Resource-Sensitive Lean-TPM and SMED Intervention to Elevate OEE: A Case Study of a Peruvian Bottle Manufacturer

International Journal of Industrial Engineering

© 2025 by SSRG - IJIE Journal

Volume 12 Issue 3

Year of Publication : 2025

Authors : Mario Andre Bocanegra-Flores, Christian Eduardo Berna-Olaya, Wilson David Calderón-Gonzales

10.14445/23499362/IJIE-V12I3P102

How to Cite?

Mario Andre Bocanegra-Flores, Christian Eduardo Berna-Olaya, Wilson David Calderón-Gonzales, "Resource-Sensitive Lean-TPM and SMED Intervention to Elevate OEE: A Case Study of a Peruvian Bottle Manufacturer," SSRG International Journal of Industrial Engineering, vol. 12,  no. 3, pp. 8-19, 2025. Crossref, https://doi.org/10.14445/23499362/IJIE-V12I3P102

Abstract:

The study expanded on earlier uses of Lean and TPM in manufacturing and addressed long-standing inefficiencies in plastic bottle SMEs. It focused on pressing problems like long mold changes, frequent unscheduled downtime, and calibration delays that limited capacity and quality. Through coordinated trials, checklists, operator training, and low-cost interventions, an integrated Lean-TPM model with SMED was put into practice. The pilot reduced estimated annual losses by PEN 76,109.98 (17% of the 500 ml line profit) by increasing OEE from 70.76% to 81%, availability from 86.76% to 91%, performance from 86% to 93%, and quality from 94.49% to 96%. Mold change time decreased from 96 to 55 minutes (−43%) and calibration from 52 to 44 minutes (−15%). These results illustrated that targeted, resource-conscious actions yielded quantifiable operational and financial benefits, contributing to academic discussions on Lean–TPM integration and realistic adoption strategies for limited SMEs. Multisite replication, extended monitoring, and low-cost condition monitoring and adoption were all suggested by the study.

Keywords:

Lean Manufacturing, Total Productive Maintenance (TPM), SMED (Quick Changeover), Overall Equipment Effectiveness (OEE), SME Production Efficiency.

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