Implementación plan piloto de gestión de mantenimiento para el taller de diseño y fabricación de prototipos funcionales del centro metalmecánico Sena

Abstract

The project is built from the need to implement a management model maintenance of assets, design workshop and manufacturing of functional prototypes; of the SENA metalworking center, based on the different philosophies that are disseminated in the world and the transformations that industrial maintenance has had. Thus, the object of this project is to design a pilot maintenance management plan adapted to the high management levels that ensure the availability and provision of the service. The project is divided into phases of which the first begins with a review bibliographical background on industrial maintenance. The second phase It focuses on making the needs and problems of the workshop known. By On the other hand, the third phase represents the bulk of the project since it is in this where designs the pilot maintenance management plan based on the information collected in the previous ones. In this way, the third phase is divided into three other subphases. where the bases of different philosophies are applied. Trust-centered maintenance or RCM was applied as a basis for the pilot plan of maintenance management, where an analysis of criticality versus complexity was made of the workshop equipment to value the assets that due to hierarchy and less complexity has priority to allocate the resources they require. The result of that were the EMCOMAT 17D conventional lathe, the Pinacho SC 200 conventional lathe and the ZX6350ZA universal milling machine. In that sense, according to the philosophy of the RCM, the functions primary and secondary aspects of systems, technologies and equipment components previously related in order to clarify the ways in which each one can fail. This served as input to evaluate the probability of risks of failure of the respective components (risk probability number) in the analysis matrix of failure modes and effects. Thus, the result of this analysis indicated that 91% of the components of the lathe EMCOMAT have low risk of failure and only 9% have medium risk. for the lathe Pinacho SC 200 the scenario is similar since 90% of the components have low probability of failure risk and 10% medium probability. And for the milling machine ZX6350ZA 70.3% of components have medium risk probability of failure while the remaining 29.7% have medium risk. With this panorama, they considered recommended actions based on preventive maintenance and tools of the total productive maintenance to improve the NPR of each of the components. With the above, the tools were built to support the management plan of RCM-based maintenance from total productive maintenance (or by its acronym in English TPM). However, due to the needs of the workshop, only implemented the first two pillars of the TPM which correspond to improvement focused and autonomous maintenance. This was done in order to get used to the work cooperative and the involvement of apprentices (SENA students), teachers and instructors in workshop maintenance management. As a result of the fusion of both philosophies; RCM and TPM, in their main bases, Technical sheets and diagnostic formats for low-risk critical equipment were prepared. Complexity, equipment condition checklists, a manual and semi-automatic tools, reporting cards and anomaly control, a profiling of the skills of collaborators who make regular use of the workshop services to finally have trained personnel to carry out the autonomous maintenance tasks through the CIL methodology (Cleaning, inspection and lubrication). Finally, the conditions were raised to formulate and implement in the future a trending philosophy that requires high technological capital and monitoring tools such as condition-based maintenance (CBM). For its acronym in English), a type of maintenance that fuses RCM with controls engineering to predict when an asset will fail. As the fourth phase of the project, the respective maintenance plans were formulated to each critical low-complexity piece of equipment, consolidating and taking into account the considerations of both maintenance philosophies; RCM and TPM, and the products that resulted from each one, where a maintenance schedule was added susceptible to changes in order to be faithful to the rhythm that the workshop has been working. Additionally, maintenance specialties, tasks, and frequencies were uploaded to the MANTUM maintenance management software used in the workshop, all in order Create resumes and maintenance alerts when necessary. Finally, the fifth phase basically represents the motive.