Improvement Design to Increase Productivity by Applying Poka Yoke, VSM and SMED in a Plastic Company (#350)

Authors

Lago-Dominguez, Eduardo Manuel

Lago-Dominguez, Maria Fe

Corzo-Chavez, Jorge Antonio

Abstract

The present research aims to conduct an analysis and diagnosis of issues using Lean Manufacturing tools to reduce errors and lead times in the finishing department of a plastic products company. In response to the identified issues, several improvement proposals have been formulated through the application of Lean Manufacturing tools. Therefore, by implementing Poka Yoke Value Stream Mapping, and the Single-Minute Exchange of Die (SMED) technique, the anticipated outcomes include a reduction in processing times, improved task distribution, and a decrease in improperly assembled products. Additionally, this approach aims to enhance the operators' understanding of their roles and establish a line leader to serve as a guide for other team members. Likewise, with the proposed designs and implementations, it will be possible to create a more organized work environment, leading to better resource management and, consequently, a more efficient product assembly. On the economic side, a significant increase in income could be seen. The reduction in production costs, facilitated by improvements in efficiency, improves the company's profitability, increasing from 68.7% to 79%. Likewise, when more efficient processes are implemented, resource management is optimized and waste reduced, this allows us to operate more profitably. This not only directly impacts profit margins but can also offer the flexibility to adjust competitive prices in the market. Improving profitability through efficiency not only strengthens the company's financial position, but also provides additional resources that can be allocated to innovation, research and development, thus contributing to long-term competitiveness, improving in different areas. In conclusion, following the implementation of all the improvements, there was a demonstrated improvement in the effective production time by 50.96%. Additionally, there was a notable enhancement in the non-conforming product rate in the polyurethane injection process by 90% and a significant improvement in the non-conforming product rate in the assembly process by 93%.