Integration of Smart Maintenance and SMED to Improve Cutting Area Efficiency in Plastic Bag Production

Winder M.H.; Cruz R.M.; Falcón P.C.G. · Proceedings of the 2025 IEEE 32nd International Conference on Electronics, Electrical Engineering and Computing, INTERCON 2025 (2025) · DOI: 10.1109/intercon67304.2025.11244668

Resumen

One of the key challenges faced by companies in the plastics sector is meeting global efficiency standards. This paper presents an improvement proposal for the plastic bag production line of a Peruvian company, which exhibited low efficiency in the cutting area compared to industry benchmarks, as measured by Overall Equipment Effectiveness (OEE). Machine availability and quality were identified as the primary contributing factors, with issues such as equipment breakdowns, extended setup times, and frequent reprocessing. To address these issues, an engineering improvement model was developed, incorporating the Single-Minute Exchange of Dies (SMED) methodology and the planned and autonomous maintenance pillars of Total Productive Maintenance (TPM), integrated with Industry 4.0 tools. Planned maintenance was implemented through a digital model supported by e-Lean software, while autonomous maintenance followed a traditional approach enhanced by Industrial Internet of Things (IIoT) technologies. As a result, availability and quality in the cutting area improved by 5.09% and 3.38%, respectively, raising the OEE from 80.59% to 86.17%. These improvements enabled the company to close the performance gap and meet the efficiency standards required by the plastics industry.

Instituciones: Universidad Peruana de Ciencias Aplicadas