Reducción de desperdicios en la empresa “Calzado Gamo's” mediante herramientas de manufactura ajustada.

Abstract

The company Calzado GAMO'S has significant waste in its production process, causing economic and resource losses that affect its operational efficiency. The objective of this research project was to analyze waste in the production process and propose operational plans based on lean manufacturing tools for its reduction. The methodology used included a comprehensive diagnosis of the company through interviews with the production manager, surveys of workers in the production process, and a time study applied to the product proposed by the company, the CAT boot. This helped with developing the current VSM, where a takt time was determined to be 1.20 minutes per pair. The shaving area was identified as the bottleneck, in addition to detecting wastes inherent to lean manufacturing. Through a criticality matrix, three main wastes were selected: defects, reprocesses, and unnecessary movements, quantifying 1,479 defects that generated 3,556.31 minutes in reprocesses and 14,435.93 meters of unnecessary movements. As a result, three operational plans were developed with implementation guidelines and performance indicators to address waste. The first manual addresses TPM, seeking to increase equipment efficiency from 76.56% to 95%. The second focuses on Poka Yoke to reduce defects by 60%, while the third seeks to minimize unnecessary movements by 30.03% through point-of-use storage and visual factory.