Improving the Operational Efficiency of a Metalworking Company Through Smed 4.0, Autonomous Maintenance, and Iot-Based Industry 4.0 Sensorization

Gonzalez S.A.A.C.; De La Cruz J.A.R.; Ramirez M.F.M.; Rivera C.M.U. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260703

Resumen

This paper aims to improve the operational efficiency of a metalworking microenterprise located in Lima, Peru, through the integrated application of the autonomous maintenance pillar of Total Productive Maintenance (TPM), SMED 4.0, and Industry 4.0 technologies. A quantitative-experimental approach was employed, utilizing Arena simulation software to model both the current and proposed systems. Historical data revealed an average Overall Equipment Effectiveness (OEE) of 62%, a Mean Time Between Failures (MTBF) of 702.54 hours, and a Mean Time To Repair (MTTR) of 8.165 hours. Key root causes, such as prolonged machine setup times, mechanical failures, human errors, lack of standardization, and insufficient training, were addressed through the implementation of autonomous maintenance, SMED 4.0, and Industry 4.0 systems, including SCADA for real-time monitoring and sensor-based data collection. The solution was validated through pretest-post test simulation, showing significant improvements in OEE, MTTR, and MTBF indicators. The findings demonstrate that the combined application of these methodologies, adapted to the context of small enterprises, offers an effective, sustainable, and replicable strategy to enhance operational competitiveness in resource-constrained industrial environments.

Instituciones: Universidad de Lima