Propuesta de mejora en la gestión de operaciones de la planta Ferreyros CRC La Joya, mediante la implementación del mantenimiento productivo total
Fecha
2018
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Editor
Universidad Antonio Ruiz de Montoya
Resumen
El presente trabajo surge ante la necesidad de poder mejorar la gestión en el proceso de la
empresa Ferreyros, específicamente en el taller de recuperación de componentes, cuya función
es la de realizar trabajos de metalizado y mecanizado de piezas desgastadas las cuales
posteriormente serán usadas para el montaje de motores y transmisiones de carros mineros.
Iniciamos el trabajo dando mención de los conceptos teóricos principales sobre el
mantenimiento productivo total (TPM), indican los pilares que este conforman, cuál es la
metodología en la cual este se alinea, así como los pasos para realizar su implementación.
Se realiza el diagnóstico de la situación actual, en el cual detallamos los indicadores que se
usan y cuál ha sido el comportamiento cuantitativo de estos durante los últimos meses de
producción; además se desarrolló los diagramas de proceso respectivos ya que no se presentaban
diagramas detallado cada uno de los procesos; para esto usamos herramientas como DOP, DAP
y VSM ; en base a estos datos recopilados, se realiza un análisis de cada una de las falencias
presentes mencionadas por la filosofía TPM y alineados a esta metodología realizamos espinas
de pescados para identificar las causa de las falencias existentes como falta de conocimiento y
capacitación en el personal operario y de mantenimiento.
Después de haber identificado las fallas se desarrolla las distintas propuestas de mejora,
como la necesidad de usar un mejor programa la gestión de mantenimiento asistida por
ordenador, clasificación a través de las 5 s, trabajos de mantenimiento autónomo, capacitación
en temas de mejora continua, calidad y seguridad; y estandarización de procesos.
Finalmente, tras haber desarrollado la propuesta de mejora, se presenta los beneficios
económicos al implantar el TPM en el área, con una inversión inicial de S/. 5075.00, la cual
lograra recuperarse en un plazo de 28 meses, desde donde obtendremos ahorros mensuales de
S/.6314.89.
The present investigation work arises from the necessity to improve the management during the processes of Ferreyros company, specifically in the workshop of component recovering, whose function is to realize works of metallization and machining of worn parts which will be used later for the assembly of the engines and transmissions of mining cars. We start the work by mentioning the main theoretical concepts about Total Productive Maintenance (TPM), indicating the pillars that make this up, in which methodology it is aligned and which are the steps to make its implementation as well. A diagnosis of the current situation is made, in which we detail the indicators that are being used and which has been the quantitative behavior of these during the last months of productión. In additon, the respective process diagrams were developed since detailed diagrams of each of the processes were not presented. For this work, we used tools as DOP, DAP and VSM. Based on the collected data, an análisis of each of the failures mentioned by the TPM philosophy was elaborated. Aligned to this methodology, we created fishbones to identify the causes of the existing failures such as lack of knowledge and training among the operating and maintenance personnel members. After identifying the failures, the next step is to develop different improvement proposals such as the necessity of using a better maintenance management program assisted by a computer, a clasification through the 5 S, self-maintenance works, training in continuous improvement, quality, safety and process standarization, etc. Finally, after we have developed the improvement proposal, the economical benefits are presented by implementing the TPM in the area, with an initial investment of S/. 5075.00 that will be recovered in a period of 28 months, from where we will obtain monthly savings of S/.6314.89.
The present investigation work arises from the necessity to improve the management during the processes of Ferreyros company, specifically in the workshop of component recovering, whose function is to realize works of metallization and machining of worn parts which will be used later for the assembly of the engines and transmissions of mining cars. We start the work by mentioning the main theoretical concepts about Total Productive Maintenance (TPM), indicating the pillars that make this up, in which methodology it is aligned and which are the steps to make its implementation as well. A diagnosis of the current situation is made, in which we detail the indicators that are being used and which has been the quantitative behavior of these during the last months of productión. In additon, the respective process diagrams were developed since detailed diagrams of each of the processes were not presented. For this work, we used tools as DOP, DAP and VSM. Based on the collected data, an análisis of each of the failures mentioned by the TPM philosophy was elaborated. Aligned to this methodology, we created fishbones to identify the causes of the existing failures such as lack of knowledge and training among the operating and maintenance personnel members. After identifying the failures, the next step is to develop different improvement proposals such as the necessity of using a better maintenance management program assisted by a computer, a clasification through the 5 S, self-maintenance works, training in continuous improvement, quality, safety and process standarization, etc. Finally, after we have developed the improvement proposal, the economical benefits are presented by implementing the TPM in the area, with an initial investment of S/. 5075.00 that will be recovered in a period of 28 months, from where we will obtain monthly savings of S/.6314.89.
Descripción
Palabras clave
Mantenimiento productivo total, Producción, Productividad, Empresas, Ingeniería industrial, Ingeniería