Enhancing machine availability in plastic SMEs through lean and TPM: evidence from a peruvian case study

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.

Name thesis:degree_name

Ingeniero Industrial

Level thesis:degree_level

Titulo profesional

Discipline thesis:degree_discipline

Ingeniería Industrial

Grantor dc:publisher

Universidad de Lima

Year dc:date.issued

2026

Authors dc:creator

• Farfan Rodriguez, Oscar Gonzalo
• Medrano Vera, Enzo Alessandro

Advisor dc:contributor.advisor

• Calderón Gonzáles, Wilson David

• Plásticos
• Industria y comercio del plástico
• Mejora continua
• Pequeñas y medianas empresas
• Mantenimiento productivo total

Licence dc:rights.uri

• https://purl.org/coar/access_right/c_abf2
• https://creativecommons.org/licenses/by-nc-sa/4.0/

Language dc:language.iso

eng

Handle dc:identifier.uri

https://hdl.handle.net/20.500.12724/24669

OAI identifier oai:identifier

oai:repositorio.ulima.edu.pe:20.500.12724/24669