Increasing Operational Efficiency in a Personal Care SME Through SMED, TPM, and IoT Within an Industry 4.0 Environment

Peña L.; Simonovich S.; Quijandria A. · Mechanisms and Machine Science (2026) · DOI: 10.1007/978-3-032-11791-5_42

Resumen

This study develops and validates an integrated improvement model aimed at increasing operational efficiency in the liquid production line of a Peruvian personal care SME. The model combines SMED, TPM (Pillars 1 and 2), and IoT technologies within an Industry 4.0 framework. SMED reduced changeover times by 26.2% through task classification and standardization. TPM Pillar 1 improved technical availability by 21.6% via autonomous maintenance, while Pillar 2, supported by IoT-based dashboards and sensor alerts, minimized unplanned downtime by 35.2%. The combined implementation was validated through in-plant pilot tests and discrete-event simulation using Arena. Results showed a projected increase in OEE of over 15% and an IRR of 122.56%, confirming both technical and economic feasibility. The model presents a replicable path for digital transformation and continuous improvement in resource-constrained MTO environments. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.

Instituciones: Universidad Peruana de Ciencias Aplicadas