Improvement Model to Increase Efficiency Applying SMED, IoT, Cloud Computing and TPM in a Peruvian Metalworking SME

Abstract

This study addresses the increase in efficiency in the production of manufacturing SMEs. In this regard, the case study reports an initial production efficiency of 64.65%, with a gap of 15.35% from the optimal level of 80%, resulting in a negative economic impact of 25.60% on the profits for 2023. The critical process involved in low efficiency is the cutting process, which presents disorganization, high setup times, and unplanned downtime. To address these issues, it is proposed to implement the 5S, SMED, IoT, Cloud Computing and TPM tools. The integration of these tools is validated through a simulation in Arena, considering three scenarios: pessimistic, moderate, and optimistic. The estimated results show significant improvements in each simulated scenario. In the optimistic case, compliance 5S increased from 28% to 80%. Also, the setup time was reduced from 117.92 minutes to 79.96 minutes by applying 5S-SMED. Furthermore, the mean time between failures increased from 29.85 to 38.20 hours (27.97%), because of the implementation of TPM, IoT, and Cloud Computing. Consequently, the initial operational efficiency increases by 14.95%, rising from 64.65% to 79.60%. Therefore, it is concluded that the proposed model enhances the operative efficiency and can be applied to other companies with similar problems and causes.