Empirical study on OEE optimization in a Peruvian flexographic printing SME: a Lean-TPM model that integrates 5S and SMED: a Lean-TPM model that integrates 5S and SMED

The flexographic printing industry plays a crucialrole in the packaging sector; however, many companies inemerging markets face low Overall EquipmentEffectiveness (OEE), primarily due to long setup times,unplanned downtime, and process inconsistencies.Previous studies have addressed these issues throughisolated applications of Total Productive Maintenance(TPM), One Minute Die Change (SMED), and 5S.However, little research has integrated these tools into aunified model tailored to the industry's challenges. Thisstudy developed a structured Lean-TPM model thatcombines 5S, SMED, and TPM to improve OEE in aPeruvian flexographic printing SME. The model wasvalidated through pilot implementations and simulationusing Arena software. The results showed an increase inOEE from 59.91% to 70.84%, a 29.05% reduction in setuptime, and a 28.26% decrease in the defect rate. Theseimprovements demonstrate the model's effectiveness inoptimizing performance while ensuring financialsustainability. This research provides a replicableframework for similar industries. Future studies shouldexplore AI applications to further improve predictivemaintenance and operational efficiency in dynamicmanufacturing environments.