Reduction of the Rate of Defective Products in A Metalworking Company, Through the Implementation of TPM, 5S And Process Standardization Tools

Currently in Peru, there are metal-mechanic companies that present deficiencies and problems in their production processes. One of these problems is the high rate of defective products, since most of them exceed the average percentage (1.60%) of defective products in total production. To all this, a company was selected for the investigation of a case study, where it was possible to identify that it presented problems with respect to the rates of defective products since, between the months between the years 2021 and 2022, the average percentage of defective products amounted to 9.91%. This problem generated an economic impact of $35,000.00, causing a considerable decrease in the company's profits. For this reason, in this investigation a continuous improvement model (PDCA) was carried out, applying 5S tools, Process Standardization, Autonomous Maintenance and Planned Maintenance, to reduce the high rate of defective products. For the development and validation of the model proposed in the case study, a pilot test and a simulation were carried out in the Arena software, obtaining as a result a reduction in the rate of defective products from 9.91% to 2.43%, an increase in the level of compliance of 5S from 48% to 76%, a decrease in standard time from 135.17 min to 95.45 min, and an increase in OEE from 53.0% to 69.30%.