In the Peruvian metalworking sector, on-time delivery (OTD) continues to be a structural challenge due to the high variability of processes, poor operational standardization, and reliance on operator-based practices. These conditions particularly affect industries such as mining and construction, where delays in repairing hydraulic cylinders generate significant costs due to downtime and lost productivity. This study seeks to improve OTD performance at a metalworking company in Lima dedicated to the repair and manufacture of hydraulic cylinders, whose initial compliance level is 43%. The diagnosis identified three main gaps: deficiencies in order and discipline, lack of a systematic setup procedure, and unstable control of the cooling process in chrome plating. To address these limitations, an improvement model based on Lean Manufacturing was designed, integrating 5S to restore operational discipline, SMED to reduce variability in setup times, and Jidoka through an automatic water level control system to stabilize the critical cooling stage. The proposal was validated through event simulation in Arena, complemented by a simulation modeled in DWSIM, which allowed for the evaluation of production flow behavior and the effect of automation on reducing variability. The main contribution of the study is to demonstrate that the joint application of Lean tools can transform an unstable and reactive process into a standardized and repeatable flow, with less rework and greater reliability.In the optimized scenario, the OTD increased from 43.2% to 83%, confirming the effectiveness of the model and the relevance of autonomous control for improving delivery punctuality in metalworking environments.

Keywords

On-Time Delivery (OTD), Lean Manufacturing, 5S, SMED, Metalworking Industry