Industry 4.0: Sustainable Transformation of Plastics SMEs Through TPM, SMED, and POKA YOKE

Diaz-Aliaga C.A.; Jurado-Toscano E.D.; Hurtado A. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260729

Resumen

The plastic industry faces operational challenges that directly impact the competitiveness of small and medium-sized enterprises (SMEs), particularly in processes such as PET bottle blow molding. This study proposes a continuous improvement model that integrates Lean Manufacturing tools with advanced Industry 4.0 technologies to optimize processes in a plastic-sector SME. The model combines traditional methodologies like SMED, TPM, and Poka-Yoke with digital Industry 4.0 solutions, including smart sensors, real-time data analytics, and automation tools such as Power BI and Power Automate. Results demonstrate significant improvements: a 35% reduction in machine downtime, a 28% decrease in production defects, and a 40% improvement in tool change times. Additionally, digital technologies enabled automated data collection, real-time alert generation, and visualization of key performance indicators, facilitating faster, evidence-based decision-making. Beyond operational efficiency, the model contributes to sustainable transformation by reducing waste, improving energy efficiency, and promoting resource-efficient manufacturing practices. This continuous improvement model, complemented by Industry 4.0 tools, offers a replicable strategy to enhance efficiency, reduce costs, and support the long-term competitiveness of SMEs in an increasingly digital and environmentally demanding industrial environment.

Instituciones: Universidad Peruana de Ciencias Aplicadas