Abstract

The global poultry processing industry faces significant challenges related to equipment availability, particularly due to insufficient maintenance practices. This study aimed to address these issues by integrating Lean Manufacturing and Total Productive Maintenance (TPM) methodologies in a poultry processing plant. The main problem identified was frequent machine breakdowns, especially with the Lincoln plucking machine, which caused over 30% of total downtime. To tackle this, the investigation applied a combination of autonomous and preventive maintenance, along with the implementation of a Poka Yoke device for optimizing rubber finger placement. The study resulted in a 5.87% increase in equipment availability and improved overall equipment effectiveness (OEE) by reducing downtime and operational errors. These improvements had significant socio-economic impacts, decreasing costs and increasing production stability. This research highlights the effectiveness of Lean-TPM integration in enhancing operational performance and calls for further exploration into automating other critical processes to achieve even greater efficiency.