Lean-TPM Integration for Quality and Efficiency Improvement in Peruvian Textile SMEs: A Study on Defect Reduction and Equipment Effectiveness

Abstract

The garment manufacturing industry, particularly in Small and Medium-sized Enterprises (SMEs), plays a crucial role in economic growth and employment generation. However, high defect rates and operational inefficiencies limit the competitiveness of textile SMEs in emerging economies. Earlier research has analyzed the advantages of Lean Manufacturing and Total Productive Maintenance (TPM). However, very few studies have looked into their combination within the context of Peruvian SMEs. This study attempts to fill that void by formulating a structured model of production that integrates Lean and TPM principles. Adopting 5S, standardized work procedures, and autonomous equipment maintenance led to a 60.52 % reduction in production defects and a 36.61% increase in Overall Equipment Effectiveness (OEE). These results highlight the continuous improvement efforts that can be made to process optimization and cost reduction. This research supports industrial engineering literature by creating a flexible model for small and medium enterprises. Further research is needed to incorporate tools from Industry 4.0 to improve productivity and efficiency further.