Addressing Operational Challenges in Plastic Manufacturing SMEs: A Lean-TPM Model for Improved Efficiency and Quality

Abstract

The research investigated the challenges faced by SMEs in the plastic product sector, particularly regarding inefficiencies in machine availability, prolonged setup times, and high defect rates. Previous studies highlighted the potential of Lean Manufacturing and Total Productive Maintenance (TPM) to optimize operations, but limited research focused on their integration in this sector. The research tackled these problems by implementing a Lean-TPM production model that integrates SMED and Poka Yoke with maintenance approaches. Important findings were the average 35.99% reduction in setup times, a 32.66% increase in MTBF, a 39.71% reduction in MTTR, and a 23.19% decrease in defective products. These results prove the effectiveness of the model in enhancing productivity and the quality of products to other SMEs. These results are of great importance in productivity and quality of products for other SMEs, thus contributing greatly to Small Engineering Enterprises. This study significantly contributes to industrial engineering by bridging the theory and practice gaps. Further studies should investigate model adaptability, the integration of technologies of Industry 4.0, and the evaluation of the changes in organizational culture toward competitiveness over time.