Improvement of Service Level Through Lean Tools in a Plastics Manufacturing Company

Abstract

The plastic industry in household items has grown significantly in Peru in recent years, becoming a highly competitive sector. In this context, a strong service level is required. The company of this research showed a low service level due to high loss incidence of product by 120 per month and a mean time between failures of 416.20 h per month in the injection molding machines. This paper proposed model based on the application of two lean tools: the 5S methodology and planned maintenance. The implementation of this model showed significant improvements: the incidence of lost products was reduced to zero, machine availability was increased by 15%, and the service level was raised by 1.24%. This model demonstrated how lean tools can be effectively used in plastics industry to improve service levels by reducing inefficiencies.