Optimization of the Aluminum Pot Spinning Process Through Lean Green and Industry 4.0: Toward Efficient and Sustainable Manufacturing

Is it possible for a traditional metalworking company to improve its competitiveness and sustainability by reducing operational inefficiencies? This research answers this question affirmatively, demonstrating the feasibility of applying the Lean Green Manufacturing methodology, which integrates continuous improvement tools such as TPM, SMED, and Poka-Yoke with principles of energy and operational sustainability. The study was conducted in a Peruvian company whose operational efficiency level reached just 67.5%, compared to the industry average of 75.98%, revealing a significant gap. To validate the proposals, pilot tests, simulations using Arena software, and energy monitoring were conducted, allowing objective quantification of the results. Key findings include a reduction in machine downtime from 31 to 4.5 h through the implementation of autonomous maintenance; a reduction in setup time from 21 to 10 min thanks to the SMED methodology; and the reduction in hours lost due to product defects from 3.73 to 1.2 with the use of Poka-Yoke. Together, these improvements represent an increase of approximately 65% in operational indicators, demonstrating that this strategy is effective, replicable, and aligned with the current challenges of the industrial sector.