Enhancing Machine Availability in Plastic SMEs through Lean and TPM: Evidence from a Peruvian Case Study
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International Journal of Recent Engineering Science (IJRES) |  |
| © 2025 by IJRES Journal | ||
| Volume-12 Issue-3 |
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| Year of Publication : 2025 | ||
| Authors : Oscar Gonzalo Farfan-Rodriguez, Enzo Alessandro Medrano-Vera, Wilson David Calderón-Gonzales |
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| DOI : 10.14445/23497157/IJRES-V12I3P106 |
How to Cite?
Oscar Gonzalo Farfan-Rodriguez, Enzo Alessandro Medrano-Vera, Wilson David Calderón-Gonzales, "Enhancing Machine Availability in Plastic SMEs through Lean and TPM: Evidence from a Peruvian Case Study," International Journal of Recent Engineering Science, vol. 12, no. 3, pp. 47-57, 2025. Crossref, https://doi.org/10.14445/23497157/IJRES-V12I3P106
Abstract
The plastic manufacturing sector in Peru faces significant challenges related to machine downtime and prolonged set-up times, which limit productivity and increase operational costs. Previous studies have highlighted the benefits of Lean Manufacturing and Total Productive Maintenance (TPM) for improving equipment efficiency, yet the integration of these methodologies in SMEs remains limited. This research addressed these challenges by developing a production model integrating Lean Manufacturing tools, such as SMED and Standardized Work, with TPM practices, specifically Autonomous and Planned Maintenance. The proposed model was validated in a Peruvian SME within the plastic sector, resulting in a 9.25% increase in machine availability and a 30.89% reduction in mold changeover time. These improvements enhanced production capacity and process stability, demonstrating the model's effectiveness in reducing unplanned stoppages. This study contributes to the body of knowledge by providing a replicable framework for optimizing manufacturing processes in plastic SMEs, suggesting further exploration of its scalability in other industrial contexts.
Keywords
Lean Manufacturing, Total Productive Maintenance, Machine Availability, Plastics SMEs, Operation Efficiency.
Reference
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