The biscuit manufacturing sector in Latin America, particularly in Peru, plays a significant role in the region's economy by contributing to the GDP and providing employment opportunities. However, the sector faces challenges such as low production efficiency, high waste levels, and frequent product defects, impacting profitability and competitiveness. Addressing these issues is crucial for sustainability and growth.

This study proposed a Lean Manufacturing-based model incorporating Poka Yoke, Centerlining, and Total Productive Maintenance (TPM) to enhance production efficiency and reduce waste. The model focused on preventing and correcting production defects, standardizing and controlling key operational parameters, and maximizing equipment effectiveness through preventive and predictive maintenance.

Key findings from the model's implementation showed significant improvements in production efficiency. The Overall Equipment Effectiveness (OEE) increased from 83% to 86.7%, machine availability improved to 95.1%, the performance rate reached 95%, and the quality rate of finished products rose to 95.9%. Additionally, the scrap rate was reduced from 15% to 4%, demonstrating the model's effectiveness in addressing the sector's critical challenges.

The academic and socioeconomic impact of this research is significant. The model offers a practical solution to improve efficiency and reduce waste in biscuit manufacturing, contributing to Lean Manufacturing literature and benefiting companies and consumers in Latin America. This study encourages further research to integrate advanced technologies with Lean Manufacturing principles to drive continuous improvement and innovation in the biscuit manufacturing sector.

The biscuit manufacturing sector in Latin America, particularly in Peru, plays a significant role in the region's economy by contributing to the GDP and providing employment opportunities. However, the sector faces challenges such as low production efficiency, high waste levels, and frequent product defects, impacting profitability and competitiveness. Addressing these issues is crucial for sustainability and growth.

This study proposed a Lean Manufacturing-based model incorporating Poka Yoke, Centerlining, and Total Productive Maintenance (TPM) to enhance production efficiency and reduce waste. The model focused on preventing and correcting production defects, standardizing and controlling key operational parameters, and maximizing equipment effectiveness through preventive and predictive maintenance.

Key findings from the model's implementation showed significant improvements in production efficiency. The Overall Equipment Effectiveness (OEE) increased from 83% to 86.7%, machine availability improved to 95.1%, the performance rate reached 95%, and the quality rate of finished products rose to 95.9%. Additionally, the scrap rate was reduced from 15% to 4%, demonstrating the model's effectiveness in addressing the sector's critical challenges.

The academic and socioeconomic impact of this research is significant. The model offers a practical solution to improve efficiency and reduce waste in biscuit manufacturing, contributing to Lean Manufacturing literature and benefiting companies and consumers in Latin America. This study encourages further research to integrate advanced technologies with Lean Manufacturing principles to drive continuous improvement and innovation in the biscuit manufacturing sector

Alexandra Katherine Rojas-Valverde

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A Lean Manufacturing Case Study: Enhancing Efficiency and Reducing Waste in Latin American Food Production