Proposed Efficiency Improvement Model in Furniture Production Using Poka-Yoke 4.0, SLP, and TPM 4.0

Eneque G.A.; Espinoza C.E.; Torres T.; Caferri A. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260679

Resumen

The Peruvian furniture sector, particularly small and medium-sized enterprises (SMEs), faces significant challenges in achieving high levels of efficiency in their production processes. This article analyzes the causes of low efficiency in a Peruvian SME dedicated to the manufacturing of melamine furniture, evidenced by an Overall Equipment Effectiveness (OEE) of 60.2%, a value considerably lower than the standard in the manufacturing sector (85%). The findings identify three main operational inefficiencies: high variability in the manual board-cutting process, unnecessary movements within the plant, and unscheduled downtime resulting from deficiencies in maintenance. To address this situation, a comprehensive improvement model is proposed that integrates Poka-Yoke 4.0, the use of Standard Work (SW), the Systematic Layout Planning (SLP) methodology, and the pillars of TPM 4.0. The intervention projects a 19% increase in productivity through layout optimization, a 17% reduction in average travel times, and a 6.2% decrease in the monthly cutting error rate through fault-detection systems. An in-depth root-cause analysis, complemented by comparisons with international cases, supports the robustness of the proposal. Finally, the implementation of a pilot test on the shop floor is recommended to validate the replicability of the approach within the manufacturing sector.

Instituciones: Universidad Peruana de Ciencias Aplicadas