Improvement proposal for the preparation and assembly processes of Smart Box considering Lean Methodologies

This research aims to address the operational challenges faced by a medium-sized metal-mechanical company in Lima, Peru, specifically in the preparation and assembly processes of the Smart Box. The Smart Box is an innovative smart lock to prevent tampering with electric meters, ensuring secure and authorized designed access. Despite its potential, production inefficiencies have resulted in bottlenecks and waiting times, causing a 20% delay in weekly deliveries, equivalent to 16 undelivered units out of a planned 80. These delays stem from poorly optimized workflows, inadequate tool organization, and delays in raw material supply chains. To address these issues, Lean methodologies, including the Kaizen philosophy and the 5S tool, were implemented. The Kaizen approach facilitated the identification and elimination of non-value-adding activities, while the 5S methodology emphasized workplace organization, order, and cleanliness. These interventions reduced production times by 13%, minimized waiting times between 10% and 15%, and decreased defective products. Additionally, simulation through Arena software validated a potential 21% increase in weekly production capacity, raising the output from 75 to 95 units per week. The research highlights the significance of Lean tools in improving operational efficiency, reducing waste, and enhancing production sustainability. Recommendations include extending Lean practices to other stages of production, considering local manufacturing for imported components to reduce delays, and implementing continuous training to sustain improvements. These findings serve as a benchmark for applying Lean methodologies in similar industrial contexts.