Lean-TPM Production Model for Efficiency and Quality Enhancement in the Brewing Industry: Insights from a Peruvian Case Study

The brewing industry in Peru faces significant challenges related to production inefficiencies, including extended setup times, downtime, and defective product rates. Prior research has demonstrated the potential of Lean Manufacturing and Total Productive Maintenance (TPM) methodologies to enhance operational performance, yet their specific application in brewing remains underexplored. This study proposed a Lean-TPM model integrating tools such as SMED, 5S, Andon, and Autonomous Maintenance, systematically applied using the PDCA cycle. The model was implemented in a Peruvian beer production SME, achieving a 29% reduction in setup time, a 72% decrease in downtime, and a 56% improvement in product quality by reducing defects. These outcomes highlight the adaptability and effectiveness of Lean-TPM tools in resource constrained settings. This study offers literature coverage and an implementation framework model for Small and Medium Enterprises (SMEs) that enables them to maintain competitiveness and sustainability. Further research should focus on how to better exploit more modern technologies.