A Structured Lean–TPM Model to Transform Setup and Downtime Management in Flexible Packaging: Evidence from Peru

International Journal of Industrial Engineering

© 2025 by SSRG - IJIE Journal

Volume 12 Issue 2

Year of Publication : 2025

Authors : Diana Carolina Apolinario-Avendano, Eleana Carolina Torres-Lima, Elmer Luis Tupia-De-La-Cruz

10.14445/23499362/IJIE-V12I2P106

How to Cite?

Diana Carolina Apolinario-Avendano, Eleana Carolina Torres-Lima, Elmer Luis Tupia-De-La-Cruz, "A Structured Lean–TPM Model to Transform Setup and Downtime Management in Flexible Packaging: Evidence from Peru," SSRG International Journal of Industrial Engineering, vol. 12,  no. 2, pp. 49-59, 2025. Crossref, https://doi.org/10.14445/23499362/IJIE-V12I2P106

Abstract:

Flexible-packaging firms repeatedly encounter low availability and lengthy setup times, issues that earlier Lean and TPM literature examined in isolation. Yet persistent waste in Small and Medium Enterprises (SMEs) reveals the need for a more cohesive and flexible approach. Therefore, this work blends those philosophies into a staged Lean-TPM framework designed to boost equipment performance and slash downtime. The plan features single-minute exchange of dies (SMED), scheduled preventive maintenance, and clear work standards, while frontline operators lead regular improvement cycles. When a Peruvian SME adopted the model, availability climbed from 75 to 92, mean time between failures rose 58, mean time to repair dropped 38, and setup duration shrank 40. Those metrics delivered steadier production and less scrap. From an academic viewpoint, the evidence highlights the roadmap's usefulness as a realistic option for resource-constrained firms. From a socioeconomic angle, the gains point to replicable pathways for similar plants across emerging markets. Researchers are urged to broaden testing to other sectors and regions.

Keywords:

Lean-TPM Model, Setup Time Reduction, Downtime Management, Flexible Packaging Industry, Operational Efficiency, Peruvian SME Case Study.

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