Optimization model to increase the efficiency of the flexible packaging production process applying the Johnson Method, SMED and TPM in a SME in the Plastics Sector

Abstract

In the current context, the plastic industry has had a recession phase caused by the COVID-19 pandemic, however, according to the Manufacturing Production Report of the year 2020 reveals a recovery of 4.7% in the manufacture of plastics compared to the previous year. Faced with this, new challenges have emerged such as the increase in demand and the demand for high quality products; these are added to the old challenges of the sector such as unproductive times and non-compliance with delivery deadlines. This research is carried out in a small Peruvian company in which the low efficiency of its production process was identified as a central problem. In this sense, we propose the implementation of an optimization model based on the Johnson method, SMED and 2 pillars ofthe TPM methodology, resulting in an increase of24.39% inthe productive efficiency of the company, product of reduced setup times and increased mean time between failures.