Tesis Ingeniería Industrial
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Item Reducción de desperdicios en la empresa “Calzado Gamo's” mediante herramientas de manufactura ajustada.(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2025-02) Iglesias Sánchez Alison Lizbeth; Naranjo Chiriboga Israel ErnestoThe company Calzado GAMO'S has significant waste in its production process, causing economic and resource losses that affect its operational efficiency. The objective of this research project was to analyze waste in the production process and propose operational plans based on lean manufacturing tools for its reduction. The methodology used included a comprehensive diagnosis of the company through interviews with the production manager, surveys of workers in the production process, and a time study applied to the product proposed by the company, the CAT boot. This helped with developing the current VSM, where a takt time was determined to be 1.20 minutes per pair. The shaving area was identified as the bottleneck, in addition to detecting wastes inherent to lean manufacturing. Through a criticality matrix, three main wastes were selected: defects, reprocesses, and unnecessary movements, quantifying 1,479 defects that generated 3,556.31 minutes in reprocesses and 14,435.93 meters of unnecessary movements. As a result, three operational plans were developed with implementation guidelines and performance indicators to address waste. The first manual addresses TPM, seeking to increase equipment efficiency from 76.56% to 95%. The second focuses on Poka Yoke to reduce defects by 60%, while the third seeks to minimize unnecessary movements by 30.03% through point-of-use storage and visual factory.Item Diseño de la metodología Lean Logistics para la gestión eficiente del proceso de despacho en la distribuidora Dismar(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08) Mayorga Zapata, Adrián Gustavo; Naranjo Chiriboga, Israel ErnestoDispatch process management at Distribuidora DISMAR faces significant challenges that impact operational efficiency and customer satisfaction. The central problem lies in the existence of activities that do not add value to the final customer, as well as the presence of waste such as waiting times, unnecessary movements, and defects in the process. Therefore, this project objective is to design a Lean Logistics based methodology to tackle these challenges and improve the dispatch process management at DISMAR. To achieve this objective, a methodology that included identifying non-value-adding activities, designing Lean tools such as Value Stream Mapping (VSM), Kaizen, and JIDOKA was employed, as well as evaluating and selecting specific solutions to enhance the dispatch process. Main results show a significant improvement in process efficiency, with reductions in waiting times, unnecessary movements, and defects. Additionally, specific solutions were implemented, such as warehouse layout redistribution, automated billing software introduction, proper warehouse signage, and the use of barcode reading equipment to avoid defects during product selection. These solutions proved effectiveness in optimizing the dispatch process. Regarding transportation, the initial monthly cost was reduced by 58.88%, from $1,627.13 to $669.19; the initial monthly waiting cost was reduced by 51.46%, from $250.23 to $128.77 and the time spent was reduced by 51.48% compared to the initial situation. Additionally, estimated annual savings from implementing the proposed solutions is $13,040.52, which justifies cost of proposals amounting to $1,200.40. These results highlight the effectiveness of Lean Logistics methodology as a solid foundation for optimizing processes and achieving more efficient management at DISMAR.Item Desarrollo de la metodología lean Healthcare como estrategia de mejora y reducción de desperdicios en la bodega de medicina y farmacia del IESS Ambato(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-08) Gallo Sánchez, Marlon Andrés; Naranjo Chiriboga, Israel ErnestoIn investigating the wastes at the Instituto Ecuatoriano de Seguridad Social (IESS) Ambato, specifically the request for medications outside the scheduled dispatch day in the medicine warehouse and errors in the preparation of medication cassettes in the inpatient pharmacy such as medications requiring others for administration, indicated but not prescribed medications, or under-dosing the aim is to develop the Lean Healthcare methodology as a strategy for improvement and waste reduction in both areas of IESS Ambato. Through analysis of orders, reports, and medication documentation from March and April 2024, coupled with a time study, a Value Stream Map (VSM) was created to evaluate the current situation. Various quantifications of wastes employed Pareto diagrams and U control charts for analysis. Among the wastes identified in both areas were defects, unnecessary transportation, waiting times, and overproduction (exclusively in the pharmacy). To mitigate these issues, manuals were developed explaining the use of tools such as poka-yoke for defects, the 5S methodology with continuous flow for waiting times, and kanban for unnecessary transportation and overproduction. The implementation of the Lean Healthcare methodology is an effective strategy to identify and eliminate these wastes, potentially reducing waiting times by an estimated 13% and minimizing errors in medication preparation and distribution by approximately 7%. Through the application of Lean tools, the aim is to improve operational efficiency and medical care for patients.Item Estudio de tiempos y movimientos para la mejora de la productividad en la Empresa Lácteos Crelac(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-02) Tello Quinteros, Juan Sebastian; Ortiz Sailema, Christian IsmaelEl proyecto de investigación se realizó en la empresa lácteos Crelac. Inicialmente, se describió a la empresa y mediante un análisis realizado a cada línea de producción se identificó que el queso fresco de 900 gramos era el producto más viable. enfocando así el estudio para su línea de producción. Para la mejora de la productividad se siguieron 4 etapas principales. La primera etapa consistió en conocer la situación actual de la empresa mediante el levantamiento de procesos. En la segunda etapa el estudio de tiempos y movimientos permitió calcular el tiempo estándar y establecer una capacidad de producción de 12 lotes diarios. Para la tercera etapa se realizó un diagnóstico a través del VSM donde se identificaron desperdicios como esperas, movimientos y transportes innecesarios. La cuarta etapa involucró propuestas de mejora como: cursogramas analíticos propuestos para optimizar actividades, balanceo de líneas para equilibrar las cargas de trabajo lo que redujo los tiempos muertos de 75.92 minutos a 13.14 minutos y elevó la eficiencia de producción del 67.41% al 90.51%, y la implementación de las 5S para lograr un entorno de trabajo limpio y organizado. Estas propuestas tuvieron como objetivo reducir los desperdicios identificados en la línea de producción de queso fresco 900 gramos. Finalmente se realizó un análisis de la mejora obtenida donde se determinó un aumento en la capacidad de producción a 13 lotes por día, esto se traduce en un aumento de la productividad del 8.3% pasando de 144 quesos por hora a 155 quesos por hora.Item Metodología lean manufacturing en los procesos productivos de la empresa Confecciones Deportivas Piscis(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-02) Santiana Navarrete, Kevin Stalin; Ortiz Guerrero, Daysi MargaritaThis research project focuses on developing Lean Manufacturing methodology in production processes at Confecciones Deportivas PISCIS company, proposing solutions based on specific tools and methodologies to optimize production. The most profitable product was identified from a survey of information, using analytical cursograms to describe activities, in the time study the General Electric method was applied and the timing back to zero for characterizing the current situation through the creation of the value chain map (VSM), identifying critical areas and opportunities for improvement. Through direct observation analysis, critical wastes were defined as defects, overproduction, and waiting times. Their causes were quantified to establish opportunities for improvement and through a bibliographic review allowed the selection of optimal tools such as JIDOKA, KAIZEN, TPM, and 5'S. These tools application generated corrective actions to eradicate production defects, an increase in OEE to 63.31%, and with the 5'S methodology a standardized work method was achieved, improving product quality and customer satisfaction. This systematic approach seeks to increase efficiency and competitiveness in the textile sector.Item Modelo Lean & Green para la mejora del desempeño operacional y ambiental en el proceso de faenamiento del camal frigorífico municipal de Ambato (CFMA)(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-03) Usiña Lema, Evelin Anabel; Franklin Geovanny Tigre Ortega, Franklin GeovannyThe objective of the research work is to design a Lean & Green model for the process of slaughtering cattle of the Camal Frigorífico Municipal de Ambato (CFMA), the presence of Lean Manufacturing waste can affect the consumption of resources and generation of environmental aspects. Through the literature, the convergence of Lean concepts and green paradigms is confirmed, specifically in the reduction of waste and resource consumption. The research work has a qualitative-quantitative approach, flowcharts, synoptic and analytical cursograms are made, in addition the measurement of the process times according to the General Electric table is developed, establishing preliminary samples with the use of a stopwatch using the zero turn method, to identify and analyze the current situation of the process. Based on the obtained data, the takt time, lead time is calculated to create the Value Stream Mapping (VSM). In addition, the waste identified are unnecessary movements, defects and waits, which influence the consumption of water and electricity, which are considered as Green waste. The Lean & Green model is integrated by the tools VSM, ACV (Life Cycle Analysis), 5S, KPIs, which allow the diagnosis, analysis and evaluation of the process. The results of the integration of both approaches allow to obtain improvements such as: reduction of the cycle time 26.86 minutes to 22.92 minutes, in addition the water consumption decreases from 2212.90 liters to 1749.36 liters of water per bovine and electric energy 1138.13 kWh per month to 978.86 kWh per month. It is concluded that analyzing the process through Lean & Green improves operational and environmental parameters using tools from both approaches simultaneously, however, depending on the situation of the company, its application requires standardized processes and resource consumption monitoring for each line of work.Item Mejora de la productividad mediante herramientas de manufactura esbelta en la producción de helados(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-03) Oña Toaza, Edgar Esteban; Tigre Ortega, Franklin GeovannyActivities that do not add value to the final product and directly affect the productivity of a company are considered waste, this is due to the lack of control or monitoring methods. Lean Manufacturing is a methodology that focuses on minimizing waste through the tools you have at your disposal, it is based on three steps which are: selection, identification and reduction or elimination. The Ivonndy Ice Cream company, is looking for new techniques that allow it to improve its production processes and manage resources efficiently. The main objective of this project is to propose Lean Manufacturing tools that improve productivity in the single flavor ice cream line, based on the selection of the most indemand product using the ABC methodology, the study of times allowed to determine which processes restrict the productive capacity, the value stream mapping (VSM) was used to identify wastage and finally a proposal was developed with the tools: 5S and standardized work. An implementation guide was developed for the 5S tool and formats for control and monitoring were established, as for the standardized work tool, improvements were evidenced by combining some activities, as for the operations ratio, a significant increase of 16.90% and 24.81% was observed in relation to time and the use of standardized worksheets was proposed, which will help as a guide to the workersItem Manufactura esbelta como metodología para reducir desperdicios en el proceso de faenamiento de ganado bovino del Camal Municipal de Ambato(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-03) Muylema Heredia, Henry Ramiro; Naranjo Chiriboga, Israel ErnestoThe lean manufacturing methodology is an excellent way to reduce waste by identifying, measuring and controlling it. Several companies have made use of this methodology that encompasses all those involved in the processes of an organization, generating as a product an organized and standardized culture. The Municipal slaughterhouse of Ambato, dedicated to the slaughter of large and small cattle, has seen the convenience of improving its processes in relation to existing waste, time in its processes, standardization of its activities. The objective of this research project is to propose improvement proposals through the application of tools belonging to the lean manufacturing methodology to mitigate or eliminate waste related to this methodology such as: unnecessary transports and movements, waiting times, defects, over-processing, within the processes of cattle slaughtering. For which a collection of information of the current slaughtering processes is developed with the help of industrial engineering tools, thus knowing which are the activities, tools, machines, personnel and current documentation used. Additionally, by means of a time study, the standard time of each of the processes was obtained as well as their respective cursograms and plant layout. These times are used for the development of the current VSM, with which the waste and activities that really add value in the production process can be identified in order to subsequently establish the most critical waste through a Pareto diagram with the use of tools such as the 5'S used to maintain order, cleanliness and discipline; TPM to maintain the equipment and tools in an optimal state to avoid plant stoppages and defects. To reduce the time of some critical processes, activities such as knife affiliation were eliminated and the proposal to acquire a pneumatic skinning machine was also made, reducing the slaughter time per bovine from 8.77 min to 6.01 min. Likewise, for traceability, improvements have been proposed in the activities, developing a process diagram for the same.Item Análisis de los niveles de desperdicio desde la perspectiva de lean manufacturing en la empresa Renova(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-03) Freire Guevara, Jonathan Santiago; Naranjo Chiriboga, Israel ErnestoThis research project is based on classic Lean Manufacturing wastes analysis that are present in production processes at RENOVA Company and is focused on proposing an action plan through Lean Manufacturing philosophy tools and methodologies application contemplated in a manual that allows the resources optimization, achieving a better productive flow and greater efficiency in the products delivery to final customer. From sales history between January and October of 2022 and through an ABC analysis the most profitable product was known, on which the information gathering of existing processes was carried out and later a time study was developed for the current VSM trace that allowed to determine initial production plant situation, where the present wastes were known as: defects of which 44% were associated to the machine factor and 56% to the human factor; reprocesses with a higher incidence of stitch jumps with 23.44% compared to the other causes; unnecessary movements by the warehouse and docking operator adding a total of 52.53% of unproductive time; waits mostly in the warehouse for finished product with 67.25% and inventory where a total of 240 garments were detected in season at the end of November. Through a cause analysis, improvement opportunities were established for each identified waste, which were complemented by a literature review of the advantages and contributions of each tool for its subsequent selection, resulting in the following methodologies: JIDOKA, TPM, APU and HEIJUNKA. By tools applying, a reduction in defects per unit percentage is established, an increase in the overall efficiency index of the equipment of 40.94%, a reduction of displaced meters of 72.86%, and finally, the elimination of waits and inventories by producing what is necessary in required time which brings an improvement of 77.27% in product delivery days to the final customer.Item Análisis de la metodología lean manufacturing para mejorar el proceso de faenamiento en el Camal Frigorífico Municipal de Ambato (CFMA)(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2023-03) Córdova Montero, Danny Javier; Gavidia García, José LuisThe activities that do not generate value, cause waste that may be present in the processes and that affect productivity, therefore, this research project focuses on the development of an analysis of the Lean Manufacturing methodology in the process of slaughtering pigs of the Camal Refrigerófico Municipal de Ambato (CFMA), since, the company does not have tools that allow it to diagnose, reduce or eliminate unproductive activities. The research has a quantitative approach, based on the calculation of numerical variables with the application of diagnostic, operational and monitoring tools of the Lean Manufacturing methodology. An initial diagnosis of the process was made, with the collection of information, using Industrial Engineering tools such as: process diagram and analytical course, describing activities, machines and inputs. A time study was developed to identify abnormalities of each process, by determining the number of samples by General Electric and timing of the activities with the back to zero method, to design a current VSM as a Lean Manufacturing diagnostic tool identifying: the activities, the times that add value and not to the process Waste was determined as: censing movements, incorrect waiting and processes, in addition, the potential causes of waste, to propose solutions with the operational tools, proposed as: 5S for the order and cleanliness of the areas, eliminating activities that do not add value to the process, and standardization to propose the reduction of incorrect processes based on work instructions and simulate them in the FlexSim 2019 program. It is concluded that the process has 30.35% of activities that do not add value to the process and affect productivity. Therefore, the process does not meet the company's specifications and improvement actions are required.