Kanban-CONWIP Hybrid Model for Improving Productivity of an Electrostatic Coating Process

The company in this study provides metallic coating services in Peru and posted increasing losses due a spike in non-conformances. This problem is recurrent in the metal-mechanic sector in the country, because of the absence of controls to mitigate problems in production lines. The application of engineering tools including 5S, systematic layout planning (SLP), and WLC to establish a background supporting the proper application of a modified Hybrid Kanban-CONWIP system centered on tools like a line signaling process capable of optimally controlling and managing each activity until perfect finish of a product is proposed as an improvement to solve the problems. The proposed improvement reduces the operating cost by 9% and increased the company's profit by 10-15.4 %, around $5 344.11.