The flexographic printing sector plays a crucial role in the global, Latin American, and Peruvian economies by efficiently producing packaging, labels, and other printed materials. Previous studies have highlighted the importance of Lean Manufacturing practices, such as SMED and 5S, in improving operational efficiency within SMEs. However, the application of these methodologies specifically in the flexographic sector has been underexplored, creating a gap in the literature.

Flexographic SMEs face significant challenges, including high variability in machine setup times, operational errors, and lack of organization in workstations. These issues lead to inefficiencies, prolonged downtimes, and reduced productivity, directly impacting their competitiveness in a demanding market. Addressing these challenges is essential to enhance the sustainability and growth of these enterprises.

This research proposed a Lean Manufacturing-based production model tailored for flexographic SMEs, integrating SMED, 5S, and standardized work. The model aimed to optimize production processes, reduce setup and changeover times, and improve overall operational efficiency. Key actions included detailed process analysis, identification and separation of internal and external activities, and implementation of best practices and clear standards.

The implementation of the model resulted in significant improvements. Setup times were reduced by 32% in bottleneck problems and 50% in configuration time, leading to a 7% increase in line efficiency. The application of 5S methodology improved workspace organization, reducing unproductive times and enhancing safety. Overall, the model contributed to a 43.24% increase in availability and substantial economic savings of 69,338 USD annually.

The academic and socio-economic impact of this research is profound. Academically, it fills the knowledge gap regarding the application of Lean tools in the flexographic sector, providing a framework for future studies. Socio-economically, the improved efficiency and productivity of flexographic SMEs enhance their competitive position, promoting economic growth and sustainability in the sector.

This study calls for further research into the application of Lean methodologies in other sectors and contexts. By exploring new directions and adapting the model to different industries, researchers and practitioners can continue to drive improvements in operational efficiency and economic performance, contributing to the broader goals of sustainable development and industrial excellence.

Fernando Fabian Villegas-Rodriguez

Affiliation

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Enhancing Operational Efficiency in Flexographic SMEs through Lean Manufacturing: A Case Study