Diseño de manual de procesos para el mantenimiento de molinos chilenos, en la empresa Produmin S.A, mediante la aplicación de métodos y tiempos

Abstract

PRODUMIN S.A. has no documented information concerning the steps to follow to perform maintenance on the equipment of the plant. The area where most maintenance is performed is the milling area, but the lack of detailed information on the processes to be followed generates extended maintenance periods and reprocessing of those activities. Therefore, it was proposed to design a Maintenance Process Manual for Chilean mills, applying methods and times, in order to optimize maintenance activities and improve equipment efficiency. The process was developed in several stages. First, the functions of the workers and the current maintenance processes were diagnosed. In addition, a Failure Modes and Effects Analysis was made to determine the degree of criticality of the components, and the availability and Overall Equipment Effectiveness (OEE), those values were calculated for each mill. Then, the manual was elaborated, which includes detailed descriptions of maintenance processes, checklists, terminology and guidelines for preventive and routine maintenance, integrating TPM recommendations, focusing on the pillars of Autonomous Maintenance, Targeted Improvements and Scheduled Maintenance. The implementation of the manual was evaluated through single event simulations, which showed significant improvements in mill availability and OEE, in percentages ranging from 6.03% to 9.96% for availability and from 9.52% to 12.37% for OEE.