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

La presente investigación desarrolla un sistema de trabajo que deriva de dos casos de éxito de implementación de la herramienta Mantenimiento Productivo Total (TPM) de la metodología Lean Manufacturing y la metodología de Estandarización del trabajo para el proceso de mantenimiento de intercambiadores de calor en la empresa RINTUSAC. Al analizar dicho proceso, se observó que existía incumplimiento en el tiempo de entrega de los intercambiadores de calor al cliente, lo que ha ocasionado disminución de pedidos. Al analizar las demoras, se detecta que existen dos causas principales. La primera, es la falta de una estandarización en el trabajo durante el proceso de mantenimiento. En segundo lugar, se evidencia que las hidrolavadoras se malogran de manera inopinada. Se consiguieron mejoras importantes como es la disminución del tiempo de ciclo, la producción por turno aumentó, la productividad y la eficiencia crecieron además de reducir los costos y tiempo en el mantenimiento de los equipos. / The objective of this investigation is the development of a working system for the maintenance process of industrial radiators in RINTUSAC. The working system derives from two successful implementations of the tools Total Productive Maintenance to the Lean Manufacturing Methodology and Standardized Work Methodology. It was observed that there was a failure in the estimated delivery timing which had led to a reduction of orders. When analyzed, the delays responded to two principal causes: the first one being the lack of working standardization during the maintenance process; and the second, the evidence of pressure washers going unexpectedly out of service. It was possible to obtain important improvements such as the shortening of the cycle timing, the production per shift increased and the productivity and efficiency escalated while the costs and time of maintenance of machinery decreased. / Trabajo de Suficiencia Profesional

The aim of this report is to analyse the use of the capacity at the CNC (computer numerical control) cutters and show how the level of set up time for these cutters at Stålöv AB. This assignment is concrete whereas there are no subjective questions to this matter and there are only cold figures presented. Production economy is getting more important as the competition hardens and there are several different ways to increase productivity and efficiency in a company. In order to increase productivity and efficiency work studies are used to, through an analysis, find developments in methods that result in improved work methods and to establish the time that are used. Increased production of different parts and customer driven production in combination with increased demands on rationalisation of capital have led to an enlarged interest for shorter set up times in the production. To point out the use of capacity and the set up time of the cutters at Stålöv AB we used frequency studies. Frequency studies are work measure methods based on random observations on predetermined events to calculate the relative occurrence of these events. The purpose is to present the objective cold figures that show the use of capacity for all machines and totally. The compilation of the seven CNC cutters shows that the use of capacity reaches 33 %. The lack of machine operators is the single largest reason, 45 % of the total use of capacity. The set up time reaches 6 % totally of the 36 hours of observation of the machines. The study of the separate CNC cutters shows that the result follows the result of the compilation of all machines; the main reason why the use of capacity is low depends on the lack of machine operators. This means that if the demand increases there will not be enough operators to meet this demand. If using SMED, the set up time percentage share of the total use of capacity are too large, but the production of prototypes that supplies great value to the company may justify the set up times. By using Total Productive Maintenance (TPM), based on the elimination of breakdowns and defective products, the stability in production and the use of capacity may increase.

<p>The aim of this report is to analyse the use of the capacity at the CNC (computer numerical control) cutters and show how the level of set up time for these cutters at Stålöv AB. This assignment is concrete whereas there are no subjective questions to this matter and there are only cold figures presented.</p><p>Production economy is getting more important as the competition hardens and there are several different ways to increase productivity and efficiency in a company. In order to increase productivity and efficiency work studies are used to, through an analysis, find developments in methods that result in improved work methods and to establish the time that are used. Increased production of different parts and customer driven production in combination with increased demands on rationalisation of capital have led to an enlarged interest for shorter set up times in the production.</p><p>To point out the use of capacity and the set up time of the cutters at Stålöv AB we used frequency studies. Frequency studies are work measure methods based on random observations on predetermined events to calculate the relative occurrence of these events. The purpose is to present the objective cold figures that show the use of capacity for all machines and totally.</p><p>The compilation of the seven CNC cutters shows that the use of capacity reaches 33 %. The lack of machine operators is the single largest reason, 45 % of the total use of capacity. The set up time reaches 6 % totally of the 36 hours of observation of the machines.</p><p>The study of the separate CNC cutters shows that the result follows the result of the compilation of all machines; the main reason why the use of capacity is low depends on the lack of machine operators. This means that if the demand increases there will not be enough operators to meet this demand.</p><p>If using SMED, the set up time percentage share of the total use of capacity are too large, but the production of prototypes that supplies great value to the company may justify the set up times.</p><p>By using Total Productive Maintenance (TPM), based on the elimination of breakdowns and defective products, the stability in production and the use of capacity may increase.</p>

This dissertation is focused on a research of using methods of Lean Production in working environment of selected companies in the Czech Republic. In the introduction the author mentioned theoretic facts about Lean Production, which is originally from Japan. The rest of dissertation also included characteristics of selected companies and description of situations in companies before and after using Lean Production methods. At the end of each part we can find conclusion and suggestion of specific new steps for these companies. A company, called Linde Pohony s.r.o. Český Krumlov, have been using these methods: TPM, 5S and visual management. In a company Rohde & Schwarz, which is located in Vimperk, have been using the methods of Lean Production. : Kanban and also visual management. And a company ČSAT a.s. Praha have been testing methods of Lean Production: MUDA, 5S, Kaizen with a diagram of Ishikawa. In conclusion of the dissertation assumptions were evaluated. The overall summary of exercising Lean Production in companies - Linde Pohony s.r.o. Český Krumlov, ČSAT a.s. Praha a Rhode & Schwarz - Vimperk, were mentioned as well. Outcomes of the dissertation can be used for companies, which had been analyzing or for other companies with similar specializations. The dissertation provides the analysis of utilization selected Japanese principles of Lean Production in Czech companies.

Diplomová práce se zabývá problematikou zvyšování produktivity pomocí metody štíhlé výroby zvané Lean. V dnešní době je potřeba udržet si přízeň zákazníka a finanční prosperitu firmy. Právě štíhlá výroba se zaměřuje na spokojenost zákazníka a na zvýšení finančního přínosu firmě, tím, že se snaží odstranit plýtvání, která se vyskytují v procesu. Lean Six Sigma je metoda, která se zaměřuje na spokojenost zákazníka (Lean) a na zdokonalování procesů (Six Sigma). Jejím cílem je zvýšit kvalitu a zároveň snížit náklady a dobu dodání. První část diplomové práce se zabývá nástroji štíhlé výroby a detailně popisuje metody, které budou použity v praxi. V praktické části diplomové práce byly využity nástroje Lean Six Sigma především metoda DMAIC, která je označována za systematický přístup k řešení problémů. Skládá se z pěti částí: definování, měření, analýza, zlepšení a kontrola.

The purpose of this thesis is to implement Total Productive Maintenance (TPM) in Nigeria Plastics Manufacturing Company. Manufacturing companies round the world pay huge amount of money for purchasing new equipments to boost their production however nothing or little is done to achieve or obtain full output from the machine for which it is intended to do. Small losses in time or deviations from planned or calculated capability are taken as usual machine performance. But currently as a result of improved capability levels and demand of quality product at lower prices, purchasing latest machine/equipment is not a way out unless it is completely used. Total Productive Maintenance (TPM) is a method that involve everybody totally, from high management to all workers to implement a complete maintenance program for all machine/equipment during its life. This method ends up in most effectiveness of tools, equipment, virtuously improved workers, tidy up working area, neat and clean working environment. A structure is going to be developed with the potential of evaluating the impact of implementing total productive maintenance within. By evaluating the result or outcome of Total Productive Maintenance (TPM), manufacturing companies can create sensible/smart decisions to improve the potency and standard of the machine, equipment and also the product on XYZ Plastics Manufacturing Company in Nigerian.

Actualmente, las empresas de alimentos en el Perú presentan una serie de deficiencias internas que contribuyen a la aparición de problemas críticos, como es el caso de los productos defectuosos. Por ello, la presente investigación propone un modelo de mejora para reducir el índice de defectos en la fabricación de productos alimenticios, mediante la estandarización del trabajo y la aplicación de herramientas del TPM. Asimismo, este modelo es desarrollado bajo un enfoque de Gestión del Cambio, con el fin de eliminar la resistencia de los trabajadores frente al cambio en su cultura laboral. La efectividad del modelo fue validada mediante una simulación con el Software Arena, obteniendo como principal resultado la reducción del porcentaje de defectos de 23.5% a 12.5%, en la empresa del caso de estudio. Esto permite concluir que el desarrollo de la propuesta mejora la calidad de la producción, lo que a su vez representa una oportunidad para obtener mayores ingresos para la empresa. / Currently, food companies in Peru have a series of internal deficiencies that contribute to the appearance of critical problems, such is the case of the defective products. Therefore, this research proposes an improvement model to reduce the rate of defects in the manufacture of food products, through the standardization of work and application of TPM tools. Likewise, this model is developed under a Change Management approach, in order to eliminate the resistance of the workers against the change in their work culture. The effectiveness of the model was validated through a simulation with the Software Arena, obtaining as the main result the reduction of the percentage of defects from 23.5% to 12.5%, in the company of the case study. This allows to conclude that the development of the proposal improve the quality of production, which in turn represents an opportunity to obtain higher income for the company. / Trabajo de investigación

El presente trabajo plantea una simulación ante el problema de imprevistos a lo largo de la línea de los ductos que transporta el gas de Camisea que causa pérdidas económicas a la empresa mantenedora “TECHINT”, a la empresa concesionaria del transporte “TGP” y al Estado Peruano. La metodología seguida ha sido la revisión del número de ocurrencias recopiladas en un horizonte de tiempo de 2 años, esto fue comparado con una simulación en el sistema Arena bajo un modelo de mejora basada en 6 pilares del TPM y OEE, Los resultados con la mejora propuesta, evaluada en un año, arrojan un aumento del indicador con una disponibilidad promedio de 74,04%, un rendimiento promedio de 85,8% y una calidad promedio 50% de los equipos, obteniendo un indicador OEE promedio del 83,01%, el cual se genera como resultado del producto de los valores mensuales de la disponibilidad, rendimiento y calidad / The present work proposes a simulation of the problem of unforeseen events along the pipeline line that transports Camisea gas, which causes economic losses to the maintenance company "TECHINT", to the transport concessionaire "TGP" and to the Peruvian State. The methodology followed has been the review of the number of occurrences collected in a time horizon of 2 years, this was compared with a simulation in the Arena system under an improvement model based on 6 pillars of TPM and OEE. The results with the proposed improvement, evaluated in one year, show an increase of the indicator with an average availability of 74.04%, an average performance of 85.8% and an average quality 50% of the equipment, obtaining an average OEE indicator of 83.01%, which is generated as a result of the product of the monthly values of availability, performance and quality. / Trabajo de Suficiencia Profesional

El presente trabajo plantea una simulación ante el problema de imprevistos a lo largo de la línea de los ductos que transporta el gas de Camisea que causa pérdidas económicas a la empresa mantenedora “TECHINT”, a la empresa concesionaria del transporte “TGP” y al Estado Peruano. La metodología seguida ha sido la revisión del número de ocurrencias recopiladas en un horizonte de tiempo de 2 años, esto fue comparado con una simulación en el sistema Arena bajo un modelo de mejora basada en 6 pilares del TPM y OEE, Los resultados con la mejora propuesta, evaluada en un año, arrojan un aumento del indicador con una disponibilidad promedio de 74,04%, un rendimiento promedio de 85,8% y una calidad promedio 50% de los equipos, obteniendo un indicador OEE promedio del 83,01%, el cual se genera como resultado del producto de los valores mensuales de la disponibilidad, rendimiento y calidad. / The present work proposes a simulation of the problem of unforeseen events along the pipeline line that transports Camisea gas, which causes economic losses to the maintenance company "TECHINT", to the transport concessionaire "TGP" and to the Peruvian State. The methodology followed has been the review of the number of occurrences collected in a time horizon of 2 years, this was compared with a simulation in the Arena system under an improvement model based on 6 pillars of TPM and OEE. The results with the proposed improvement, evaluated in one year, show an increase of the indicator with an average availability of 74.04%, an average performance of 85.8% and an average quality 50% of the equipment, obtaining an average OEE indicator of 83.01%, which is generated as a result of the product of the monthly values of availability, performance and quality. / Trabajo de Suficiencia Profesional