Operational Model to Improve On-Time Delivery: A Peruvian Case Study in Metalworking SMEs Integrating Lean Tools and TPM

The Peruvian metalworking sector has historically faced delays in deliveries due to poor process standardization and inadequate equipment maintenance. While previous studies have addressed Lean tools separately, limited empirical evidence exists regarding their integrated application within a single model for SMEs in this sector. This research addressed key challenges—machine stoppages, production delays, and disorganized workspaces—through an operational model combining Standard Operating Procedure (SOP), 5S, Total Productive Maintenance (TPM), and Single Minute Exchange of Die (SMED), validated through simulation and pilot implementation. SOP was defined as a standardized set of instructions ensuring the correct execution of operational tasks. The 5S tool increased audit scores from 34.4% to 84.3%, TPM improved OEE from 24% to 67%, and SMED and SOP together reduced changeover time by 64.8 minutes. The findings demonstrated measurable gains in productivity and process organization. At the industrial level, the model provides practical implications for SMEs aiming to enhance operational performance in emerging markets with resource and time constraints.