Citation :

Nataly Jesus Barzola-Ninanya, Alessandra Solange Cuadros-Pita , Wilson David Calderón-Gonzales, 2025. "Improving Operational Efficiency and Reducing Material Waste in a Precast Concrete SME: Insights from a Peruvian Case Study" ESP International Journal of Science, Humanities & Management Studies(ESP-IJSHMS)  Volume 3, Issue 2: 15-26.

Abstract :

Precast concrete SMEs often suffered from operational inefficiencies, particularly due to non-standardized procedures, excessive material waste, and poorly designed layouts. Previous studies highlighted Lean Manufacturing as an effective methodology, yet its adaptation to resource-constrained SMEs remained underexplored. This research addressed those challenges by developing and implementing an integrated production model based on Lean Manufacturing, Kaizen, and Systematic Layout Planning. The model proposed key actions including work standardization, ergonomic redesign, supplier management, and layout optimization. Validation in a Peruvian SME revealed a 31.58% increase in value-added operations, an 80% reduction in rejected materials, and a 32.31% decrease in travel time. These results confirmed the model’s effectiveness in reducing waste and improving productivity. Academically, the study contributed a replicable framework for lean implementation in SMEs. Socioeconomically, it strengthened the competitiveness and sustainability of small manufacturers in emerging economies. Future research should explore its scalability and digital integration to further enhance real-time process control and impact.

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Keywords :

Lean Manufacturing, Kaizen, Precast Concrete SME, Material Waste Reduction, Systematic Layout Planning, Work Standardization.