Improve Efficiency in the Cereal Bar Production Process by Using SMED, Autonomous Maintenance, Preventive Maintenance and Line Balancing

Chichizola-Mina I.; Ochoa-Artola M.F.; Urbina-Rivera C.; Avalos-Ortecho E. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260705

Resumen

This study addresses low operational efficiency (68.58%) in the packaging process of a Peruvian healthy food manufacturer, which operates below the industry benchmark of 77.1%. The inefficiencies are mainly driven by excessive setup times, unplanned equipment stoppages, and workload imbalance causing bottlenecks. To mitigate these issues, a pilot improvement project integrating Single-Minute Exchange of Die (SMED), Total Productive Maintenance (TPM), and Line Balancing was implemented. The proposed solution was validated through discrete-event simulation using Arena software on a representative production sample. Results indicate an efficiency increase to 81.13%, a 17.94% improvement in Takt Time compliance, and an MTBF increase exceeding 69% for critical equipment. In conclusion, the integrated application of these tools increased process efficiency by 13 pp, demonstrating that integrated engineering interventions allow small and medium-sized food enterprises to close technical gaps and enhance competitiveness without substantial capital investment.

Instituciones: Universidad de Lima