Implementation of Lean and Logistics Principles to Reduce Non-conformities of a Warehouse in the Metalworking Industry

Abstract

The main objective of the work is to analyze the problem of non-conforming products in the warehouse, which affects delivery on time and perfect orders, directly impacting the OTIF (On Time, In Full) logistics indicator of manufacturing companies in Peru. For this reason, the analysis was carried out in XY, which accounts for 64.03% of non-conforming parts, composed of reprocessed products (72.93%) and discarded (27.07%), which causes costs to increase to $ 347,234.67. This is due to the following causes: Dispatch of unsolicited products (35.88%), damaged products (35.68%), fictitious stock (17.94%) and delay in dispatch (10.94%). To reduce the impact of the problem, Lean Warehousing, slooting and wave picking techniques were used; and 5S developing the model with the PDCA methodology, using VSM for the analysis of the flow of activities and measurement of the identified indicators. After the implementation of the model, the process time was reduced by 19.12%. The distance traveled to prepare an order was reduced from 244.5 meters to 173.5 meters; and an OTIF value increased by 44.33%. The output of the model provides an example for potential application in warehouses of companies in the manufacturing industry.