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.