Application of 5S, Standardized Work, and Heijunka to Increase Productivity in A Peruvian Packaging SME

Abstract

The objective of the research is to improve the productivity of an extra virgin olive oil bottling plant to meet its demand. The initial diagnosis of the company's situation was carried out, revealing three main causes for its issues, leading to the application of lean tools. The 5S implementation was used to clean and organize the production area, the simulation of Standardized Work addressed the lack of task assignment by optimizing the production flow through the efficient implementation of work sheets for operators, and the simulation of Heijunka was used to reduce the frequency of production changes due to a lack of production planning. The results obtained with Minitab Statistics software were evaluated after the implementation, comparing the indicators with the initial state of the company. The results show a 32% increase in productivity. Furthermore, the process changeover time decreased by 71%, and the bottle waiting time for each activity was reduced by 18%. It is important to mention that this work serves as a reference for future research and for replication in similar companies. © 2024 IEEE.