Elaboración de un plan de mantenimiento centrado en la confiabilidad (RCM) para el área de bunchado en planta Electrocables de la ciudad de Guayaquil.
Fecha
2017-12-06
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Universidad de Guayaquil. Facultad de Ingeniería Industrial. Carrera de Ingeniería Industrial.
Resumen
El presente proyecto muestra una propuesta de mejora que se basa en la elaboración de un plan de mantenimiento centrado en la confiabilidad RCM mantenimiento de cuarta generación, que es una de las técnicas organizativas aplicadas actualmente al cuidado de maquinarias, equipos, componentes y sistemas de las maquina mejorando significativamente los resultados, aplicado esto en el área de bunchado de la empresa Electrocables en la ciudad de Guayaquil, con el objetivo de reducir el número de averías, horas de averías, tiempo medio entre fallos MTBF y tiempo medio entre reparación de fallos MTTR. Se establece el análisis de modo de fallas y efectos AMFE lo cual ayuda a estudiar los mismos, también se realizar el análisis de modo de fallos, efectos y criticidad AMFEC a cada uno de los sistemas de las maquinas del área de bunchado, para reconocer los modos de fallas, efectos y criticidad, respecto al impacto operacional, frecuencia, mantenibilidad y detección que se consideran para impedir el incremento del índice de criticidad de máquinas, equipos, componentes y sistemas de la maquina. En el estudio económico de los problemas de la gestión del mantenimiento se establecen los costos por parada programada y no programada más el activo circulante no generado por los tiempos improductivos, el valor de estas dos últimas variables de análisis es de $ 19.680,70. Con la adaptación de la propuesta RCM se obtuvo un costo total de mantenimiento de $ 11.700,00 que representa un flujo de caja para el primer periodo por un valor de $ 5.172,28 y para el segundo periodo se presenta un incremento por un valor de $1.188,15, lo cual demuestra la importancia de la aplicación del presente trabajo de investigación. Con la metodología RCM se incrementa el tiempo medio entre fallos MTBF de 8.8 horas a 29.3 horas, también muestra un aumento de tiempo medio de reparación MTTR de 2.8 horas a 6.8 horas. Para la aplicación y continuidad del RCM se recomienda implementar capacitaciones con los siguientes temas: Mantenimiento basado en la confiabilidad RCM, Análisis de modos de fallas, efectos y criticidad AMFEC, Mantenimiento programado y autónomo, Metodología de las 5 S, Norma PAS 55.
This project shows a proposal for improvement that is based on the elaboration of a plan of reliability centered maintenance RCM maintenance of fourth generation, which is one of the organizational techniques currently applied to the care of machinery, equipment, components and systems of the machine significantly improving results, applied this in the area of the company bunchado ELECTROCABLES in the city of Guayaquil, with the goal of reducing the number of malfunctions, hours of troubleshooting, meantime between failure MTBF and Mean time between repair of faults MTTR. Sets the analysis failure mode and effects analysis FMEA which helps to study the same, also carry out the analysis of failure mode, effects and criticality AMFEC to each one of the systems of the machines in the area of bunchado, to recognize the failure modes, effects and criticality, with respect to the operational impact, frequency, maintainability and detection that are considered to prevent the increase in the rate of criticality of machines, equipment, components and systems of the machine. In the economic study of the issues in the management of the maintenance costs for scheduled and unscheduled stop more assets not generated by downtime, the value of these two variables of analysis is $19.680,70. With the adaptation of the proposal RCM was obtained a total cost of maintenance of $ 11.700,00 that represents a cash flow for the first period with a value of $5.172,28 and for the second period is increased by a value of $1.188,15, which demonstrates the importance of the application of this research work. With the RCM methodology increases the mean time between failures MTBF of 8.8 hours to 29.3 hours, also shows an increase in mean time to repair MTTR from 2.8 hours to 6.8 hours. For the implementation and continuity of the RCM is recommended to implement training sessions with the following themes: the reliability Based Maintenance RCM, analysis of failure modes, effects and criticality AMFEC, scheduled maintenance and autonomous, Methodology of the 5 S, standard PAS 55.
This project shows a proposal for improvement that is based on the elaboration of a plan of reliability centered maintenance RCM maintenance of fourth generation, which is one of the organizational techniques currently applied to the care of machinery, equipment, components and systems of the machine significantly improving results, applied this in the area of the company bunchado ELECTROCABLES in the city of Guayaquil, with the goal of reducing the number of malfunctions, hours of troubleshooting, meantime between failure MTBF and Mean time between repair of faults MTTR. Sets the analysis failure mode and effects analysis FMEA which helps to study the same, also carry out the analysis of failure mode, effects and criticality AMFEC to each one of the systems of the machines in the area of bunchado, to recognize the failure modes, effects and criticality, with respect to the operational impact, frequency, maintainability and detection that are considered to prevent the increase in the rate of criticality of machines, equipment, components and systems of the machine. In the economic study of the issues in the management of the maintenance costs for scheduled and unscheduled stop more assets not generated by downtime, the value of these two variables of analysis is $19.680,70. With the adaptation of the proposal RCM was obtained a total cost of maintenance of $ 11.700,00 that represents a cash flow for the first period with a value of $5.172,28 and for the second period is increased by a value of $1.188,15, which demonstrates the importance of the application of this research work. With the RCM methodology increases the mean time between failures MTBF of 8.8 hours to 29.3 hours, also shows an increase in mean time to repair MTTR from 2.8 hours to 6.8 hours. For the implementation and continuity of the RCM is recommended to implement training sessions with the following themes: the reliability Based Maintenance RCM, analysis of failure modes, effects and criticality AMFEC, scheduled maintenance and autonomous, Methodology of the 5 S, standard PAS 55.
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Palabras clave
SISTEMAS PRODUCTIVOS, PLAN DE MANTENIMIENTO, CONFIABILIDAD RCM, REDUCCIÓN DE AVERÍAS EN MÁQUINAS