Publication: PROPUESTA DE MEJORAMIENTO DE LA MANTENIBILIDAD (MTTR) MEDIANTE HERRAMIENTAS DE CALIDAD (LEAN)
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Date
2020-12
Authors
LÓPEZ RIVERA, JULIO ANTONIO
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Abstract
El presente trabajo de tesis tiene como objetivo general, elaborar un plan de mejoramiento de la mantenibilidad, a través del uso de herramientas de la filosofía Lean Maintenance. En particular, el objetivo es optimizar las actividades que forman parte del proceso genérico de mantenimiento correctivo, en busca de la reducción del tiempo medio de reparación (MTTR). El plan de trabajo diseñado para alcanzar este objetivo consta de 5 pasos. En primer lugar, en el capítulo 3 se realiza una descripción del proceso genérico de reparación de una falla imprevista, a través del mapeo de su cadena de valor (VSM). Con esto es posible identificar actividades que no agregan valor al proceso, y todos los desperdicios que hacen crecer el MTTR de una máquina. En el capítulo 4 se realiza un análisis a los desperdicios encontrados anteriormente, usando la herramienta 5W + 1H, que define el qué, por qué, cómo, quién, cuándo y dónde se presenta cada uno de ellos en el proceso. Así, de un total de 16 desperdicios se obtienen 10 causas raíces distintas. Luego en el capítulo 5, las causas raíces son definidas como oportunidades de mejora, las que son evaluadas según su criticidad en una matriz de costo – beneficio, considerando la dificultad de su implementación y el impacto esperado sobre el MTTR. En base a los resultados se establece una escala de prioridad, de dónde sólo 6 de las 10 oportunidades de mejora logran calificar para seguir siendo parte del estudio. El capítulo 6 comienza con la selección de herramientas del Lean Maintenance para desarrollar cada oportunidad de mejora. Entre ellas se encuentran: TPM (en sus 8 pilares), 5S, JIT/PULL, control visual, Poka – Yoke, SMED. En este mismo capítulo, se diseña el plan de mejora definitivo para cada oportunidad, considerando todos los resultados obtenidos anteriormente, y explicando en detalle los procedimientos para llevar cabo acciones específicas de mejora que permitan disminuir el MTTR. Finalmente, se presentan las conclusiones generales del trabajo, donde se reconoce el cumplimiento de los objetivos específicos planteados a través de los 5 pasos del plan, y se realizan recomendaciones para la aplicación y/o adaptación de esta tesis en casos particulares de empresas, entendiendo que el trabajo no incluye una aplicación en un caso específico, pero si sirve y tiene la capacidad para formar parte importante de los cimientos que abren y promueven la investigación del mantenimiento correctivo en las empresas.
The general objective of the thesis is to develop a plan to improve maintainability, through the use of tools of the Lean Maintenance philosophy. In particular, the objective is to optimize the activities that are part of the generic corrective maintenance process, in search of the reduction of the average repair time (MTTR). The work plan designed to achieve this objective consists of 5 steps. First, Chapter 3 provides a description of the generic process of repairing an unforeseen failure, through his Value Stream Mapping (VSM). With this it is possible to identify activities that do not add value to the process, and all the waste that grows the MTTR of a machine. Chapter 4 analyses the wastes found above, using the 5W+ 1H tool, which defines what, why, how, who, when and where each of them is presented in the process. Thus, a total of 16 wastes come from 10 different root causes. Then in Chapter 5, root causes are defined as opportunities for improvement, which are evaluated according to their criticality in a cost-benefit matrix, considering the difficulty of their implementation and the expected impact on MTTR. Based on the results, a priority scale is established, from where only 6 of the 10 opportunities for improvement manage to qualify to remain part of the job. Chapter 6 begins with the selection of Lean Maintenance tools to develop each opportunity for improvement. Among them are: TPM (in its 8 pillars), 5S, JIT/PULL, visual control, Poka – Yoke, SMED. In this same chapter, the final improvement plan is designed for each opportunity, considering all the results obtained above, and explaining in detail the procedures to carry out specific improvement actions that allow to decrease MTTR. Finally, the general conclusions of the work are presented, which recognizes the fulfillment of the specific objectives raised through the 5 steps of the plan, and recommendations are made for the implementation and / or adaptation of this thesis in particular cases of companies, understanding that the work does not include an application in a specific case, but if it serves and has the capacity to be an important part of the foundations that open and promote the research of corrective maintenance in companies.
The general objective of the thesis is to develop a plan to improve maintainability, through the use of tools of the Lean Maintenance philosophy. In particular, the objective is to optimize the activities that are part of the generic corrective maintenance process, in search of the reduction of the average repair time (MTTR). The work plan designed to achieve this objective consists of 5 steps. First, Chapter 3 provides a description of the generic process of repairing an unforeseen failure, through his Value Stream Mapping (VSM). With this it is possible to identify activities that do not add value to the process, and all the waste that grows the MTTR of a machine. Chapter 4 analyses the wastes found above, using the 5W+ 1H tool, which defines what, why, how, who, when and where each of them is presented in the process. Thus, a total of 16 wastes come from 10 different root causes. Then in Chapter 5, root causes are defined as opportunities for improvement, which are evaluated according to their criticality in a cost-benefit matrix, considering the difficulty of their implementation and the expected impact on MTTR. Based on the results, a priority scale is established, from where only 6 of the 10 opportunities for improvement manage to qualify to remain part of the job. Chapter 6 begins with the selection of Lean Maintenance tools to develop each opportunity for improvement. Among them are: TPM (in its 8 pillars), 5S, JIT/PULL, visual control, Poka – Yoke, SMED. In this same chapter, the final improvement plan is designed for each opportunity, considering all the results obtained above, and explaining in detail the procedures to carry out specific improvement actions that allow to decrease MTTR. Finally, the general conclusions of the work are presented, which recognizes the fulfillment of the specific objectives raised through the 5 steps of the plan, and recommendations are made for the implementation and / or adaptation of this thesis in particular cases of companies, understanding that the work does not include an application in a specific case, but if it serves and has the capacity to be an important part of the foundations that open and promote the research of corrective maintenance in companies.
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Keywords
MANTENIMIENTO INDUSTRIAL , MANTENCION DE PLANTA , DESECHOS INDUSTRIALES