Mejoramiento del proceso de producción de la empresa Industrias Saga de Colombia

Abstract

The purpose of this project was to improve the production area of Industrias Saga de Colombia using Lean Manufacturing tools based on a methodology focused on three phases: diagnosis, design of the improvement plan, implementation, and evaluation of results. In the diagnostic phase, the following tools were used: process diagram, route diagram, time study, value stream map (VSM), and measurement of KPI indicators, identifying two main critical points: emma automated cutting machine subprocess and deliming subprocess. The improvement plan included the application of kaizen techniques and the elimination of the 7 wastes, where the critical points were intervened based on an individual analysis according to each situation. In terms of implementation and evaluation of results, there was an 81.48% increase in productivity on the emma cutting machine and a 10% increase in trimming, as well as improvements in the use of machine time (up to 93.12%) and a 20.7% reduction in total process time. The use of materials was also optimized: microfiber (10.53%), plantitex (6.98%), and synthetic (17.39%). In addition, it was shown that the implementation of lean manufacturing made it possible to intervene in critical points, generating a projected savings of COP 464,050,363.95 in one year, thus establishing a solid base for continuous improvement.