Improvement proposal to increase the OEE in a mechanical press in the metalworking sector through SMED and TPM

Abstract

The metalworking sector is one of the industries that has more impact on Peru, representing 25.9% of the manufacturing industry’s workforce. Therefore, it is crucial for them to approach the biggest availability possible for its machines. In this case study, it was identified that a company that belonged to this sector had an OEE (Overall Equipment Efficiency) of 56.39%. This resulted in a monthly economic loss of $55,892.85, caused by numerous machine failures and a deficient set-up process. A model that combined TPM (Total Productive Maintenance) and SMED (Single-Minute Exchange of Die) methodologies was proposed to solve the issue, supported by the 5S tool. As a result, the OEE increased to 88.45%, and the set-up time was reduced from an initial value of 24.09 to 12.85 minutes. Additionally, the availability was increased by 40.58%. Furthermore, it is important to note that an economic evaluation was done, showing that after one year, a Net Present Value (NPV) of $99,286.89 was achieved, with an Internal Rate of Return (IRR) of 67% and a payback period of 4 months and 13 days. Finally, it is worth mentioning that the proposed model was validated using a simulation through Arena software.