Process Improvement for the Reduction of Rework Applying TPM and Kaizen in a Company in the Metalworking Sector.

This article shows the implementation of a Lean Manufacturing tools model based on Total Productive Maintenance TPM and Kaizen. The implementation of the TPM and Kaizen tools of the proposed model allowed the reduction of reprocessing rates in the CNC machining line in a company in the metalworking sector. First, an investigation based on success stories has carried out to corroborate that there is a significant relationship between the two tools. Finally, a model based on the TPM and Kaizen tools has proposed, consisting of four stages: system research, planning, implementation, and control. In the implementation stage, the Autonomous Maintenance pillar of the TPM and 5S is included. Indeed, successful results has obtained. Reprocesses decreased by 30% nd Overall Equipment Effectiveness (OEE) from 39.4% initial to 50.7%.