En el presente trabajo se describen los resultados alcanzados de incorporar las herramientas del Mantenimiento Productivo Total para mejorar el nivel de calidad, reducir el desperdicio y Producto No Conforme en el proceso de Flexografía en la empresa Amcor. En primer lugar, se hizo el análisis de la situación actual, en la cual se identificó que la empresa tiene problemas de baja calidad en el proceso de fabricación del envase flexible proveniente del proceso de Flexografía, lo cual se debe al alto índice de desperdicio y producto no conforme, causados por la falta de procedimientos estandarizados. En segundo lugar, se utilizó la metodología del Mantenimiento Productivo Total aplicando los pilares del Mantenimiento Autónomo y Planificado a fin de solucionar los problemas sistémicos del operador. A raíz de ello, se estandarizó los procedimientos de limpieza de limpieza y trabajo. También, se insertó tareas básicas de mantenimiento al operador empleando el mantenimiento autónomo, logrando reducir los problemas sistémicos en el proceso. Por último, con la implementación del TPM aplicando los pilares del Mantenimiento Autónomo y Planificado se logró aumentar la tasa de índice de calidad de 92% a 95%, reducir el desperdicio por empalme y defectos en un 13% y 17% respectivamente, y el Producto No Conforme en un 17%, logrando un ahorro anual de USD 320,512. En resumen, la implementación de Mantenimiento Productivo Total en el proceso de Flexografía con los resultados obtenidos puede ser útil a los investigadores que necesiten mejorar los procesos de producción en una organización. / This work describes the results achieved by incorporating the tools of Total Productive Maintenance to improve the level of quality, reduce waste and Non-Conforming Product in the Flexography process in the Amcor Company dedicated to the manufacture of flexible envelopes. In the first place, the analysis of the current situation was made, in which it was identified that the company has low quality problems in the manufacturing process of the flexible packaging from the Flexography process, this is due to the high rate of waste and non-conforming product, caused by the lack of standardized procedures. Secondly, the methodology of Total Productive Maintenance was used applying the pillars of Autonomous and Planned Maintenance in order to solve the systemic problems of the operator. As a result, cleaning and work cleaning procedures were standardized. Also, basic maintenance tasks were inserted to the operator using autonomous maintenance, managing to reduce systemic problems in the process. Finally, with the implementation of the TPM applying the pillars of the Autonomous and Planned Maintenance, it was possible to increase the rate of quality index from 92% to 95%, reduce waste by splicing and defects by 13% and 17% respectively, and the Product Not Conform to 17%, achieving annual savings of USD 320,512. In summary, the implementation of Total Productive Maintenance in the Flexography process with the results obtained, may be useful to researchers who need to improve production processes in an organization. / Mantenimiento Autónomo / Tesis

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / At present, companies in the Peruvian plastic sector have an average capacity utilization indicator of 71.45%. However, in Peru many SMEs are with 50% well below this indicator. After a study performed in a representative company of the Peruvian plastic sector, the causes of low efficiency in resource utilization were determined through a problems tree and a Pareto analysis. These causes are failures, reprocesses and Setup times in the extrusion machines, taking around 1008 h a year to solve these problems. This article proposes a model to improve efficiency, integrating Lean Manufacturing tools such as 5s, SMED, and autonomous maintenance. The first one was used as a support tool, while SMED was used to reduce the configuration time and autonomous maintenance to reduce the failures number and the reprocesses number. The model was validated through a case study, obtaining as results the reduction of the setup time by 50%, breakdowns by 50% and reprocesses by 60%.

The study improved the overall equipment effectiveness (OEE) of machines and processes through the implementation of a total productive maintenance (TPM) approach at Company S over a three-month period. By comparing the OEE of equipment before and after the implementation of autonomous maintenance, this study concluded that autonomous maintenance improves OEE. The target of this study was one general product line at a polytetrafluoroethylene (PTFE) plant. Due to time limitations, the study only applied autonomous maintenance to operational activities. This research involved machine and processes selection, condition assessment, baseline OEE assessment, operator training, execution of autonomous maintenance, and OEE measurement. The approach was based on the steps of autonomous maintenance but was simplified for the conditions of the plant.

El texto completo de este trabajo no está disponible en el Repositorio Académico UPC por restricciones de la casa editorial donde ha sido publicado. / Nowadays, organizations in the cotton knitwear industry have had to adapt to a client who is not willing to pay an additional cost for activities that do not add value to the product. In Peru, many companies that export cotton knitwear closes every year since they cannot compete with countries such as China and Hong Kong due to their high production costs. This paper introduces a production management model based on Lean Manufacturing techniques and standardization of operations to reduce waste in the production flow, thus improving quality, and reducing production time and costs. So, a Production and Continuous improvement model (PDCA) were implemented. The validation was performed in a representative Peruvian company that exports cotton knitwear, resulting in an efficiency improvement of 10%, reduction of defective products of 20%, and generating savings of almost 5,000 soles monthly.

Orientador: Antonio Cesar Germano Martins / Resumo: Buscar alternativas ao que usualmente é feito diariamente nas empresas, possibilita construir uma visão diferenciada de processos e atitudes, que permite propor um conjunto de ações para se obter resultados diferentes dos observados até então. Neste contexto encontra-se a utilização do pilar de Manutenção Autônoma (MA) da ferramenta de Manutenção Produtiva Total (TPM), sendo proposto nesta tese, sua utilização com um novo propósito, inovador, o de mitigar a geração de resíduos. Usualmente o pilar é utilizado para envolver os diversos atores dos processos produtivos na conservação dos equipamentos, com o objetivo de melhorar seu desempenho, reduzindo falhas não previstas ou aumentando a disponibilidade e confiabilidade. Em um cenário composto prioritariamente por micro e pequenas empresas produtoras de calçados femininos, instaladas em um Arranjo Produtivo Local (APL) no município de Jaú/SP, encontrou-se um cenário com possibilidades de se alterar o ambiente de trabalho com estas ações inéditas. Explorando um cenário que usualmente não utiliza ferramentas de manutenção, tal como a TPM, para introduzir a nova proposta, visando reduzir a geração de resíduos perigosos originados no processo produtivo. Assim, a proposta aqui, foi utilizar de forma inovadora a MA da TPM, aplicada ao setor de corte manual de uma empresa produtora de calçados femininos, instalada no APL de Calçados Femininos de Jaú/SP, com o objetivo de obter os mesmos resultados no tocante à redução dos resíduos dos... (Resumo completo, clicar acesso eletrônico abaixo) / Doutor

The content of this thesis is a set of approaches that lead to a leaner enterprise. Besides the basic lean methods that are described in the theoretical part of this paper, the most attention is devoted to total productive maintenance (TPM). The practical part of this paper primarily focuses on a complete analysis of the maintenance system in Parker Hannifin and then on a project designed to implement the basic elements of TPM in the above mentioned enterprise. At the end of the piece, the project is evaluated and further ideas and recommendations for the future development of TPM in the enterprise are proposed.

This master thesis concerns modern method of TPM used in the production companies for maintenance of machinery. In the theoretical part, general maintenance is first described, as well as the TPM method. There is also described the technical diagnostics, which was emphasized in the practical part in terms of the use of vibrodiagnostics in predictive maintenance. In the practical part there is presented the proposal for introduction of the TPM method at the SMC Industrial Automation s.r.o. in Vyškov.

El propósito de este trabajo es presentar un estudio de mantenimiento centrado del TPM (mantenimiento productivo total) y RCM (mantenimiento centrado en la confiabilidad), que llevó a cabo dentro de un proyecto de instalación de una red sanitaria a través de equipos de construcción pesada en Lima, Perú. Su enfoque se basa en los primeros pilares del TPM, mantenimiento preventivo y autónomo, así como el análisis FMEA del RCM para el análisis de mantenimiento, que se lleva a cabo en estudio. La aplicación del TPM tiene éxito en su aplicación de diversas políticas de Mantenimiento Preventivo (MP) asignados a los activos y demuestra que su aplicación en la industria de la construcción podría reducir la excesiva acumulación de mantenimiento por la misma optimización eficaz, apoyado del análisis del RCM y su análisis de los sistemas de los equipos pesados. El excesivo mantenimiento correctivo representa un alto índice de inversión y retrasos en tiempos de trabajo del proyecto asignado. Los métodos tradicionales de garantía de Disponibilidad, como el mantenimiento reactivo o de rutina, son insuficientes para satisfacer un plan de mantenimiento de equipos pesados, por lo tanto, cuenta para la aplicación sistemática RCM y TMP, permitirán seleccionar y aplicar tareas efectivas de PM. Se utiliza un enfoque que desarrolla y analiza a fondo las estrategias de mantenimiento correctivo y preventivo continuo con el ambiente de incertidumbre y datos operativos limitados por la crítica. Los resultados nos arrojan una mejora de la disponibilidad al 90%. / The purpose of this paper is to present a maintenance study focused on total productive maintenance (TPM) and reliability-centered maintenance (RCM). Its approach is based on the first pillars of TPM, preventive and autonomous maintenance, as well as the FMEA analysis of RCM for maintenance analysis, which was conducted in this study. The implementation of TPM was successful in that various preventive maintenance (PM) policies assigned to the assets were implemented and it was demonstrated that TPM application in the construction industry could reduce the excessive accumulation of maintenance with the same effective optimization, and with support from RCM analysis and its heavy equipment systems analysis. Excessive corrective maintenance accounts for high investment and delay rates in work times of the assigned project. Traditional methods of availability guarantee, such as reactive or routine maintenance, are insufficient to satisfy a heavy equipment maintenance plan; therefore, what is called for is the systematic application of RCM and TMP because they allow the selection and application of effective PM tasks. An approach that develops and thoroughly analyzes the strategies of continuous corrective and PM is used with an atmosphere of uncertainty and with operational data limited by criticism. Results show a 90% improvement in availability. / Trabajo de Suficiencia Profesional

Este proyecto de tesis fue aplicado en la empresa Industrias Corcor S.R.L., dedicada a la producción exclusiva de escaleras metálicas, la cual fue objeto de análisis y diagnóstico, y así hacer posible la implementación de la propuesta de mejora en sus procesos de producción. En el último año se han identificado costos elevados producidos por diversos problemas en los procesos de producción que no permiten alcanzar las cantidades que, como empresa, se ha proyectado para cubrir con la demanda anual. La aparición de distintos tipos de defectos durante los procesos de elaboración de escaleras generó la baja eficiencia y un impacto económico de 15.71% en la utilidad anual. Por ello, para solucionar o mitigar este problema se optó por diseñar y desarrollar un proyecto de mejora continua para las MYPE, el cual se orienta en la manufactura esbelta y el estudio de trabajo. El presente proyecto inicia con la descripción de los antecedentes, marco teórico y estado del arte, en donde se señalan las diferentes herramientas a utilizar, como el estudio de método de trabajo, el mantenimiento autónomo, entre otros. Luego, se realizará un análisis y diagnóstico de la situación inicial en general de la empresa. Posteriormente, se analizarán los factores causantes de la baja eficiencia y su impacto en la empresa, para que finalmente, se puedan plantear propuestas de mejora y así, aplicarlas correctamente. / This thesis project was applied in the company Industrias Corcor S.R.L., dedicated to the exclusive production of metal stairs, which was the object of analysis and diagnosis, and thus make possible the implementation of the improvement proposal in its production processes. In the last year, high costs have been identified due to various problems in the production processes that do not allow reaching the quantities that, as a company, has been projected to cover with the annual demand. The appearance of different types of defects during the stair manufacturing processes generated low efficiency and an economic impact of 15.71% in the annual profit. Therefore, to solve or mitigate this problem, it was decided to design and develop a continuous improvement project for MSEs, which is oriented towards lean manufacturing and the work study. This project begins with the description of the background, theoretical framework and state of the art, where the different tools to be used are indicated, such as the study of work method, autonomous maintenance, among others. Then, an analysis and diagnosis of the initial situation in general of the company will be carried out. Subsequently, the factors causing low efficiency and their impact on the company will be analyzed, so that finally, proposals for improvement can be proposed and thus, applied correctly. / Trabajo de investigación

El consumo de aguas envasadas ha experimentado un gran aumento desde el 2013. La industria del agua embotellada, actualmente, está presente en la mayoría de las principales ciudades del país, es un producto de consumo masivo e indispensable para las actividades diarias de la población. De tal manera, en el Perú las plantas de tratamiento de agua en el sector de Pyme presentan una baja eficiencia operacional en sus líneas de producción. Este problema genera incumplimientos en las entregas de los pedidos, lo cual representa pérdidas económicas que bordea alrededor de un 15% de sus ventas anuales, esto se debe a que se incurre en tiempos improductivos y la falta de mantenimiento necesarios. Por lo tanto, este estudio desarrolló un modelo que permitirá aumentar la eficiencia en planta mediante la aplicación de la herramienta SMED y mantenimiento autónomo que reducirá tiempos de set up y averías respectivamente. El modelo propuesto tiene como objetivo reducir los tiempos de set up hasta en un 36%, mientras que para el tiempo de paradas por averías hasta un 60%, alcanzando así un porcentaje superior al 80% de eficiencia en planta (OEE). / The consumption of bottled water has experienced a great increase since 2013. The bottled water industry, currently, is present in most of the main cities of the country, it is a product of massive consumption and indispensable for the daily activities of the population. Thus, in Peru, water treatment plants in the SME sector have low operational efficiency in their production lines. This problem generates defaults in the deliveries of the orders, which represents economic losses that border around 15% of their annual sales, this is due to the fact that they incur in downtime and the lack of necessary maintenance. Therefore, this study developed a model that will increase plant efficiency through the application of the SMED tool and autonomous maintenance that will reduce set-up times and breakdowns, respectively. The proposed model aims to reduce set up times by up to 36%, while for breakdown time by up to 60%, thus reaching a percentage greater than 80% in-plant efficiency (OEE). / Trabajo de investigación