Building the Foundation for Smart Manufacturing: An Integrated Lean-TPM Framework for OEE Optimization in Peruvian Textile SMEs

Morillo-Dávila Y.; Morillo-Dávila L.; Maradiegue-Tuesta F.; Pinzón-Hoyos F.; Straujuma A. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260691

Resumen

While Industry 4.0 technologies promise significant productivity gains, many small and medium enterprises in emerging markets lack the operational stability required to implement them effectively. This challenge is directly illustrated by analysis of a women's clothing manufacturer in Lima, Peru, where the cutting area operated at just 73.7% OEE - well below the 85% industry benchmark - resulting in annual losses of approximately S/ 181,298. Rather than proceeding directly to the implementation of IoT sensors or predictive analytics, we recognized that the company first needed to address fundamental operational issues: machine downtime accounted for 69% of losses, followed by unproductive time (17%) and rework (14%). In response, an integrated framework - combining 5S, SMED, and Jishu Hozen - was designed that would not only close this performance gap but also establish the process discipline necessary for future digital transformation. Using Value Stream Mapping and statistical process control for diagnosis, the proposed approach was validated through literature-based projections, anticipating improvements in MTBF (from 3.64 to 10 hours), cycle time (from 81 to 65 seconds), and first-pass yield (from 86% to 95%). The findings suggest that for resource-constrained SMEs in Latin America, building this Lean-TPM foundation is an essential prerequisite before investing in smart manufacturing technologies. This phased approach is proposed as a more realistic pathway to Industry 4.0 for the thousands of traditional manufacturers in emerging economies.

Instituciones: Universidad Peruana de Ciencias Aplicadas