Production Model Integrating TOC and Lean for Lead Time Reduction in Chemical Manufacturing: An Empirical Research in Peru

Abstract

The chemical industry allows the creation of a wide range of products such as polymers, emulsions, among others. In the world, this sector generates $5.7 billion of the world's Gross Domestic Product (GDP), and in Peru it represents 1% of the national GDP. This article describes the implementation of an integrated system containing the Theory of Constraints (TOC) and Lean Manufacturing (5s and Single Minute Exchange of Die) for the reduction of the lead time in the production process of the RA-401 resin in a chemical SME in Peru. The general problem is analyzed through the Value Stream Mapping tool, where the root causes, the time of each activity, and the incidence of the worker are evidenced. The validation of the developed model was carried out in the stage of filling and labeling of 200 kg resin cylinders through Arena Simulator. The results showed that the processing lead time was reduced by 7.88%, cycle time by 7.94% and productivity was increased by 8.48%.