Improvement plan to reduce operating costs of Empresas Chang S.R.L

Abstract

The objective of this study was to determine the effect of the implementation of an improvement plan in Chang S.R.L., a company dedicated to the production of sandal footwear. Historical and current data was acquired through interviews and documentary analysis, which resulted in a comprehensive diagnosis using FODA analysis, Porter's 5 Forces, Stakeholders, 5S initial audit, Pareto Diagram and PDCA. The problems encountered were uncoordinated production, the need for stock of materials, no n-fulfillment of orders, machinery breakdowns and production losses. Improvement plan 1 was chosen and designed, consisting of: PMP, MRP, Heijunka, TPM, 5S and Poka Yoke that included Occupational Health and Safety standards, together with Environmental and Quality Management Systems with Peruvian technical regulations. The improvement plan was simulated using Ms. Excel software using the macro developer and the Monte Carlo method for the evaluation. A reduction of 78.01%, an IRR of 46%, a TMAR of 1.12% per month and an NPV of S/. 84, 981.08 were found, which indicated the viability of the project due to the early return on investment. A cost benefit of 2.04 was also calculated.