Improvement proposal to increase the oee in a mechanical press in the metalworking sector through SMED and TPM

Abstract

El sector metalmecánico es uno de los impactan en mayor medida al Perú, poseyendo el 25.9% de la PEA de industria manufacturera. Por ello mismo, es vital aprovechar al máximo la disponibilidad de sus máquinas. En el caso de estudio, se identificó que una empresa perteneciente a este sector contaba con un OEE del 56.39%. Esto generaba que, mensualmente, la organización tuviera una pérdida económica de $55,892.85. Esto era provocado por numerosas fallas de máquina y un deficiente set up. Para solucionar ello, se propuso un modelo que combina las herramientas TPM y SMED, con un soporte de la herramienta 5S. De este modo, se logró incrementar el OEE a 88.45% y reducir los tiempos de set up de un valor inicial de 24.09 a 12.85 minutos. Además, se logró aumentar la disponibilidad en un 40.58%. Por otro lado, es importante indicar que se realizó una evaluación económica en la que se logró demostrar que al cabo de un año se obtuvo un VAN de $99,286.89, un TIR de 67% y un periodo de recuperación de 4 meses y 13 días. Cabe resaltar que el presente modelo propuesto fue validado por medio del software de simulación Arena.

The metalworking sector is one of the industries that has more impact on Peru, representing 25.9% of the manufacturing industry's workforce. Therefore, it is crucial for them to approach the biggest availability possible for its machines. In this case study, it was identified that a company that belonged to this sector had an OEE (Overall Equipment Efficiency) of 56.39%. This resulted in a monthly economic loss of $55,892.85, caused by numerous machine failures and a deficient set-up process. A model that combined TPM (Total Productive Maintenance) and SMED (Single-Minute Exchange of Die) methodologies was proposed to solve the issue, supported by the 5S tool. As a result, the OEE increased to 88.45%, and the set-up time was reduced from an initial value of 24.09 to 12.85 minutes. Additionally, the availability was increased by 40.58%. Furthermore, it is important to note that an economic evaluation was done, showing that after one year, a Net Present Value (NPV) of $99,286.89 was achieved, with an Internal Rate of Return (IRR) of 67% and a payback period of 4 months and 13 days. Finally, it is worth mentioning that the proposed model was validated using a simulation through Arena software.