Citation :

Carmen Cajusol, Judith Gamarra, Percy Castro-Rangel, José C. Alvarez, Duilio Aranda, Robert Lepore, "Improvement Proposal to Increase the Availability of Napkin Production Machinery Through Planned Maintenance, IoT, and SMED," International Journal of Engineering Trends and Technology (IJETT), vol. 74, no. 5, pp. 1-16, 2026. Crossref, https://doi.org/10.14445/22315381/IJETT-V74I5P101

Abstract

In recent years, the paper and cardboard industry has grown globally, with China and India leading production at approximately 30% and 15% of the global total, respectively. However, the situation in Peru is different, as the sector's contribution to GDP declined by 6.6% in 2023, and many factories barely utilized 11% of their installed capacity. Even so, demand for tissue paper increased, and the industry is expected to grow by 8.83% in 2024. The biggest obstacle for a local tissue paper producer is the low availability of their equipment, which reaches only 62.71%. Because maintenance is reactive, failures are addressed after they occur, causing constant interruptions and increasing costs. To change this scenario, a model was proposed that combines three strategies: SMED to reduce setup time, planned maintenance to prevent failures, and IoT sensors to monitor conditions in real time and act predictively. The model was validated using historical data and expert review, with availability as the key indicator. As a result of its implementation, availability improved to 86.02%, representing a gain of 23.31 percentage points. Economically, the impact of downtime decreased by 9.78%, and annual savings of S/ 5,251.95 are estimated thanks to fewer repairs, better use of spare parts, and increased productive hours. In short, combining lean techniques with Industry 4.0 tools can significantly improve plant performance, even in small- to medium-sized operations.

Keywords

Machine Availability, SMED, TPM, Industry 4.0, IoT.

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