Innovative Filter Overhaul Optimization PF 96 Series 1195 and 1196 at a Copper Mine in Peru Through 5S and TPM

Optimizing maintenance in mining is essential for sustainability and productivity. This study applies 5S and Total Productive Maintenance (TPM) to the overhaul of a PF 96 filter press at a copper mine in Tacna, Peru. The implementation of these methodologies yielded substantial improvements. Accessibility increased by 30% through better space organization and tool classification, reducing search times. Operating errors fell by 40% due to staff training and standardized procedures. Shift coordination improved by 80% with structured schedules and handovers, ensuring operational continuity. Equipment availability rose to 90%, with the remaining 10% allocated to preventive maintenance. Downtime costs were reduced by 35%, leading to notable time and resource savings. Additionally, the project recorded zero safety incidents over five years, enhancing workplace safety. The results demonstrate that 5S and TPM are effective strategies for reducing intervention time and optimizing operations. This case offers a replicable model for continuous improvement in mining, balancing efficiency, safety, and sustainability.