This study develops a production improvement model for a Peruvian company dedicated to manufacturing pet products. The initial diagnosis revealed a productivity of 0.038 L/Man-Hour, below the sector benchmark of 0.063 L/Man-Hour, resulting in a technical gap of 0.025 L/Man-Hour. The process also presented 40% defective units per lot, 83% equipment availability, and a cycle time of 41.8 seconds. To address these issues, two tools were implemented: SMED to reduce non-productive time and a preventive maintenance plan to improve equipment reliability. The proposal was validated through simulation, showing significant improvements. Changeover time was reduced by 72% (from 250 to 68 minutes), equipment availability increased from 83% to 92%, and defective output decreased from 40% to 9%, equivalent to a reduction from about 803 to 181 defective units per lot. Cycle time decreased from 41.8 to 20.0 seconds, increasing productivity to 0.058 L/Man-Hour and closing 80% of the original technical gap. Economically, the improvements enabled the recovery of unproduced volume valued at USD 163,000 per year. The results confirm that integrating SMED with preventive maintenance significantly enhances productivity, quality, and operational stability in resource-constrained manufacturing environments.

Keywords 

Productivity, Preventive Maintenance, SMED, Continuous Improvement