Improvement proposal based on Lean Manufacturing tools to reduce overcosts in the production and maintenance areas at Molinera de cereales, Trujillo 2021

Abstract

The general objective of this investigation was to determine the influence of the improvement based on Lean Manufacturing tools on cost overruns in production and maintenance areas at Molinera de Cereals, Trujillo 2021. Data collection techniques such as observation and documentary analysis were used. Based on this, the problems that affect the costs in the company were determined, being: the lack of production programming, lack of supplier management, lack of quality control, lack of machinery, lack of staff training, lack of a maintenance plan and lack of stock of spare parts, for this reason an improvement proposal was developed in the areas of production and maintenance applying Lean Manufacturing tools such as: MRP, Diffused AHP Supplier Management, Training, Line Balance, Preventive Maintenance and Management of critical spare parts stock, obtaining an annual benefit of S/79,640.20, in addition, a total reduction in the costs of the production area of 64.28% was achieved, that is, there is a saving of S/307,858.58 per year and of the area of maintenance of 72.88%, that is, there is a saving of S/539,543.61 per year. Finally, the results obtained were compared, showing that Lean Manufacturing tools reduced cost overruns. Finally, the contributions of this study will be used for future research taking into account the variables used and the Milling sector.