Mejora de la productividad de la planta de producción de la empresa MB Mayflower Buffalos S.A. mediante la implementación de un sistema de producción esbelta

Abstract

The aim of this project was the evaluation of the MB Mayflower Buffalos S.A.’s productivity in order to identify viable production processes to be improved and to implement in them a lean production system to increase the productivity without affecting products’ quality and staff welfare. For these purposes, the facilities’ plane scale was developed and the activities of each analyzed process were registered. Based on these data the Outline process charts and flow diagrams were developed to perform the work measurement by timing. The flow process and worker - machine activity charts were developed to know the process cycle time. The basic and standard production times were calculated, with rate of working and estimated allowances, and also the labor productivity was calculated. Cycle efficiencies of each process and cycle time were calculated with the identification of activities that add value to the product according to the customer. The application of the first two principles of lean production allowed identifying six of meat production's processes as feasible to be improved. With the application of the three following principles, the productivity was improved by reorganizing facilities’ layout, purchasing of new equipment and reallocate staff. The transport of materials and timeouts were identified as muda type II at the meat processing. The distribution of the physical space was the main limitation on productivity. The implementation of lean production system was able to decrease the cycle times of processes to 23,92%, in the production of chaufa beef cuts while the process cycle efficiencies increased to 71,00%, in the production of chaufa chicken cuts, and the weekly labor productivity in the processing of meat increased by 21.01%, with an increment of amounts of raw materials and processed products obtained by 35,71% and 33,69% respectively. These improvements did not require hiring additional staff, only fixed costs were incurred to relocating the cold room where the meats’ marinating is performed and the acquisition and installation of a new meat's unwinder machine, an electric saw and an air compressor to the cooling area. Working conditions for operators were not affected due to implement active pauses to prevent possible musculoskeletal injuries.