Diante de um crescimento econômico, as empresas de maneira geral e, em particular, a indústria de manufatura, acabam procurando um meio de eliminar perdas que estão em evidência e outras que não estão tão expostas, para assim maximizar seus lucros. Este trabalho mostra uma programação de produção otimizada, de modo a aumentar a disponibilidade de um equipamento responsável em manufaturar mais de um modelo de produto. Com exigências cada vez maiores, os consumidores obrigam a indústria a variar seu mix de produção de modo a não poder mais possuir equipamentos dedicados para cada tipo de modelo produzido. Com isso, exige-se cada vez mais o uso de abordagens de pesquisa operacional para poder montar um cronograma de produção de forma mais rápida e assertiva. Não se pode deixar de considerar a influência da disponibilidade do equipamento para o bom andamento da programação da produção. Alinhado a isto ao avaliar as maiores perdas de um equipamento, verifica-se a necessidade de se reduzir seu tempo de set-up. Para que isto seja possível, é sugerida a aplicação da metodologia SMED, a qual foi criada dentro do sistema Lean Manufacturing, mais especificamente do sistema TPM. Do ponto de vista da otimização, o problema proposto é desafiador, já que há múltiplos processadores idênticos, em paralelo e o set-up entre os produtos é dependente da sequência de produção. Assim, cabe ao sistema proposto definir quanto da demanda total de cada produto será produzida em cada um dos processadores, visando a minimização do tempo total de set-up. Ou seja, os lotes de produção não têm tamanho fixo. Foi proposta uma abordagem híbrida usando regras de despacho (heurísticas) para a solução do problema proposto, com resultados satisfatórios. / Due to economic growth, companies in general – but particularly manufacturing industries - end up looking for a way to eliminate losses that are evident and others that are not so easy to identify so as to maximize profits. This project seeks for an optimal production schedule to increase the availability of a device responsible for manufacturing more than one product. With increased demands from customers, industry is compelled to vary its production mix so that it can not have equipment dedicated to each produced model type. Thus, the use of operational research approaches is more and more required to be able to set up a production schedule in a faster and assertive way. One can not stop considering the influence of equipment availability for a smoother production scheduling. Aligned with this, when evaluating the major losses at the equipment, there is a need to reduce the set-up time. To make this possible, it is suggested the implementation of the SMED methodology, which was created within Lean Manufacturing - more specifically, by TPM system. From the perspective of optimization, the proposed problem is challenging since there are multiple identical parallel processors with sequence dependent set-ups. Thus, it is up to the proposed system to define how much of the total demand for each product will be produced in each of the processors in order to minimize the total set-up time. In other words, production lots have no fixed size. It was proposed a hybrid approach using dispatch rules (heuristics) for the solution of the proposed problem that have presented satisfactory results.

This thesis deals with the optimisation of the selected manufacturing process. The aim is to analyse the effectiveness of the selected welding and assembly lines. Another objective is to do a detailed analysis for the line with the lowest efficiency in terms of cycle time and the Overall Equipment Effectiveness and calculate the lost production time due to availability, performance and defects. The third objective is to identify possible measures leading to higher utilization of manufacturing line and to propose a possible implementation. The theoretical part is based on the literature examining the term standardization, the norms of labour intensity, the cycle time, the Total Productive Maintenance and the calculation of the Overall Equipment Effectiveness. In the practical part the profile of Car manufacturing is being presented, the analysis of secondary data to calculate the Overall Equipment Effectiveness is being done and the appropriate manufacturing line for the innovative plan is being selected. Furthermore, the analysis of secondary data regarding the effectiveness of the using time of the manufacturing line is being done, the calculation of the Overall Equipment Effectiveness and the collection of primary data is being carried out. Subsequently, the problematic spots of the manufacturing line are being found and the possible measures leading to higher efficiency of manufacturing line are being proposed.

This master thesis deals with position of the maintenance in the company structure and with modern management approaches. One of the highest levels of maintenance is the proactive maintenance, which is using the technical diagnostics to find out the causes of failures. The most inportant in case of machines are vibrodiagnostics and thermodiagnostics, which are going to be applied on the motors in company Bosch Diesel s.r.o.

The diploma work deals with measurement of Production Overall Equipment Effectiveness in manufacturing company Alfa. Firstly, is processed the theoretical part concerning general production, TPM, lean manufacturing and OEE. After than is described the company, monitored device and technology used by the device. In the final section is evaluated the OEE for January, February and March; analyze downtimes, mistakes and losses and their solutions are proposed. The last chapter is devoted to the economic evaluation of the proposal.

En el presente trabajo se especifican los resultados alcanzados al implementar un sistema de gestión de mantenimiento basado en Lean Manufacturing para una empresa de papel y cartón en el área de mantenimiento y dentro del proceso de fotocopia, el cual tiene como objetivo general, elevar el nivel del servicio al cliente interno y brindar una ventaja competitiva a la organización; y como objetivos específicos, elevar el nivel de disponibilidad operativa, reducir los costos de mantenimiento e incrementar la producción en la línea fotocopia. En primer lugar, se realizó un análisis y diagnóstico de la situación actual de la empresa, se identificó diversos problemas que demostraron que la gestión de mantenimiento es llevada de manera deficiente, la cual es percibida mediante la subutilización de los recursos humanos, económicos, materiales y de maquinaria. En segundo lugar, se optó por utilizar la metodología Lean Manufacturing, la cual previamente fue analizada a través de la matriz PHP dando como resultado un 77% de priorización frente a la metodología Lean Six Sigma, a fin de lograr la eficiente gestión de mantenimiento. Finalmente, con la implementación de la metodología Lean Manufacturing se logró elevar el nivel de disponibilidad operativa de 87.9% a 96.9%, reducir los costos de mantenimiento correctivo en un 84%, e incrementar la productividad en un 96%. En conclusión, la implementación de la metodología Lean Manufacturing en el área de mantenimiento en el proceso de Fotocopia resulta ser viable y eficiente para la mejora de procesos dentro de la organización. / This document specifies the results achieved by implementing a maintenance management system based on Lean Manufacturing for a paper and cardboard company in the maintenance area and within the photocopying process, which has the general objective of raising the level of internal customer service and providing a competitive advantage to the organization; and the specific objectives of raising the level of operational availability, reducing maintenance costs and increasing production on the photocopying line. Firstly, a diagnosis and analysis of the current situation of the company was carried out, identifying various problems that showed that maintenance management is deficiently carried out, which is perceived through the underutilization of human, economic, material and machinery resources. Secondly, it was decided to use the Lean Manufacturing methodology, which was previously analyzed through the PHP matrix, resulting in a 77% prioritization against the Lean Six Sigma methodology, to achieve efficient maintenance management. Finally, with the implementation of the Lean Manufacturing methodology, it was possible to increase the level of operational availability from 87.9% to 96.9%, reduce corrective maintenance costs by 84%, and increase productivity by 96%. In conclusion, the implementation of the Lean Manufacturing methodology in the maintenance area in the photocopying process is viable and efficient for the improvement of processes within the organization. / Trabajo de Suficiencia Profesional

El siguiente trabajo de investigación se realizó en una empresa de la industria plástica que se dedica a la inyección y soplado de productos plásticos. Durante el análisis del área de Producción se observa que la empresa tiene una demanda insatisfecha de 206.84Tn mensuales en promedio de material plástico procesado, para determinar el problema se evalúa el OEE de la producción y se encuentra en 50.9%, el mismo está por debajo de una empresa de clase mundial que tiene 68.5% (Ames et al., 2019), al revisar los componentes del OEE (disponibilidad, rendimiento y calidad) se encuentra que la disponibilidad es la más baja con 65.5%. De esta manera, se determina que el problema es la baja disponibilidad de las máquinas inyectoras de plástico. Para determinar las causas se evalúa las horas de trabajo de las máquinas, en ella se encuentra un exceso de horas parada con 189,498.16 horas. Esto debido a tres áreas: Mantenimiento, Matricería y Planta Inyección que representan el 75% con 64,150.00h, 45,184.00h y 32,846.16h respectivamente. Las principales causas son: Fallas eléctricas, hidráulicas y electrónicas, fallas en los moldes del sistema de refrigeración, calefacción, expulsión, demoras en la regulación y cambio de molde. El impacto económico de estas causas es de $4, 518,583.63 anuales que representa el 24.25% del margen anual. Nuestra propuesta es implementar la metodología Lean Manufacturing y sus herramientas de ingeniería tales como: 5S como pilar de todas las herramientas, TPM con mantenimiento preventivo, autónomo y predictivo para las máquinas y moldes, el SMED para reducir los tiempos de cambio de molde y estandarización de procesos. / This research work was carried out in a plastic company engaged in the injection and blow molding of plastic products. During the analysis of the Production area, it is noted that the company has an unsatisfied demand of 206.84 Tn per month on average of processed plastic material. In order to determine the problem, the OEE of the production is evaluated and it is found to be at 50.9 %, which is below a world class company that has 68.5 % (Ames et al., 2019). When reviewing the components of the OEE (availability, performance and quality), it is found that the availability is the lowest with 65.5 %. Along these lines, it is determined that the problem is the low availability of plastic injection molding machines. In order to determine the causes, the working hours of the machines are evaluated, in which there is an excess of 189,498.16 hours downtime. This is due to three areas: Maintenance, Tool and Die Making and Injection Plant, which represent 75 % with 64,150.00 h, 45,184.00 h and 32,846.16 h, respectively. The main causes are: Electrical, hydraulic and electronic faults, defects in the molds of the cooling, heating and ejection systems, delays in the regulation and mold change. The economic impact of these causes is $4,518,583.63 per year, which represents 24.25 % of the annual margin. Our proposal is to implement the Lean Manufacturing methodology and its engineering tools such as: 5S as a pillar of all tools, TPM with preventive, autonomous and predictive maintenance for machines and molds, SMED to reduce mold changeover times and standardization of processes. / Trabajo de Suficiencia Profesional

This master’s thesis is focused on an analysis and data evaluation of effectiveness of tool machines and their maintenance. There is a description of a technical production handling in the first part of the theoretical section. In the second part one of the most productive options to increase the productivity of the machine maintenance is described, and so it is the TPM (total productive maintenance). The practical part consists of an analysis of given dates and their evaluation for company needs. Recommendations and suggestions for the improvement are presented at the end of the thesis.

Master thesis is focused on the study of effectiveness of selected machines in the company through indicators of Overall Equipment Effectiveness. The aim is to increase productivity of machinery by monitoring machine run. Analyses are performed on selected machines which are found out downtimes reducing machine run. Methods and tools of lean manufacturing are used for determine downtimes as a core part. Specifically, the implementation of the first phase of TPM – “Total Productive Maintenance” which is used in manufacturing, for determine current status of machines. Maintenance of machinery is also referred in the master thesis as important part of Overall Equipment Effectiveness. Individual factors of OEE are identified as a result of these analyses which are directly affected to productivity of machines. The output of these analyses is to design countermeasures against each downtime and system design of monitoring tools including technical and economical evaluation. Machine monitoring with automatic data collection based on calculated data is suitable option for the company.

Esta investigación desarrolla un modelo de gestión para el área de mantenimiento de una empresa de panadería. Las técnicas utilizadas son los 3 pilares del Total Productive Maintenance (TPM), mantenimiento autónomo, mantenimiento planificado y mejora continua, integrado con la metodología Reliability Centered Maintenance (RCM) para proponer un plan de mantenimiento preventivo. El objetivo es aumentar la disponibilidad de una línea de producción y reducir los costos de mantenimiento. El caso de estudio analiza principalmente una línea de panadería cuyos equipos tiene una alta tasa de paradas. Para validar los efectos del modelo se desarrolla un sistema de simulación de la línea de producción que incluye el porcentaje de producción perdida por fallas y los tiempos de parada de la máquina. Los resultados mostraron un aumento en la disponibilidad de línea en un 9,72% y un ahorro del 35% en los costos anuales de mantenimiento. / This research develops a management model for the maintenance area of ​​a bakery company. The techniques used are the 3 pillars of Total Productive Maintenance (TPM); autonomous maintenance, planned maintenance and continuous improvement, integrated with the Reliability Centered Maintenance (RCM) methodology to propose a preventive maintenance plan. The goal is to increase the availability of a production line and reduce maintenance costs. The case study mainly analyzes a bakery line whose equipment has a high stop rate. To validate the effects of the model, a simulation system of the production line is developed that includes the percentage of production lost due to failures and machine downtime. The results showed an increase in line availability by 9.72% and a saving of 35% in annual maintenance costs. / Trabajo de investigación

En este proyecto se plantea una alternativa para mejorar la gestión de mantenimiento del área producción de la Empresa Construcciones Metálicas Unión S.A.C., incorporando las herramientas del TPM para incrementar la efectividad global del equipos OEE, aumentando la taza de calidad, taza de disponibilidad y taza de rendimiento, así mismo esto ayudara a reducir el alto índice de productos no conforme en el proceso de pintura, bajando el nivel actual de costos y reprogramaciones. El primer capítulo, mostramos el desarrollo de los conceptos que contempla nuestro marco teórico, como las metodologías y algunas herramientas que traten sobre la gestión de mantenimiento, enfocándonos en “Mantenimiento Productivo Total” (TPM) básicamente en los pilares del Mantenimiento Autónomo y Planificado. En el siguiente capítulo se muestra el diagnóstico de la situación actual en el proceso de pintura, empleando información proporcionada por el área de producción de la empresa, con esta data se llega a identificar el problema raiz y las causas de este. En el tercer capítulo, se diseña y desarrolla la propuesta de gestión del mantenimiento en el área de pintura, aplicando el TPM. El cuarto capítulo comprende la verificación de la propuesta usando el simulador Arena, lo cual ayudara a la evaluación de los escenarios para las decisiones y ejecución de la alternativa planteada. Finalmente, en el último capítulo se realiza las recomendaciones y conclusiones. / In this project an alternative is proposed to improve the maintenance management of the production area of ​​the Construcciones Metálicas Unión SAC Company, incorporating the TPM tools to increase the overall effectiveness of the OEE equipment, increase the quality rate, availability rate and rate performance, also this will help reduce the high rate of non-conforming products in the painting process, lowering the current level of costs and reprogramming. The first chapter, we show the development of the concepts that our theoretical framework contemplates, such as methodologies and some tools that deal with maintenance management, focusing on "Total Productive Maintenance" (TPM) basically on the pillars of Autonomous and Planned Maintenance. The next chapter shows the diagnosis of the current situation in the painting process, using information provided by the company's production area, with this information it is possible to identify the root problem and its causes. In the third chapter, the maintenance management proposal in the painting area is designed and developed, applying the TPM. The fourth chapter includes the verification of the proposal using the Arena simulator, which will help to evaluate the scenarios for the decisions and execution of the proposed alternative. Finally, in the last chapter the recommendations and conclusions are made. / Trabajo de Suficiencia Profesional