The metal-mechanical industry, particularly the small and medium-sized enterprises (SMEs), plays a critical role in economic development globally, especially in Latin America and Peru. Previous studies have highlighted the importance of this sector in fostering industrial growth and innovation. Despite its significance, SMEs in this sector face numerous production challenges, including deficiencies in machine setups, operational errors leading to rework, and inadequate inventory management, which disrupt supply chains and affect overall efficiency. This research aimed to address these urgent challenges by proposing a Lean Manufacturing-based production model tailored for SMEs in the metal-mechanical industry.
The proposed model incorporated Lean Manufacturing tools such as Poka Yoke, SMED, 5S, Kanban, and A3 reports to streamline production processes and enhance operational performance. The model focused on reducing setup times, minimizing operational errors, and optimizing inventory management. Through a structured implementation of these tools, the model sought to eliminate waste and improve production efficiency, thereby ensuring timely order fulfillment and high product quality.
Key findings from the study showed significant improvements in several performance indicators. The on-time delivery rate improved from 66.40% to 87.85%, setup times were reduced by 30.11%, productivity increased by 28.00%, and cycle times decreased by 23.77%. These results demonstrate the effectiveness of the proposed Lean Manufacturing model in addressing the critical production issues faced by SMEs in the metal-mechanical sector.
The impact of this research extends beyond operational improvements. Academically, it contributes to the existing body of knowledge on Lean Manufacturing applications in SMEs, providing a robust framework for future studies. Socioeconomically, the enhanced production efficiency and reliability can lead to increased competitiveness and sustainability for SMEs, fostering economic stability and growth within the region.
In conclusion, this study calls for further exploration and validation of Lean Manufacturing tools in diverse industrial settings. The demonstrated success of the proposed model highlights the potential for broader application, encouraging researchers and practitioners to continue innovating and refining production processes to meet evolving market demands and technological advancements.