Track: Graduate Student Paper Competition

Abstract

The textile and clothing sector is one of the activities that contributes the most to the economy. In 2019, it contributed 6,345 million soles to Peru's manufacturing gross domestic product (GDP); however, in recent years, this sector has lost participation due to the contraction in its production. The objective of this research is to reduce the production cycle time of baby socks, which impacts the monthly production levels and productivity in a clothing Micro and Small-sized Enterprise (MSE). Success cases previously obtained through literature review were analyzed, and a proposed model was designed by applying lean manufacturing tools such as Value Stream Mapping (VSM) in the diagnosis component, Total Productive Maintenance (TPM) to improve Overall Equipment Effectiveness (OEE) score, and Single-Minute Exchange of Die (SMED) to reduce setup time. The model was validated through simulation in Arena software. The result obtained showed a decrease in the production cycle time of 5.45% (from 1,829.53 minutes to 1,729.77 minutes). This result is explained by the expected improvement of OEE by 13.88% and the expected reduction of setup time by 36.61%, so monthly production is expected to increase from 1,134 dozen socks to 1,200 dozen socks. Finally, the initial productivity of 1.82 dozen/man-hours reached a final value of 1.92 dozen/man-hours, representing an increase in productivity of 5.49%. This case study can lead to the implementation of the model in MSEs in the textile and clothing sector that seek to improve productivity. Likewise, it can guide MSEs on the inclusion of lean manufacturing tools as an opportunity for continuous improvement.