Improving operational efficiency remains a challenge in The Liquefied Petroleum Gas (LPG) bottling plants in Peru, where production systems seldom exceed the 85% efficiency benchmark, a level still considered low compared with international standards that typically surpass this value in stable and well-controlled operations. This demonstrates that efficiency continues to be a critical issue, especially in plants with high variability and limited preventive maintenance. The studied facility illustrates this problem clearly, operating at 72.85% efficiency and experiencing significant losses due to reprocessing and recurrent hose failures. To address this gap, the research proposes a production management model based on Standard Work (SW) and Autonomous Maintenance (AM), tools selected for their ability to reduce variability and prevent failures in critical tasks. The model adapts Lean Manufacturing principles to the hydrocarbon sector, where structured production systems remain limited despite strict safety and reliability requirements. The proposal standardizes filling, weighing, and sealing processes and enhances equipment availability through operator-led maintenance routines. Validation through pilot tests and simulation showed strong improvements, increasing efficiency from 72.85% to 94.75%, reducing rework from 31.4% to 13.7%, and lowering hose failures from 32 to 6 per 8-hour shift.

Keywords

Lean Manufacturing, Standard Work, Autonomous Maintenance, Efficiency, LPG