Optimización de la eficiencia productiva a través de la metodología Kaizen en el proceso productivo de inyección de suelas para calzado en la empresa textiles industriales Ambateños S.A.

Abstract

The technical project aim was to optimize the production efficiency of the process of injection of soles for footwear in the company "Textiles Industriales Ambateños SA," through the standardization of the process, segregating the star products according to the level of participation by injection machine and press, in addition to determining the production capacity in the jobs. The Injection Plant at “Textiles Industriales Ambateños S.A.” With a high production capacity in pairs of shoe soles per day, it did not have a standard procedure; each operator worked according to his empirical knowledge in material handling. It is essential to mention the inclusion of the pressing process on Eva material, considering it a conflictive position due to the percentage of defects handled by 24%, mainly due to: porosities in the sole, contamination of the material, and burning. The Kaizen methodology solved the problem in the XFP 150-6 Press. According to the process's statistical control with a 2^k experimental design that associated factors and levels such as temperature, pressing times, and weight of the material. The design analysis led to establishing the level of participation that the three factors' interaction has in the percentage of defects. Management techniques were also managed with the 5's tool in the injection process so that the procedures and methods performed at each work station are efficient, incorporating all the elements and production factors, therefore, the increase in production and productive efficiency at 20%, highlighting the identification of changes such as bottlenecks, long delays in the process, movements and excess inventories. It established that the continuous improvement process must be constant and disciplined in the injection plant to show substantial changes.