Optimizing Production in Ceramic Tile Manufacturing through Lean Manufacturing Tools: A Case Study in Peru

The ceramic tile sector in Peru faces significant challenges related to the efficiency and quality of production processes. Previous studies have shown substantial improvements with the implementation of Lean Manufacturing in various industries, but its specific application in the Peruvian ceramic tile sector has been little explored, justifying this research. Critical issues include high levels of waste, low productivity, and lack of standardization. These problems, aggravated by global competition, require immediate solutions. The implementation of Lean Manufacturing and TPM tools, such as 5S, Poka Yoke, work standardization and SMED, was proposed as a strategy to address these deficiencies. The proposed integrated model included staff training, process standardization and preventive maintenance. The results showed a 25% improvement in daily production, reducing the cycle time to 136 minutes per batch and decreasing the cost of production per piece by 0.79 PEN. The 5S audit score improved from 88 to 136 points, evidencing greater efficiency and quality. This study has a significant academic and socioeconomic impact, providing a replicable model for other companies in the ceramic tile sector and other industrial sectors. Future research on the integration of advanced technologies with lean manufacturing methodologies is recommended to maintain continuous improvements in production processes.