Integrating Lean Manufacturing and TPM for Process Optimization in Bakery SMEs: A Case Study from Peru

The bakery SME sector in Latin America, particularly in Peru, plays a critical role in food security and local economic development but faces significant inefficiencies in production, equipment downtime, and inconsistent product quality. Despite the potential of Lean Manufacturing and Total Productive Maintenance (TPM) to mitigate these challenges, their application in the bakery sector remains underexplored. This study implemented 5S, work standardization, and autonomous maintenance in a bakery SME to reduce delays, equipment failures, and defects. The approach focused on optimizing operations, enhancing equipment reliability, and promoting continuous improvement. The key results included a 70% improvement in workplace organization and cleanliness, a 60% reduction in defective products, and a 35% decrease in machine repair time, demonstrating the efficacy of Lean and TPM tools. The research offers a replicable model for bakery SMEs, contributing to operational efficiency and product quality improvements, which are crucial for regional economic development. Further exploration of Lean and TPM integration in SMEs is essential to foster innovative solutions to industry challenges.