Citation :

Rodrigo Santiago Baca-Vial, Alessandra Sánchez-Sánchez, Wilson David Calderón-Gonzales, "A Lean-Based Integrated Production Model Combining Layout Optimization and Visual Control for Metalworking SMEs," International Journal of Recent Engineering Science (IJRES), vol. 13, no. 1, pp. 38-51, 2026. Crossref, https://doi.org/10.14445/23497157/IJRES-V13I1P102

Abstract

Metalworking SMEs in developing economies had suffered inefficiencies for a long time, even after Lean and layout adjacent studies that reported only partial gains. This initiative addressed urgent issues of variability, huge amounts of internal transport, weak standardization of work processes, and unreliable production information. An integrated production model based on Lean Manufacturing, Systematic Layout Planning, and Kanban-type visual control was proposed and tested out in a Peruvian metalworking SME. New work methods were designed, plant layout was optimized, and information flow was improved with simple means of visual records. Results indicated that production efficiency improved from 80.20% to 90.80%, that systemic time per product was reduced by 9.44%, total travel time also by 8.13%, while information recording errors were reduced by 60.34%. Results indicated that some degree of operational stability was attained with measurable improvements in productivity, all without expending large amounts of capital. Theoretically, the initiative added more empirical information about synchronizing methods, spaces, and information in SMEs. From a social point of view, it is hoped that the additional competitiveness thus gained will contribute to reliable delivery ability extending downstream. Further studies are desired to extend the model.

Keywords

Lean Manufacturing Integration, Systematic Layout Planning (SLP), Kanban Visual Control, Operational Efficiency, Process Standardization.

References

[1] Chien-Yi Huang et al., “A Lean Manufacturing Progress Model and Implementation for SMEs in the Metal Products Industry,” Processes, vol. 10, no. 5, 2022.
[CrossRef] [Google Scholar] [Publisher Link]

[2] Sheyla Lesly Arbizu-Huaraca, Martha Silvana Cuno-Tipso, and Wilson David Calderón-Gonzales, “Cycle Time Reduction through SMED and Systematic Layout Planning in a Peruvian SME Producing Aluminum Cookware,” International Journal of Recent Engineering Science, vol. 12, no. 4, pp. 24–33, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[3] Pablo Soriano, “Developing a Lean Implementation Framework for SMEs through Case Research,” Journal of Industrial Engineering and Management, vol. 18, no. 3, 2025.
[CrossRef] [Google Scholar] [Publisher Link]

[4] Nyeoh Cheng Ying, Hasnida Ab-Samat, and Shahrul Kamaruddin, “Practical Production Layout Design for Multi-product and Small-Lot-size Production: A Case Study,” Jurnal Teknologi, vol. 78, no. 7, 2016.
[CrossRef] [Google Scholar] [Publisher Link]

[5] Bambang Suhardi, Lulu Elvira, and Rahmaniyah Dwi Astuti, “Facility Layout Redesign using Systematic Layout Planning,” Journal of Technology and Operations Management, vol. 16, no. 1, no. 57-68, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[6] Calvin Aidil Febri, and Anita Susilawati, “Productivity Improvement based on Systematic Layout Planning and 5S,” Journal of Ocean, Mechanical and Aerospace – Science and Engineering, vol. 66, no. 1, pp. 8-13, 2022.
[CrossRef] [Google Scholar] [Publisher Link]

[7] Carlos Monteiro et al., “Improving the Machining Process of the Metalworking Industry using the Lean Tool SMED,” Procedia Manufacturing, vol. 41, pp. 555–562, 2019.
[CrossRef] [Google Scholar] [Publisher Link]

[8] Mariusz Salwin et al., “Using Value Stream Mapping to Eliminate Waste: A Case Study of a Steel Pipe Manufacturer,” Energies, vol. 14, no. 12, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[9] Yosef Adji Baskoro, Prianggada Indra Tanaya, and Tanika D. Sofianti, “Relocation of a Factory using Systematic Layout Planning Combined with Flow Analysis,” Jurnal Ilmiah Teknik Industri, vol. 10, no. 2, 2011.
[Google Scholar] [Publisher Link]

[10] A.W. Nuruddin et al., “Implementation of Lean Manufacturing Concept to Minimize Delay Time in Completion of Product "A" as Customer Value (Case Study of PT. Tsw (Tuban Steel Work),” Mechanical Engineering Journal, vol. 4, no. 2, pp. 147–156, 2013.
[Google Scholar] [Publisher Link]

[11] Sebastian Cáceres-Gelvez et al., “A Systematic Layout Planning and TOPSIS application for the design of a Power Generation Turbine Parts Repair Workshop,” Engineering and University, vol. 26, no. 2, pp. 1–20, 2022.
[CrossRef] [Google Scholar] [Publisher Link]

[12] Gwendolyn Holowecky, Mark Dolsen, and Angie Lafferty, “Facilities Layout Planning in a TPS Environment using Modified Systematic Layout Planning,” Proceedings of the 2^nd World Congress on Industrial Engineering and Operations Management, Windsor, Canada, pp. 496–509, 2025.
[Publisher Link]

[13] Ahmad Nauval Ariq et al., “Optimizing the Facility Layout and Material Handling using Systematic Layout Planning Method: A Case Study at PT EDS Manufacturing Indonesia,” Proceedings of the International Conference on Industrial Engineering and Operations Management (IEOM), 2024.
[CrossRef] [Google Scholar] [Publisher Link]

[14] Ardiansyah Rendi Naufalah, Moh Ridwan Enan Sanusi, and Ardhy Lazuardy, “Redesign of Facility Layout using Systematic Layout Planning (SLP),” Proceedings of the 5^th International Conference on Industrial & Mechanical Engineering and Operations Management, Dhaka, Bangladesh, pp. 977–987, 2022.
[Google Scholar] [Publisher Link]

[15] Ana Paula Lista et al., “Lean Layout Design: A Case Study Applied to the Textile Industry,” Production, vol. 31, 2021.
[CrossRef] [Google Scholar] [Publisher Link]

[16] W. Fazinga et al., “Implementation of Standard Work in the Construction Industry,” Revista Ingeniería de Construcción, vol. 34, no. 3, pp. 288–298, 2019.
[CrossRef] [Google Scholar] [Publisher Link]

[17] Manotas-Duque Diego Fernando, and Leonardo Rivera-Cadavid, “Lean Manufacturing Measurement: The Relationships Between Lean Activities and Lean Metrics,” Estudios Gerenciales, vol. 23, no. 105, pp. 69–83, 2007.
[CrossRef] [Google Scholar] [Publisher Link]

[18] Katherine Kathleen Rojas, Juan Carlos Quiroz-Flores, and S. Nallusamy, “Minimization of Product Distribution Delays through an Integration Model of Lean Manufacturing Tools and A3 Report: Case Study,” SSRG International Journal of Mechanical Engineering, vol. 10, no. 9, pp. 31–43, 2023.
[CrossRef] [Publisher Link]

[19] Raquel Beatriz Goncalves Ralha Trindade Lyra, “Design and Implementation of a Supplier Kanban System,” Master’s Thesis, Instituto Politécnico do Porto, 2021.
[Google Scholar] [Publisher Link]

[20] J. Beetz, J.P. van Leeuwen, and B de Vries, “An Ontology Web Language Notation of the Industry Foundation Classes,” Proceedings of the 22^nd CIB W78 Conference on Information Technology in Construction, pp. 193-198, 2005.
[Google Scholar] [Publisher Link]

[21] R.M. Florez-Cáceres, C.E. Huamán-Echevaría, and J.C. Quiroz-Flores, “Improving Productivity in an SME in the Metalworking Sector through Lean Manufacturing and TPM Tools: A Case Study in Peru,” South African Journal of Industrial Engineering, vol. 35, no. 2, 2024.
[Google Scholar] [Publisher Link]

[22] Luigi Renzo Vargas Fiestas, Harry Sebastian Fry Guimet, and Alberto Enrique Flores-Pérez, “Increased Productivity through SMED and TPM in a Metalworking SME: An Empirical Investigation in the Peruvian Industry,” Proceedings of the International Conference on Industrial Engineering and Operations Management (IEOM), 2024.
[CrossRef] [Google Scholar] [Publisher Link]