Optimización del proceso productivo en la línea de producción automática de paneles de resortes de la Empresa Productos Paraíso del Ecuador S.A. a través de una gestión de mantenimiento

Abstract

This curricular integration work is focused on optimizing the production process of the automatic production line of spring panels of the company Productos Paraíso del Ecuador S.A. through the development of a Maintenance Management. For which Lean Manufacturing tools were used, based on the guidelines of two pillars of TPM (Total Productive Maintenance) that are Autonomous and Planned. The study began with the analysis of the production process, at this stage the activities to be developed during the process were organized using the Deming Cycle (PDCA), where the causes and potential problems were identified and prioritized through quality management tools in order to show and propose improvement opportunities. Subsequently, a pilot machine was selected through a Criticality Analysis (CA, an initial diagnosis was made at the machine´s workstation, which allowed determining a productivity of 68,02% and an OEE (Overall Equipment Efficiency) of 65,59%, in addition, a questionnaire was established to verify the initial compliance with the 5S´s in the production process, with a result of 53%. In the development of Maintenance Management with initial emphasis on Autonomous Maintenance as established by the TPM, the 5S´s were implemented in the production process, improving order, cleanliness and establishing discipline as a basis for continuous improvement, later a flexible Mantenance Plan was developed for the pilot machine through a FMEA (Failure Mode and Effects Analysis) according to the NTP 679, 2004 standard, which allowed establishing actions and maintenance ranges, work orders and an annual preventive maintenance schedule so that it can be projected to the other machines of the production process, resulting in a increase in productivity at the work station, an improvement of 13,18% in the OEE of the machine, an increase in compliance with 84% of the 5S´s philosophy and a reduction of 14% in wire waste, thus significantly affecting the optimization of the production process.