Reliability-Centered Maintenance Model to Improve OEE in a Mass-Consumption Food Company: A Case Study from Peru

A high rate of failures, frequent unplanned stoppages, and low equipment effectiveness characterized the production process of a medium-sized cookie manufacturer in Peru. Previous studies addressed similar challenges using Lean and TPM methodologies, but limited evidence existed on integrating Reliability-Centered Maintenance (RCM) in food manufacturing contexts. This study aimed to design and implement a maintenance management model based on RCM to enhance operational availability and reduce losses. The proposed model combined AMEF, criticality analysis, and a five-phase RCM strategy. Key actions included failure mode identification, task prioritization, and customized maintenance planning. After implementation, availability increased from 75.67% to 80%, unplanned stoppages dropped significantly, and overall maintenance costs decreased. These results validated the model’s effectiveness and practical adaptability. The findings contribute to the academic discourse on RCM applications in food manufacturing SMEs and present socioeconomic benefits through improved productivity. Future research is encouraged to replicate the model in similar sectors and scale its integration.