The small and medium-sized enterprises (SMEs) sector in the fashion industry, particularly in jeans manufacturing, is crucial globally, in Latin America, and specifically in Peru. However, it faces significant challenges such as excessive waste in the cutting phase, unproductive times during manufacturing, and low quality of subcontracted products, affecting operational efficiency and market competitiveness.
To address these challenges, a production model based on Lean Manufacturing philosophy and Work Study was proposed, structured into four phases: organization of workstations using the 5S methodology, critical process analysis, production process control using poka-yoke, and consolidation of the production process. This model aimed to improve operational efficiency and product quality by standardizing processes and reducing errors and waste.
The results showed an improvement in operational efficiency from 68% to 74%, a 177.08% increase in the 5S audit, and a 50% reduction in the occurrence of errors. Additionally, labor productivity increased from 4.6 to 5.2 units per PEN, representing a 13.04% improvement. These findings demonstrated the model's effectiveness in optimizing the jeans production process in SMEs.
The academic and socioeconomic impact of this research is significant, as it provides a comprehensive framework for continuous improvement in jeans production, contributing to the sustainable and competitive development of the fashion sector in Peru. It also offers a solid foundation for future research on implementing Lean methodologies in other manufacturing contexts.
It is imperative that researchers and professionals in industrial engineering explore new directions to further enhance operational efficiency and sustainability in jeans manufacturing. This study invites continued development and adaptation of Lean models to address the dynamic challenges of the industry.