Ingeniería en Sistemas, Electrónica e Industrial
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Item Modelo de teoría de restricciones para la empresa CEPESA(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial, 2024-02) Romero Moncayo, Kevin Andre; Ortiz Guerrero, Daysi MargaritaCEPESA, a company specialized in bus seats manufacturing in Ambato, faces a challenge in its production line, identifying a bottleneck in the assembly process of seat structures. Tasks overlad for operator in charge has generated a decrease in efficiency, especially in high demand periods, affecting company's ability to meet deadlines and satisfy customer needs. Research work objective is to apply the 5 steps of the Theory of Constraints to determine and improve this bottleneck. Research project adopted a mixed, qualitative and quantitative approach. Bibliographic research was based on reliable sources, such as scientific articles and books, to theoretically and conceptually support the study. Field research involved a close relationship with the processes and people at CEPESA, facilitating obtaining of relevant information and a complete understanding of operations, supporting informed decisions and effective improvements in production performance and efficiency. Results include restriction identification through a time study, an assembly line balance and creation of a process manual as a guide for operators. Application of the theory of constraints involved a critical analysis of activities using the ILO (International Labor Organization) interrogation technique, achieving the subdivision of tasks to reduce congestion and adapt to the cycle time of the line. These actions seek to improve process efficiency and allow CEPESA to more effectively face the production challenges imposed by its demanding market.Item Teoría de restricciones para el mejoramiento de la capacidad de producción en la empresa Edy Sánchez Sport(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2022-01) Sánchez Zapata, Ana Mercedes; Tigre Ortega, Franklin GeovannyThis research project deals with the development of the Theory of Restrictions for the improvement of the productive capacity within the textile company Edy Sánchez Sport, by identifying the operational problems of the organization through a time study and thus being able to apply the DBR algorithm to achieve the mentioned improvement. In the first place, work will be carried out jointly with the company that will provide the corresponding information on the inventories and sales records of the products offered in the sports line, and in this way determine the current situation of the textile company Edy Sánchez Sport. Subsequently, with the help of the sales history, the ABC analysis is carried out, where 24 products represent 80% of the total sales in the company and the product with the highest demand corresponds to the size 36 sports sweater of the Santo Domingo Educational Unit. Guzman. Next, the description of the existing machinery within the production process will be carried out and then the process survey (cutting, preparation, packaging) will be carried out by means of the flowchart and the different activities that intervene in the production areas are described. Next, a time study is carried out for each production process based on General Electric's criteria and, based on the data obtained, the analytical flow chart is drawn up. Then we proceed with the application of the DBR algorithm derived from TOC. Through the simulation in FlexSim, an improvement percentage of 86.48% is achieved within the cutting process, increasing the production capacity to 109.26 units per hour, while in the manufacturing process the improvement is 58.29% and in the packaging no improvement was obtained. In the current and proposed process, the effective transfer rate is $9.00 and operating expenses are reduced from $4.15 to $3.94 per unit, or a 5.03% reduction per unit. product, which is verified in the financial indicator, where the net profit of the process increased by 4.30% per product with the proposed model.Item Optimización de Los procesos operativos mediante la teoría de restricciones en empresas metalmecánicas(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Maestría en Producción y Operaciones Industriales, 2021) Espín Guerrero, Ricardo David; Ortiz Sailema, Christian IsmaelThe research is about the operational processes optimization using the theory of constraints in the metal-mechanical Maquinarias Espín. Initially, delays and bottlenecks were detected in the production of wood processing machines, these aspects forced the extension of the working day. The production of the seven machines with the highest demand was considered, taking into account the information of the average monthly quantity required according to the orders of the last two years. A time study was carried out and the available resources were evaluated to quantify the use of the workstations. Two constraints were identified in hand saw cutting and turning as part of the application of the theory of constraints, with utilization ercentages of 111.82% and 105.11%, which implied an inability to meet the average monthly demand. From exploiting the constraints based on the application of the PLE to maximize the return and once everything was subordinated to them, the maximum possible monthly return was determined to be $78470, with a maximum net profit of $68362.68. However, the maximized production volume did not meet the average monthly demand, with a shortfall of 5% of circular saws and 75% of band saws. A CNC plasma cutting machine was added as well as the distribution of workers at the workstations was rearranged. It was determined that there were no longer any constraints once the actions were implemented, but the PLE was again applied to optimize production based on the available resources. These actions allowed obtaining a maximum yield of $ 87768.74, with an optimal monthly gross profit of $ 77188.10, an increase of 12.91% of the gross profit from the sale of the machines, having covered the production capacity required by the demand.Item Niveles óptimos de inventario para satisfacer demanda de clientes utilizando teoría de restricciones en la empresa Vulcano Shoes(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2020-01) Suárez Acosta, Cristian Xavier; Reyes Vásquez, John PaulEl presente proyecto busca obtener niveles óptimos de inventario a través de la metodología Tambor Cuerda Amortiguador TAC de la teoría de restricciones debido a que la empresa Vulcano Shoes presenta un manejo inadecuado de su inventario Se identifican los procesos que posee la empresa seguidamente se examina los registros históricos de ventas que ayudan en la clasificación de los productos que generen mayor rédito, de esa clasificación se halla el pronóstico de la demanda el cual brinda soporte al tambor el cual nivela el flujo de producción, después se establecen amortiguadores de inventario mismo que serán controlados a través de una gerencia de amortiguadores, finalmente se estable un sistema de pedidos especiales con el cual se controla que el stock no crezca más allá del nivel del amortiguador. Con la aplicación de la metodología TAC se establece una gerencia de inventario acorde a las 5 zonas del mismo logrando los siguientes resultados: reducción total de la zona negra que representa ventas perdidas, reducción del 100% en la zona roja, un 10% en la zona amarilla, un 25,71% de sobre inventario y un aumento de la zona verde en un 137,5% logrando un ahorro de inventario de 7.715,36 dólares al año. SUMMARY The present project seeks to have optimal levels of inventory through the methodology TAC Drum String Damper of the restriction theory because the company Vulcano Shoes presents an inadequate management of its inventory The processes that the company owns are identified, then the historical records of sales that help in the classification of the products that generate the company's revenue are examined, from that classification is the demand forecast which provides support to the drum which Levels the production flow, after inventory dampers are established, which will be controlled through a buffer management, finally a special order system is established with which it is controlled that the stock does not grow beyond the level of the buffer. With the application of the TAC methodology, inventory management is established according to the 5 inventory zones, which achieves the following results: total reduction of the black zone that represents lost sales, 100% reduction in the red zone by 10 % in the yellow zone 25.71% of over-inventory and an increase of the green zone in 137.5% achieving an inventory saving of $ 7,715.36 per year.Item Implementación de la teoría de restricciones (TOC) para reducir pérdidas de inventarios de la farmacia del Hospital IESS Ambato(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Maestría en Gestión de Operaciones, 2018) Romero Tricerri, Francisco Xavier; Pilco Salazar, Ana MaríaEl Hospital IESS de Ambato brinda atención de salud a la zona central del país, este centro hospitalario cuenta con los servicios de consulta externa, hospitalización, emergencia, intervenciones quirúrgicas. Además sus especialidades médicas son medicina interna, cardiología, nefrología, neurología, gastroenterología, psiquiatría, cirugía vascular, pediatría, odontología, farmacia entre otras. Las modalidades de seguro son: general, campesino, voluntario y jubilados. En el presente proyecto se analiza la gestión de inadecuada de las medicinas en la farmacia del hospital del IESS – Ambato, debido a la falta de implementación de un modelo de restricciones lo que ha provocado pérdidas de inventario. Para delimitar el campo de análisis e intervención se plantean objetivos uno general y específicos. La información que se obtiene es contextualizada en tres dimensiones macro, meso y micro para tener un panorama exacto de la magnitud de la realidad. La metodología de la investigación parte de la determinación del paradigma de investigación, se introduce a la observación y verificación de los sucesos existentes en la farmacia para proponer alternativas de solución. Para la gestión de los datos que se aplican técnicas e instrumentos de investigación, la encuesta dirigida a los empleados de la farmacia del hospital del IESS – Ambato y el correspondiente cuestionario estructurado con preguntas abiertas de selección múltiple. Se obtiene la necesidad de incorporar un proceso de mejora en el sistema de gestión del inventario para una mejor atención a los afiliados. Además se realiza una visita a las instalaciones de la farmacia para recabar evidencia de las falencias en la administración y como refuerzo a la encuesta. La ficha de observación describe el chequeo a la infraestructura, procesos, talento humano, e inventarios, para la determinación real de las necesidades que atraviesa esta jefatura. Como alternativa de solución se propone la implementación del modelo DBR en base a la teoría de restricciones para determinar cuellos de botella en la gestión de inventarios de la farmacia. Esta metodología innovadora en los procesos de gestión involucra a todo el personal para que ejecuten acciones de mejoramiento de sus procesos, utilizando la capacidad de análisis e interpretación de la realidad y actuar de forma inmediata, la finalidad es cumplir con las metas establecidas y dar valor agregado a los pacientes. EXECUTIVE SUMMARY He IESS Ambato Hospital provides health care to the central area of the country, this hospital center has the services of external consultation, hospitalization, emergency, surgical interventions. In addition, its medical specialties are internal medicine, cardiology, nephrology, neurology, gastroenterology, psychiatry, vascular surgery, pediatrics, dentistry, pharmacy among others. The insurance modalities are: general, peasant, volunteer and retired. The present project analyzes the inadequate management of medicines in the pharmacy of the IESS - Ambato hospital, due to the lack of implementation of a restriction model, which has caused inventory losses. To delimit the field of analysis and intervention, general and specific objectives are set. The information that is obtained is contextualized in three macro, meso and micro dimensions to have an exact panorama of the magnitude of reality. The methodology of the investigation starts from the determination of the research paradigm, it is introduced to the observation and verification of the existing events in the pharmacy to propose alternative solutions. For the management of the data that apply research techniques and instruments, the survey addressed to the employees of the pharmacy of the IESS - Ambato hospital and the corresponding structured questionnaire with open questions of multiple selection. The need to incorporate an improvement process in the inventory management system for better attention to members is obtained. In addition, a visit is made to the pharmacy facilities to collect evidence of the shortcomings in the administration and as a reinforcement to the survey. The observation form describes the check of the infrastructure, processes, human talent, and inventories, for the real determination of the needs that this headquarter goes through. As an alternative solution, the implementation of the DBR model is proposed based on the theory of restrictions to determine bottlenecks in the inventory management of the pharmacy. This innovative methodology in management processes involves all staff to execute actions to improve their processes, using the ability to analyze and interpret reality and act immediately, the goal is to meet the established goals and give value added to the patients.Item Estrategia de manufactura para el control de la producción en el área de lavado y teñido de la Fábrica Ram Jeans(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera Ingeniería Industrial en Procesos de Automatización, 2017-06) Amán Morales, Ricardo Javier; Aldás Salazar, Darwin SantiagoEsta investigación tiene como propósito realizar un estudio comparativo entre las estrategias de control de la producción tipo Pull: Kanban, Conwip y DBR, las cuales se basan en el uso de tarjetas y la teoría de restricciones respectivamente, con el fin de clarificar las diferencias existentes entre los distintos mecanismos de funcionamiento empleados por cada uno de los sistemas comparados, y además el de seleccionar la estrategia que presente un mejor desempeño en base a los parámetros de producción obtenidos. Para cumplir con el objetivo propuesto en este proyecto, se construyeron modelos de simulación utilizando el software Promodel. El estudio inicia con la identificación de las condiciones generales de los procesos del área de lavado y teñido, el cual se realiza mediante el levantamiento de procesos y estudio de tiempos, con el fin de establecer los parámetros de simulación necesarios para la elaboración de cada modelo, además se hace el uso de herramientas como los cursogramas de ensamble, analítico y diagramas de recorrido los cuales permiten establecer de una manera clara la ejecución del trabajo y el desplazamiento del producto a lo largo de la línea de fabricación. Mediante el desarrollo de la investigación, y los modelos de simulación propuestos se concluye que, la estrategia que presenta un mejor resultado respecto a los parámetros de producción establecidos es Kanban, puesto que muestra un nivel de inventario en proceso promedio de 4 lotes, un tiempo de ciclo de 6,11 horas y una tasa de producción de 0,65 lotes/hora. ABSTRACT This research aims to make a comparative study of Pull production control strategies: Kanban, Conwip and DBR, which are based on the use of cards and the theory of constraints respectively, in order to clarify the existing differences Between the different operating mechanisms used by each of the systems compared, and also to select the strategy that presents a better performance based on the production parameters obtained. In order to fulfill the objective proposed in this project, simulation models were constructed using Promodel software. The study begins with the identification of the general conditions of the processes of the washing and dyeing area, which is performed by means of the process survey and time study, in order to establish the simulation parameters necessary for the elaboration of each model, In addition to the use of tools such as assembly, analytical cursograms and travel diagrams which allow to establish in a clear way the execution of the work and the movement of the product along the manufacturing line. Through the development of the research, and the proposed simulation models, it is concluded that the strategy that presents a better result with respect to the established production parameters is Kanban, since it shows an inventory level in average process of 4 lots, a cycle time of 6.11 hours and a production rate of 0.65 lots / hour.Item Modelo TAC (Tambor - Amortiguador - Cuerda) para el abastecimiento de materia prima en la Empresa Calzado Gamo's(Universidad Técnica de Ambato. Facultad de Ingeniería en Sistemas, Electrónica e Industrial. Carrera de Ingeniería Industrial en Procesos de Automatización, 2014-11) Álvarez Rojas, Kevin Marcelo; Reyes Vásquez, John PaúlRESUMEN El proyecto de investigación se centra en elaborar el modelo TAMBOR – AMORTIGUADOR – CUERDA de la Teoría de las Restricciones ya que la empresa Calzado Gamo´s tiene gran cantidad de inventario en sus bodegas de materia prima. Se identifica a la demanda del mercado como la restricción propia del sistema para el desarrollo del plan de producción (tambor) con lo que se nivela el flujo, a continuación se agrega los materiales a la bodega central de materia prima y se establece los niveles óptimos de amortiguamiento de inventario los cuales se revisa periódicamente a través de la gerencia dinámica de amortiguadores y al final se ahoga la liberación de materiales (cuerda). El inventario se gerencia con el sistema de colores de prioridades azul (sobre stock), verde (inventario óptimo), amarillo (prevención), rojo (inventario bajo) y negro (venta perdida) y se logra reducir en 100%, 92,87% y 13,07% la zona negro, rojo y azul respectivamente y se aumenta en 5,14 y 1,14 veces las zonas verde y amarillo respectivamente. El ahorro anual de dinero en inventario es de 124.016,47 dólares americanos. ABSTRACT The research project focuses on elaborate the model DRUM - BUFFER - ROPE application of Theory of Constraints because the company Gamo´s have lot of inventory in their warehouses feedstock. First identified market demand as their own constraint system for the development of the master production schedule (drum), with this the flow is leveled, then the materials are added to the central warehouse feedstock and optimal levels of buffering are set, the buffers are reviewed periodically with dynamic buffer management and finally the release of materials (rope) drowns. The inventory management system is with priority colors: blue (excess stock), green (optimal inventory), yellow (prevention), red (low stock) and black (lost sale) and will reduce 100%, 92.87% and 13.07% the black, red and blue areas respectively and increased 5.14 and 1.14 times the green and yellow areas respectively. Saving money in inventory is U.S. $ 124,016.47.