Lean Manufacturing Tools Driving Operational Efficiency in Peruvian Upholstered Furniture Production: An Industrial Case Study

The Peruvian bedroom furniture industry, predominantly composed of micro and small enterprises with artisanal processes, has long faced delays, waste, and low operational efficiency. Previous studies have demonstrated that Lean methodologies—such as VSM, SMED, 5S, work standardization, Kaizen, and Kanban—can optimize workflow and reduce losses in manufacturing contexts. This research applied these tools to the cutting and upholstery stages, focusing on minimizing transportation, streamlining setup changes, and improving workplace organization. Results showed an increase in operational efficiency from 53.39% to 81.04% (a 51.79% improvement), a rise in setup time rate from 37% to 65% (a 75.68% improvement), and a reduction in cycle time from 59.37 to 52.81 minutes (-11.05%). These improvements reinforced process stability and sector competitiveness. Academically, the study provides empirical evidence of Lean’s adaptability to artisanal manufacturing; socioeconomically, it enhances productivity and employment. The findings encourage further exploration of Lean adaptation strategies in creative and small-scale industries.