Integrated Model of TPM, SMED, Poka Yoke, and 5S to Improve OEE in Pole Production in Peru

Resumen

This study presents a management model to increase productivity in pole manufacturing in Lima, Peru, through the implementation of SMED, 5S, TPM, and Poka Yoke techniques. The research addresses the issue of low utilization of installed capacity in a fiberglass-reinforced polymer (FRP) pole manufacturing company, which did not exceed 70% in 2023 despite sector growth. The importance of this study lies in its potential to significantly improve OEE indices. The proposed model includes detailed steps for implementing SMED, which reduces setup times; 5S, which organizes the workplace; TPM, which ensures operational availability of equipment; and Poka Yoke, which minimizes production errors. The validation of the model in a case study involved measuring key performance indicators, such as Overall Equipment Effectiveness (OEE), which improved by 40%, reaching an average of 80.56%. The results also demonstrated a 13% reduction in cycle times and a 40% reduction in setup times. The main conclusion is that integrating these techniques can substantially improve efficiency and profitability in the manufacturing sector.