Optimization of the operations of a paint production plant applying 5S, Poka Yoke 4.0 and TPM

Abstract

Manufacturing SMEs show that unplanned production line stoppages, technical failures, and workplace disorder reduce operational reliability and limit productivity, highlighting the need to apply methodologies that stabilize operations and reduce errors. Operational variability, mechanical failures, and lack of standardization were addressed through a Lean approach integrating 5S to organize and standardize the work area, TPM to increase mean time between failures, and a sensor-based Poka Yoke system designed to prevent input shortages during the injection process. The results were validated through a hybrid model, with on-site implementation of 5S, a laboratory pilot for the digital Poka Yoke system, and an Arena simulation for TPM and the integrated model, respectively. The optimization showed an increase in productivity from 45.75 to 59.77 units per man-hour, mean time between failures increased by 24.87%, unproductive time was reduced by 70.55%, and the 5S index improved by 28%. These findings demonstrate that integrating Lean methodologies with accessible solutions constitutes a viable strategy to increase productivity, reduce variability, and enhance operational reliability in resource-constrained SMEs.