Improvement Model Based on Standardization and TPM to Reduce Defective Products in a Textile SME

Autores/as

DOI:

https://doi.org/10.26439/ciii2025.8645

Palabras clave:

Defect reduction, textile manufacturing, Total Productive Maintenance (TPM), trial testing, work standardization

Resumen

The Peruvian textile industry, a key contributor to the national economy representing approximately 8% of manufacturing GDP, faces a persistent production decline of 4.45% and a defective product rate of 6.6% among small and medium-sized enterprises (SMEs). Despite extensive research on defect reduction through Six Sigma, Total Quality Management (TQM), and Total Productive Maintenance (TPM), gaps remain in scalable and low-cost solutions tailored to resource-constrained SMEs in developing contexts. This study introduces novel variables—ergonomic improvements and iterative operator feedback loops—that have been underexplored in Peruvian textile SMEs. Focusing on a Lima-based SME dedicated to jeans production, a mixed-methods approach was applied to implement process standardization and TPM, reducing the overall defect rate from 10.15% to 6.75%. Unlike prior studies, this research integrates real-time operator input to continuously refine interventions, resulting in a replicable and cost-effective model suitable for SMEs with limited resources. Future research may explore automated fault detection systems to further enhance scalability.

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Biografía del autor/a

  • Sebastian P. Caballero-Trujillo, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Sebastian Pedro Caballero-Trujillo holds a Bachelor’s degree in Industrial Engineering from Universidad de Lima, Peru. He currently works as a Business Specialist at Banco de Crédito del Perú. He has experience as an intern in information management and in the Payment Solutions Tribe. His main research interests are risk management, collections, and payment solutions.

  • Renzo J. P. Mestanza-Ames, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Renzo Jean Pierre Mestanza-Ames holds a Bachelor’s degree in Industrial Engineering from Universidad de Lima, Peru. He is currently a professional intern in processes at Universidad de Lima. He has experience in operations, logistics, project management, productivity improvement, and health, safety, and environment. His main research interests are lean manufacturing and logistics.

  • Gino Viacava-Campos, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Gino Viacava-Campos holds a Master’s degree in Operations and Logistics from Universidad Peruana de Ciencias Aplicadas, Peru, and a degree in Industrial Engineering from Universidad de Lima, Peru. He is currently a professor in the Industrial Engineering Program at Universidad de Lima. He has experience in industrial and service companies, focusing on productivity improvement, business model development, and compensation system structuring. He has worked in human resources, operations, and logistics areas of a transnational company, both locally and overseas. As a consultant, he has experience in the construction, manufacturing, services, mining, commercial, finance, and education sectors. He has co-authored papers including “A Production Process Efficiency Improvement Model at a MSME Peruvian Metalworking Company,” published in the Proceedings of the 2022 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM). His main research interests are lean manufacturing, master production schedules, logistics, and compensation systems for small and medium sized enterprises.

  • Jorge A. Corzo-Chavez, Carrera de Ingeniería Industrial, Universidad de Lima, Perú

    Jorge Antonio Corzo-Chavez holds a Master’s degree in Business Administration from Universidad ESAN, Peru; a Master’s degree in Marketing Science from ESIC Business & Marketing School, Spain; and a degree in Industrial Engineering from Universidad de Lima, Peru. He is currently a professor in the Industrial Engineering Program at Universidad de Lima and Chief Executive Officer at Conquista Lab. He has advised industrial and service companies on productivity improvement and business model development, and has worked in entrepreneurship, innovation, and commercial roles in the construction, mining, services, and education sectors. He has co-authored papers including “Improvement of Productivity by Applying 5S, Work Standardization, Ergonomic Analysis and Poka Yoke in a Metalworking Company,” published in the Proceedings of the 23rd LACCEI International Multi-Conference for Engineering, Education, and Technology; “Production Model Based on Lean Manufacturing and Systematic Layout Planning to Reduce Waste in a Company in the Poultry Sector: A Case Study,” published in the International Journal of Environmental Pollution and Remediation, volume 12; and “Model for Reducing Mean Absolute Percentage Error through Smoothing and Time Series Forecasting in a Tourism SME: A Case Study,” published in the Journal of Machine Intelligence and Data Science, volume 5. His main research interests are lean manufacturing, logistics, and machine learning for enterprises.

Referencias

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Publicado

2026-06-08

Número

Núm. 004 (2025): IV Congreso Internacional de Ingeniería Industrial

Sección

Ponencias

Licencia

Derechos de autor 2026 Congreso Internacional de Ingeniería Industrial de la Universidad de Lima

Creative Commons License

Esta obra está bajo una licencia internacional Creative Commons Atribución 4.0.