Open AccessLean Manufacturing Production Method using the Change Management Approach to Reduce Backorders at SMEs in the Footwear Industry in Peru
Author(s) -
D. Dextre-Del-Castillo,
S. Urruchi-Ortega,
Juan Peñafiel-Carrera,
Carlos Raymundo-Ibañez,
Francisco Domı́nguez
Publication year - 2020
Publication title -
iop conference series. materials science and engineering
Language(s) - English
Resource type - Journals
eISSN - 1757-899X
pISSN - 1757-8981
DOI - 10.1088/1757-899x/796/1/012021
Subject(s) - kaizen , lean manufacturing , production (economics) , value stream mapping , manufacturing engineering , work (physics) , phase (matter) , production line , lean laboratory , manufacturing , product (mathematics) , process management , operations management , computer science , business , engineering , marketing , mechanical engineering , software construction , chemistry , geometry , mathematics , organic chemistry , software , software system , economics , macroeconomics , programming language
This article proposes a production method that aims to increase the manufacturing capacity of a footwear small- and medium-sized enterprise (SME) to reduce backorders. Therefore, an assessment is carried out and delays in production processes, excess product transport time, defective products, and inefficient work methods are identified. This article proposes designing a Lean manufacturing method using the change management approach, whose methodology is composed of six phases. In phase 0, change management is carried out; in phase 1, the company’s current situation is reviewed using the Value Stream Mapping (VSM); in phase 2, the work area is reorganized (implementing SLP and 5S); in phase 3, production is balanced (implementing Line Balancing); in phase 4, continual improvement is established using the Kaizen tool; and finally, in phase 5, the results are evaluated. Through validation, it was possible to confirm that Lean manufacturing tools along with change management increased order deliveries by 82%.