Can TPM improve packaging quality in a tinplate factory?

Abstract

In this research, the Total Productive Maintenance methodology was implemented in a tinplate packaging factory, with the purpose of improving product quality and increasing customer satisfaction. The implementation process included training of operators, improvement of equipment maintenance and optimization of machinery availability. The study was conducted due to the presence of recurring defects in production, mainly caused by worn and outdated machinery. Through quantitative and qualitative analysis, quality management tools such as Pareto and Ishikawa diagrams were used to identify the root causes of the problems, highlighting factors such as lack of preventive maintenance and inefficient personnel training. Key variables such as overall equipment efficiency, failure rate and productivity were analyzed. The results showed a 0.5% increase in the operating efficiency of the most critical machines, as well as a notable reduction in the defect rate of the final product. The research concludes that the application of TPM not only improves quality and reduces defects but also fosters a culture of continuous improvement in the company. Furthermore, the particularity of the present research is to provide an approach to ensure the long-term sustainability of the organization in the manufacturing sector, marking a significant difference with respect to previous studies by focusing on long-term solutions and a comprehensive approach to continuous improvement.