Improving productivity in an SME in the metalworking sector through lean manufacturing and TPM tools: a case study in Perú

Abstract

The objective of this study is to increase the efficiency and productivity of a business that offers sandblasting and painting services. An integrated model incorporating lean manufacturing tools, including preventative and autonomous maintenance, 5S, and SMED, is presented in this article. The model consists of four distinct phases. The initial stage consists of diagnosing the company’s beginning state. The second stage entails the execution of the 5S methodology to arrange workstations. Following this, a maintenance programme was implemented, which ultimately resulted in the reduction of setup times for the painting machine configuration. Furthermore, an assessment was conducted on the realised enhancements, and metrics were compared both before and after deployment. Statistical validation was performed via a pilot study that occupied an extended period. The findings validated a productivity improvement of 10% and an efficiency increase of 23.8%. In addition, a 32.04% reduction in setup time was observed. © 2024, Southern African Institute for Industrial Engineering. All rights reserved.