A DOW é uma empresa que busca continuamente por alternativas para agregar maior valor aos seus produtos através da avaliação das tendências apresentadas pela indústria química. Dentro desta dinâmica, identificou-se uma grande necessidade do mercado de fluidos de corte por inibidores de corrosão mais eficientes e adequados às novas questões regulatórias. Desta avaliação surgiu o tema deste Mestrado Profissional, no qual se estudou a síntese e aplicação de alcanolamidas em fluidos de corte como inibidores de corrosão. Optou-se pela síntese enzimática na ausência de solventes orgânicos por se tratar de uma nova tecnologia à DOW e estar alinhada aos preceitos de sustentabilidades promovidos pela empresa. A escolha pela avaliação das alcanolamidas surgiu de um estudo realizado pela companhia sobre novas tecnologias utilizadas neste segmento e a possibilidade de aplicação destes compostos em outros mercados de atuação da empresa. Foram sintetizadas quatro alcanolamidas, RMEA, RMIPA, RDIPA e RAEPD, obtidas respectivamente da reação entre o ácido ricinoléico e os aminoálcoois: 2-hidroxietilamina, 1-amino-2-propanol, bis-(2-hidroxipropil)amina e 2-amino-2-etil-1,3-propanodiol. O catalisador Novozym 435 (lipase) foi utilizado em todas as sínteses, e estas realizadas de acordo com um planejamento fatorial completo 23. Os produtos sintetizados foram caracterizados por RMN 13C, 1H e dept 135, Espectroscopia no Infravermelho e Espectroscopia de Massas. O rendimento das reações foi mensurado através da técnica de HPLC. Com base nos resultados obtidos foi possível, através do planejamento fatorial, determinar as condições reacionais nas quais o rendimento é maximizado (T = 80 °C; Catalisador = 15 mol/g de ácido ricinoléico; rotação = 600 rpm). A única desvantagem deste processo de síntese foi o custo inerente ao catalisador utilizado. Após o término do planejamento fatorial foram formulados oito fluidos de corte semissintéticos com as alcanolamidas sintetizadas e dois fluidos com o inibidor convencionalmente utilizado. Após verificar a estabilidade térmica destes fluidos, a eficiência à inibição da corrosão foi mensurada através da técnica de manchamento em ferro fundido. Os fluidos contendo as alcanolamidas apresentaram melhor desempenho à inibição da corrosão, porém, não foi possível mensurar quantitativamente as diferenças observadas através desta técnica. Com isso, os compostos foram submetidos a ensaios de perda de massa e polarização potenciodinâmica em ácido clorídrico, além de microscopia atômica para avaliar o efeito dos inibidores na superfície metálica. Através destes estudos foi possível comprovar que os produtos RDIPA e RAEPD possuem maior eficiência à inibição da corrosão. O mecanismo de inibição destes compostos, determinado através de isotermas de Langmuir, ocorre por fisissorção. Após a comprovação das propriedades anticorrosivas dos compostos sintetizados, foram analisadas as seguintes propriedades dos fluidos produzidos: viscosidade, formação de espuma, ângulo de contato, desgaste Reichert, alcalinidade e contaminação microbiológica. Observou-se um aumento da viscosidade e formação de espuma do fluido concentrado. Entretanto, comprovou-se que não há impacto significativo destas propriedades durante a aplicação destes fluidos. As alcanolamidas impactaram positivamente no aumento da lubricidade e reserva alcalina dos fluidos, além de diminuir a taxa de corrosão e a susceptibilidade dos fluidos à contaminação microbiológica, e facilitar o tratamento do resíduo gerado no processo de usinagem devido a maior biodegradabilidade das alcanolamidas. / DOW is a company that continuously searches for alternatives to add greater value to their products through the assessment of trends presented by the chemical industry. Within this dynamic it was identified a great need for more efficient and suitable (to new regulatory issues) corrosion inhibitors applied in metalworking fluids. This Master Thesis came up from this evaluation, where it was studied the synthesis and application of alkanolamides in metalworking fluids as corrosion inhibitors. The enzymatic synthesis in the absence of organic solvents was the chosen production process of alkanolamides because it\'s a new technology to DOW and it\'s aligned with sustainable precepts promoted by the company. The choice for the evaluation of alkanolamides emerged from a study conducted by the company on new technologies applied in metalworking fluids and the possibility of application of these compounds in other markets. It was synthesized four alkanolamides, RMEA, RMIPA, RDIPA and RAEPD, respectively obtained from the reaction between ricinoleic acid and following amino alcohols: 2-hydroxyethylamine, 1-amino-2-propanol, bis(2-hydroxypropyl)amine and 2-amino-2-ethyl-1,3-propanediol. The Novozym 435 catalyst (lipase) was used for all syntheses, and these were carried out according to a full factorial design for three factors. The synthesized products were characterized by NMR 13C, 1H and dept 135, Infrared and Mass Spectroscopy. The yield of the reactions was measured by HPLC technique. Based on the results it was possible, through the factorial design, determine the reaction conditions in which the yield is maximized (T = 80 ° C; Catalyst = 15 mol / g of ricinoleic acid; Speed = 600 rpm). The only disadvantage found of this synthesis process was the cost of the catalyst used. After the factorial design eight semi-synthetic metalworking fluids were formulated with the synthesized alkanolamides and two with the corrosion inhibitor conventionally used. After checking the thermal stability of these fluids, the corrosion inhibition efficiency was measured by staining technique of cast iron. Fluids containing alkanolamides performed better corrosion inhibition, however, was not possible to measure quantitatively the differences observed using this technique. Thus, the compounds were subjected to weight loss and potentiodynamic polarization tests in hydrochloric acid, besides the atomic microscopy to evaluate the effect of the inhibitors on the metal surface. Through these studies it was possible to demonstrate that RDIPA and RAEPD products were more efficient at inhibiting corrosion. The mechanism of inhibition of these compounds, as determined by Langmuir isotherms, is by physisorption. After checking the anticorrosive properties of the synthesized compounds, the following properties were analyzed from the formulated fluids: viscosity, foaming, contact angle, Reichert friction, alkalinity and microbiological contamination. It was observed an increase in viscosity and foaming on the concentrated fluids. However, it was found that there is no significant impact of these properties during the application of these fluids. Alkanolamides enabled an increase in lubricity and alkalinity of the formulated fluids. Additionally they reduced the corrosion rate and the susceptibility of fluids to microbiological contamination, and would make easier the treatment of the waste generated in cutting process due to their higher biodegradability.

A DOW é uma empresa que busca continuamente por alternativas para agregar maior valor aos seus produtos através da avaliação das tendências apresentadas pela indústria química. Dentro desta dinâmica, identificou-se uma grande necessidade do mercado de fluidos de corte por inibidores de corrosão mais eficientes e adequados às novas questões regulatórias. Desta avaliação surgiu o tema deste Mestrado Profissional, no qual se estudou a síntese e aplicação de alcanolamidas em fluidos de corte como inibidores de corrosão. Optou-se pela síntese enzimática na ausência de solventes orgânicos por se tratar de uma nova tecnologia à DOW e estar alinhada aos preceitos de sustentabilidades promovidos pela empresa. A escolha pela avaliação das alcanolamidas surgiu de um estudo realizado pela companhia sobre novas tecnologias utilizadas neste segmento e a possibilidade de aplicação destes compostos em outros mercados de atuação da empresa. Foram sintetizadas quatro alcanolamidas, RMEA, RMIPA, RDIPA e RAEPD, obtidas respectivamente da reação entre o ácido ricinoléico e os aminoálcoois: 2-hidroxietilamina, 1-amino-2-propanol, bis-(2-hidroxipropil)amina e 2-amino-2-etil-1,3-propanodiol. O catalisador Novozym 435 (lipase) foi utilizado em todas as sínteses, e estas realizadas de acordo com um planejamento fatorial completo 23. Os produtos sintetizados foram caracterizados por RMN 13C, 1H e dept 135, Espectroscopia no Infravermelho e Espectroscopia de Massas. O rendimento das reações foi mensurado através da técnica de HPLC. Com base nos resultados obtidos foi possível, através do planejamento fatorial, determinar as condições reacionais nas quais o rendimento é maximizado (T = 80 °C; Catalisador = 15 mol/g de ácido ricinoléico; rotação = 600 rpm). A única desvantagem deste processo de síntese foi o custo inerente ao catalisador utilizado. Após o término do planejamento fatorial foram formulados oito fluidos de corte semissintéticos com as alcanolamidas sintetizadas e dois fluidos com o inibidor convencionalmente utilizado. Após verificar a estabilidade térmica destes fluidos, a eficiência à inibição da corrosão foi mensurada através da técnica de manchamento em ferro fundido. Os fluidos contendo as alcanolamidas apresentaram melhor desempenho à inibição da corrosão, porém, não foi possível mensurar quantitativamente as diferenças observadas através desta técnica. Com isso, os compostos foram submetidos a ensaios de perda de massa e polarização potenciodinâmica em ácido clorídrico, além de microscopia atômica para avaliar o efeito dos inibidores na superfície metálica. Através destes estudos foi possível comprovar que os produtos RDIPA e RAEPD possuem maior eficiência à inibição da corrosão. O mecanismo de inibição destes compostos, determinado através de isotermas de Langmuir, ocorre por fisissorção. Após a comprovação das propriedades anticorrosivas dos compostos sintetizados, foram analisadas as seguintes propriedades dos fluidos produzidos: viscosidade, formação de espuma, ângulo de contato, desgaste Reichert, alcalinidade e contaminação microbiológica. Observou-se um aumento da viscosidade e formação de espuma do fluido concentrado. Entretanto, comprovou-se que não há impacto significativo destas propriedades durante a aplicação destes fluidos. As alcanolamidas impactaram positivamente no aumento da lubricidade e reserva alcalina dos fluidos, além de diminuir a taxa de corrosão e a susceptibilidade dos fluidos à contaminação microbiológica, e facilitar o tratamento do resíduo gerado no processo de usinagem devido a maior biodegradabilidade das alcanolamidas. / DOW is a company that continuously searches for alternatives to add greater value to their products through the assessment of trends presented by the chemical industry. Within this dynamic it was identified a great need for more efficient and suitable (to new regulatory issues) corrosion inhibitors applied in metalworking fluids. This Master Thesis came up from this evaluation, where it was studied the synthesis and application of alkanolamides in metalworking fluids as corrosion inhibitors. The enzymatic synthesis in the absence of organic solvents was the chosen production process of alkanolamides because it\'s a new technology to DOW and it\'s aligned with sustainable precepts promoted by the company. The choice for the evaluation of alkanolamides emerged from a study conducted by the company on new technologies applied in metalworking fluids and the possibility of application of these compounds in other markets. It was synthesized four alkanolamides, RMEA, RMIPA, RDIPA and RAEPD, respectively obtained from the reaction between ricinoleic acid and following amino alcohols: 2-hydroxyethylamine, 1-amino-2-propanol, bis(2-hydroxypropyl)amine and 2-amino-2-ethyl-1,3-propanediol. The Novozym 435 catalyst (lipase) was used for all syntheses, and these were carried out according to a full factorial design for three factors. The synthesized products were characterized by NMR 13C, 1H and dept 135, Infrared and Mass Spectroscopy. The yield of the reactions was measured by HPLC technique. Based on the results it was possible, through the factorial design, determine the reaction conditions in which the yield is maximized (T = 80 ° C; Catalyst = 15 mol / g of ricinoleic acid; Speed = 600 rpm). The only disadvantage found of this synthesis process was the cost of the catalyst used. After the factorial design eight semi-synthetic metalworking fluids were formulated with the synthesized alkanolamides and two with the corrosion inhibitor conventionally used. After checking the thermal stability of these fluids, the corrosion inhibition efficiency was measured by staining technique of cast iron. Fluids containing alkanolamides performed better corrosion inhibition, however, was not possible to measure quantitatively the differences observed using this technique. Thus, the compounds were subjected to weight loss and potentiodynamic polarization tests in hydrochloric acid, besides the atomic microscopy to evaluate the effect of the inhibitors on the metal surface. Through these studies it was possible to demonstrate that RDIPA and RAEPD products were more efficient at inhibiting corrosion. The mechanism of inhibition of these compounds, as determined by Langmuir isotherms, is by physisorption. After checking the anticorrosive properties of the synthesized compounds, the following properties were analyzed from the formulated fluids: viscosity, foaming, contact angle, Reichert friction, alkalinity and microbiological contamination. It was observed an increase in viscosity and foaming on the concentrated fluids. However, it was found that there is no significant impact of these properties during the application of these fluids. Alkanolamides enabled an increase in lubricity and alkalinity of the formulated fluids. Additionally they reduced the corrosion rate and the susceptibility of fluids to microbiological contamination, and would make easier the treatment of the waste generated in cutting process due to their higher biodegradability.

ABSTRACT AN INVESTIGATION OF COMPACTED GRAPHITE IRON PRODUCTION BY MEANS OF THERMAL ANALYSIS TECHNIQUE AND OTHER PROCESS CONTROL WINDOWS El-mabrouk, Omar PhD, Metallurgical and Material Engineering Department Supervisor: Prof. Dr. Ali Kalkanli January 2007, 123 pages Compacted graphite irons have been proved valuable in many applications such as exhaust manifolds, hydraulic valves, and diesel engine blocks, the process of producing compacted graphite irons is not a straight forward process because of its narrow processing windows and its high sensitivity to the section thickness, treatment reaction time, pouring temperatures and charge composition. In this thesis, compacted graphite was produced with minimum variations through all section thickness and the effect of Mg/S ratio, section thickness, and treatment agents on the graphite morphology, electrical resistivity property and fracture strength at high temperatures was investigated. The range of Mg/S ratio and the section thickness was from 2/3 to 7/1 and 5 mm to 40 mm respectively. FeSiMg and FeSiMg cermish metal were used as a treatment agent. Optical metallographic method was implemented to investigate the graphite morphology change. For being a distinguishable characteristic for compacted graphite iron over ductile iron, thermal conductivity changes at high temperatures ranging from room temperature to 500 0C was examined by a suitable electrical setup in the manner of electrical conductivity changes by measuring the electrical resistance. On the other hand, due to the higher values of mechanical properties of compacted graphite iron over those of gray iron, tensile strength was also examined by means of tensile test. The relation between the compacted graphite shape and the alloy properties such as fracture strength and thermal conductivity was investigated. The most important controlling parameters to produce compacted graphite are Mg/S ratio and oxygen activity. The relation between these parameters with both fracture strength and thermal conductivity was established by means of multiple regression analysis technique.

A gestão por processos de negócio (BPM) surgiu para facilitar a integração e coesão dos diversos setores da organização, centrados em seus processos e buscando gerar maior valor ao cliente. O objetivo desta dissertação é de investigar a utilização de BPM nas organizações de pequeno, médio e grande porte do setor metalmecânico de Caxias do Sul, pertencente a um dos maiores pólos metalmecânicos do estado do Rio Grande do Sul. Uma pesquisa do tipo survey, com questionário adaptado de Paim (2007), foi aplicada numa amostra de 106 empresas. O resultado aponta que 47,2% das empresas utilizam BPM como o estilo de gestão predominante, sendo que para fomentar este estilo investiram na faixa de R$ 0,00 a R$ 100 mil nos últimos quatro anos. Na média, o grau de gestão por processos praticado pelas empresas respondentes foi de 2,98 entre o grau 1 (não pratica) e o grau 5 (pratica habitualmente). Entre os motivos pelos quais as empresas decidiram utilizar BPM destaca-se a melhoria dos processos internos (22,4%). Uma das conclusões é que mesmo as organizações que dizem utilizar gestão por processos estão numa fase de transição, migrando de uma gestão funcional. A adoção de BPM de maneira holística, como definido pela literatura, ainda não é plenamente observada no cenário desse estudo. / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-04-29T13:03:25Z No. of bitstreams: 1 Dissertacao Michele Ortobeli.pdf: 2871571 bytes, checksum: 0e18db5997ceb7f6fcd1ae95cd3ab969 (MD5) / Made available in DSpace on 2014-04-29T13:03:25Z (GMT). No. of bitstreams: 1 Dissertacao Michele Ortobeli.pdf: 2871571 bytes, checksum: 0e18db5997ceb7f6fcd1ae95cd3ab969 (MD5) / Business Process Management (BPM) emerged to facilitate integration and cohesion of different areas of an organization, which focuses on creating greater value to customer. This master thesis aims to investigate BPM application in small, medium and large metalworking companies located in Caxias do Sul, one of the largest metalworking regions of the State of Rio Grande do Sul, Brazil. A survey instrument, adapted from Paim (2007), was applied on a sample of 106 companies. Results show that 47.2% of the companies have used BPM as a predominant management style and in order to foster this style they have invested in the range of R$ 0,00 to R$ 100.000,00 in the last four years. Moreover, the average degree of BPM practiced by respondent companies was 2.98, where 1 means no practice at all and 5 indicates solid practice. Improvement of internal processes was most appointed (22.4%) as the reason why companies decided to use BPM. One of the major conclusions of the research is that even organizations that say to be involved with BPM are in a transition phase from traditional management style. The use of BPM to the fullest extent has not been observed in the scope of this research.

A gestão por processos de negócio (BPM) surgiu para facilitar a integração e coesão dos diversos setores da organização, centrados em seus processos e buscando gerar maior valor ao cliente. O objetivo desta dissertação é de investigar a utilização de BPM nas organizações de pequeno, médio e grande porte do setor metalmecânico de Caxias do Sul, pertencente a um dos maiores pólos metalmecânicos do estado do Rio Grande do Sul. Uma pesquisa do tipo survey, com questionário adaptado de Paim (2007), foi aplicada numa amostra de 106 empresas. O resultado aponta que 47,2% das empresas utilizam BPM como o estilo de gestão predominante, sendo que para fomentar este estilo investiram na faixa de R$ 0,00 a R$ 100 mil nos últimos quatro anos. Na média, o grau de gestão por processos praticado pelas empresas respondentes foi de 2,98 entre o grau 1 (não pratica) e o grau 5 (pratica habitualmente). Entre os motivos pelos quais as empresas decidiram utilizar BPM destaca-se a melhoria dos processos internos (22,4%). Uma das conclusões é que mesmo as organizações que dizem utilizar gestão por processos estão numa fase de transição, migrando de uma gestão funcional. A adoção de BPM de maneira holística, como definido pela literatura, ainda não é plenamente observada no cenário desse estudo. / Business Process Management (BPM) emerged to facilitate integration and cohesion of different areas of an organization, which focuses on creating greater value to customer. This master thesis aims to investigate BPM application in small, medium and large metalworking companies located in Caxias do Sul, one of the largest metalworking regions of the State of Rio Grande do Sul, Brazil. A survey instrument, adapted from Paim (2007), was applied on a sample of 106 companies. Results show that 47.2% of the companies have used BPM as a predominant management style and in order to foster this style they have invested in the range of R$ 0,00 to R$ 100.000,00 in the last four years. Moreover, the average degree of BPM practiced by respondent companies was 2.98, where 1 means no practice at all and 5 indicates solid practice. Improvement of internal processes was most appointed (22.4%) as the reason why companies decided to use BPM. One of the major conclusions of the research is that even organizations that say to be involved with BPM are in a transition phase from traditional management style. The use of BPM to the fullest extent has not been observed in the scope of this research.

Orientador: Angela Maria Moraes, Silvia Yuko Eguchi / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Quimica / Made available in DSpace on 2018-08-07T08:16:36Z (GMT). No. of bitstreams: 1 Capelletti_RaquelVannucci_M.pdf: 647054 bytes, checksum: c35c09b03ca4ad293e07ecb39071b2b4 (MD5) Previous issue date: 2006 / Resumo: Biofilmes são associações de espécies microbianas interdependentes, funcionando de forma complexa e coordenada como mecanismo de colonização de superfícies. Quando indesejavelmente instalados em uma planta industrial, os biofilmes contribuem para a contaminação de muitas áreas de processo, pois representam fontes de liberação e disseminação de microrganismos que podem deteriorar produtos, causando prejuízos financeiros e retrabalho, situação esta que pode ser prevenida e/ou controlada. No entanto, sua remoção representa um desafio, principalmente no que diz respeito à determinação do tipo e da dosagem adequada de biocida para este fim. Freqüentemente, a abordagem para a resolução deste problema é empírica. O presente trabalho teve por objetivo desenvolver um protocolo reprodutível para a formação de biofilmes em laboratório a partir de consórcios microbianos e a avaliação de sua susceptibilidade aos biocidas mais recomendados. Foram utilizados como inóculo microrganismos presentes em fluido de corte proveniente da indústria de usinagem de metais, por ser este um dos principais segmentos industriais sujeitos à formação de biofilmes. A metodologia adotada foi a recomendada para a utilização do dispositivo MBEC¿, um aparato amplamente empregado nas áreas médica e odontológica para o estudo de patógenos isolados, enfocando-se no estudo a influência de variáveis como tipo e concentração do inóculo, tempo e temperatura de incubação para a obtenção do biofilme e tempo de sonicação para desagregação do biofilme. Os resultados obtidos mostraram que o procedimento estabelecido para a obtenção in vitro de biofilmes foi plenamente satisfatório utilizando o inóculo constituído do fluido contaminado, e que tais biofilmes foram eficientemente erradicados na presença de biocidas não-oxidantes em concentrações 12 vezes superiores às normalmente empregadas. A temperatura de 25 ou 35°C e período de 48 h de incubação devem ser empregados para o desenvolvimento do biofilme e, para sua desagregação, recomenda-se efetuar a sonicação por 30 minutos. O isolamento das culturas puras a partir do consórcio microbiano original da amostra de fluido de corte, e o estudo dos biofilmes formados a partir das cepas isoladas não resultou na formação de biofilmes com número suficiente de células aderidas, indicando a ocorrência de seleção de cepas sem grande capacidade de adesão e de cepas fastidiosas e até mesmo não-cultiváveis, que requerem condições especiais de cultivo e que são essenciais para corresponder à flora original da amostra na formação do biofilme / Abstract: Biofilms are complex structures consisting of interdependent microbial species associations acting as surface colonization mechanism. Once undesirably installed at an industrial plant, biofilms contribute to contaminate many process areas, because they represent sources of microbial release and dissemination, which can deteriorate products, causing financial damages and work rebdoing, undesirable situations that can be controlled and/or prevented. However, biofilm removal represents a challenge, mainly referring to biocide type and dosage selection. Frequently, empiric approaches are used to solve this problem. The aim of the present work was to develop an in vitro experimental protocol for biofilm formation employing microbial consortia and to evaluate its susceptibility to recommended biocides. Microrganisms contaminating cutting fluid used in metalworking industry were employed as inoculum, since this is one of the main industrial segments subject to frequent biofilm formation. The adopted methodology was the recommended for the use of the MBEC¿ device thoroughly employed in the medical and dentistry areas for the study of isolated pathogenic microorganisms, and the study of the influence of variables such as inoculum type and concentration, incubation time and temperature for biofilm development, and sonication time for disaggregating the biofilms were focused. The achieved results showed that the established procedure for in vitro biofilm development was fully satisfactory when using the inoculum consisting of contaminated cutting fluid and that these biofilms were efficiently eradicated using non-oxidant biocide concentrations twelve times superior to those usually employed. Incubation temperature of 25 or 35°C and 48 h time period should be employed for biofilm development, while a 30 minute sonication period is recommended for disaggregating the biofilm. The isolation of the microorganisms in consortium, in the same cutting fluid, and their use for biofilm formation resulted in insufficient adhered cell numbers, indicating the occurrence of unadherent cells as well as unculturable strains, which require special culture conditions, and are essential for to reflect the original flora in the biofilm formation / Mestrado / Desenvolvimento de Processos Biotecnologicos / Doutor em Engenharia Química

A menudo las pequeñas y medianas empresas dependen en gran medida de su proceso productivo para posicionarse en el mercado. Sin embargo, son escasas las situaciones donde las empresas cuentan con los conocimientos y recursos financieros necesarios para mejorar su desempeño operativo y cumplir con los estándares de productividad. El presente artículo plantea un modelo de producción en la industria de fabricación de muebles metálicos combinando las herramientas de la filosofía Lean Manufacturing (5s, SMED y SLP) para la reducción de mayoría de las actividades que no añadan valor dentro del proceso de producción. El modelo se valida mediante una simulación del proceso de producción con los cambios planteados, en el cual se obtuvo una reducción en el lead time, a causa de la reducción de los tiempos improductivos identificados, de 6.79%. / Small and medium-sized companies often depend to a great extent on their production process to position themselves in the market. However, there are few situations where companies have the knowledge and financial resources necessary to improve their operational performance and meet productivity standards. This article presents a production model in the metal furniture manufacturing industry combining the tools of the Lean Manufacturing philosophy (5s, SMED and SLP) for the reduction of most of the activities that do not add value within the production process. The model is validated through a simulation of the production process with the proposed changes, in which a reduction in lead time was obtained, due to the reduction of identified unproductive times, of 6.79%. / Trabajo de investigación

El presente proyecto de investigación presenta como factor limitante en PYMES, la baja eficiencia de producción de cimbras con un valor del 68.48%, este valor se encuentra debajo del estándar mundial del sector industrial 75 %. Este déficit es ocasionado por la inadecuada programación de mantenimiento y ejecución de máquinas, ausencia de procedimiento en el cambio de línea, deficiente orden y clasificación de materia prima y merma en el proceso de cortado y soldadura, falta de estandarización de proceso de soldadura y responsabilidad no asignada en el control de calidad de soldadura. El impacto de la problemática se refleja en costos asociados a horas extras, costo de reprocesamiento y penalidades por demora en entregas de pedidos. El principal aporte de la investigación es el diseño del modelo mediante la adaptación de las herramientas de la filosofía de Lean Manufacturing enfocadas en una PYME como TPM, SMED, 5S, estandarización de procesos y Jidoka. El diseño propuesto presenta dos niveles, estratégico y táctico. En el nivel estratégico, mediante gestión de KPI’s y la identificación de desperdicios a través del mapa de flujo de valor (VSM) y poder eliminarlos mediante las herramientas de Lean Manufacturing. El modelo está basado en la aplicación de herramientas relacionando el nivel táctico con todos los actores de los procesos mediante el diseño de los procesos de fabricación, el diseño de métodos de trabajo y el diseño del producto. Finalmente, los procesos son evaluados para la evolución de los indicadores de cada uno de los procesos. La implementación de las técnicas mejoró la eficiencia de producción a 75%. Los indicadores fueron validados a través de la simulación del modelo, en el proceso de rolado el OEE se incrementó de 65.03% a 78.23% y el tiempo de preparación interna disminuyó en 61.53%. En el proceso de cortado se mejoró el puntaje de auditoría de 1.58 a 4.25, en escala de 5 puntos. En el proceso de soldadura el OEE se aumentó de 62.20% a 76.14%, el tiempo promedio de soldadura se aminoró en 25%, el número de cimbras reprocesadas disminuyó en 58.33% y la cantidad de cimbras aprobadas ascendió de 87% a 90%. Finalmente, los resultados de la aplicación de la propuesta resaltaron la viabilidad del proyecto desde el aspecto técnico y económico. / The present research project presents as a limiting factor in SMEs, the low production efficiency of falsework with a value of 68.48%, this value is below the world standard of the industrial sector 75%. This deficit caused by the inadequate programming of maintenance and execution of machines, absence of procedure in the change of line, deficient order and classification of raw material and reduction in the cutting and welding process, lack of standardization of the welding process and responsibility not assigned in welding quality control. The impact of the problem is reflected in costs associated with overtime, a reprocessing cost and penalties for late delivery of orders. The main contribution of the research is the design of the model by adapting the tools of the Lean Manufacturing philosophy focused on an SME such as TPM, SMED, 5S, process standardization and Jidoka. The proposed design has two levels, strategic and tactical. At the strategic level, by managing KPIs and identifying waste through the value stream map (VSM) and being able to eliminate them using Lean Manufacturing tools. The model is based on the application of tools relating the tactical level with all the actors of the processes through the design of the manufacturing processes, the design of working methods and the design of the product. Finally, the processes are evaluated for the evolution of the indicators of each of the processes. The implementation of the techniques improved production efficiency to 75%. The indicators were validated through the simulation of the model, in the rolling process the OEE increased from 65.03% to 78.23% and the internal preparation time decreased by 61.53%. In the cutting process, the audit score was improved from 1.58 to 4.25, on a 5-point scale. In the welding process, the OEE increased from 62.20% to 76.14%, the average welding time decreased by 25%, the number of reprocessed forms decreased by 58.33% and the number of approved forms rose from 87% to 90%. Finally, the results of the application of the proposal highlighted the viability of the project from the technical and economic aspect. / Trabajo de Suficiencia Profesional

La manufactura peruana ha evidenciado una demanda creciente, especialmente para el rubro metalmecánico, debido a los proyectos de inversión anunciados en los próximos años. Cabe resaltar que, el sector metalmecánico es uno de los sectores productivos más importantes ya que impulsa y dinamiza la economía del país. Por esa razón, se hizo un análisis de la situación actual del sector y se identificó que las empresas metalmecánicas presentan problemas de eficiencia en sus procesos productivos y una baja disponibilidad de sus máquinas. Bajo ese contexto, se hizo una búsqueda en la literatura para identificar diferentes herramientas que puedan eliminar el problema en casos de estudio similares. Luego, se seleccionó un caso de estudio que refleje el problema que aqueja el sector para garantizar un impacto en el mercado. Se analizaron las causas raíz del problema y las pérdidas monetarias que le generaban a la empresa para luego proponer un modelo que permita mejorar la eficiencia de la compañía. Se implementó el modelo propuesto y se verificaron las mejoras respectivas. Finalmente, se realizó una evaluación económica para verificar la vialidad del proyecto, así como sus impactos tanto internos como externos de la empresa. En ese sentido, el propósito de la investigación es proporcionar un modelo de producción basado en herramientas Lean Manufacturing para eliminar el problema identificado en el sector aplicado en un caso de estudio. En la revisión de la literatura, se ha encontrado pocos artículos de investigación sobre empresas de este sector que se hayan desarrollado en Latinoamérica, especialmente en Perú. Por esa razón, el presente estudio contribuirá a la comunidad científica latina con un nuevo sistema de producción para las empresas metalmecánicas peruanas. / The current context of peruvian manufacturing has evidenced an increasing demand, especially for the metal-mechanical sector, due to the investment projects announced for this year and next. It should be noted that the metalworking sector is one of the most important productive sectors since it drives and energizes the country's economy. For this reason, an analysis was made of the current situation in the sector and it was identified that companies in this area have efficiency problems in their production processes and a low availability of their equipment on production lines. This would bring as a consequence an unsatisfied and unsatisfactory demand which leads to a lesser amount of monetary income for Peru. In this context, an exhaustive search was made in the literature to identify different tools that can eliminate the problem in similar study cases. Then, a case study was selected that reflects the problem faced by the sector to guarantee a relevant impact on the market. The root causes of the problem and the impact it had on the company were analyzed to then propose a model that would improve the company's efficiency. The proposed model was implemented, and the respective improvements were verified. Finally, an economic evaluation was carried out to verify the viability of the project, as well as its internal and external impacts on the company. In this sense, the purpose of the research is to provide a production model based on Lean Manufacturing tools to eliminate the problem identified in the sector applied in a case study. In the literature review, few research articles have been found on companies in this sector that have developed in Latin America, especially in Peru. For this reason, our research will contribute to the Latin scientific community with a new production system for peruvian metalworking companies. / Trabajo de Suficiencia Profesional

Diploma thesis focuses on the analysis of selected process of company JOSA KOVO s.r.o. and on the detection of selected risks. Acquired knowledge from the theoretical part is utilized for the application of selected risk analysis method in the practical part. Detection of risks will be performed with the use of analysis of internal and external company environment and risk analysis method. Identified risks will be evaluated and with the use of acquired knowledge there will be made a proposal of recommendations and measures, which will lead to reduction of risks. Diploma thesis provides a comprehensive view of measuring and reducing risks in business environment, in terms of theoretical methods and also practical application for a selected company.