TPM, SMED and 5S model to increase efficiency in an automated production line for a company in the food sector

Currently, a great challenge for Peruvian companies is to face industrial evolution due to the need to continuously improve in order to increase the production of products and thus stand out from the competition. It requires a high level of commitment and implies constant research, trial and error in any situation, especially when it comes to machines and the search to solve their problems. The various studies for this type of situation propose different ways of covering it, among them, the Lean Manufacturing methodology. Previous studies have shown that mechanical stoppages due to breakdowns are a recurring element in production plants, as well as machine obstructions and excessive time to make a tool change. Those problems cause instability and production losses. Based on this, the present research seeks to improve the operation of the machines using the Lean Manufacturing methodology. For this, the results of a solution model were proposed, evaluated and estimated, which focused on creating a work discipline with the 5S tool, increasing production availability by 39% through the SMED tool, followed by TPM (Pillar II) Autonomous Maintenance where the obstructions decreased by 42% and the production capacity was increased based on the TPM (Pillar III) Planned Maintenance by 26%. Based on the Arena simulation software, it is estimated that this model would improve the OEE efficiency of a food production line from 83.17% to 93.14% and significantly reduce the magnitude of the problems. This report aims to provide a solution method for industries in the field that have low efficiency.

I. Introduction

The production and export of food is an increasingly popular trade for developing countries. This includes Peru since in recent years it has managed to position itself among the best production and export countries in both the world and Latin American markets. [1] [2].