Thesis OPTIMIZACIÓN DE PROCESOS EN LÍNEAS DE CALIBRACIÓN Y EMPAQUE EN PACKING DE FRUTAS
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Date
2018
Authors
LIRA SOTO, CAMILO JOSÉ
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Abstract
FRUTÍCOLA DOSAL LTDA es una empresa frutícola de Curicó, Región del Maule, encargada de procesar fruta del tipo pomácea, seleccionando y embalando el producto para su exportación, cumpliendo normas de exigencia para su proceso y calidad de producto.Durante la temporada 2016 se procesaron cerca de 60.000 toneladas de manzana, equivalentes a 160.000 bins procesados entre Packing y Presizer, para lo cual se tuvo una pérdida de $170.000.000 correspondiente al 7% de la producción procesada durante el 2016.Esta pérdida corresponde a la monetización del tiempo productivo perdido en el proceso de la Línea 01, Línea 02 (día y noche) y Presizer, en donde se tuvieron 4.969, 10.963 y 5.172 minutos perdidos respectivamente. Esta información se recopiló de las bitácoras de producción que se emitían diariamente, en base a las cuales se clasificó la información de los sucesos y detenciones en las líneas.Para la Línea 01 se determinó a través de los diagramas de Pareto que la mayor pérdida de tiempo se produce en los “cambios en la línea”, generándose mayor pérdida de tiempo en los cambios de calibre y de calidad, y en menor medida en los cambios de embalaje y de variedad, factores de gran impacto pero poca frecuencia. Junto con esto el reembalaje y la saturación provocaron pérdidas considerables de tiempo productivo.Para la línea 02 turnos día y noche, se identificó que la saturación, específicamente la “saturación en mesas Traypack” representan el mayor tiempo perdido del proceso. Además se determinó que para “cambios en la línea”, los cambios de productor y de embalaje para la fruta proveniente del huerto producen mayor tiempo perdido. Mientras que para el proceso de fruta ya calibrada se produce mayor pérdida en los cambios de calibre, calidad y embalaje.La serie de medidas de mejora propuestas invitan a la empresa a trabajar en un método de recopilación de datos, con el propósito de mantener un flujo de información transversal entre las áreas de la organización, de forma de estimar el rendimiento de las líneas según el programa de la jornada y monitoreando cualquier desviación en los tiempos productivos del proceso. Con estas propuestas se espera reducir un 15% el tiempo perdido en una primera fase, lo cual significaría un ahorro aproximado de $27.000.000 para FRUTÍCOLA DOSAL LTDA.
FRUTÍCOLA DOSAL LTDA is a fruit company of Curicó city, Maule Region, dedicated to process apples, select and package products to be exported, accomplishing exigency standards for its process and product quality.During the 2016 season, about 60.000 tons of apples were processed, which equivalents to 160,000 processed bins, between Packing and Presizer, which led to a loss of CLP$170,000,000 corresponding to 7% of the processed production during 2016.This loss corresponds to the monetization of productive time lost in the process of line 01, line 02 (day and night duty) and Presizer, where 4,969, 10,963 and 5,172 minutes were lost respectively. This information was collected from the production logs, which were completed daily and then, the information of the events and stops in the lines was classified.It was determined through the Pareto diagrams that the greatest loss of time occurs in the "changes in the line" for line 01, generating a greater loss of time in caliber and quality changes, and to a lesser extent in packaging and variety changes, factors of great impact but with less frequency. Along with this, the repackaging and the saturation caused considerable losses of productive time.It was identified that the saturation, specifically the "saturation in Traypack tables", represents the longest lost time of the process for line 02, for day and night duty. In addition, it was determined that for "line changes", the changes of producer and packaging in the process of fruit coming directly from the orchard produce more time lost, the changes of producer and change of packaging while there is greater loss in the changes of caliber, quality and packaging for the process of calibrated fruit.The proposed improvement measures invite the company to work on a method of data collection, keeping information flow across the areas of the organization, in order to estimate the performance of the lines according to the program of the day and monitoring any deviation in the productive times of the process. These proposals are expected to reduce the time lost in a first phase by 15%, which would mean an approximate saving of CLP$27,000,000 for FRUTÍCOLA DOSAL LTDA.
FRUTÍCOLA DOSAL LTDA is a fruit company of Curicó city, Maule Region, dedicated to process apples, select and package products to be exported, accomplishing exigency standards for its process and product quality.During the 2016 season, about 60.000 tons of apples were processed, which equivalents to 160,000 processed bins, between Packing and Presizer, which led to a loss of CLP$170,000,000 corresponding to 7% of the processed production during 2016.This loss corresponds to the monetization of productive time lost in the process of line 01, line 02 (day and night duty) and Presizer, where 4,969, 10,963 and 5,172 minutes were lost respectively. This information was collected from the production logs, which were completed daily and then, the information of the events and stops in the lines was classified.It was determined through the Pareto diagrams that the greatest loss of time occurs in the "changes in the line" for line 01, generating a greater loss of time in caliber and quality changes, and to a lesser extent in packaging and variety changes, factors of great impact but with less frequency. Along with this, the repackaging and the saturation caused considerable losses of productive time.It was identified that the saturation, specifically the "saturation in Traypack tables", represents the longest lost time of the process for line 02, for day and night duty. In addition, it was determined that for "line changes", the changes of producer and packaging in the process of fruit coming directly from the orchard produce more time lost, the changes of producer and change of packaging while there is greater loss in the changes of caliber, quality and packaging for the process of calibrated fruit.The proposed improvement measures invite the company to work on a method of data collection, keeping information flow across the areas of the organization, in order to estimate the performance of the lines according to the program of the day and monitoring any deviation in the productive times of the process. These proposals are expected to reduce the time lost in a first phase by 15%, which would mean an approximate saving of CLP$27,000,000 for FRUTÍCOLA DOSAL LTDA.
Description
Catalogado desde la version PDF de la tesis.
Keywords
MEJORAMIENTO CONTINUO , OPTIMIZACION DE PROCESOS , PACKING DE FRUTAS