Reducción del tiempo de liberación de cilindros en el taller de mantenimiento

Abstract

This project focuses on reducing the cylinder release lead time within an industrial maintenance workshop located in Guayas, Ecuador, where operational delays were adversely impacting the supply chain and final customer service levels. The primary objective was to decrease the average release time from 12.86 days to 10 days by applying the DMAIC methodology over a four-month period. The development phase utilized Lean Manufacturing tools, including SIPOC diagrams, Voice of the Customer, process mapping, and root cause verification. The diagnostic results revealed that 42% of activities were non-value-added and that the process was statistically out of control due to the randomized selection of cylinders. Following the implementation of solutions based on record standardization, FIFO systems, and digital Kanban boards, the process achieved 100% stabilization. The average release time was reduced to 10.96 days, representing a 15% improvement in the total cycle and a 66% reduction in the initial gap. It is concluded that visual management and material flow discipline are decisive factors in achieving operational excellence. Keywords: DMAIC, Maintenance Management, FIFO, Kanban Board