Implementation of Improvements to Increase the Availability of Production Equipment Using TPM 4.0 and SMED Tools in a PVC Pipe Factory

Llontop C.E.C.; Rodriguez K.M.P.; Vidigal J.F.C. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260711

Resumen

This study aims to increase the operational availability of a critical PVC pipe extrusion line through the integrated implementation of TPM 4.0 and SMED methodologies. The research was conducted using an applied approach, with a quasi-experimental before-and-after (AS IS-TO BE) design, employing a controlled pilot test for 91 days on the MMKSJSZ65/132 machine. The challenge was to close a 7.73% technical gap compared to global industry standards, generating a financial impact of S/ 1,635,860.07, or its equivalent in US dollars $487,008.06 (exchange rate S/ 3.3590 of the Central Reserve Bank of Peru (BCRP) as of January 16, 2026), representing 12.94% of the economic impact on the company under study. The study adopted a mixed-methods approach, combining quantitative analysis - based on MTTR, MTBF, and setup times - with qualitative causal analysis, supported by expert judgment techniques such as FMEA, the Five Whys, and structured brainstorming sessions. These tools allowed for the identification and prioritization of root causes associated with low equipment availability, attributed to: electric motor failures (18%), damage to the cooling system and blade changes (15.38%), and extrusion head failures (11.18%). The results show an 18.91% reduction in MTTR, a 29.55% increase in MTBF, and reductions of 34.09% and 41.27% in blade and extrusion head change times, respectively. The implementation of the model generated a positive economic impact of 28.75%, which validates the effectiveness of integrating TPM 4.0, focused on the Internet of Things (IoT), within the framework of Planned Maintenance (Preventive and Predictive) and SMED, to improve reliability, efficiency and operational sustainability in industrial extrusion processes.

Instituciones: Universidad Peruana de Ciencias Aplicadas