Vilchez Ruiz Erick Domingo

摘要

Lean tools are a set of methods and techniques that allow the elimination of waste, that is, everything that does not generate value, in order to achieve excellence. In this sense, the present article aims to increase productivity in a textile manufacturing workshop, reducing waste through the application of Value Chain Mapping (VSM), Waste Assessment Model Analysis (WAM) and the implementation of 9S. In this sense, the objective of this research is to increase productivity in a textile manufacturing workshop, identifying waste within the production process in order to reduce waste and residues with greater severity such as inventory, defects and overproduction. After applying these methodologies, the main types of waste were identified: inventory (21.82%), defects (20.50%) and overproduction (17.44%). The lead time was reduced from 8.63 days to 2.65 days, the search times in the cutting process were reduced by 75%, sewing by 28%, finishing by 97% and warehouse by 52%; the number of defective products from internal production by 4% and from third-party production by 37%; which led to an increase in productivity for shorts by 26%, leggings by 22% and sports polo shirts by 49%. Finally, the motivation of workers, the feeling of well-being, internal communication and making 9S a new work culture were increased.