The increasing operational complexity in plastic manufacturing has intensified the need to ensure high equipment availability as a key driver of productivity and cost efficiency. In the studied plastic preform plant, equipment availability reached 84.01%, below the industry benchmark, due to recurrent failures, inadequate maintenance planning, and operational errors. This research proposes an improvement model based on the Focused Improvement and Autonomous Maintenance pillars of Total Productive Maintenance (TPM), including diagnostic analysis, redesign of maintenance routines, operator training, and validation through discrete-event simulation using Arena. The results show a significant improvement in equipment availability from 84.01% to 92.83%, representing an increase of approximately 10%. Additionally, the Mean Time Between Failures (MTBF) increased by 53.5%, while the Mean Time to Repair (MTTR) decreased by 36.17%, indicating enhanced reliability and maintenance efficiency. These findings confirm that the integration of TPM pillars effectively reduces unplanned downtime and improves operational performance, providing a structured approach to enhance equipment availability in manufacturing systems.
Keywords
Total Productive Maintenance (TPM), Equipment Availability, Autonomous Maintenance, Focus Improvement, Plastic Manufacturing.