Empirical study on OEE optimization in a Peruvian flexographic printing SME a Lean-TPM model that integrates 5S and SMED

The flexographic printing industry plays a crucial role in the packaging sector; however, many companies in emerging markets face low Overall Equipment Effectiveness (OEE), primarily due to long setup times, unplanned downtime, and process inconsistencies. Previous studies have addressed these issues through isolated applications of Total Productive Maintenance (TPM), One Minute Die Change (SMED), and 5S. However, little research has integrated these tools into a unified model tailored to the industry's challenges. This study developed a structured Lean-TPM model that combines 5S, SMED, and TPM to improve OEE in a Peruvian flexographic printing SME. The model was validated through pilot implementations and simulation using Arena software. The results showed an increase in OEE from 59.91% to 70.84%, a 29.05% reduction in setup time, and a 28.26% decrease in the defect rate. These improvements demonstrate the model's effectiveness in optimizing performance while ensuring financial sustainability. This research provides a replicable framework for similar industries. Future studies should explore AI applications to further improve predictive maintenance and operational efficiency in dynamic manufacturing environments.