SMED 4.0 Model to Improve Operational Efficiency and Sustainability in an Agricultural Chemical Industry

Verano R.; Aguilar G.; Hurtado A. · Advances in Transdisciplinary Engineering (2026) · DOI: 10.3233/atde260702

Resumen

The study adapts and applies an SMED 4.0 model, an evolution of the Single Minute Exchange of Die (SMED) approach, to reduce changeover times, improve operational efficiency, and promote sustainability in the agricultural chemical industry. This model integrates Industry 4.0 technologies, such as machine learning and the Internet of Things, enabling the optimization of format changeover times through a predictive system that automatically adjusts operating parameters using historical and real-time data, thereby reducing waste and variability. Its implementation in agrochemical product packaging processes reduced the average setup time from 45 to 28 minutes and decreased startup defects from 3% to 2.50%, demonstrating greater operational stability. Although previous cases have employed the method in other sectors, the originality of the present study lies in providing further evidence of the model's applicability in a company within the agricultural insecticide industry, thereby extending its reach to a relatively unexplored environment. From a practical perspective, the results offer a replicable tool for data-driven decision-making, facilitating the standardization of format changes, reducing reliance on individual operators' experience, and improving operational control.

Instituciones: Universidad Peruana de Ciencias Aplicadas