Application of Lean Manufacturing Tools and ICT to Increase Productivity Levels and Reduce Costs in the Brewing Industry in Ensenada, Baja California, Mexico

Abstract

Abstract: This investigation was prepared to evaluate productivity levels because in 2018 there were low rates due to inadequate planning in the manufacturing stages of a brewing industry, located in the city of Ensenada, Baja California, Mexico. Starting in 2019 and 2020, even with the presence of Covid19, productivity rates increased. Said increase in productivity was due to the application of lean manufacturing tools, such as the Value Flow Map (MFV), Kanban and Kaizen, managing to generate an efficient fluid process, and thereby increasing levels of competitiveness. In addition, an automated system was used using Information and Communication Technology (ICT) to control time and improve the flow of the production process. With the analysis of the aforementioned tools, the stages of the production lines with the highest incidence of causes that caused, in certain manufacturing stages, poor productive performance of personnel and machinery were determined, indicating levels less than 50% and thus costs of production increased, generating great concern in the directive, managerial and supervisory personnel. In addition to the lean manufacturing analysis, an automated system was designed and applied, controlled by ICT, to help detect when the process flow was not optimal, indicating the moments in which the machines performed technical stoppages and stopped the production line. The investigation was carried out in 2020, even with the presence of Covid19, the industry where the analysis was carried out continued operating normally with the safety and hygiene protocols.