Improvement Model to Increase the Efficiency of the Plastic Injection Process Through Planned Maintenance, Autonomous, SMED and 6R

The plastics production sector is growing and serves various sectors such as agrochemical, industrial, laboratory, lubricants, food and paints, highlighting its importance in the country. In recent years, global production has exceeded 3.8 billion units. However, this expansion has also raised a growing need to improve efficiency indicators to maintain competitiveness. In this context, this research analyzes the benefits and impact of implementing standardization tools focused on sustainability in the plastic bucket injection process of a Peruvian company, whose initial diagnosis evidenced challenges in the efficiency of the production process, especially due to mechanical failures, frequent reprocesses and non-productive times. Currently, the company has an OEE of 53%, below the sector standard of 70.5%. Consequently, an improvement model based on Lean Green methodology integrating SMED and 6R principles, and TPM through autonomous and planned maintenance tools is proposed. The proposal was validated through simulation of discrete events, increasing the overall efficiency of the equipment (OEE) to 66.4%. In this way, it is expected that companies in the plastics sector and related areas can take these results as a reference to promote improvements in their processes.