Improving SME Manufacturing in the Footwear Sector through an Operational Model Based on TQM, Standardized Work, and Autonomous Maintenance

Autores/as

DOI:

https://doi.org/10.26439/ciii2025.8644

Palabras clave:

Leather waste, productivity improvement, Standardized Work, Total Quality Management (TQM), Total Productive Maintenance (TPM)

Resumen

The footwear sector in Peru has experienced sustained growth over time, playing a significant role in the national economy and contributing substantially to employment and exports. Consequently, companies in the sector must continuously evolve to meet new market demands and address production-related challenges that affect their competitiveness. In this context, identifying the root causes of these challenges is essential, such as the high level of leather waste, which is directly linked to insufficient input inspection, the absence of standardized cutting procedures, and recurrent sewing machine failures. This research proposes an improvement model based on three key tools—Total Quality Management (TQM), Standardized Work, and Total Productive Maintenance (TPM)—with the main objective of reducing leather waste in footwear companies to enhance material utilization, productivity, and profitability. The results confirm the effectiveness of the proposed model, achieving a reduction in overall leather waste from 33.2% to 20.1%, a 20% increase in productivity, and a return on investment in less than three months.

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Biografía del autor/a

  • Renzo A. Gutierrez Rodriguez, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Renzo Alexis Gutierrez Rodriguez is an Industrial Engineering student at Universidad de Lima who has
    completed all coursework for the degree. He currently serves as an Analyst in the Channel Planning
    Department at Banco de Crédito del Perú (BCP). His areas of interest include strategic planning, data
    analysis, and project management.

  • Maricielo D. V. Marín Marmolejo, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Maricielo Danna Victoria Marín Marmolejo holds a Bachelor’s degree in Industrial Engineering from
    Universidad de Lima, with a specialization in Business Engineering. She has experience in the banking
    sector, specifically in special accounts management and credit monitoring at Banco de Crédito del Perú
    (BCP). She specializes in business intelligence and data analytics. Her research interests include agile
    project management, internal control, and predictive analytics.

  • Wilson D. Calderón Gonzales, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Wilson David Calderón Gonzales is a doctoral candidate in Business Administration at Universidad de
    Lima. He holds a Master’s degree in Strategic Business Administration from Centrum Católica and a
    degree in Industrial Engineering from Universidad de Lima. He currently serves as Operations Manager
    for a Movistar franchise and as a professor in the Industrial Engineering Program at Universidad de Lima. He is a member of the Beta Gamma Sigma international honor society. His research interests include
    consumer experience, operations management, and process improvement.

  • Gustavo A. Luna Victoria-Leon, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Gustavo Adolfo Luna Victoria León is a doctoral candidate in Global Business Administration at
    Universidad Ricardo Palma. He holds a Master’s degree in Business Administration from Universidad
    del Pacífico and a Bachelor’s degree in Industrial Engineering from Universidad de Lima. He is a certified
    Project Management Professional (PMP) and Scrum Master. He currently serves as a professor in the
    Industrial Engineering Program at Universidad de Lima. He has more than 30 years of experience leading
    consultative sales, operations, and large-scale technology projects for companies such as Telefónica del
    Perú and GMD, serving both the public and private sectors. He specializes in high-value B2B account
    management. He has co-authored the articles “The Production Master Plan and Uncertainty in the
    Manufacturing Sector: A Literature Review” and “Scientific Research on Graphene in the Construction Industry,” both published in the Ingeniería Industrial journal of Universidad de Lima. His research interests include industrial engineering improvement solutions, project management, and applications of
    artificial intelligence, particularly in project management.

Referencias

[1] Ministerio de la Producción (PRODUCE), "Análisis sectorial: Desempeño e importancia de la industria de cuero y calzado 2019–2024," Oficina General de Evaluación de Impacto y Estudios Económicos, Lima, Perú, Feb. 2025.

[2] A. F. Espinoza Espinoza, C. O. Venturo Orbegoso, and O. J. Bravo Chávez, “Factores que inciden en el crecimiento de las mypes de calzado [Factors affecting the growth of footwear MSEs],” Inno. Res. J., vol. 5, no. 2, pp. 67-81, 2020.

[3] R. Calderón-Andrade, E. S. Hernández-Gress, and M. A. Montufar Benítez, "Productivity improvement through reengineering and simulation: A case study in a footwear-industry," Applied Sciences, vol. 10, no. 16, p. 5590, 2020.

[4] S. E. Munive Silvestre, V. D. Paucar Chaicha, J. C. Alvarez Merino, and S. Nallusamy, "Implementation of a Lean Manufacturing and SLP-based system for a footwear company," Production, vol. 32, e20210072, 2022.

[5] G. A. Laura-Ulloa, G. N. Chinchay-Morales, and J. C. Quiroz-Flores, “Lean model applied to increase the order fulfillment in SMEs in the footwear industry,” in IEIM 2022: 2022 The 3rd International Conference on Industrial Engineering and Industrial Management. New York, United States: Association for Computing Machinery, 2022, pp. 141-146, doi: 10.1145/3524338.3524360.

[6] M. Tauhiduzzaman, M. A. Mottalib, M. J. Rahman, and M. A. Kalam, “Preparation and characterization of composite sheets from solid leather waste with plant fibers: A waste utilization effort,” Clean Technol. Environ. Policy, vol. 26, pp. 1025–1038, 2023.

[7] N. D. Al-Qahtani, S. S. Alshehri, and A. Abd. Aziz, "The impact of Total Quality Management on organizational performance," Eur. J. Bus. Manag., vol. 7, no. 36, pp. 119-127, 2015.

[8] J. Fin, G. Vidor, I. Cecconello, and V de C. Machado, "Improvement based on standardized work: An implementation case study [Mejora basada en el trabajo estandarizado: Un estudio de caso de implementación]," Brazilian Journal of Operations & Production Management, vol. 14, no. 1, pp. 388-395, 2017.

[9] B. B. Solomon, “Leather cutting waste minimization techniques in Ethiopian footwear industry: Case study ELICO–Universal Leather Products Industry,” Research Square, 2021.

[10] A. C. Phan, A. B. Abdallah, and Y. Matsui, “Quality management practices and competitive performance: Empirical evidence from Japanese manufacturing companies,” International Journal of Production Economics, vol. 133, no. 2, pp. 518-529, 2011.

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Publicado

2026-06-08

Número

Núm. 004 (2025): IV Congreso Internacional de Ingeniería Industrial

Sección

Ponencias

Licencia

Derechos de autor 2026 Congreso Internacional de Ingeniería Industrial de la Universidad de Lima

Creative Commons License

Esta obra está bajo una licencia internacional Creative Commons Atribución 4.0.