Integrating Lean Manufacturing and TPM for Production Efficiency Improvement: A Peruvian Case Study in the Bottled Water Industry

The validation scenario was conducted in a case study focusing on small and medium-sized enterprises (SMEs) in the bottled water industry, which play a vital role in Latin America, especially in Peru. Previous studies have highlighted inefficiencies, particularly in production processes, due to machine stoppages and poor inventory management. Existing research suggests that Lean Manufacturing and Total Productive Maintenance (TPM) can address these inefficiencies. The key challenge identified was the low production rate caused by unproductive activities during washing and packaging. Addressing this problem was critical to improving efficiency, lowering costs, and ensuring access to affordable, high-quality bottled water for the population. The study integrated Lean and TPM tools to create a model that increased productivity and reduced waste. The research findings showed a 48.79% reduction in washing process time and a 50.78% decrease in bottling process cycle time. Equipment availability rose to 76%, and production efficiency significantly improved, with a yield increase from 76.83% to 94.02%. The impact of this research was notable both academically and socioeconomically, providing SMEs with practical tools to enhance competitiveness and operational efficiency while supporting public health through better water accessibility. This study calls for further exploration of Lean and TPM integration in other sectors to unlock similar productivity gains and cost reductions.