Improvement model to reduce defects in airtight buckets: Application of SMED 4.0, TPM and DOE in the plastics sector

Ynga N.H.; Arteaga J.L.A.; Taipe V.V. · ETCM 2025 - 9th Ecuador Technical Chapters Meeting (2025) · DOI: 10.1109/etcm67548.2025.11304382

Resumen

In the plastics industry, reducing defective parts is essential to ensure quality, efficiency, and competitiveness. This study presents a model to reduce the defective part rate in the sealed pail line by integrating three complementary tools: Total Productive Maintenance (TPM), focused on preventing anomalies in injection molds; Single Minute Exchange of Die (SMED) with an IoT approach, to reduce color changeover time; and Design of Experiments (DOE), to optimize the pigment ratio in the mixing process. The defective part rate was reduced from 9.38% to 3.50%, demonstrating the model's effectiveness. The proposal is applicable to other production lines with similar conditions, providing a scalable methodology aligned with Industry 4.0 principles.

Instituciones: Universidad Peruana de Ciencias Aplicadas