Diseño de un sistema automatizado de producción usando controladores lógicos programables en la Empresa Ricca Pasta de la ciudad de Guayaquil.
Fecha
2015-03-20
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Universidad de Guayaquil. Facultad de Ingeniería Industrial. Carrera de Ingeniería en Teleinformática.
Resumen
El objetivo de la presente tesis es: diseñar un sistema automatización con el uso de PLC y microcontroladores para la eficiencia de la producción de pastas cortas (fideo sopa) en la empresa Ricca Pasta. Para diagnosticar la situación actual de la empresa, se analizó la manufactura de pastas cortas con el uso de flujogramas de procesos, cálculo de la eficiencia, identificando que las causas principales de la problemática en estudio referido al tiempo improductivo y reproceso, de acuerdo a la aplicación de los diagramas de Ishikawa y de Pareto, lo constituye en primer lugar la falta de un dispositivo automatizado de control para el correcto funcionamiento de la prensa No. 2, además que la defectuosidad que es ocasionada porque el fideo frágil tiene un indicador de homogeneidad mayor al 40% y el fideo duro causado porque la humedad del producto semielaborado es superior al 10%, situación conflictiva que genera una pérdida anual igual a $6.986,48. La propuesta para enfrentar estas disconformidades en la planta de la compañía, están vinculadas a la instalación de un sistema de control con PLC para la prensa No. 2, de modo que se reduzca el tiempo improductivo en el cambio de moldes, además de disminuir el porcentaje de producto defectuoso, estrategia que impactará en un incremento de 14,50% de la eficiencia de la producción, desde 76% hasta 90,50%. El monto de la inversión inicial asciende a $6.990,00 de los cuales la inversión fija asciende a $3.384,00 (62,78%), mientras que los costos de operación corresponden a $2.006,00 (37,22%), recuperándose la inversión inicial en un año, generando una tasa TIR de 139,08%, un VAN igual a $16.232,30, un coeficiente beneficio costo igual a 4,80, indicadores que evidencian que la alternativa escogida es factible y conviene su implementación en la planta.
The objective of this thesis is: design a system automation using PLC and microcontrollers for efficient production of short pasta (noodle soup) in the company Ricca Pasta. To diagnose the current situation of the company, the manufacture of short pasta with the use of flowcharts of processes, efficiency calculation was analyzed, identifying the main causes of the problem under study referred to downtime and rework, according to the applying Ishikawa diagrams and Pareto first constitutes the lack of an automated control device to correct operation of the press # 2, in addition to the defect that is caused because the fragile noodle has an uniformity indicator and greater than 40%, because the hard noodle caused semifinished product moisture that exceeds 10%, generating a conflict situation equal to $ 6986.48 annual loss. The proposal to address these disagreements on the ground of the company, are linked to the installation of a control system with PLC for press No. 2, so that downtime is reduced by changing molds, besides reducing the percentage of defective product strategy impact on a 14.50% increase in the production efficiency from 76% to 90.50%. The amount of the initial investment amounts to $ 5,390.00 of which fixed investment amounts to $ 3,384.00 (62.78%), while operating costs correspond to $ 2,006.00 (37.22%), recovering investment starting in a year, generating an IRR rate of 139.08%, a NPV equal to $16,232.30, a benefit-cost ratio equal to 4.80, indicators show that the chosen alternative is feasible and appropriate implementation in plant.
The objective of this thesis is: design a system automation using PLC and microcontrollers for efficient production of short pasta (noodle soup) in the company Ricca Pasta. To diagnose the current situation of the company, the manufacture of short pasta with the use of flowcharts of processes, efficiency calculation was analyzed, identifying the main causes of the problem under study referred to downtime and rework, according to the applying Ishikawa diagrams and Pareto first constitutes the lack of an automated control device to correct operation of the press # 2, in addition to the defect that is caused because the fragile noodle has an uniformity indicator and greater than 40%, because the hard noodle caused semifinished product moisture that exceeds 10%, generating a conflict situation equal to $ 6986.48 annual loss. The proposal to address these disagreements on the ground of the company, are linked to the installation of a control system with PLC for press No. 2, so that downtime is reduced by changing molds, besides reducing the percentage of defective product strategy impact on a 14.50% increase in the production efficiency from 76% to 90.50%. The amount of the initial investment amounts to $ 5,390.00 of which fixed investment amounts to $ 3,384.00 (62.78%), while operating costs correspond to $ 2,006.00 (37.22%), recovering investment starting in a year, generating an IRR rate of 139.08%, a NPV equal to $16,232.30, a benefit-cost ratio equal to 4.80, indicators show that the chosen alternative is feasible and appropriate implementation in plant.
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Palabras clave
MICROCONTROLADORES, AUTOMATIZACIÓN PLC, PRODUCCIÓN DE PASTAS