Production process efficiency depends on the synchronized performance of equipment, personnel, tooling, materials, and workplace discipline. In industrial manufacturing, Lean initiatives, 5S workplace organization, and Total Productive Maintenance (TPM) metrics are frequently treated as disconnected activities, resulting in uncoordinated interventions and transient improvements. This paper presents an integrated, closed-loop framework combining multi-factor asset criticality screening, standardized Overall Equipment Effectiveness (OEE) measurement, 5S auditing, seven-waste mapping, and root-cause analysis (RCA). The proposed framework was empirically validated on a high-precision CNC Machining Centre (M-01) prioritized via criticality rating ($C = 0.69$). Baseline assessment over an eight-week evaluation window revealed an OEE of 77.78% (Availability: 90.00%, Performance: 88.89%, Quality: 97.22%) and a workplace 5S compliance score of 56.0%. Pareto loss classification and Six Big Losses analysis isolated equipment breakdowns (55.6% of downtime) and minor idling stoppages (66.7% of speed losses) as primary operational constraints. A Five-Why root-cause investigation traced recurring breakdowns to unstandardized autonomous lubrication routines. Prioritized interventions—comprising an autonomous maintenance lubrication checklist, 5S Set-in-Order shadow boards, and SMED fixture pre-setting—were executed. Post-intervention evaluation established an OEE improvement to 88.68% (+10.90 percentage points; 14.0% relative gain) and a 5S audit score increase to 88.0%. Six months of sustainment tracking confirmed long-term retention within the 83%–85% score range, demonstrating the operational efficacy of the integrated approach.

Manthan Bodalkar, Prof. Dr. Prabhat Kumar Giri, "Optimization of Production Process Efficiency Through Integration of Lean Manufacturing, 5S and Overall Equipment Effectiveness Techniques" International Journal of Scientific Research and Engineering Development, V9(5): Page(1303-1306) September - October 2026. ISSN: 2581-7175. www.ijsred.com. Published by Scientific and Academic Research Publishing.