Optimización del flujo de materiales con enfoque esbelto para la industria carrocera

Abstract

EXECUTIVE SUMMARY This research project proposes materials flow optimization through the redistribution of areas for the bodywork manufacturing process. Three groups of areas are identified: processes, subassemblies and warehouses according to layout. For each process, the product maintains a fixed position and it is inferred that in this type of production the support areas: subassemblies and warehouses must have an adequate location so that travel distances are shorter and travel times and wait decrease. The analysis begins with the survey of process flow and the identification of the amount of materials that moves per area in which it is observed that finished, covered and structured have high concentration of material flow. Subsequently, the general route and by areas are diagrammed, distance vs. intensity diagrams in which the main transport relationships that must be approached are identified and with the use of a waste identification diagram this analysis is condensed into a single graph. The project proposes the use of FlowPlanner as a factory design evaluation tool in which the level of traffic is visualized and a new distribution is proposed based on five principles of material flow. FlowPlanner studies the design from three premises, flow between areas, flow through aisle and level of congestion in which it is observed that warehouse 2 must have a central location and the subassembly areas can be unified. Total distance between areas for one unit bodywork goes from 570,2 m to 509,7 m with a reduction of 10,61 percent. The annual results show a reduction of 46 percent in distance traveled, travel time changes from 206,85 h to 144,69 h, cost of trips is reduced by 30 percent with a saving of $ 3108,3 and a reduction of 32 percent for the average travel time per material between related areas.