The On Time In Full (OTIF) indicator is one of the main metrics used to evaluate logistics service levels in automotive spare-parts warehouses, where inventory availability and order-picking efficiency are key factors in customer satisfaction. However, many companies show low compliance levels due to stockouts and long picking times. This study aimed to evaluate the effect of implementing an integrated Lean Warehousing model, comprising Poka Yoke, ABC Classification, Systematic Layout Planning (SLP), and Standard Work, on OTIF performance in an automotive company. The research used a quantitative correlational-explanatory approach and validated the proposal through discrete-event simulation in Arena by comparing the current scenario (AS IS) with the proposed scenario (TO BE). The results showed an increase in OTIF from 57.91% to 86.13%, an improvement in inventory accuracy to 98.46%, a reduction of 3.23 minutes in the average picking time per order, and an IRR of 48.02%, confirming the technical and economic feasibility of the proposal. These results demonstrate that the integrated implementation of Lean Warehousing tools is an effective strategy for improving service levels and the competitiveness of automotive spare-parts warehouses.

Keywords

Lean Warehousing; OTIF; Poka Yoke; ABC Classification; Systematic Layout Planning; Standard Work; Warehouse Management