FACTORES DE ÉXITO QUE OPTIMIZAN LA MATERIA PRIMA EN LA INDUSTRIA DE PRODUCTOS DE MADERA

• DOI: https://doi.org/10.22533/at.ed.1317632627037

• Palavras-chave: Merma de madera, Manufactura esbelta, Optimización de materia prima, Gestión de calidad, Mejora continua (PHVA).

• Keywords: Wood waste, Lean manufacturing, Raw material optimization, Quality management, Continuous improvement (PDCA)

• Abstract: The wood products manufacturing industry faces significant challenges related to the management and efficient use of its primary raw material due to the intrinsic variability of wood. Even when components are cut from the same tree and to identical dimensions, wood differs in density, weight, and structural properties, which complicates production processes and contributes to high levels of material waste. This situation is particularly critical in maquiladora-type manufacturing companies operating in developing countries, where limitations in management systems and process control intensify material losses. In this context, the main objective of this study is to develop a comprehensive management methodology aimed at identifying improvement opportunities, strengthening quality awareness, and reducing the factors that generate waste of wood components within manufacturing plants. The research adopts a quantitative approach under a case study methodology and is theoretically supported by the principles of Lean Manufacturing, the Deming continuous improvement cycle (Plan–Do–Check–Act, PDCA), the Pareto principle, and competency-based training. The central hypothesis proposes that wood waste is closely related to the quality of raw material received from suppliers and to deficiencies in the current manufacturing system. Furthermore, it argues that waste levels can be significantly reduced through the systematic application of continuous improvement tools and the integration of all personnel involved in the production process. Data collection was carried out using a structured instrument consisting of an eight-question questionnaire addressed to managers and supervisors from the engineering, production, materials, and quality departments of 44 furniture manufacturing companies located in the state of Baja California, Mexico. A simple random sampling method for finite populations was applied, resulting in a representative sample of 27 companies. In addition to the questionnaire, interviews and direct observation of production processes were used as complementary techniques to strengthen the analysis. The diagnostic results indicate that, on average, 22% of the wood raw material used by the companies is considered waste, and only up to 25% of this waste is recovered. The main causes of material loss include the receipt of raw material that does not meet supplier specifications, machinery and equipment failures, inadequate production decisions that classify recoverable components as waste, and insufficient training of personnel. These issues not only affect production efficiency but also have a negative impact on other key departments such as planning, finance, human resources, and quality, ultimately compromising the company’s competitiveness and financial performance. To validate the proposed methodology, it was applied in a model company known as “Mi Arbolito.” The implementation made it possible to identify critical suppliers delivering defective or incomplete materials, deficiencies in preventive maintenance practices, opportunities for material recovery, and gaps in workforce training. As a result, improvement actions were implemented, including collaborative work with suppliers, the creation of a wood recovery area, the establishment of preventive and corrective maintenance plans, and the design of competency-based training programs. In conclusion, the findings confirm that wood waste represents a significant problem in the wood products industry; however, they also demonstrate that it can be effectively reduced through the integration of management systems, disciplined application of continuous improvement tools, and active participation of personnel. The proposed methodology contributes to optimizing raw material utilization, improving operational efficiency, and enhancing the sustainability and competitiveness of wood manufacturing companies.