Diseño y aplicación de un sistema MRP asociado al Lean Manufacturing para el cumplimiento de producción de una empresa azucarera
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Date
2024
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Universidad Nacional de Trujillo
Abstract
En esta presente investigación se obtuvo el diseño y aplicación de un sistema
MRP, el cual estuvo asociado a la metodología Lean Manufacturing utilizando la
herramienta RCM, logrando obtener mayor producción de azúcar y por ende cumpliendo
la programación mensual y anual de producción.
La investigación tiene como objetivo aumentar la producción en el departamento
de elaboración de una empresa azucarera. Para ello, primero se analizó el proceso de
elaboración de azúcar para poder seleccionar la herramienta Lean Manufacturing que se
utilizara, debido a los problemas de cumplimiento de producción por paradas de
máquinas, los cuales se dan por fallos intempestivos, los cuales además ocasionan
tiempos muertos y desperdicios.
Se detallo los tipos de equipos de los procesos con las principales paradas de
máquina durante el periodo de un año, para luego realizar el análisis de Pareto donde se
determinó los tres principales equipos que tienen la mayor cantidad de paradas y
relevancia en el No complimiento de la producción programada.
Se evaluó las distintas herramientas de la metodología Lean Manufacturing
integrando como herramienta de solución el Mantenimiento centrado en la Confiabilidad
(RCM). Para los tres equipos se realizó el Análisis de Modos y Efecto de Fallas (AMEF)
y se realizó el análisis de los componentes críticos de acuerdo a nivel de criticidad
cuantificándolo con el cálculo del Número de Prioridad de Riesgo (NPR).
Se procedió a desarrollar las acciones correctivas a las causas inaceptables
identificadas por medio del NPR para cada equipo, estableciendo un programa de
mantenimiento basado en la aplicación del RCM, elaborando instructivos de trabajo para
la intervención de los equipos y programas anuales de capacitación al personal;
posteriormente se realizó el análisis del cumplimiento de producción con el ello el diseño
del MRP para la materia prima, insumos químicos y materiales para el envasado
necesarios para el procesos de producción de azúcar.
Como parte final se realizó la evaluación económica de la aplicación de la
propuesta para comprobar si el estudio realizado es factible de aplicar en el área de
producción, teniendo como resultado de un VAN de S/ 112,000.16 TIR de 68.14% y B/C
de S/ 1.505, con ello podemos determinar que esta aplicación de herramientas es factible
ya que se obtuvo una disminución de parada de equipo de 1964.75 horas, el cual se tiene
una recuperación de horas perdidas en mantenimiento por fallos de S/. 92,998.26.
teniendo con ello un beneficio significativo al área de producción de la empresa, así
mismo un retorno de inversión en 1 año, 4 meses y 20 días.
In this present investigation, the design and application of an MRP system was obtained, which was associated with the Lean Manufacturing methodology using the RCM tool, achieving greater sugar production and therefore complying with the monthly and annual production schedule. The research aims to increase production in the processing department of a sugar company. To do this, first the sugar production process was analyzed in order to select the Lean Manufacturing tool to be used, due to production compliance problems due to machine stops, which occur due to untimely failures, which also cause downtime. and waste. The types of equipment of the processes with the main machine stops during the period of one year were detailed, to then carry out the Pareto analysis where the three main equipment that have the greatest number of stops and relevance in the Noncompliance of scheduled production. The different tools of the Lean Manufacturing methodology were evaluated, integrating Reliability Centered Maintenance (RCM) as a solution tool. For the three teams, the Failure Mode and Effect Analysis (FMEA) was carried out and the analysis of the critical components was carried out according to the level of criticality, quantifying it with the calculation of the Risk Priority Number (RPN). Corrective actions were developed for the unacceptable causes identified through the NPR for each piece of equipment, establishing a maintenance program based on the application of the RCM, developing work instructions for the intervention of the equipment and annual training programs for personnel; Subsequently, the analysis of production compliance was carried out, thereby designing the MRP for the raw materials, chemical inputs and packaging materials necessary for the sugar production processes. As a final part, the economic evaluation of the application of the proposal was carried out to verify if the study carried out is feasible to apply in the production area, resulting in an NPV of S/ 112,000.16, IRR of 68.14% and B/C of S / 1,505, with this we can determine that this application of tools is feasible since a reduction in equipment downtime of 1964.75 hours was obtained, which has a recovery of hours lost in maintenance due to failures of S/. 92,998.26. thereby having a significant benefit to the company's production area, as well as a return on investment in 1 year, 4 months and 20 days.
In this present investigation, the design and application of an MRP system was obtained, which was associated with the Lean Manufacturing methodology using the RCM tool, achieving greater sugar production and therefore complying with the monthly and annual production schedule. The research aims to increase production in the processing department of a sugar company. To do this, first the sugar production process was analyzed in order to select the Lean Manufacturing tool to be used, due to production compliance problems due to machine stops, which occur due to untimely failures, which also cause downtime. and waste. The types of equipment of the processes with the main machine stops during the period of one year were detailed, to then carry out the Pareto analysis where the three main equipment that have the greatest number of stops and relevance in the Noncompliance of scheduled production. The different tools of the Lean Manufacturing methodology were evaluated, integrating Reliability Centered Maintenance (RCM) as a solution tool. For the three teams, the Failure Mode and Effect Analysis (FMEA) was carried out and the analysis of the critical components was carried out according to the level of criticality, quantifying it with the calculation of the Risk Priority Number (RPN). Corrective actions were developed for the unacceptable causes identified through the NPR for each piece of equipment, establishing a maintenance program based on the application of the RCM, developing work instructions for the intervention of the equipment and annual training programs for personnel; Subsequently, the analysis of production compliance was carried out, thereby designing the MRP for the raw materials, chemical inputs and packaging materials necessary for the sugar production processes. As a final part, the economic evaluation of the application of the proposal was carried out to verify if the study carried out is feasible to apply in the production area, resulting in an NPV of S/ 112,000.16, IRR of 68.14% and B/C of S / 1,505, with this we can determine that this application of tools is feasible since a reduction in equipment downtime of 1964.75 hours was obtained, which has a recovery of hours lost in maintenance due to failures of S/. 92,998.26. thereby having a significant benefit to the company's production area, as well as a return on investment in 1 year, 4 months and 20 days.
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