This paper addresses the problem of a low OTIF (On Time In Full) performance level in a lubricant distribution company operating in a highly competitive logistics environment. The initial OTIF level of 90.14% was below the industry benchmark of 95%, generating annual losses of approximately S/302,144.50 due to rescheduling, delivery penalties, additional logistics costs, and loss of customer confidence. To address this issue, a quantitative and applied research approach was adopted, integrating ABC Analysis, Systematic Layout Planning, and Poka-Yoke as complementary industrial engineering tools. ABC Analysis was used to reorganize inventory based on product rotation and criticality, reducing product search time, while SLP enabled the redesign of the warehouse layout to improve material flow and significantly decrease transfer distances between operational areas. In addition, Poka-Yoke mechanisms were implemented to eliminate human errors in picking and order assembly processes. The results demonstrated a complete elimination of picking and order assembly errors, a reduction of 26.4% in product search time, and a 51.45% reduction in transfer time between activities. As a result, the OTIF level increased to 95.8%, exceeding the industry standard. The findings confirm that the integrated application of industrial engineering tools provides an effective and replicable approach for improving logistics.

Keywords

OTIF, ABC Analysis, SLP, Poka Yoke, lubricant distributor.