Mejora de los Indicadores de productividad en una empresa textil mediante la sinergia de herramientas de Lean Manufacturing y el enfoque Sociotécnico

During the last decade, the sales of Peruvian textile companies for exportation have been decreasing, due to quality problems, high prices and late deliveries, which generates a low competitiveness of this sector. This research arises from the need to generate a higher competitive level in the optimization of its resources and increase the client service level in the company of study through the use of Lean Manufacturing tools in the social context of Peru. Initially, it describes the main products, the organizational profile, and the productive processes using Value Stream Mapping and the analysis of the current key performance indicators. Subsequently, the sociotechnical approach was used to lay the foundations of a powerful organizational culture and the empowerment of workers, then the 5S method was used to generate discipline in them and order in their processes. Once the bases for generating productive value within the organizational culture were established, the methodology of Total Productive Maintenance was implemented, then the inventory level in process was minimized and the flow batch was optimized using Kanban methodology. Finally, Poka Yoke was used to reduce the cycle time and reduce the level of error in flow. The set of applied methodologies resulted in the elimination of unnecessary processes, increasing plant capacity by 30% and the amount of deliveries in time by 25%, impacting the finances of the company with a IRR of 51%.