Lean-TPM Approach to Improve Delivery Compliance and Downtime Reduction in a Peruvian Microenterprise: A Transport Sector Case Study
| International Journal of Economics and Management Studies |
| © 2025 by SSRG - IJEMS Journal |
| Volume 12 Issue 6 |
| Year of Publication : 2025 |
| Authors : Connie Shomara Jiménez-Pinto, Aurora Luz Palacios-Espinoza, Elmer Luis Tupia-De-La-Cruz |
How to Cite?
Connie Shomara Jiménez-Pinto, Aurora Luz Palacios-Espinoza, Elmer Luis Tupia-De-La-Cruz, "Lean-TPM Approach to Improve Delivery Compliance and Downtime Reduction in a Peruvian Microenterprise: A Transport Sector Case Study," SSRG International Journal of Economics and Management Studies, vol. 12, no. 6, pp. 83-94, 2025. Crossref, https://doi.org/10.14445/23939125/IJEMS-V12I6P108
Abstract:
Peru's micro and small transport enterprises face persistent operational inefficiencies, often worsened by limited access to structured improvement methodologies. Previous studies have demonstrated the effectiveness of Lean Manufacturing and TPM tools in larger industrial settings, but their adaptation to small-scale services remains underexplored. Through a tailored improvement model, this study addressed the challenge of low delivery compliance and excessive downtime in a microenterprise. The proposal integrated 5S, Autonomous Maintenance, and SMED, implemented over five months. The actions focused on standardization, technical inspections, and changeover time reduction. Results showed an increase in delivery compliance from 58% to 90%, a 60.69% reduction in component changeover time, and an improvement in machine inspection rates from 33% to 83%. These advances contributed to greater service reliability and operational continuity. The findings reveal the viability of Lean-TPM applications in constrained environments. Future research is encouraged to replicate and extend this model in diverse contexts to strengthen its impact.
Keywords:
Lean Manufacturing, Total Productive Maintenance, Delivery Compliance, Transport Sector, Operational Efficiency.
References:
[1] Laila Driouach, Khalid Zarbane, and Zitouni Beidouri, “Literature Review of Lean Manufacturing in Small and Medium-sized Enterprises,” International Journal of Technology, vol. 10, no. 5, pp. 930-941, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[2] ReportLinker, Instant Access to the Latest Industry Reports. [Online]. Available: https://www.reportlinker.com/p06479946/Metal-Working-Global-Market-Report.html?utm_source=GNW
[3] Ministerio de la Producción, 2022 Enero: Reporte de Producción Manufacturera, 2022. [Online]. Available: https://ogeiee.produce.gob.pe/index.php/en/shortcode/oee-documentos-publicaciones/boletines-industria-manufacturera/item/1028-2022-enero-reporte-de-produccion-manufacturera
[4] Conexión ESAN, ¿Cómo Aplicar El Lean Manufacturing En Las PYMES?, 2017. [Online]. Available: https://www.esan.edu.pe/conexion-esan/como-aplicar-el-lean-manufacturing-en-las-pymes
[5] KLog.co, Perú: Un Motor del Comercio Internacional en Latinoamérica, 2025. [Online]. Available: https://klog.co/blog/peru-un-motor-del-comercio-internacional-en-latinoamerica
[6] Rocio Mercedes Florez-Cáceres, Christian Elian Huamán-Echevaría, and Juan Carlos Quiroz-Flores, “Improving Productivity in an SME in the Metalworking Sector Through Lean Manufacturing and TPM Tools: A Case Study in Peru,” South African Journal of Industrial Engineering, vol. 35, no. 2, pp. 91-109, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[7] Ahmed Maged et al., “Machine Learning Aided Six Sigma: Perspective and Practical Implementation,” IEEE Transactions on Engineering Management, vol. 71, pp. 1519-1530, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[8] G. Pinto et al., “TPM Implementation and Maintenance Strategic Plan - A Case Study,” Procedia Manufacturing, vol. 51, pp. 1423-1430, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Nicole Barrientos-Ramos et al., “Lean Manufacturing Model of Waste Reduction using Standardized Work to Reduce the Defect Rate in Textile MSEs,” 18th LACCEI International Multi-Conference for Engineering, Education, and Technology, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[10] Yash Dave, and Nagendra Sohani, “Improving Productivity Through Lean Practices in Central India-based Manufacturing Industries,” International Journal of Lean Six Sigma, vol. 10, no. 2, pp. 601-621, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[11] Dilsad Guzel, “Increasing Productivity of Furniture Factory with Lean Manufacturing Techniques (Case Study),” Tehnicki Glasnik, vol. 16, no. 1, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[12] Andrew Souza De Oliveira et al., “Application of Lean Manufacturing Methodology to Industrial Maintenance Management,” Revista de Gestao e Secretariado, vol. 14, no. 6, pp. 8997-9018, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[13] Carlos Monteiro et al., “Improving the Machining Process of the Metalwork Industry by Upgrading Operative Sequences, Standard Manufacturing Times and Production Procedure Changes,” Procedia Manufacturing, vol. 38, pp. 1713-1722, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[14] Yamileth Román, Wilmer Atoche, and Victor Farro, “Improvement of the Manufacturing Process of Reinforced Concrete Poles, using Lean Manufacturing Tools,” 20th LACCEI International Multi-Conference for Engineering, Education, and Technology, 2022.
[CrossRef] [Publisher Link]
[15] Sukhpreet Singh et al., “Implementation of Total Productive Maintenance Approach: Improving Overall Equipment Efficiency of a Metal Industry,” Inventions, vol. 7, no. 4, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[16] Saihong Tang et al., “Case Study on Lean Manufacturing System Implementation in Batch Printing Industry Malaysia,” MATEC Web of Conferences, vol. 70, 2016.
[CrossRef] [Google Scholar] [Publisher Link]
[17] Edith Luz Vargas Crisóstomo, and Jose William Camero Jiménez, “Application of Lean Manufacturing (5S and Kaizen) to Increase Productivity in the Production Area of Water-based Adhesives of a Manufacturing Company,” Industrial Data, vol. 24, no. 2, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Jose Velasquez-Costa, “Impact of the 5S Methodology in the Optimization of Resources in Metalworking Companies,” 20th LACCEI International Multi-Conference for Engineering, Education, and Technology, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[19] Ministerio de la Producción, Reporte de Producción Manufacturera, Agosto 2022, 2022. [Online]. Available: https://ogeiee.produce.gob.pe/index.php/en/shortcode/oee-documentos-publicaciones/boletines-industria-manufacturera/item/1070-2022-agosto-reporte-de-produccion-manufacturera
[20] Sachin N. Waghmare et al., “Enhancing Reliability and Quality for SMEs in India using Failure Mode Effect Analysis and Total Productive Maintenance,” International Journal of Indian Culture and Business Management, vol. 14, no. 1, pp. 44–54, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[21] Adnan Bakri et al., “Addressing the Issues of Maintenance Management in SMEs: Towards Sustainable and Lean Maintenance Approach,” Emerging Science Journal, vol. 5, no. 3, pp. 367–379, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[22] Sean Carlos Junior Garay-Livia, Diego Andres Chavarry-Pinazo, and Wilson David Calderon-Gonzales, “Driving Operational Reliability through Lean-TPM Synergy: A Case Study in a Freight SME from Peru,” International Research Journal of Economics and Management Studies, vol. 4, no. 5, pp. 233–246, 2025.
[CrossRef] [Google Scholar] [Publisher Link]
[23] G. Arrascue-Hernandez et al., “LEAN Maintenance Model based on Change Management Allowing the Reduction of Delays in the Production Line of Textile SMEs in Peru,” IOP Conference Series: Materials Science and Engineering, vol. 796, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[24] Soo-Fen Fam et al., “Overall Equipment Efficiency (OEE) Enhancement in the Electronic Components Industry through Total Productive Maintenance Practices,” MATEC Web Conference, vol. 150, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[25] Jorge Luiz Valencia Jarama, Victor Hugo Ortiz Moscoso, and Ricardo Rashuaman Flores, “Current Trends in Total Productive Maintenance,” e-Revista Multidisciplinaria del Saber, vol. 2, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[26] Angela Johana Callan-Villanueva, Sebastian Alejandro Núñez-Gonzales, and Wilson David Calderón-Gonzales, "Addressing Operational Challenges in Plastic Manufacturing SMEs: A Lean-TPM Model for Improved Efficiency and Quality,” SSRG International Journal of Economics and Management Studies, vol. 12, no. 2, pp. 1-10, 2025.
[CrossRef] [Publisher Link]
[27] Bhavesh Kanabar et al., “The Impact and Challenges of the Implementation of 5S Methodology in Healthcare Settings: A Systematic Review,” Cureus, vol. 16, no. 7, 2024.
[CrossRef] [Google Scholar] [Publisher Link]
[28] Vivaan Mehta, “Implementing 5S Technique in an Indian MSME: A Case Study,” International Journal of Research in Engineering Application and Management, vol. 6, no. 7, pp. 12–19, 2020.
[CrossRef] [Publisher Link]
[29] Angga Saenagri, Osly Usman, and Gos Ishak, “Implementation of Total Productive Maintenance and Lean Manufacturing in the Pharmaceutical Industry: An Empirical Study,” Journal of Business and Management Studies, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[30] Melesse Wakjira Wakjira, and Ananth Shalvapulle Iyengar, “Autonomous Maintenance: A Case Study on Assela Malt Factory,” Bonfring International Journal of Industrial Engineering and Management Science, vol. 4, no. 4, pp. 170–178, 2014.
[CrossRef] [Google Scholar] [Publisher Link]
[31] Abdullatif Ben Hassan, and Walid Abdul-Kader, “Short-Term TPM Implementation in SME: A Case Study,” Proceedings of the 5th NA International Conference on Industrial Engineering and Operations Management, 2020.
[Google Scholar] [Publisher Link]
[32] Ilesanmi Daniyan et al., “Application of Lean Six Sigma Methodology using DMAIC Approach for the Improvement of Bogie Assembly Process in the Railcar Industry,” Heliyon, vol. 8, no. 3, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[33] Antonio Carrizo Moreira, and Gil Campos Silva Pais, “Single Minute Exchange of Die: A Case Study Implementation,” Journal of Technology Management and Innovation, vol. 6, no. 1, pp. 129–146, 2011.
[CrossRef] [Google Scholar] [Publisher Link]
[34] Ernesto Altamirano, Karen Caballero-Rojas, and Oscar Palacios-Aguilar, “Total Productive Maintenance Model Applying SMED and FMEA to Increase the Overall Efficiency of Equipment (OEE) in the Food Sector,” Human Systems Engineering and Design (IHSED2021): Future Trends and Applications, 2021.
[CrossRef] [Google Scholar] [Publisher Link]
[35] M. Bevilacqua et al., “A Changeover Time Reduction through an Integration of Lean Practices: A Case Study from Pharmaceutical Sector,” Assembly Automation, vol. 35, no. 1, pp. 22-34, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[36] F.T.S. Chan et al., “Implementation of Total Productive Maintenance: A Case Study,” International Journal of Production Economics, vol. 95, no. 1, pp. 71–94, 2005.
[CrossRef] [Google Scholar] [Publisher Link]
[37] K.C. Ng, G.G.G. Goh, and U.C. Eze, “Critical Success Factors of Total Productive Maintenance Implementation: A Review,” 2011 IEEE International Conference on Industrial Engineering and Engineering Management, 2011.
[CrossRef] [Google Scholar] [Publisher Link]
[38] Jose Alejandro Vargas-Acha, Tomas Aramburu-Linares, and Juan Carlos Quiroz-Flores, “Application of the SMED Method to Increase the Efficiency of the Sealing Process in a Peruvian Company that Produces Flexible Plastic,” Proceedings of the 12th Annual International Conference on Industrial Engineering and Operations Management, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[39] Mirella Espinoza-Huamash, Irvin Arana-Hurtado, and Claudia León-Chavarri, “Maintenance Management Model to Increase Availably in a Metalworking SME Applying TPM, SMED and PDCA,” 2nd LACCEI International Multiconference on Entrepreneurship, Innovation and Regional Development - LEIRD 2022, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[40] S.P. Orlov, and S.V. Susarev, “Decision Support System for Autonomous Vehicle Maintenance Management,” Ontology of Designing, vol. 13, no. 3, pp. 424–436, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[41] Cesar E. Santos Gonzales, Carlos E. Mendoza Ocaña, and Geraldine J. Arqueros Mendocilla, “Total Productive Maintenance to Increase the Availability of a Transport Company's Bus Fleet, Trujillo 2024,” Memorias de la Vigésima Tercera Conferencia Iberoamericana en Sistemas, Cibernética e Informática (CISCI 2024), pp. 82-89, 2024.
[CrossRef] [Publisher Link]
[42] Jorge Enrique Ortiz Porras et al., “A Management Model based on Total Productive Maintenance (TPM) and Six Sigma to Increase Overall Equipment Effectiveness (OEE) in a Clothing Company in Lima, Peru,” Revista Industrial Data, vol. 27, no. 2, 2024.
[CrossRef] [Google Scholar] [Publisher Link]

10.14445/23939125/IJEMS-V12I6P108