Business consulting - Hialpesa reducir el reproceso de teñido de tela en la unidad de tintorería
Date
2019-08-27
Authors
Perales Vallejos, Alan Gabriel
Príncipe Alfaro, Anika Rocío
Calsín Robles, Hugo Roger
Reyes Sánchez, Luis Patricio
Journal Title
Journal ISSN
Volume Title
Publisher
Pontificia Universidad Católica del Perú
Acceso al texto completo solo para la Comunidad PUCP
Abstract
Hialpesa, fundada en 1979, es una empresa peruana dedicada a la confección de
prendas de vestir para marcas internacionales de moda; asimismo, realiza servicios de
tejeduría y tintorería para el mercado local y América Latina, posicionándose dentro de las 10
principales compañías exportadoras del sector textil en el Perú. Tiene una estrategia de
liderazgo en costos y ha optado por realizar una integración vertical hacia atrás; con la
finalidad, de obtener un mayor control de la calidad del producto terminado, plazos de
entrega y el uso eficiente y eficaz de sus recursos, siendo sus principales unidades
productivas la Hilandería, Tejeduría, Tintorería y Manufactura. Es importante resaltar que el
95% de la facturación de productos terminados corresponde a clientes en el mercado
americano y el 5% al mercado europeo. Después de analizar el proceso productivo de
Hialpesa se ha identificado que la unidad más importante es la tintorería, debido a que a partir
de esta se inicia con el cumplimiento de las especificaciones del cliente en relación con la
tonalidad del color y calidad de la tela; es por ello, que al hacer una evaluación de la unidad
se identificó que el principal problema es de no lograr teñir la tela correctamente al primer
intento. Esto con lleva a que se reprocese la tela en un ratio del 9.7% de la producción,
representando un costo de USD 645,536 al cierre del 2018. Para solucionar el problema
descrito se hizo el análisis de causa raíz, logrando identificar cuatro soluciones relacionadas
directamente con el problema de estudio y una solución de oportunidad de mejora para la
empresa; las cuales, están orientadas a la estandarización y control de procesos, mejora
continua, capacitación del personal de planta y planes de mantenimiento. La implementación
de las soluciones propuestas representa un total de inversión de PEN 15,443.00, proyectando
que dicho ratio de reproceso se reduzca a 5.45%, el cual representa un ahorro de USD
282,280.
Hialpesa, founded in 1979, is a Peruvian company dedicated to the manufacture of garments for international fashion brands, it also performs weaving and dyeing services for the local market and Latin America, positioning itself among the 10 main exporting companies of the textile sector in Peru. It has a cost leadership strategy and has opted for vertical integration backwards; with the purpose of obtaining greater control over the quality of the finished product, delivery times and the efficient and effective use of its resources, being its main productive units the Spinning mill, Weaving, Dyeing and Manufacturing. It is important to highlight that 95% of the invoicing of finished products corresponds to customers in the American market and 5% to the European market. After analysing the production process of Hialpesa, it has been identified that the most important unit is the Dyeing, because from this it starts with the fulfilment of the customer’s specifications in relation to the colour tone and quality of the fabric; that is why, when making an evaluation of the unit, it was identified that the main problem is Not to achieve the correct dyeing of the fabric at the first-time. This generates to the reprocessing of the fabric with a ratio of 9.7% of the production, representing a cost of USD 645,536 at the close of 2018. To solve the problem described, the root cause analysis was done, identifying four solutions directly related to the problem of study and an improvement solution for the company, which are oriented to the standardization and control of processes, continuous improvement, training of plant workers and maintenance plans. The implementation of the proposed solutions represents a total investment of PEN 15,443.00, projecting to reduce the reprocessing ratio to 5.45%, representing a saving of USD 282,280.
Hialpesa, founded in 1979, is a Peruvian company dedicated to the manufacture of garments for international fashion brands, it also performs weaving and dyeing services for the local market and Latin America, positioning itself among the 10 main exporting companies of the textile sector in Peru. It has a cost leadership strategy and has opted for vertical integration backwards; with the purpose of obtaining greater control over the quality of the finished product, delivery times and the efficient and effective use of its resources, being its main productive units the Spinning mill, Weaving, Dyeing and Manufacturing. It is important to highlight that 95% of the invoicing of finished products corresponds to customers in the American market and 5% to the European market. After analysing the production process of Hialpesa, it has been identified that the most important unit is the Dyeing, because from this it starts with the fulfilment of the customer’s specifications in relation to the colour tone and quality of the fabric; that is why, when making an evaluation of the unit, it was identified that the main problem is Not to achieve the correct dyeing of the fabric at the first-time. This generates to the reprocessing of the fabric with a ratio of 9.7% of the production, representing a cost of USD 645,536 at the close of 2018. To solve the problem described, the root cause analysis was done, identifying four solutions directly related to the problem of study and an improvement solution for the company, which are oriented to the standardization and control of processes, continuous improvement, training of plant workers and maintenance plans. The implementation of the proposed solutions represents a total investment of PEN 15,443.00, projecting to reduce the reprocessing ratio to 5.45%, representing a saving of USD 282,280.
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Keywords
Industria textil--Perú, Producción--Administración
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