This study proposes the implementation of 5S and Standardized Work tools under the Lean Manufacturing approach to reduce the preventive maintenance cycle time of electric hoists in a Peruvian metalworking SME. The process was executed empirically, averaging 8.87 hours per equipment with a standard deviation of 13.30 minutes, generating annual labor cost overruns of USD 8,451. A four-phase continuous improvement model was designed and implemented as a pilot test conducted over approximately 3 months on non-consecutive days, applied to electric hoists with a maximum of 2 lifting chains and load capacities between 125 and 2,500 kilograms. Results showed a cycle time reduction from 531.93 to 387.10 minutes (27.23%), a decrease in standard deviation from 13.30 to 4.18 minutes (68.57%), and an improvement in 5S compliance from 45.8% to 64.0%. Statistical validation through an Anderson-Darling normality test and a paired T-Student test yielded T = 53.83 and p = 0.000, confirming the significance of the improvements. The findings demonstrate that the combined application of 5S and Standardized Work constitutes a viable and low-cost alternative to reduce operational variability and standardize maintenance processes in SMEs of the metalworking sector.

Keywords

Lean Manufacturing, 5S, Standardized Work, Cycle Time, Preventive Maintenance.