Publication: PROPUESTA DE PLAN DE MANTENIMIENTO PARA EQUIPOS CRÍTICOS DE PLANTA DE HIDROCICLONADO EN UNA EMPRESA DE ÁRIDOS
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Date
2022-11
Authors
ESCUDERO LABBÉ, BRYAN MARCELO
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Abstract
El presente trabajo de título tiene como objetivo principal generar una propuesta de plan de mantenimiento a equipos y componentes críticos de la planta de hidrociclonado de una empresa de áridos, con la finalidad de optimizar las tareas y disminuir los costos actuales del área. Para cumplir el objetivo principal, se plantean objetivos específicos, junto con un plan de trabajo, el cual establece los pasos a seguir en la ejecución de este trabajo.
La primera parte de este trabajo consiste en realizar una introducción a la empresa, mostrando sus valores y principios corporativos, proceso productivo, materia prima, productos elaborados, máquinas y equipos más relevantes. Con esto se sientan las bases del contexto en el cual se desarrolla el trabajo y se entiende la importancia de la planta de hidrociclonado en el proceso productivo.
Luego de esto, se explica el funcionamiento de la planta de hidrociclonado, dividiéndola en sus 3 módulos; bombeo, escurrido y ciclonado. Se recopila data acerca del historial de fallas de la planta, con la cual se realiza un análisis preliminar con un diagrama de Pareto.
Posteriormente, se realiza un análisis de criticidad a los equipos y componentes principales de la planta, mediante la metodología RCM y las herramientas contenidas en las normas ISO 31000 e ISO 31010. Este análisis se realiza mediante FMEA a cada equipo o componente de la planta. Con esto realizado, se procede a ejecutar la herramienta denominada matriz de riesgo, evaluando las consecuencias que tendrían fallas funcionales en cada equipo o componente, con la finalidad de determinar su nivel de criticidad en el contexto, clasificando en críticos, semi críticos y no críticos.
Luego de todo el análisis previo, se procede a diseñar el plan de mantenimiento en base a la metodología RCM y las siete preguntas de base, obteniendo resultados con mantenimiento preventivo, predictivo y correctivo. Considerando todos los planes elaborados, se construye el plan matriz, el cual contiene la programación en un año calendario de las tareas a ejecutar.
Finalmente, se realiza un análisis económico del plan propuesto, considerando costos fijos y variables. Se compara con los costos que se generarían por paradas no programadas en la planta, obteniendo un ahorro con respecto a estos, concluyendo que el plan es rentable, tanto en el aspecto económico, como en el operacional
The main objective of this work is to generate a proposal for a maintenance plan for critical equipment and components of the hydrocycloning plant of an aggregates company, to optimize the tasks and reduce the current costs of the area. To fulfill the main objective, specific objectives are proposed, together with a work plan, which establishes the steps to follow in the execution of this work. The first part of this work consists of an introduction to the company, showing its corporate values and principles, production process, raw materials, manufactured products, most relevant machinery, and equipment. This lays the foundations of the context in which the work is developed and the importance of the hydrocycloning plant in the production process is understood. After this, the operation of the hydrocycloning plant is explained, dividing it into its 3 modules: pumping, dewatering and cycloning. Data is collected about the plant's failure history, with which a preliminary analysis is carried out with a Pareto diagram. Subsequently, a criticality analysis of the plant's equipment and main components is performed using the RCM methodology and the tools contained in ISO 31000 and ISO 31010 standards. This analysis is performed by means of FMEA to each equipment or component of the plant. Once this is done, the risk matrix tool is executed, evaluating the consequences of functional failures in each equipment or component, to determine their level of criticality in the context, classifying them as critical, semi-critical and non-critical. After all the previous analysis, the maintenance plan is designed based on the RCM methodology and the seven basic questions, obtaining results with preventive, predictive and corrective maintenance. Considering all the plans elaborated, the matrix plan is built, which contains the schedule for a calendar year of the tasks to be executed. Finally, an economic analysis of the proposed plan is performed, considering fixed and variable costs. It is compared with the costs that would be generated by unscheduled shutdowns in the plant, obtaining a saving with respect to these, concluding that the plan is profitable, both economically and operationally
The main objective of this work is to generate a proposal for a maintenance plan for critical equipment and components of the hydrocycloning plant of an aggregates company, to optimize the tasks and reduce the current costs of the area. To fulfill the main objective, specific objectives are proposed, together with a work plan, which establishes the steps to follow in the execution of this work. The first part of this work consists of an introduction to the company, showing its corporate values and principles, production process, raw materials, manufactured products, most relevant machinery, and equipment. This lays the foundations of the context in which the work is developed and the importance of the hydrocycloning plant in the production process is understood. After this, the operation of the hydrocycloning plant is explained, dividing it into its 3 modules: pumping, dewatering and cycloning. Data is collected about the plant's failure history, with which a preliminary analysis is carried out with a Pareto diagram. Subsequently, a criticality analysis of the plant's equipment and main components is performed using the RCM methodology and the tools contained in ISO 31000 and ISO 31010 standards. This analysis is performed by means of FMEA to each equipment or component of the plant. Once this is done, the risk matrix tool is executed, evaluating the consequences of functional failures in each equipment or component, to determine their level of criticality in the context, classifying them as critical, semi-critical and non-critical. After all the previous analysis, the maintenance plan is designed based on the RCM methodology and the seven basic questions, obtaining results with preventive, predictive and corrective maintenance. Considering all the plans elaborated, the matrix plan is built, which contains the schedule for a calendar year of the tasks to be executed. Finally, an economic analysis of the proposed plan is performed, considering fixed and variable costs. It is compared with the costs that would be generated by unscheduled shutdowns in the plant, obtaining a saving with respect to these, concluding that the plan is profitable, both economically and operationally
Description
Keywords
PLAN DE MANTENIMIENTO , RCM , ADMINISTRACIÓN DE LA PRODUCCIÓN
