Integrating Lean-TPM Strategies for Enhanced Production Efficiency: A Case Study on Textile SMEs in Peru

The textile sector, particularly within small and medium-sized enterprises (SMEs) in Latin America, plays a vital role in regional economic development. However, these enterprises face significant challenges, including inefficiencies in production processes and high reprocessing rates that threaten their competitiveness. This research aimed to address these challenges by proposing a Lean-TPM production model specifically designed to optimize knitting and dyeing processes in textile SMEs. The model integrated Lean Manufacturing principles with Total Productive Maintenance (TPM) strategies, focusing on improving operational efficiency, reducing waste, and enhancing equipment reliability. The implementation of the model yielded notable improvements. On-Time Delivery (OTD) rates increased by 102%, reprocessing rates in the dyeing process were reduced by 44%, and audit compliance with the 5S methodology reached 88.10%. These results demonstrate the model's effectiveness in addressing the critical issues faced by textile SMEs. The research contributes significantly to the academic discourse on process optimization in manufacturing and offers practical solutions with socio-economic benefits, including increased productivity and reduced operational costs. Future research should explore the model's adaptability to other manufacturing sectors, encouraging continued innovation in process optimization.