This study presents a production model based on Lean Manufacturing tools to optimize the On-Time In-Full (OTIF) indicator in a Peruvian SME dedicated to footwear manufacturing. The initial diagnosis identified critical inefficiencies in the cementing and lasting areas, linked to disorganization, technical failures, low standardization, and deficient maintenance. These issues resulted in defective products, unplanned stoppages, and low delivery reliability. The methodology employed combined trial testing of the 5S tool with simulations in Arena software to validate the impact of Standardized Work and Total Productive Maintenance (TPM). The results show an increase in OTIF from 80.70% to 88.1%, a reduction in the percentage of defective products from 9.63% to 3.03%, and an improvement in equipment availability from 84.70% to 87.60%. Furthermore, the model underwent an economic evaluation, confirming its viability in resource-constrained environments. This research substantiates that the structured integration of Lean tools enhances operational performance, product quality, and process efficiency in SMEs.
Lean Production Model to Improve OTIF Using 5S, Standardized Work and TPM in a Footwear SME: A Case Study
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