This research study seeks to identify and prioritize the causes of order fulfillment delays in a small wooden furniture manufacturing company. The authors propose a 5-phase Lean Optimization model to address and reduce this problem. Post-implementation results yielded a 54.87% reduction in material search and transportation times, a 32.86% reduction in travel times between stations, and a 19.81% increase in line efficiency. In addition, order fulfillment percentages increased from 12.5% to 60%.

Currently, small- and medium-sized enterprises face order fulfillment issues, thus generating reduced service levels. In addition, these companies are usually not aware of the importance of continuous improvement tools or of training staff as a mitigation strategy for this situation. Within this framework, the authors performed a literature review to compile production models through which downtimes could be reduced. The production model designed therefrom comprises Lean Manufacturing and work study tools within a Change Management approach. This design focuses on model implementation by small companies without requiring large investment, cutting-edge technology, or qualified personnel. Finally, an application case study was conducted in a small textile manufacturing company located at the Gamarra Fashion Center in Lima, Peru. The results that were reported revealed that late order fulfi...

This article examines the problem of production line delays in a textile small- and medium-sized enterprise (SME) that produces polyester fibre from recycled bottles, based on orders. Factors that have resulted in production line delays include prolonged unscheduled maintenance time, and preparations and adjustments prior to operating the equipment. To address the problem, a model was developed applying lean manufacturing tools through change management, with the aim of increasing equipment availability and useful life. To validate the model, a pilot was developed to determine how the increase in equipment availability helps reduce delays in the production line, which eventually improves completion of customer orders.