Optimizing operational efficiency using Lean Manufacturing tools in a baking company

Abstract

The study was aligned with Sustainable Development Goal No. 8, which aims to promote decent work and economic growth. Its objetive was to determine the influence of applying Lean Manufacturing tools on the operational efficiency of a bakery company in Nuevo Chimbote in 2025. It was an applied research with a pre-experimental pre-test and post-test design, in which the 5S, Poka-Yoke, and Just in Time tools were implemented. The sample included 348 batches selected through proportional stratified sampling according to the type of bread produced. Initially, efficiency stood at 67.46%; after implementing improvements focused on organization, error prevention, and production synchronization, 84.6% of unnecessary materials were eliminated and waste was reduced by 62.7%. As a result, efficiency increased to 79.37%, reflecting a 17.65% improvement, while profitability rose by 13.42%, from 39.5% to 44.8%. The Wilcoxon test (p = 0.023 < 0.05) confirmed significant differences between the pre- and post-intervention stages. In summary, the application of Lean tools strengthened organization, productivity, and resource utilization, demonstrating their effectiveness in promoting continuous improvement and operational efficiency in small bakery businesses.