The research study aimed to address critical challenges within the Peruvian textile sector through the implementation of Lean Manufacturing and Total Productive Maintenance (TPM) tools. This sector, historically significant in Peru, has faced increasing competition and efficiency demands. Previous studies have highlighted the necessity for enhanced production processes and waste reduction strategies. Lean Manufacturing, known for its systematic waste elimination and efficiency improvement principles, and TPM, focused on equipment effectiveness and maintenance, were identified as suitable methodologies for this purpose.
The sector faced several urgent challenges, including low productivity rates, high levels of waste, and equipment downtime, which hindered operational efficiency and competitiveness. The study proposed a model integrating Lean Manufacturing and TPM tools to address these issues. The implementation required a detailed analysis of current workflows, identification of inefficiencies, and strategic application of Lean and TPM methodologies to streamline operations and enhance productivity.
Key results of the study included significant improvements in various operational metrics. The productivity index increased from 47.66% to 91.15%, surpassing the target of 90%. Efficiency rates also showed marked improvement, with overall equipment efficiency increasing from 74.84% to 97.91%. These metrics underscored the effectiveness of the integrated model in transforming production processes, reducing waste, and optimizing equipment usage. The implementation of the 5S methodology further contributed to a cleaner, more organized workspace, which supported sustained operational improvements.
The study's findings have considerable academic and socio-economic implications. Academically, the research contributes to the body of knowledge on Lean Manufacturing and TPM, providing empirical evidence of their effectiveness in a developing country context. Socio-economically, the enhanced efficiency and productivity of the textile sector can lead to increased competitiveness, higher employment rates, and economic growth within the region. The study's success also demonstrates the potential for broader application of these methodologies across various industrial sectors in Peru.
The research calls for further exploration into the integration of Lean and TPM tools across different industries. Future studies could focus on long-term sustainability and the adaptation of these methodologies to other contexts, potentially leading to widespread improvements in industrial efficiency and competitiveness. The promising results of this study underscore the importance of continuous improvement and the need for ongoing research to drive innovation and operational excellence in the industrial sector.