Desarrollo de estrategias de mantenimiento para la gestión de equipos críticos a través de análisis de confiabilidad en la empresa CMPC Pulp planta Santa Fe.
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Date
2025
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
La presente memoria de título tiene como objetivo desarrollar una metodología estructurada que permita definir estrategias de mantenimiento para equipos críticos A de Planta Santa Fe que actualmente no cuentan con una estrategia asociada. El trabajo comprende la consideración de impacto económico y productivo, herramientas basadas en análisis de confiabilidad y validación mediante metodología FMECA, acorde tanto a normativa nacional, internacional y estándares internos de planta.
Inicialmente, se verifica el análisis de criticidad realizado por la UC&GA de planta, seleccionando equipos de alta criticidad (A) que no presenten plan de mantenimiento asociado. Posteriormente, se analizan las estrategias y directrices de mantenimiento presentes actualmente, detectando brechas y oportunidades de mejora.
Con el fin de caracterizar el historial de falla de los equipos seleccionados, se aplica el modelo de Weibull, el cual responde con parámetros como: confiabilidad, tasa de falla, MTBF, MTTR, β y η, lo que permite visualizar y caracterizar las fallas de cada activo. Además, con el fin de priorizar activos de manera mas técnica se consideran análisis de Pareto y Jack Knife.
De esta manera, se seleccionan equipos representativos para Planta Santa Fe los cuales son analizados mediante FMECA, lo que permite identificar modo de falla, causa, efecto, severidad, detectabilidad, impacto, entre otros, definiendo así estrategias de mantenimiento basadas en la metodología RCM.
Finalmente, se estimaron indicadores clave de desempeño, tales como disponibilidad operativa y tasa de falla, así como también se propuso que, una vez evaluada la metodología por parte de planta, se estimaran la confiabilidad y disponibilidad de los activos en cuestión, lo que permite evaluar la efectividad de la metodología desarrollada.
En base a lo anterior, la memoria de título concluye que es posible caracterizar detalladamente el comportamiento de falla por equipo, lo que conlleva directamente a priorizar activos de manera estratégica y definir estrategias de mantenimiento efectivas, lo cual contribuye no tan sólo a una toma de decisiones alineada con lineamientos internos, sino también con la gestión de activos.
This thesis aims to develop a structured methodology for defining maintenance strategies for critical A equipment at the Santa Fe Plant, which currently lack an associated maintenance plan. The work includes economic and production impact assessments, the use of reliability-based analysis tools, and validation through the FMECA methodology, all in accordance with national and international standards, as well as the plant's internal guidelines. The process begins by reviewing the criticality analysis conducted by the plant's UC&GA team, identifying high criticality (A) equipment without an existing maintenance strategy. The current maintenance strategies and guidelines are then analyzed to identify gaps and opportunities for improvement. To better understand the failure history of the selected equipment, the Weibull model is applied. This model provides key parameters such as reliability, failure rate, MTBF, MTTR, β, and η, allowing for a clear characterization of each asset’s failure behavior. Additionally, Pareto and Jackknife analyses are used to technically prioritize the assets. Representative equipment for the Santa Fe Plant is then selected and analyzed using FMECA. This allows for the identification of failure modes, causes, effects, severity, detectability, impact, and more ultimately enabling the development of maintenance strategies based on the RCM methodology. Finally, key performance indicators such as operational availability and failure rate are estimated. The methodology proposes that, once reviewed by plant personnel, reliability and availability metrics be calculated for the selected assets to assess the effectiveness of the developed approach. In conclusion, this thesis demonstrates that it is possible to accurately characterize failure behavior at the equipment level. This enables the strategic prioritization of assets and the definition of effective maintenance strategies, contributing not only to decision making aligned with internal guidelines but also to broader asset management efforts.
This thesis aims to develop a structured methodology for defining maintenance strategies for critical A equipment at the Santa Fe Plant, which currently lack an associated maintenance plan. The work includes economic and production impact assessments, the use of reliability-based analysis tools, and validation through the FMECA methodology, all in accordance with national and international standards, as well as the plant's internal guidelines. The process begins by reviewing the criticality analysis conducted by the plant's UC&GA team, identifying high criticality (A) equipment without an existing maintenance strategy. The current maintenance strategies and guidelines are then analyzed to identify gaps and opportunities for improvement. To better understand the failure history of the selected equipment, the Weibull model is applied. This model provides key parameters such as reliability, failure rate, MTBF, MTTR, β, and η, allowing for a clear characterization of each asset’s failure behavior. Additionally, Pareto and Jackknife analyses are used to technically prioritize the assets. Representative equipment for the Santa Fe Plant is then selected and analyzed using FMECA. This allows for the identification of failure modes, causes, effects, severity, detectability, impact, and more ultimately enabling the development of maintenance strategies based on the RCM methodology. Finally, key performance indicators such as operational availability and failure rate are estimated. The methodology proposes that, once reviewed by plant personnel, reliability and availability metrics be calculated for the selected assets to assess the effectiveness of the developed approach. In conclusion, this thesis demonstrates that it is possible to accurately characterize failure behavior at the equipment level. This enables the strategic prioritization of assets and the definition of effective maintenance strategies, contributing not only to decision making aligned with internal guidelines but also to broader asset management efforts.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Mecánico/a.
Keywords
Mantenimiento de plantas industriales, Confiabilidad (Ingeniería), Celulosa