Mejora del nivel de producción en máquinas inyectoras de Amcor Pet Packaging del Ecuador.
Fecha
2008-04-04
Autores
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Universidad de Guayaquil. Facultad de Ingeniería Industrial. Carrera de Ingeniería Industrial.
Resumen
El propósito del presente trabajo es el analizar el rendimiento del área de Inyección de la
empresa Amcor Pet Packaging del Ecuador S.A. y relacionar los resultados con los
aspectos tecnológicos de los equipos, evaluación del personal operativo de planta, de
mantenimiento técnico, de los procedimientos y registros de control con el fin de
determinar las propuestas de solución viables y cuyo impacto e incidencia repercuta en
mejorar los índices de eficiencia de la empresa a estándares establecidos por el grupo a
nivel regional. Mediante la verificación de registros de producción, calidad y estadísticas,
fue posible elaborar un cuadro de fallas comunes y su impacto en tiempo y ocurrencias,
además fue requerido el soporte técnico del personal involucrado con el equipo para
elaborar una lista de repuestos prioritarios y como asistencia técnica externa recurrir al
proveedor de la máquina inyectora en la búsqueda de la mejor alternativa tecnológica
previo a la identificación de los problemas presentados. La cuantificación de pérdidas es
de $ 368.858,4 proyectada a un año para lo cual se propone las siguientes alternativas.
Realizar tareas técnicas de mantenimiento correctivo a la máquina inyectora y un
overhaull al hot runner del molde. Finalmente se va a capacitar al personal técnico y de
operaciones para reducir los paros prolongados por paro imprevisto de equipos,
implementar un software de mantenimiento para poder llevar un soporte técnico confiable
de los diferentes tipos de mantenimientos a realizar y la adquisición de un equipo de dry
ice para moldes y reducir los paros por mantenimiento preventivo en máquina del molde.
El estudio económico determino la factibilidad de este conjunto de acciones correctivas y
su alcance en los resultados financieros, mejorando la eficiencia del equipo de 65,23% al
92%, reduciendo el índice de scrap y producto retenido por motivos de producto no
conforme de 1,59% a 0,53% y de 3,53% a 1.17% respectivamente, el costo de la
inversión es de $ 142.977,16 y su recuperación es a 2 años.
The purpose of this work is to analyze the performance of the Injection area of the company Amcor Pet Packaging del Ecuador S.A. and relate the results to the technological aspects of the equipment, evaluation of plant operating personnel, technical maintenance of control procedures and records in order to determine viable solution proposals and whose impact and incidence have repercussions on improve the efficiency rates of the company to standards established by the group to regional level. By verifying production, quality and statistical records, it was possible to draw up a table of common failures and their impact on time and occurrences, In addition, the technical support of the personnel involved with the equipment was required to prepare a list of priority spare parts and, as external technical assistance, use the injection machine supplier in search of the best technological alternative prior to the identification of the problems presented. The quantification of losses is of $ 368,858.4 projected for one year, for which the following alternatives are proposed. Carry out corrective maintenance technical tasks to the injection machine and a overhaull the hot runner from the mold. Finally, the technical and technical personnel will be trained. operations to reduce prolonged shutdowns due to unexpected equipment shutdowns, implement maintenance software to provide reliable technical support of the different types of maintenance to be carried out and the acquisition of a dry equipment ice for molds and reduce stoppages for preventive maintenance in the mold machine. The economic study determined the feasibility of this set of corrective actions and its scope in financial results, improving team efficiency from 65.23% to 92%, reducing the rate of scrap and product withheld for reasons of non-product according to 1.59% to 0.53% and 3.53% to 1.17% respectively, the cost of the investment is $ 142,977.16 and its recovery is 2 years.
The purpose of this work is to analyze the performance of the Injection area of the company Amcor Pet Packaging del Ecuador S.A. and relate the results to the technological aspects of the equipment, evaluation of plant operating personnel, technical maintenance of control procedures and records in order to determine viable solution proposals and whose impact and incidence have repercussions on improve the efficiency rates of the company to standards established by the group to regional level. By verifying production, quality and statistical records, it was possible to draw up a table of common failures and their impact on time and occurrences, In addition, the technical support of the personnel involved with the equipment was required to prepare a list of priority spare parts and, as external technical assistance, use the injection machine supplier in search of the best technological alternative prior to the identification of the problems presented. The quantification of losses is of $ 368,858.4 projected for one year, for which the following alternatives are proposed. Carry out corrective maintenance technical tasks to the injection machine and a overhaull the hot runner from the mold. Finally, the technical and technical personnel will be trained. operations to reduce prolonged shutdowns due to unexpected equipment shutdowns, implement maintenance software to provide reliable technical support of the different types of maintenance to be carried out and the acquisition of a dry equipment ice for molds and reduce stoppages for preventive maintenance in the mold machine. The economic study determined the feasibility of this set of corrective actions and its scope in financial results, improving team efficiency from 65.23% to 92%, reducing the rate of scrap and product withheld for reasons of non-product according to 1.59% to 0.53% and 3.53% to 1.17% respectively, the cost of the investment is $ 142,977.16 and its recovery is 2 years.
Descripción
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Palabras clave
INGENIERÍA DE PLANTA, MÁQUINAS INYECTORAS, ASISTENCIA TÉCNICA, MANTENIMIENTO PREVENTIVO