Increase of OEE in the Flexible Packaging Industry Through Planned Maintenance and Standardized Work Supported by Digital Centerline and Andon Systems

The reduction of Overall Equipment Effectiveness (OEE) remains one of the main challenges in the flexible packaging industry, where unplanned stoppages, mechanical misalignments, and prolonged setup times generate losses equivalent to 3.08% of annual revenue. This study proposes a comprehensive continuous improvement model based on the integration of Planned Maintenance with Digitalized Centerline and Standardized Work with Digital Andon, aimed at stabilizing critical operating parameters and optimizing equipment reliability. Validation was carried out through simulation using Arena software, analyzing the printing and sealing processes as critical points of the system. The results show significant improvements: an increase in Mean Time Between Failures (MTBF) from 12 h to 20 h, a reduction in Mean Time to Repair (MTTR) from 4.2 h to 2.5 h, an increase in availability from 77.04% to 86.3%, and a reduction in setup time from 45 min to 28 min. These improvements raised the OEE from 69.47% to 83.6%, bringing performance closer to the standard. The findings confirm that the convergence between Lean 4.0 tools and digital technologies represents an effective, replicable, and low cost strategy to strengthen the productivity and competitiveness of manufacturing SMEs.