An Operations Management Model Based on TPM and SMED to Enhance OEE in a Pasta Manufacturing Plant

The food manufacturing sector plays a vital role in global economic development, particularly in emerging economies where production and export volumes continue to grow. However, the industry faces persistent challenges related to operational inefficiencies, such as equipment downtime and extended setup times, which compromise competitiveness and profitability. This study presents the design, application, and validation of an operations management model based on the integration of Total Productive Maintenance (TPM), Single Minute Exchange of Die (SMED), and 5S to enhance Overall Equipment Effectiveness (OEE) in a pasta manufacturing plant. The model was tested through a real-world pilot application on a selected production line, focusing on reducing setup times, unplanned stoppages, and equipment inefficiencies. Results demonstrated a significant improvement in workplace organization (5S score +39 points), a drastic reduction in setup time (−445 minutes), and an overall OEE increase of 13.4%. The integration of SMED and 5S proved to be the most impactful in the short term, while TPM represents a key area for deeper implementation and sustained long-term gains. This research contributes empirical evidence supporting the effectiveness of combining these methodologies under real industrial conditions.