Aplicación de Lean Manufacturing en los procesos de osmosis y su efecto en sus costos en una empresa de Trujillo
No Thumbnail Available
Date
2023
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad Nacional de Trujillo
Abstract
En los últimos años se ha visto como el precio de la azúcar ha ido descendiendo y el impacto del covid-19 ha conllevado a que muchas empresas tomen acciones de sobrevivencia.
Esto en la empresa agroindustrial Laredo no es ajeno a este problema donde han tenido que priorizar sus presupuestos, es por ello que este trabajo tiene como objetivo en reducir los costos a través de eliminación de despilfarros, para este propósito se hizo uso de la aplicación de lean manufacturing con sus respectivas herramientas para los procesos de la planta de ósmosis.
En la etapa del diagnóstico se ha usado la herramienta mapa de flujo de valor (VSM), donde se ha podido observar tiempos de esperas y actividades que no agregaban valor por lo cual se ha aplicado un nuevo layout reubicando; el punto de alimentación para la planta de ósmosis y la dosificación de antiincrustante a las membranas, logrando mejorar el flujo de agua ablandada por hora de 6 m3 a 13 m3 y la dosificación antiincrustante de una manera más continúa pretendiendo alargar la vida útil de las membranas. También se aplicó SMED reduciendo; el tiempo de reinicio de la planta de ósmosis de 52,7 min a 17 min, el tiempo de actividades en verificación de bombeo de antiincrustante de 369 min a 363 min y un ahorro en desplazamiento de 590 metros en actividades que no generaban valor. Con el apoyo de herramienta TPM se ha podido mejorar el indicador OEE de 57.3% a 69.3%.
Por último, los beneficios obtenidos fueron el costo de producir un metro cúbico de agua ablandada que se redujo de s/.2,86 a s/.1,37 y se mejoró la disponibilidad de agua ablandada en el año de 33 040 m3 (2020) a 68 302 m3.
In recent years, the price of sugar has been falling and the impact of covid-19 has led many companies to take survival measures. The agro-industrial company Laredo is no stranger to this problem and has had to prioritise its budgets, which is why this work aims to reduce costs by eliminating waste. For this purpose, the application of lean manufacturing was used with its respective tools for the processes of the osmosis plant. In the diagnosis stage, the value stream mapping (VSM) tool was used, where it was possible to observe waiting times and activities that did not add value, so a new layout was applied, relocating the feeding point for the osmosis plant and the dosing of antifouling to the membranes, managing to improve the flow of softened water per hour from 6 m3 to 13 m3 and the dosing of antifouling in a more continuous manner, with the aim of extending the useful life of the membranes. SMED was also applied, reducing the restart time of the osmosis plant from 52.7 min to 17 min, the time of antifouling pumping verification activities from 369 min to 363 min and a saving in travel of 590 metres in activities that did not generate value. With the support of the TPM tool it has been possible to improve the OEE indicator from 57.3% to 69.3%. Finally, the benefits obtained were the cost of producing a cubic metre of softened water was reduced from s/.2.86 to s/.1.37 and the availability of softened water in the year was improved from 33 040 m3 (2020) to 68 302 m3.
In recent years, the price of sugar has been falling and the impact of covid-19 has led many companies to take survival measures. The agro-industrial company Laredo is no stranger to this problem and has had to prioritise its budgets, which is why this work aims to reduce costs by eliminating waste. For this purpose, the application of lean manufacturing was used with its respective tools for the processes of the osmosis plant. In the diagnosis stage, the value stream mapping (VSM) tool was used, where it was possible to observe waiting times and activities that did not add value, so a new layout was applied, relocating the feeding point for the osmosis plant and the dosing of antifouling to the membranes, managing to improve the flow of softened water per hour from 6 m3 to 13 m3 and the dosing of antifouling in a more continuous manner, with the aim of extending the useful life of the membranes. SMED was also applied, reducing the restart time of the osmosis plant from 52.7 min to 17 min, the time of antifouling pumping verification activities from 369 min to 363 min and a saving in travel of 590 metres in activities that did not generate value. With the support of the TPM tool it has been possible to improve the OEE indicator from 57.3% to 69.3%. Finally, the benefits obtained were the cost of producing a cubic metre of softened water was reduced from s/.2.86 to s/.1.37 and the availability of softened water in the year was improved from 33 040 m3 (2020) to 68 302 m3.
Description
Keywords
Empresa agroindustrial Laredo, Herramienta TPM, Planta de ósmosis, Covid-19