Service model to increase the fulfillment of complete orders in a warehouse based on SLP, Poka Yoke and Time Study in a Textile MSE

Efficient warehouse management in the textile sector is crucial for optimizing material flow and reducing production errors. However, many companies face challenges related to space utilization, material identification, and process standardization, which impact operational efficiency. This research applies Lean Manufacturing tools to improve raw material warehouse management, aiming to increase service levels and optimize operational processes. Systematic Layout Planning (SLP), Poka Yoke, and Time Study were implemented to reorganize material flow, reduce errors, and minimize idle times. As a result, the average time between batch outputs was reduced from 3.3 to 2.8 hours, while the number of defect-free batches increased from 3 to 5 per day, representing a 33.33% improvement. These tools enabled process optimization, improved inventory management, and reduced operational variability. The findings highlight the importance of adapting Lean Manufacturing methodologies to the specific characteristics of the textile sector, enhancing competitiveness and sustainability. This study provides an improvement model applicable to other companies facing similar warehouse management challenges.