Operations management model based on 5S, TPM, and SMED to increase the effectiveness of equipment in a plastics company

Organizations strive to enhance their operational efficiency, addressing a key challenge faced by companies in the plastics industry: the limited availability of equipment, particularly in relation to molding processes. This equipment scarcity leads to delays in fulfilling customer orders, resulting in customer dissatisfaction. This research delves into the causes of prolonged setup and changeover times, as well as frequent interruptions during the injection molding process. Furthermore, it investigates the suboptimal performance of the injection molding machine, which currently operates at a mere 53.1% efficiency. To address this issue, a Lean Manufacturing model incorporating 5S, TPM, and SMED methodologies, along with standardization, is proposed. The objective is to improve the injection machine’s effectiveness in a plastic industry, as measured by the Overall Equipment Effectiveness (OEE) indicator.