Mejora en el proceso de lavado y teñido de prendas de vestir usando herramientas de manufactura esbelta y optimización matemática

In Peru, during last decade, both SME and MSE represent the biggest percentage of the enterprise sector. Likewise, the textile sector has a high potential added value to position itself in the local and international market; however, due to the international market competence, its positioning in Latin America has been decreasing. This is the reason why this research appears in order to produce value in a textile sector SME, this SME dedicates exclusively to the finishing process of clothes. The principal objective is the optimization of the production processes and the resources usage in the laundry and dying lines through the applying of both lean manufacturing and mathematic optimization tools. The research started with the SME diagnosis and the analysis of its process through waste identification and critical areas and factors. Tools such as Value Stream Mapping and 5 Whys were applied showing that the main problems were the number of reprocessed clothes and work in process inventory. After that, the 5s methodology was implemented as the base of the continual improvement organizational culture, the kanban system minimized the work in progress inventory; both of this with the kaizen philosophy in mind; finally, resources usage optimization through work standardization and operations research tools. For the final step, the economic impact of the research proposals was evaluated and showed an annual profit increase of approximately S/. 200757.744. Besides process waste was removed which was reflected in a 12% capacity increase.