Análisis de línea de producción de sacos mediante la herramienta Value Stream Mapping (VSM) en CMPC Biopackaging.
Date
2024
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
Value Stream Mapping (VSM, mapa de flujo de valor) es una herramienta de la metodología Lean, la cual tiene por objetivo reducir o eliminar los desperdicios que puedan estar presentes en cualquier proceso productivo mediante sus diferentes herramientas. El mapa de flujo de valor es una de estas herramientas que consiste en la visualización del todo el proceso productivo que se quiere estudiar, incluyendo cada etapa desde que el cliente realiza su pedido de compra hasta que el producto es despachado a él.
En esta memoria de título se aplica esta herramienta sobre una línea de producción de sacos en la Planta Sack Kraft Chillán de CMPC Biopackaging, identificando así cada una de sus etapas, sus tiempos de ciclo, materia prima y operadores que requiere. La aplicación de este análisis se debió llevar a cabo ya que en el último tiempo se han identificado constantes problemas por aumentos de costos, baja productividad de las maquinarias y desviaciones de calidad de los productos.
Un VSM conlleva tanto un flujo de valor como un flujo de tiempo, los cuáles son construidos en primera instancia con la situación actual en la cual se presenta el proceso productivo y al final se realiza la construcción del flujo, pero aplicando las mejoras identificadas como manera de visualizar la situación futura esperada. El estudio se basa en una familia de productos específica, los sacos tipo CVP (cierre valvulado fondo pegado), la cual fue seleccionada según tres criterios diferentes que fueron evaluados en una matriz de selección. Por último, la obtención de los tiempos de ciclo de cada una de las etapas de la línea se realiza en terreno para diferentes sacos pertenecientes a la misma familia.
Con la identificación de las etapas que agregan valor, se pudieron obtener variadas medidas correctivas de procesos que son valiosos y que presentaron oportunidades de mejora, y al mismo tiempo se recomendó la eliminación de ciertas etapas que no contribuían de manera positiva al proceso ni al producto.
Value Stream Mapping (VSM) is a tool from the Lean methodology, which aims to reduce or eliminate waste that may be present in any production process through its different tools. The value stream map is one of these tools that consists of visualizing the entire production process to be studied, including each stage from the moment the customer places their purchase order until the product is shipped to them. The objective of this thesis is to apply this tool to a sack production line at CMPC Biopackaging’s Sack Kraft Chillán Plant, thus identifying each of its stages, its cycle times, raw material and operators required. The application of this analysis had to be carried out since in recent times constant problems have been identified due to cost increases, low productivity of machinery and deviations in product quality. A VSM involves both a value stream and a time flow, which are built in the first instance with the current situation in which the production process is presented and in the end the construction of the flow is carried out but applying the identified improvements as a way of visualizing the expected future situation. The study is based on a specific product family, the PVC type sacks (valved closure glued bottom), which was selected according to three different criteria that were evaluated in a selection matrix. Finally, the cycle times of each of the stages of the line are obtained in the field for different bags belonging to the same family. By identifying the value-adding stages, it was possible to obtain various corrective actions of processes that are valuable and presented opportunities for improvement, and at the same time recommended the elimination of certain stages that did not contribute positively to the process or the product.
Value Stream Mapping (VSM) is a tool from the Lean methodology, which aims to reduce or eliminate waste that may be present in any production process through its different tools. The value stream map is one of these tools that consists of visualizing the entire production process to be studied, including each stage from the moment the customer places their purchase order until the product is shipped to them. The objective of this thesis is to apply this tool to a sack production line at CMPC Biopackaging’s Sack Kraft Chillán Plant, thus identifying each of its stages, its cycle times, raw material and operators required. The application of this analysis had to be carried out since in recent times constant problems have been identified due to cost increases, low productivity of machinery and deviations in product quality. A VSM involves both a value stream and a time flow, which are built in the first instance with the current situation in which the production process is presented and in the end the construction of the flow is carried out but applying the identified improvements as a way of visualizing the expected future situation. The study is based on a specific product family, the PVC type sacks (valved closure glued bottom), which was selected according to three different criteria that were evaluated in a selection matrix. Finally, the cycle times of each of the stages of the line are obtained in the field for different bags belonging to the same family. By identifying the value-adding stages, it was possible to obtain various corrective actions of processes that are valuable and presented opportunities for improvement, and at the same time recommended the elimination of certain stages that did not contribute positively to the process or the product.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Industrial.
Keywords
Procesos de producción, Productividad industrial Estudio de casos, Industria manufacturera del papel