Application of Lean Manufacturing Tools to Reduce Downtime in a Small Metalworking Facility

Abstract

This article analyzes the extensive downtimes found throughout the process of manufacturing metal structures, and how to minimize them in order to increase productivity. The overall process includes welding, beveling, and transfer to the assembly area, the three of which were identified as the most critical, because they have the highest downtimes. This downtime is generated by several factors, among which are a lack of order and cleanliness in the various work stations, and the absence of mechanisms to control production. A proposal was developed to improve the process of manufacturing brick dryer screens using Lean Manufacturing tools such as Kanban and 5'S to reduce downtimes and increase the profitability of the company. The results obtained through a simulation in Arena Software show an overall reduction of downtime by 62%.