Standarización del proceso productivo mediante lean six sigma y automatización en Python en panadería RICHS, Villavicencio

Abstract

Richs Bakery, located in Villavicencio, specifically in the Rosa Blanca sector, faces difficulties in its production process stemming from a lack of strategic demand planning. The absence of a defined criterion for determining daily bread production quantities led to shortages on some days and overproduction on others, resulting in waste and a risk of loss of freshness and perceived quality. To standardize production and ensure an appropriate balance between actual demand and production volume, the project was developed using the Lean Six Sigma philosophy, applying the DMAIC methodology to guarantee sustainable process improvement. During development, multiple diagnostic tools were implemented, including Project Charter and SIPOC, lane diagrams, and flowcharts. To measure this information, check sheets were created for actual plant data, and a time study was conducted. Statistical tools such as Pareto analysis, descriptive statistics, and Sigma level calculations were used to analyze this data. In addition to constructing the value stream map of the current state, an Ishikawa diagram, and an analysis of the seven wastes (mudas), the main problems in the process were identified. Based on these findings, an improvement proposal was designed, focused on standardizing production. This proposal was supported by the development of Python software that centralizes the historical record of sales and production, enabling data-driven decision-making for the first time in the company. Activating this system generated tangible results: surpluses were reduced by 15% and shortages by 10%, and economic losses associated with waste and overproduction were decreased, achieving an estimated savings of $1,380,000, thus strengthening the bakery's profitability and sustainability. Finally, an action plan was structured to guide implementation and sustain a culture of continuous improvement within the organization.