Production management model to increase productivity through lean manufacturing tools as SMED, TPM and 5S in a SME in the plastic sector

The production of plastics has experienced
significant growth globally in recent decades. This growth has led
to an increase in national demand, which small companies often
struggle to meet due to low productive capacity. Various studies
show that this low productivity is mainly caused by inefficient use
of company resources, extended setup times and low machine
availability. This research aimed to address these issues by
applying Lean Manufacturing tools, specifically Single Minute
Exchange of Dies (SMED), Total Productive Maintenance (TPM),
and 5S, in a Peruvian plastics sector company. The project focused
on improving productivity in the company’s plastic bag
production line, which mainly included extrusion, printing, and
sealing operations. The model was subsequently validated through
simulation in the Arena software, where its effectiveness was
verified. Finally, it was demonstrated that implementing these
tools could achieve a setup time reduction of 17.09% for extrusion,
26.63% for printing, and 28.84% for sealing. Additionally,
regarding machine availability, extruders and printers showed
improvements of 1.23% and 4.81%, respectively. All these
improvements translated into an overall productivity increase of
33.57% in the production line. Future studies could focus on
exploring its application in other production environments or
industries to validate its broader impact. Future work could focus
on exploring its application in other production environments or
industries to validate its broader impact.