Improving Production Plan Compliance through the Application of SMED and Standardized Work in a Soybean Oil and Shortening Company

Authors

DOI:

https://doi.org/10.26439/ciii2025.8656

Keywords:

Lean Manufacturing, operational efficiency, plan production compliance, SMED, Standardized Work

Abstract

This study was conducted in a Peruvian company engaged in the production and commercialization of oils and shortenings. An initial assessment revealed that average production plan compliance was 81%, below the industry benchmark of 90–95%, adversely impacting operational efficiency and customer satisfaction. The objective was to evaluate whether the combined application of SMED (Single-Minute Exchange of Die) and Standardized Work could improve this metric. Field observations and document reviews informed the design of a pilot project involving targeted workflow modifications. Both the baseline and optimized scenarios were modeled using Arena simulation software and executed with 18 replications each. The optimized model achieved 88.4% compliance, reduced bottle transport time from 21.7 to 16.4 min (-24.4%), and shortened format change duration from 60.1 to 48.7 min (-19%). Shift production increased from 4,086 to 4,596 bottles (+12.5%). These improvements were driven by task reorganization, the use of a pallet jack, tool centralization, and a pre-operational checklist. The findings provide empirical evidence that integrating SMED with Standardized Work can deliver significant operational improvements in mass-consumption production environments, while reinforcing the applicability of Lean principles within the Peruvian industrial context. It is recommended to scale these interventions and conduct medium-term evaluations to ensure sustained impact.

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Author Biographies

  • Gonzalo A. Montoya-Marín, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Gonzalo Montoya-Marín holds a Bachelor’s degree in Industrial Engineering from Universidad de Lima. He currently works in the Purchasing Department of a leading multinational company in the food and dairy industry, recognized as one of the largest corporations in Peru and Latin America. In this role, he is involved in procurement and supply management for raw materials and inputs, continuous coordination with suppliers, and operational and administrative purchasing processes to ensure efficiency and continuity of operations. His professional interests focus on logistics, supply chain management, and operations, with a strong orientation toward process optimization and operational efficiency.

  • Diego Mogollón-Sotomayor, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Diego Mogollón-Sotomayor holds a Bachelor’s degree in Industrial Engineering from Universidad de Lima. He currently works in the B2B Projects area at an international telecommunications company, where he participates in the planning, coordination, and management of projects for corporate clients. His professional interests include operations management, procurement, project management, and continuous process improvement.

  • Jorge A. Corzo-Chavez, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Jorge Antonio Corzo-Chavez holds a Master’s degree in Business Administration from Universidad ESAN, Peru; a Master’s degree in Marketing Science from ESIC Business & Marketing School, Spain; and a degree in Industrial Engineering from Universidad de Lima, Peru. He is currently a professor in the Industrial Engineering Program at Universidad de Lima and Chief Executive Officer at Conquista Lab. He has advised industrial and service companies on productivity improvement and business model development, and has worked in entrepreneurship, innovation, and commercial roles in the construction, mining, services, and education sectors. He has co-authored papers including “Improvement of Productivity by Applying 5S, Work Standardization, Ergonomic Analysis and Poka Yoke in a Metalworking Company,” published in the Proceedings of the 23rd LACCEI International Multi-Conference for Engineering, Education, and Technology; “Production Model Based on Lean Manufacturing and Systematic Layout Planning to Reduce Waste in a Company in the Poultry Sector: A Case Study,” published in the International Journal of Environmental Pollution and Remediation, volume 12; and “Model for Reducing Mean Absolute Percentage Error through Smoothing and Time Series Forecasting in a Tourism SME: A Case Study,” published in the Journal of Machine Intelligence and Data Science, volume 5. His main research interests are lean manufacturing, logistics, and machine learning for enterprises.

  • Gino Viacava-Campos, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Gino Viacava-Campos holds a Master’s degree in Operations and Logistics from Universidad Peruana de  Ciencias Aplicadas, Peru, and a degree in Industrial Engineering from Universidad de Lima, Peru. He is  currently a professor in the Industrial Engineering Program at Universidad de Lima. He has experience in industrial and service companies, focusing on productivity improvement, business model development,

    and compensation system structuring. He has worked in human resources, operations, and logistics areas of a transnational company, both locally and overseas. As a consultant, he has experience in the construction, manufacturing, services, mining, commercial, finance, and education sectors. He has co-authored papers including “A Production Process Efficiency Improvement Model at a MSME Peruvian Metalworking Company,” published in the Proceedings of the 2022 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM). His main research interests are lean manufacturing, master production schedules, logistics, and compensation systems for small and medium-sized enterprises.

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Published

2026-06-08

Issue

No. 004 (2025): IV Congreso Internacional de Ingeniería Industrial

Section

Ponencias

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