This paper analyzes order fulfillment performance in the finished goods warehouse of Gexim S.A.C., a Peruvian company dedicated to the production of plastic monofilaments, where operational inefficiencies were identified related to an inadequate warehouse layout, lack of standardization, and misalignment between demand planning and logistics operations. Based on an initial diagnosis, an OTIF (On-Time In-Full) level of 89.5% was observed, mainly affected by excessive travel distances and long picking times, which resulted in a significant annual economic impact. To address these gaps, this paper proposes an integrated approach combining workplace organization tools (5S), layout design through Systematic Layout Planning (SLP), and aggregate planning via Sales and Operations Planning (S&OP) within a unified methodological framework. The effectiveness of the proposed approach was evaluated using discrete-event simulation in Arena, allowing a comparison between As-Is and To-Be scenarios. The results show a 40% reduction in picking times, compliance levels above 90% in order and cleanliness standards, a substantial improvement in 5S audit results to 72.53%, and a 95% alignment between demand and inventory. The findings demonstrate that the joint and coordinated application of layout, standardization, and planning tools significantly improves order fulfillment performance in industrial environments, highlighting the value of integrated approaches in warehouse management.

Keywords

Warehouse management; Systematic Layout Planning; 5S; Sales and Operations Planning; Discrete-event simulation