Model to improve the efficiency in the extrusion area in a manufacturing sme of the industrial plastic sector based on smed, autonomous maintenance and 5s

Abstract

At present, companies in the Peruvian plastic sector have an average capacity utilization indicator of 71.45%. However, in Peru many SMEs are with 50% well below this indicator. After a study performed in a representative company of the Peruvian plastic sector, the causes of low efficiency in resource utilization were determined through a problems tree and a Pareto analysis. These causes are failures, reprocesses and Setup times in the extrusion machines, taking around 1008 h a year to solve these problems. This article proposes a model to improve efficiency, integrating Lean Manufacturing tools such as 5s, SMED, and autonomous maintenance. The first one was used as a support tool, while SMED was used to reduce the configuration time and autonomous maintenance to reduce the failures number and the reprocesses number. The model was validated through a case study, obtaining as results the reduction of the setup time by 50%, breakdowns by 50% and reprocesses by 60%.