Management model for the application of lean manufacturing tools to reduce returns of incorrect orders in a pharmaceutical company
DOI:
https://doi.org/10.26439/ing.ind2025.n48.7755Keywords:
returns, lean manufacturing, 5S, SMED, kaizenAbstract
The research seeks to apply lean manufacturing tools to reduce returns of wrong orders, the main problem that affects the company under study, which is a pharmaceutical company. For which it will begin by developing a value stream mapping that determines the waste and the Lean tools to use (5S, SMED and Kaizen). Data analysis was done using inferential statistical techniques, with the objective of testing the proposed hypotheses. For this, an evaluation was carried out to measure reliability and normality. After the application of various improvement tools, each result obtained from January to December 2023 was evaluated. The final result was that the percentage of returns of incorrect orders decreased from 14 % to 7 %. It was concluded that the adoption of Lean tools generated significant advantages for the company, ranging from the detection of inefficiencies, standardization to continuous improvement.
Downloads
References
Ajuria, J., Arambarri, J., & Rojas, J. (2023). Metodología de transformación digital para incrementar la competitividad de las pymes de logística ligera en el Perú. Revista Industrial Data, 26(1), 63-90. https://doi.org/10.15381/idata.v26i1.23745
Arica-Hernandez, M., Llagas-Llontop, S., & Khaburzaniya, I. (2022). Implementation of lean manufacturing principles to increase productivity in SMEs in the manufacturing sector of clothing. En 3rd International Conference on Industrial Engineering and Industrial Management (pp. 162-166). Association for Computing Machinery. https://doi.org/10.1145/3524338.3524363
Asociación Nacional de Laboratorios Farmacéuticos. (2024). Disponibilidad de productos farmacéuticos. https://alafarpe.org.pe/disponibilidad-de-productos-farmaceuticos
Bian, Y., & Xiao, T. (2025). Returns management in a supply chain considering freight insurance and consumer disappointment aversion. Transportation Research Part E: Logistics and Transportation Review, 195, 103975. https://doi.org/10.1016/j.tre.2025.103975
Bravo, J. (2023). Aplicación de herramientas lean manufacturing (5S, andon y tiempo estándar) para el aumento de la productividad en el área de producción de una empresa metalmecánica. Revista Industrial Data, 26(1), 217-245. https://doi.org/10.15381/idata.v26i1.24580
Büyüközkan, K., Gürsoy, B., Özçelik, G., & Faruk, O. (2025). An optimization model and customized solution approaches for in-plant logistic problem within the context of lean management. Computers & Industrial Engineering, 200, 110832. https://doi.org/10.1016/j.cie.2024.110832
Dias, J., Pinto, L., Gonçalves, M., Silva, F., & Ares, E. (2019). Analysis of an order fulfilment process at a metalwork company using different lean methodologies. Procedia Manufacturing, 41(1), 399-406. https://doi.org/10.1016/j.promfg.2019.09.025
Frank, A., Sturgeon, T., Benitez, G., Marodin, G., & Ferreira e Cunha, S. (2025). How lean and industry 4.0 affect worker outcomes and operational performance: A quantitative assessment of competing models. International Journal of Production Economics, 279, 109475. https://doi.org/10.1016/j.ijpe.2024.109475
Gómez, G., Álvarez, A., & Sarmiento, J. (2025). Proyectos preliminares relacionados con LC, BIM e IA en la industria de construcción. Revista Ingeniería y Competitividad, 24(1). https://doi.org/10.25100/iyc.v27i1.14401
Gunaki, P., Devaraj, S., & Patil, S. (2022). Process optimization by value stream mapping. Materials Today: Proceedings, 54(2), 251-254. https://doi.org/10.1016/j.matpr.2021.08.304
Haro, A., Martínez, E., Chango, T., Zambrano, T., & Zambrano, M. (2023). Enterprise resource planning (ERP) procesos para una implementación óptima y eficiente. Prometeo Conocimiento Científico, 3(1), e21. https://doi.org/10.55204/pcc.v3i1.e21
Hernández, R., Fernández, C., & Baptista, P. (2014). Metodología de la investigación (6.a ed.). McGraw Hill.
Iparraguirre, G., & Torres, G. (2023). Lean manufacturing como metodología para el aumento de la productividad empresarial: una revisión sistemática. Revista Científica Ingeniería: Ciencia, Tecnología e Innovación, 10(2), 61-68. https://doi.org/10.26495/icti.v10i2.2650
Jadidi, O., Cavalieri, S., & Firouzi, F. (2024). Supplier selection and order allocation problem under demand and supply uncertainty with return policy. Applied Mathematical Modelling, 133(1), 65-78. https://doi.org/10.1016/j.apm.2024.05.014
Khan, R., Talha, M., Sarwar, G., Haider, Y., Sarwar, U., Akbar, A., & Umair, M. (2022). The current status of lean manufacturing in small, medium and large scale manufacturing companies. Journal of Applied Engineering Science, 20(3), 707-715. https://doi.org/10.5937/jaes0-35761
Khouja, M., & Hammami, R. (2023). Optimizing price, order quantity, and return policy in the presence of consumer opportunistic behavior for online retailers. European Journal of Operational Research, 309(2), 683-703. https://doi.org/10.1016/j.ejor.2023.01.035
Muñoz, C. (2011). Cómo elaborar y asesorar una investigación de tesis (2.a ed.). Pearson Educación.
Naranjo, S., & Gutiérrez, E. (2024). Reingeniería en el proceso de medición de datos maestros. Revista Industrial Data, 27(1), 69-88. https://doi.org/10.15381/idata.v27i1.20817
Ortiz, J., Bancovich, A., Candia, T., Huayanay, L., & Salas, J. (2023). Método de aplicación de la herramienta value stream mapping para aumentar la competitividad en una empresa textil y de confecciones. Revista Industrial Data, 26(1), 33-61. https://doi.org/10.15381/idata.v26i1.22874
Ricra, M., & Valenzuela, A. (2023). Herramientas lean en la gestión de operaciones aplicado a las empresas de confección de prendas de algodón orgánico. Revista de Investigación Multidisciplinaria CTS Café, 7(19), 3-17. https://ctscafe.pe/index.php/ctscafe/article/view/235
Vara, A. (2012). Los 7 pasos para una tesis exitosa. Universidad San Martín de Porres.
