Production Model Based on Lean Tools to Increase the Overall Efficiency of the Equipment in the Sole Pressing Process of a Footwear Company

Abstract

The present investigation was carried out in a rubber soles production company in the footwear industry in Peru, which belongs to the manufacturing sector. In this sector, several problems affecting the Overall Equipment Effectiveness (OEE) of small and medium-sized companies were identified, either due to a large amount of downtime, low availability and performance of equipment, or low quality, among others; this study has its main objective to improve OEE according to the global industry standard (85%). The proposed solution implemented a production model in which SMED, TPM, and Poka-Yoke methodologies were applied. With this, the simulation of the current and the improved situation was carried out with the Arena software. Additionally, it was demonstrated that the proposed model improved the OEE to 86.17% because availability, performance, and quality improved to 95.85%, 89.95%, and 99.94%, respectively. Finally, this research was done to contribute to the sector's growth and to be a reference for companies with similar processes that want to increase OEE.