Minimization of Product Distribution Delays through An Integration Model of Lean Manufacturing Tools and A3 Report-Case Study

Abstract

Latin American and Caribbean Gross Domestic Product (GDP) is about 70% of manufacturing. Product supply is vital for mass consumption enterprises due to population consumption. Improving value chain logistics maximizes business opportunities. Hygiene products sell well. Pallet shortages impede delivery. This study proposes a model that integrates the Lean Six Sigma framework, the lean manufacturing principles, and the A3 report as communication and monitoring tools to ensure improvement success. Increased pallets supply sped product delivery. The integrated model uses the design for Six Sigma and standardized work tools to design the new process and the A3 report methodology to show the importance of the problem, the countermeasures proposed for immediate implementation, and the indicators for monitoring and controlling the improvement project. Performance increased pallet availability by 92%. The new process of pallet repairs increased efficiency to 95%. This study sets the stage for future research and may help other firms with comparable difficulties.