Improvement Proposal to Increase Efficiency in the Production Process Through the Implementation of TPM 4.0 and SMED 4.0 in a Peruvian Metalworking SME

Jimenez A.; Rosales P.; Caferri A.; Torres T. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260700

Resumen

The metalworking sector faces increasing demands for productivity and faster response times. In this context, the problem of low operational efficiency in the production of metal structures at a metalworking company is addressed. This situation arises from long setup times (11%), poor maintenance management (13%), inadequate machinery calibration (27%), and non-standardized welding procedures (48%). Therefore, a comprehensive improvement plan is proposed based on the implementation of Industry 4.0 tools, specifically TPM and SMED, supported by IoT technologies. TPM was applied to improve the reliability of CNC machinery and standardize welding procedures, reducing rework by 10% and increasing equipment availability by 9%. SMED, for its part, enabled a reduction in setup times of more than 50%, optimizing the performance of the production flow. Finally, the integration of IoT ensured real-time monitoring, strengthening data-driven decision-making. The projected results reflect significant improvements: an increase in Overall Equipment Effectiveness (OEE). The application of these methodologies demonstrates the viability of Industry 4.0, constituting a replicable model for SMEs seeking to increase their efficiency and sustainability.

Instituciones: Universidad Peruana de Ciencias Aplicadas