The plastic sector in Peru has experienced significant growth, but SMEs face challenges such as high rates of defective products and low operational efficiency. Lean Manufacturing tools have been shown to improve productivity, but their combined application to reduce defects in SMEs in the plastic sector is limited.

Challenges include inadequate machine maintenance and low calibration efficiency, leading to significant economic losses. This research proposes a model combining Lean tools like 5S, Poka Yoke, and Standardized Work with Autonomous and Preventive Maintenance from TPM to organize and optimize production processes.

The results show a 2.68% reduction in defective products and a 4.77% increase in machine efficiency. Additionally, 5S audits improved by 41% and setup times were reduced by 26%. These findings validate the effectiveness of the proposed model in enhancing the competitiveness of SMEs in the plastic sector.

Academically, this research provides a framework for future studies. Socioeconomically, the model can improve the competitiveness and sustainability of the plastic sector in Peru. It is recommended to explore new directions in the application of Lean Manufacturing and TPM in SMEs to maximize operational and economic benefits.

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Mr. Carlos Ramos-Almerco