A Case Study on Integrating Lean, TPM, and RCM to Improve Equipment Availability in Peruvian Metalworking SMEs

This study addresses the persistent issue of low equipment availability in Peruvian SMEs within the metalworking industry. Previous research has highlighted the need for tailored maintenance strategies to enhance operational efficiency in similar contexts. This investigation focused on a small company specializing in office furniture manufacturing, which faced recurring downtime and insufficient maintenance practices. The proposed model integrated Lean Manufacturing, Total Productive Maintenance (TPM), and Reliability-Centered Maintenance (RCM) to foster sustainable improvements. Key actions included implementing autonomous maintenance for early fault detection, prioritizing equipment reliability through RCM, and establishing standardized maintenance procedures. Quantitative results demonstrated an 11.80% increase in equipment availability and a 20.73% reduction in cycle time. These enhancements not only improved productivity but also contributed to employee engagement and a proactive maintenance culture. Future research is encouraged to explore similar models in other SMEs, addressing sector-specific challenges and fostering industrial resilience in dynamic markets.