Implementación de la Herramienta TPM y SLP para Mejorar la Eficiencia en el Sector Metalmecánico
Resumen
En el dinámico entorno de la industria manufacturera, la eficiencia operativa es un factor clave para la competitividad, especialmente en el sector metalmecánico, donde la presión por optimizar recursos y reducir desperdicios es creciente. En este contexto, la presente investigación se desarrolló en una empresa dedicada a la fabricación de cajas portamedidoras monofásicas, donde se detectó un bajo nivel de eficiencia operativa, alcanzando apenas un 68.41 %, frente al 75.98 % del promedio del sector. Resolver esta brecha no solo era crucial para mejorar la eficiencia, sino también para asegurar la sostenibilidad y competitividad a largo plazo de la empresa. Para ello, se adoptó un enfoque Lean Green, mediante la implementación de herramientas como 5S, SLP, SMED y TPM, enfocadas en la mejora continua de procesos y la reducción del impacto ambiental. Este enfoque no solo permitió optimizar tiempos y espacios, sino también reducir significativamente el impacto ambiental mediante la creación de un circuito cerrado en el área de pintado, evitando la contaminación del entorno y promoviendo un uso más eficiente de los recursos. La validación se realizó mediante pruebas piloto (para 5S y SMED) y simulaciones en el software Arena (para SLP y TPM). Como resultado, se logró una mejora sustancial: el OEE se elevó al 87 %, el tiempo de set-up y la distancia recorrida se redujeron en 21.05 % y 26.35 %, respectivamente, y la evaluación 5S alcanzó un 64 %. Estos resultados evidencian que la brecha de eficiencia fue cerrada exitosamente y que la metodología Lean Green aplicada puede replicarse en otros entornos industriales con características similares, constituyendo una alternativa efectiva para mejorar el desempeño productivo de manera sostenible.
Descargas
Citas
Bataineh, O., Al-Hawari, T., Alshraideh, H., & Dalalah, D. (2019). A sequential TPM-based scheme for improving production effectiveness presented with a case study. Journal of Quality in Maintenance Engineering, 25(1), 144–161. https://doi.org/10.1108/JQME-07-2017-0045
Bataineh, O., Al-Hawari, T., Alshraideh, H., & Dalalah, D. (2019). A sequential TPM-based scheme for improving production effectiveness presented with a case study. Journal of Quality in Maintenance Engineering, 25(1), 144–161. https://doi.org/10.1108/JQME-07-2017-0045
Braglia, M., Castellano, D., & Gallo, M. (2019). A novel operational approach to equipment maintenance: TPM and RCM jointly at work. Journal of Quality in Maintenance Engineering.
https://doi.org/10.1108/JQME-05-2016-0018
Cabrera, O., Tejeda, J., Llontop, J., Mendoza, P., Alvarez, J. C., & Demirkesen, S. (2023). A validation model to reduce non-contributory time based on Lean tools: Case of a construction company in Perú. Cogent Engineering, 10(1).
https://doi.org/10.1080/23311916.2023.2236838/ASSET/DBF1D7D9-D4B5-4F43-8841
Choudhary, S., Nayak, R., Dora, M., Mishra, N., & Ghadge, A. (2019). An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the U.K. Production Planning & Control, 30(5–6), 353–368.
https://doi.org/10.1080/09537287.2018.1501811
Del Rosario-Malasquez, L., Dulce-Meneses, E., Viacava-Campos, G., & Cardenas, L. (2023). A Production Process Efficiency Improvement Model at a MSME Peruvian Metalworking Company. AIP Conference Proceedings.
https://scopus.upc.elogim.com/record/display.uri?eid=2-s2.0-85148029540&origin=resultslist&sort=plf
Domínguez-Alfaro, D., Mendoza-Muñoz, I., Montoya-Reyes, M. I., Vargas-Bernal, O. Y., & Jacobo-Galicia, G. (2023). Design and Implementation of Integral Ergo-Value Stream Mapping in a Metal-Mechanical Company to Improve Ergonomic and Productive Conditions: A Case Study. Logistics. https://doi.org/10.3390/logistics7040100
Drewniak, R., & Drewniak, Z. (2022). Improving business performance through TPM method: The evidence from the production and processing of crude oil. PLOS ONE, 17(9), e0274393.
https://doi.org/10.1371/JOURNAL.PONE.0274393
el Caribe, C. E. P. A. L. y. (s/f). Comisión Económica para América Latina y el Caribe (CEPAL). Comisión Económica para América Latina y el Caribe. Recuperado el 17 de septiembre de 2024, de https://www.cepal.org/es.
Espinoza-Huamash, M., Arana-Hurtado, I., & León-Chavarri, C. (2022). Maintenance management model to increase availably in a metalworking SME applying TPM, SMED and PDCA. Proceedings of the LACCEI International Multi-Conference for Engineering, Education and Technology, 2022-December. https://doi.org/10.18687/LEIRD2022.1.1.704
Findik, D., Tirgil, A., & Özbuğday, F. C. (2023). Industry 4.0 as an enabler of circular economy practices: Evidence from European SMEs. Journal of Cleaner Production, 410.
https://doi.org/10.1016/j.jclepro.2023.137281
Gaikwad, L. M., & Sunnapwar, V. K. (2024). Validation of Lean–Green–Six Sigma practice model for improving performance and competitiveness in an Indian manufacturing industry. International Journal of System Assurance Engineering and Management, 1, 1–14.
https://doi.org/10.1007/S13198-024-02357-0/FIGURES/5
Gelaw, M. T., Kitaw Azene, D., & Berhan, E. (2023). Assessment of critical success factors, barriers and initiatives of total productive maintenance (TPM) in selected Ethiopian manufacturing industries. Journal of Quality in Maintenance Engineering. https://doi.org/10.1108/JQME-11-2022-0073
Greinacher, S., Overbeck, L., Kuhnle, A., Krahe, C., & Lanza, G. (2020). Multi-objective optimization of lean and resource efficient manufacturing systems. Production Engineering, 14(2), 165–176. https://doi.org/10.1007/s11740-019-00945-9
Hagedorn, Wiebke., Greiff, Kathrin., Pauliuk, Stefan. (2024). An environmental assessment framework for circular steel products. Sustainable Production and Consumption.
https://doi.org/10.1016/j.spc.2024.05.031
Hardt, F., Kotyrba, M., Volna, E., & Jarusek, R. (2021). Innovative Approach to Preventive Maintenance of Production Equipment Based on a Modified TPM Methodology for Industry 4.0. Applied Sciences 2021, Vol. 11, Page 6953, 11(15), 6953. https://doi.org/10.3390/APP11156953
Huang, Z., Jowers, C., Kent, D., Dehghan-Manshadi, A., & Dargusch, M. S. (2022). The implementation of Industry 4.0 in manufacturing: from lean manufacturing to product design. International Journal of Advanced Manufacturing Technology, 121(5–6), 3351–3367.
https://doi.org/10.1007/s00170-022-09511-7
Huertas-Reyes, A., Quispe-Huerta, S., Leon-Chavarri, C., & Velasquez-Costa, J. A. (2022). Increased efficiency of a metalworking SME through process redesign using SMED, Poka Yoke and Work Standardization (Issue 1). https://doi.org/10.18687/LEIRD2022.1.1.69
INEI. (2023). Informe Técnico de Producción Nacional. Biblioteca Virtual INEI.
https://www.inei.gob.pe/media/MenuRecursivo/boletines/boletin_produccion_1.pdf
Instituto de Investigación y Desarrollo de Comercio Exterior-CCL (Idexcam).
Jara, B., Calderon, S., & Avalos-Ortecho, E. (2023). Application of Lean Manufacturing to Increase Productivity of a Company in the Metalworking Sector. Advances in Transdisciplinary Engineering, 35, 740–753. https://doi.org/10.3233/ATDE230102
Juárez-Vite, A., Corona-Arment, J. R., Rivera-Gómez, H., Montaño-Arango, O., & MedinaMarín, J. (2023). Application of the SMED methodology through folding references for a bus manufacturing company. International Journal of Industrial Engineering and Management, 14(3), 232–243. https://doi.org/10.24867/IJIEM-2023-3-335
Kanan, M., Dilshad, A. R., Zahoor, S., Hussain, A., Habib, M. S., Mehmood, A., Abusaq, Z., Hamdan, A., & Asad, J. (2023a). An Empirical Study of the Implementation of an Integrated Ergo-Green-Lean Framework: A Case Study. Sustainability (Switzerland), 15(13).
https://doi.org/10.3390/su151310138
Leme, R. D., Nunes, A. O., Message Costa, L. B., & Silva, D. A. L. (2018). Creating value with less impact: Lean, green and eco-efficiency in a metalworking industry towards a cleaner production. Journal of Cleaner Production, 196, 517–534.
https://doi.org/10.1016/j.jclepro.2018.06.064
Manzanares-Cañizares, C., Sánchez-Lite, A., Rosales-Prieto, V. F., Fuentes-Bargues, J. L., & González-Gaya, C. (2022). A 5S Lean Strategy for a Sustainable Welding Process. Sustainability (Switzerland), 14(11). https://doi.org/10.3390/su14116499
Oliveira, C., & Lima, T. M. (2023). Setup Time Reduction of an Automotive Parts Assembly Line Using Lean Tools and Quality Tools. Eng 2023, Vol. 4, Pages 2352-2362, 4(3), 2352–2362.
https://doi.org/10.3390/ENG4030134
Orellana-Nuñez, N., Puerta-Girón, M., & León-Chavarri, C. (2022). Production management model to reduce late deliveries in a metal-mechanical SME using lean tools. Proceedings of the LACCEI International Multi-Conference for Engineering, Education and Technology, 2022-December.
https://doi.org/10.18687/LEIRD2022.1.1.133
Padilla-Triveno, J., & Quiroz-Flores, J. C. (2022). Lean Production Model to Increase Equipment Availability in the Manufacturing Process of Gas Hose Connectors in Metalworking SMEs. ACM International Conference Proceeding Series, 275–281.
https://doi.org/10.1145/3568834.3568893
Pawlak, S. (2024). The Impact of Selected Lean Manufacturing Tools on the Level of Delays in the Production Process. A Case Study. Management Systems in Production Engineering, 32(1), 103–107. https://doi.org/10.2478/MSPE-2024-0011
Pinto, G., Silva, F. J. G., Fernandes, N. O., Casais, R., Baptista, A., & Carvalho, C. (2020). Implementing a maintenance strategic plan using TPM methodology. International Journal of Industrial Engineering and Management, 11(3), 192–204. https://doi.org/10.24867/IJIEM-2020-3-264
Queiroz, G. A., Filho, A. G. A., Núñez, J. F., Santa-Eulalia, L. A., Delai, I., & Torkomian, A. L. V. (2024). Lean and Green Manufacturing in operations strategy: cases from the automotive industry. Operations Management Research, 1–25. https://doi.org/10.1007/S12063-024-00477-1/FIGURES/3
Rodrigues, J., Sá, J. C., Silva, F. J. G., Ferreira, L. P., Jimenez, G., & Santos, G. (2020). A rapid improvement process through “quick-win” lean tools: A case study. Systems.
https://doi.org/10.3390/systems8040055
Rodriguez, L., Loyo, J., & Silva, U. (2023). LAYOUT EVALUATION WITH THE INDUSTRY 4.0 APPROACH FOR A MANUFACTURING LABORATORY. International Journal of Simulation Modelling, 22(4), 551–561. https://doi.org/10.2507/IJSIMM22-4-642
Salins, S. S., Zaidi, S. A. R., Deepak, D., & Sachidananda, H. K. (2024). Design of an improved layout for a steel processing facility using SLP and lean Manufacturing techniques. International Journal on Interactive Design and Manufacturing, 1–22. https://doi.org/10.1007/S12008-024-01828-9/FIGURES/27
Schindlerová, V., Šajdlerová, I., Michalčík, V., Nevima, J., & Krejčí, L. (2020). Potential of using TPM to increase the efficiency of production processes. Tehnicki Vjesnik, 27(3), 737–743.
https://doi.org/10.17559/TV-20190328130749
Siegel, R., Antony, J., Garza-Reyes, J. A., Cherrafi, A., & Lameijer, B. (2019). Integrated green lean approach and sustainability for SMEs: From literature review to a conceptual framework. Journal of Cleaner Production, 240, 118205. https://doi.org/10.1016/J.JCLEPRO.2019.118205
Siegel, R., Antony, J., Govindan, K., Garza-Reyes, J. A., Lameijer, B., & Samadhiya, A. (2022). A framework for the systematic implementation of Green-Lean and sustainability in SMEs. Production Planning and Control. https://doi.org/10.1080/09537287.2022.2052200
Silvestre, S. E. M., Chaicha, V. D. P., Merino, J. C. A., & Nallusamy, S. (2022). Implementation of a Lean Manufacturing and SLP-based system for a footwear company. Production, 32.
https://doi.org/10.1590/0103-6513.20210072
Singh, J., & Singh, H. (2020). Justification of TPM pillars for enhancing the performance of manufacturing industry of Northern India. International Journal of Productivity and Performance Management, 69(1), 109–133. https://doi.org/10.1108/IJPPM-06-2018-0211/FULL/PDF
Sukma, D. I., Prabowo, H. A., Setiawan, I., Kurnia, H., & Fahturizal, I. M. (2022). Implementation of Total Productive Maintenance to Improve Overall Equipment Effectiveness of Linear Accelerator Synergy Platform Cancer Therapy. International Journal of Engineering, Transactions A: Basics, 35(7), 1246–1256. https://doi.org/10.5829/ije.2022.35.07a.04
Urain, I., Eguren, J. A., & Justel, D. (2022). Development and validation of a tool for the integration of the circular economy in industrial companies: Case study of 30 companies. Journal of Cleaner Production, 370. https://doi.org/10.1016/j.jclepro.2022.133318
Vaz, E., Vieira De Sá, J. C., Santos, G., Correia, F., & Ávila, P. (2023). The value of TPM for Portuguese companies. Journal of Quality in Maintenance Engineering, 29(1), 286–312.
https://doi.org/10.1108/JQME-12-2020-0121/FULL/PDF
Yağlı, E., Şencan, A. Ç., Koçak, M. R., & Şencan, C. (2024). Investigation of the effect of 5s application on production efficiency in machining: A field study at an aviation company. Journal of the Faculty of Engineering and Architecture of Gazi University, 39(2), 1067–1082.
Derechos de autor 2026 Ernesto Altamirano Flores , Elvira Cáceres Cayllahua, Jhon Pérez Ayala, María Fernanda Delgado Pucurimay, Valeria Francia Quispe
Esta obra está bajo licencia internacional Creative Commons Reconocimiento 4.0.
.png)
.png)
1.png)
