Increasing Efficiency in the Paint Industry: Integrating Industrial Automation and Standardized Work for Smart Manufacturing

Alvarado-Vasquez R.; Espinoza-Gonzales D.; Velásquez-Costa J.; Minaya-Gonzales L.; Mendez-Pallares B. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260710

Resumen

The Peruvian paint industry continues to grow, but its competitiveness is limited by operational gaps in manual dosing, mixing, and capping processes, leading to unstable operations and higher reprocessing costs. In the company analyzed, operational efficiency stands at 74.8%, well below the sector benchmark of 88%, with volume variability ranging from 6% to 8%, operational errors reaching 59.18%, and losses equivalent to 4.5% of annual revenue due to overfilling, spillage, and repeated manual adjustments. In response to this scenario, the research develops a comprehensive model based on programmable automation using PLCs, photoelectric, capacitive, and inductive sensors, solenoid valves, and pneumatic actuators, structured into four phases: container classification, automatic dosing, sequenced mixing, and standardized capping. Experimental validation through a physical prototype and an As-Is / To-Be comparison demonstrates substantial improvements: an increase in efficiency to 84.7%, a reduction in cycle time to 11 s, 99% compliance with the dosed volume, a decrease in volume variability to 2.5%, a reduction in operational errors to 38.47%, and a decline in mixing variations to 18.3%. The results confirm that the integration of automation and standardized work constitutes a technically viable strategy to enhance the precision, stability, and reliability of the production process in the paint industry.

Instituciones: Universidad Peruana de Ciencias Aplicadas