Lean Manufacturing: effective tools to optimize dairy beverage production. Evidence based on a statistical analysis.
DOI:
https://doi.org/10.56294/saludcyt20251504Keywords:
Lean Manufacturing, Dairy Industry, Value Stream Mapping (VSM), Layout, KanbanAbstract
Lean Manufacturing is a set of tools with a production management approach that aims to maximize customer value by reducing waste and optimizing processes; in industries, it helps improve efficiency, reduce costs, and increase quality by eliminating non-value-added activities, thus promoting a culture of continuous improvement and flexibility in production. The objective of this research is aimed at the application of these tools to optimize the production line of dairy beverages. The research approach is quantitative, for which the inductive-deductive and analytical methods were applied. The current situation of the production process was analyzed to identify existing problems such as inefficient use of production time, lack of process standardization, absence of a production control plan, and untrained personnel. To mitigate these issues, optimal Lean tools such as VSM (Value Stream Mapping), 5S, Layout, and Kanban were applied, which allowed for a 5.34% increase in productivity by eliminating activities that do not add value to the production process, with an improvement in the Value-Added Index (VAI) from 86.48% to 92.75%. Additionally, efficiency and effectiveness increased by 3% and 2%, respectively. The implementation of Kanban cards as management tools significantly influences the reduction of shift changeover time, decreasing the time variability from 19% to 11%, and the average value from 42.62 minutes to 12.43 minutes.
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