This study addresses the low operational efficiency of the pelletizing line in a Peruvian animal feed production company, where the Overall Equipment Effectiveness (OEE) averaged 80%, falling short of the international benchmark of 85%. The diagnostic analysis identified five critical sources of performance loss: unplanned stoppages caused by mechanical failures, high levels of reprocessed waste, dosing deviations, manual operational errors, and defective products requiring rework. To overcome these limitations, an integrated improvement strategy combining Total Productive Maintenance (TPM) and Standard Work was designed to strengthen equipment reliability, reduce process variability, and stabilize operational performance. The proposed approach was evaluated through a discrete-event simulation model developed in Arena v.16, comparing the current operating condition (As-Is) with an improved scenario (To-Be). The results demonstrated substantial and measurable gains: waste reprocessing events decreased from 11.4 to 5.5 per round (–51.8%), defective output dropped from 0.867 to 0.233 bags (–73.1%), total production increased from 368 to 464 bags (+26.1%), and total cycle time was reduced from 2.29 h to 1.82 h (–20.5%). These improvements enabled the pelletizer to reach an OEE of 85%, closing the performance gap and aligning the process with international standards. Overall, the study provides a practical and replicable methodology showing how combining TPM and Standard Work can significantly enhance operational efficiency, optimize resource use, and improve the stability and competitiveness of feed manufacturing systems.
Published in: 8th IEOM Bangladesh International Conference on Industrial Engineering and Operations Management, Dhaka, Bangladesh
Publisher: IEOM Society International
Date of Conference: December 20
-21
, 2025
ISBN: 979-8-3507-4441-5
ISSN/E-ISSN: 2169-8767