This study addresses the critical issue of low productivity in the "Pan francés” line of a Peruvian food retail chain. The current productivity rate is 15.77 kg/Man-Hours (MH), falling below the sector benchmark of 17.60 kg/MH. This inefficiency results in a technical gap of 1.83 kg/MH and generates significant annual economic losses. The diagnosis identified that 67.55% of the problem is due to Loss of Availability and Operational Efficiency (mainly machine failures and cleaning delays), while 32.45% corresponds to Product Defects.

Based on successful cases in the industry, an integrated Lean Manufacturing model was designed and implemented, combining Autonomous Maintenance (AM) to reduce mechanical failures, the 5S methodology to optimize cleaning times, and Standardization and Kaizen to minimize process variations and defects. The validation was performed using a hybrid method: an eight-week pilot implementation in the plant and a discrete-event simulation using Arena software (30 replicas). The results confirmed the technical efficacy of the model, showing a 25% reduction in shrinkage (from 2.2% to 1.65%), a 48.3% decrease in average cleaning time (from 60 min to 31 min), and a stabilization of machine availability. The financial analysis confirms the project's viability with a positive Net Present Value (NPV) of S/. 70,066.86. The study concludes that the integrated Lean-HACCP model is a technically sound solution for high-rotation food retail environments, translating legal compliance into operational competitive advantages.