Abstract

The footwear manufacturing sector is crucial for Peru's economy, reflecting both its cultural identity and economic significance. However, it faces significant challenges in operational efficiency, such as machine setup deficiencies, lack of process standardization, and production quality issues. This study presents a production model based on Lean Manufacturing philosophy and the PDCA-Kaizen methodology, aimed at improving operational efficiency in a Peruvian footwear company. The model was implemented in four phases: planning, execution, verification, and action, with an emphasis on systematic layout planning, work standardization, and the SMED technique to reduce machine setup times.

The notable results include a 38% improvement in production efficiency, a 39.63% reduction in effort measured in Kg-m, a 38.64% decrease in transfer distances, and a 36.74% reduction in unnecessary transfer times. These indicators demonstrate that the proposed model successfully addressed critical operational efficiency problems, significantly improving the company's productivity and competitiveness in the footwear market. In conclusion, the implementation of Lean Manufacturing and PDCA-Kaizen has provided a robust framework for continuous improvement and sustainability in footwear manufacturing in Peru.