Design and Implementation of a New Layout in a New Production Area of a Cork Stopper Factory Following Lean Manufacturing Principles

Abstract

The current market conditions and purchasing power put pressure on selling prices. To maintain corporate profits, it is important to increase manufacturing efficiency and lower costs. The industrial unit in which this project was developed aims to increase the annual production of cork stoppers and by doing so, maintain the high standards of the quality and accuracy in their processes. To respond to this growth, Lean Manufacturing was implemented, and it was decided to build a new production area. The goal is to create a new production area for cork stoppers capable of producing around half a million cork stoppers per day. The use of Total Flow Management (TFM) tools allowed for the design of the layout and to level production. With the construction of a continuous flow between processes, the storage areas were gradually reduced, and the volume of WIP stock decreased by 63%. The results have also shown a decrease in the complaint rate of 3.5%, which was reduced under the established threshold of 5%, fulfilling the objectives proposed by the company for the project.