This research presents an engineering-based intervention aimed at optimizing productivity in a water bottling company through the integrated application of Lean Six Sigma methodologies, specifically 5S, SMED, preventive maintenance, DMAIC, and process standardization. A diagnostic assessment identified an operational productivity level of 12.53 L/sol, representing a 34.7% deviation below the sector benchmark of 19.2 L/sol and an estimated annual economic loss of S/ 83,191.82. Following validation through a pilot implementation and discrete-event simulation, the proposed improvement framework is projected to increase productivity by 39.5%, recover 17,239 non-productive minutes per year, and enhance Overall Equipment Effectiveness (OEE) from 62% to 83%. Specifically, applying 5S would reduce tool search time by 30.7% (16.93 minutes per shift), while SMED would decrease setup time by 67.01% (from 56.55 to 18.67 minutes). Likewise, preventive maintenance would reduce downtimes due to mechanical failures by 83.15% (from 73.83 to 12.44 minutes per shift), and DMAIC would help reduce defective products by 40%, equivalent to over 17,000 annually recovered units. The results confirm the technical feasibility, operational impact, and economic relevance of the proposed methodology, demonstrating its scalability potential and applicability to similar industrial environments in the beverage manufacturing sector. The findings reveal that the strategic integration of Lean Six Sigma tools represents a high-impact solution for low-automation settings with limited resources, highlighting its industrial relevance and contribution to the scientific knowledge base on continuous improvement methodologies.
Track: Lean Six Sigma Competition
Published in: 8th IEOM Bangladesh International Conference on Industrial Engineering and Operations Management, Dhaka, Bangladesh
Publisher: IEOM Society International
Date of Conference: December 20
-21
, 2025
ISBN: 979-8-3507-4441-5
ISSN/E-ISSN: 2169-8767