Improvement of productivity by applying poka yoke, SMED and TPM in a SME in the brick production sector

• Autores: Becerra Flores, Alonso Arturo, Salas Sotelo, Jhonny Sergio Wildo
• Formato: tesis de grado
• Fecha de Publicación: 2024
• Institución: Universidad de Lima
• Repositorio: ULIMA-Institucional
• Lenguaje: inglés
• OAI Identifier: oai:repositorio.ulima.edu.pe:20.500.12724/21872
• Enlace del recurso: https://hdl.handle.net/20.500.12724/21872
• Nivel de acceso: acceso abierto
• Materia: Comercio de ladrillos; Pequeñas y medianas empresas; Industria de la construcción; Mantenimiento productivo total; Competitividad; Producción eficiente; Productividad; https://purl.org/pe-repo/ocde/ford#2.11.04

By the end of 2022, the construction sector in Peru had experienced a growth of 6.02%, consequently benefiting the brick industry as well. This research focuses on studying a small and medium-sized enterprise (SME) facing productivity challenges that compromise its profitability and competitiveness. Periodic visits were conducted to the company to gather data. The main issues were identified using a Pareto diagram, including excessive production time, human error, unplanned machinery downtime, and reprocessing, with the first three being the most remarkable. Root causes of each problem were identified to link them to solutions based on Lean Manufacturing principles, such as TPM, SMED, Poka Yoke and activity standardization. Improvement proposals were suggested and validated through simulation in Arena, yielding positive results, such as an increase in total productivity of 4%, a 7-hour reduction in total production time, a 40% decrease in setup times, a 2% reduction in defective products, and a 75% decrease in the incidence of human errors in some activities, such as mixing. Finally, the financial evaluation of the proposal demonstrated high profitability, with a Net Present Value (NPV) of 15,745 USD, an Internal Rate of Return (IRR) of almost 30% and a payback period of the initial investment in just. 3 months.