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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Universidad Antonio Ruiz de Montoya
Resumen
El presente trabajo surge ante la necesidad de mejorar la gestión en los procesos de la empresa Ferreyros, específicamente en el taller de recuperación de componentes, cuya función es realizar trabajos de metalizado y mecanizado de piezas desgastadas que posteriormente serán usadas para el montaje de motores y transmisiones de carros mineros. Iniciamos el trabajo mencionando los principales conceptos teóricos sobre el mantenimiento productivo total (TPM), indicando los pilares que lo conforman, la metodología a la que se alinea y los pasos para su implementación. Se realiza un diagnóstico de la situación actual, en el que se detallan los indicadores utilizados y su comportamiento cuantitativo durante los últimos meses de producción. Además, se elaboraron los diagramas de proceso respectivos, ya que no existían diagramas detallados de cada proceso; para ello se utilizaron herramientas como DOP, DAP y VSM. Con base en los datos recopilados, se realizó un análisis de cada una de las falencias identificadas por la filosofía TPM y, alineados a esta metodología, se elaboraron diagramas de espina de pescado para identificar las causas de las deficiencias, como la falta de conocimiento y capacitación del personal operativo y de mantenimiento. Tras identificar las fallas, se desarrollaron distintas propuestas de mejora, como la necesidad de utilizar un mejor programa de gestión de mantenimiento asistido por ordenador, clasificación a través de las 5S, trabajos de mantenimiento autónomo, capacitación en temas de mejora continua, calidad y seguridad, y estandarización de procesos. Finalmente, tras desarrollar la propuesta de mejora, se presentan los beneficios económicos de implantar el TPM en el área, con una inversión inicial de S/. 5075.00, que se recuperará en un plazo de 28 meses, generando ahorros mensuales de S/. 6314.89.
The present investigation arises from the need to improve the management of processes at Ferreyros company, specifically in the component recovery workshop, whose function is to carry out metallization and machining of worn parts, which will later be used for assembling engines and transmissions of mining trucks. The work begins by presenting the main theoretical concepts of Total Productive Maintenance (TPM), describing its pillars, the methodology it aligns with, and the steps for its implementation. A diagnosis of the current situation was carried out, detailing the indicators used and their quantitative behavior over recent months of production. Additionally, the respective process diagrams were developed, as detailed diagrams for each process were previously unavailable; for this, tools such as DOP, DAP, and VSM were applied. Based on the collected data, an analysis was conducted of the deficiencies identified by TPM philosophy, and aligned with this methodology, fishbone diagrams were developed to pinpoint the root causes of the failures, such as lack of knowledge and training among operating and maintenance personnel. Once the failures were identified, several improvement proposals were developed, including the need to implement a better computer-assisted maintenance management program, classification using the 5S methodology, autonomous maintenance tasks, training in continuous improvement, quality, and safety, as well as process standardization. Finally, after developing the improvement proposal, the economic benefits of implementing TPM in the area are presented, with an initial investment of S/. 5075.00, recoverable in 28 months, generating monthly savings of S/. 6314.89.
The present investigation arises from the need to improve the management of processes at Ferreyros company, specifically in the component recovery workshop, whose function is to carry out metallization and machining of worn parts, which will later be used for assembling engines and transmissions of mining trucks. The work begins by presenting the main theoretical concepts of Total Productive Maintenance (TPM), describing its pillars, the methodology it aligns with, and the steps for its implementation. A diagnosis of the current situation was carried out, detailing the indicators used and their quantitative behavior over recent months of production. Additionally, the respective process diagrams were developed, as detailed diagrams for each process were previously unavailable; for this, tools such as DOP, DAP, and VSM were applied. Based on the collected data, an analysis was conducted of the deficiencies identified by TPM philosophy, and aligned with this methodology, fishbone diagrams were developed to pinpoint the root causes of the failures, such as lack of knowledge and training among operating and maintenance personnel. Once the failures were identified, several improvement proposals were developed, including the need to implement a better computer-assisted maintenance management program, classification using the 5S methodology, autonomous maintenance tasks, training in continuous improvement, quality, and safety, as well as process standardization. Finally, after developing the improvement proposal, the economic benefits of implementing TPM in the area are presented, with an initial investment of S/. 5075.00, recoverable in 28 months, generating monthly savings of S/. 6314.89.
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Palabras clave
Mantenimiento productivo total, Producción, Productividad, Empresas, Ingeniería industrial, Ingeniería