Citation:

Sindy Caroline Santamaria-Fernández, Ariana Fernanda Carrión-Garro, Elmer Luis Tupia-De-La-Cruz. "Lean Manufacturing and Work Study Integration to Enhance Production Efficiency in an Industrial Footwear SME: A Case Study in Peru" International Research Journal of Economics and Management Studies, Vol. 4, No. 4, pp. 198-214, 2025.

Abstract:

This study addressed the persistent inefficiencies in industrial footwear production processes within Peruvian SMEs, where disorganized workspaces and prolonged setup times hinder operational performance. Despite the recognized potential of Lean Manufacturing and Work Study techniques, their combined application in this sector remains underexplored. The objective of this research was to develop and implement an integrated production model to enhance operational efficiency and product quality. A methodological approach based on Lean tools—5S, SMED—and Work Study techniques, including bimanual diagrams and work standardization, was applied in a case study of a medium-sized industrial footwear company in Lima. The results showed a 28.53% improvement in process efficiency, a 38.95% reduction in mold changeover time, and a 62.73% decrease in defective products at critical stations. These outcomes demonstrate the model’s capacity to optimize resource use and reduce variability. The study offers practical guidance for SMEs in labor-intensive industries, contributing to sustainable operational improvements without significant technological investment.

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Keywords:

Operational Improvement, Waste Reduction, Work Study, Resource Utilization, SMED, 5S Methodology.