Optimizing Mill Bolt Production Efficiency in a Metal Mechanical Firm via Digital Twin Technology and Lean Methodologies

Document Type : Case Study

Authors

1 Universidad Peruana de Ciencias Aplicadas UPC

2 Universidad Peruana de Ciencias Aplicadas

3 Florida International University College of Business Florida, USA

Abstract

Objective: This study evaluates the impact of integrating Digital Twin technology with Lean methodologies on the operational efficiency of a firm in the Peruvian metal‑mechanic sector, focusing on a mill‑bolt production line. The company currently experiences substantial operational challenges, including high variability in production times, an inadequate facility layout, and limited technological integration. These deficiencies contribute to a low overall efficiency level of 44.04%. The purpose of this research is to demonstrate how the combined application of Digital Twin–based modeling and Lean process improvement strategies can enhance system performance, reduce operational inefficiencies, and strengthen organizational productivity.
Methods: This study employs an applied research approach using a quasi‑experimental design. Data was collected through informal conversations with production operators and the review of historical production records. The methodological process was structured in two phases. In the first phase, model validation was conducted through pilot experimentation focused on Lean methodologies. In the second phase, the proposed enhancements were evaluated and validated through computational simulations, enabling a controlled assessment of their impact on system performance. 
Results: The findings indicate an increase in operational efficiency from 44.04% to 61.66%, demonstrating the effectiveness of integrating Digital Twin technology with Lean methodologies. These results support the significance of the combined model in enhancing system performance and reducing operational inefficiencies
Conclusion: The results of this study underscore the substantial impact that a comprehensive, integrated intervention can have on the operational efficiency of metal‑mechanic production environments. The research highlights the critical value of uniting traditional process‑improvement approaches with emerging digital tools. This integration not only enhances decision‑making and process control but also strengthens the organization’s capacity for continuous improvement and long‑term competitiveness.

Keywords

References

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Available Online from 03 April 2026

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