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Improve Efficiency in the Cereal Bar Production Process by Using SMED, Autonomous Maintenance, Preventive Maintenance and Line Balancing

Year: 2026

Type: book-chapter

Abstract: This study addresses low operational efficiency (68.58%) in the packaging process of a Peruvian healthy food manufacturer, which operates below the industry benchmark of 77.1%. The inefficiencies are mainly driven by excessive setup times, unplanned equipment stoppages, and workload imbalance causing bottlenecks. To mitigate these issues, a pilot improvement project integrating Single-Minute Exchange of Die (SMED), Total Productive Maintenance (TPM), and Line Balancing was implemented. The proposed solution was validated through discrete-event simulation using Arena software on a representative production sample. Results indicate an efficiency increase to 81.13%, a 17.94% improvement in Takt Time compliance, and an MTBF increase exceeding 69% for critical equipment. In conclusion, the integrated application of these tools increased process efficiency by 13 pp, demonstrating that integrated engineering interventions allow small and medium-sized food enterprises to close technical gaps and enhance competitiveness without substantial capital investment.

Source: Advances in transdisciplinary engineering

DOI: 10.3233/atde260705

Authors: Isabella Chichizola-Mina, María Fe Ochoa-Artola, Carlos Urbina-Rivera, Edilberto Avalos-Ortecho

Institution: Universidad de Lima

Language: English

Topic: Management and Optimization Techniques

Subfield: Strategy and Management

Field: Business, Management and Accounting

Domain: Social Sciences

SDGs: Industry, innovation and infrastructure, Responsible consumption and production, Zero hunger, Decent work and economic growth

Open Access status: diamond

OpenAlex ID: W7213352750

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