Evaluación técnico-económica de la implementación de grúas estacionarias en el sistema de alimentación de Aserradero El Colorado – Arauco.
Loading...
Date
2024
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
Universidad de Concepción
Abstract
El rubro forestal es una actividad económica relevante para la región del Biobío y presenta una oportunidad de desarrollo. Este proyecto tiene como objetivo evaluar la viabilidad técnica y económica de reemplazar el uso de una grúa móvil en el Aserradero El Colorado de Arauco. La problemática surge ante la necesidad de optimizar los costos operativos y considerando la disponibilidad de grúas estacionarias tras el cierre de la planta Horcones II. La metodología consistió en varias etapas: Se realizó un estudio de la operación actual, enfocándose en el análisis de fallas en la zona de alimentación. Este análisis permitió identificar las funciones críticas y las soluciones actuales. Luego, se procedió a registrar en terreno cada interrupción del proceso con precisión temporal y se identificaron las zonas críticas de intervención dentro del aserradero. Con esta información, se propuso un diseño que incluye la instalación de dos grúas estacionarias en ubicaciones estratégicas, considerando un análisis técnico que abarcó la compatibilidad operacional, el alcance de las grúas y las restricciones de espacio. Además, se desarrolló un modelo de simulación en Flexsim para analizar los impactos en la producción bajo diferentes escenarios operativos, incorporando variables clave como el ajuste de la velocidad de los feeders y la distribución de probabilidad de interrupciones. Los resultados del estudio técnico indican que la implementación de las grúas estacionarias es viable, siempre y cuando se realice un ajuste en el ritmo de alimentación de los feeders a 21 trozos por minuto. La simulación mostró que, sin este ajuste, la producción disminuiría hasta un 16%, con pérdidas mensuales de hasta $300 millones en escenarios con diámetros de trozos de 14 a 20 cm. En contraste, al optimizar el ritmo de alimentación, se logra mantener el mismo nivel de producción que con la grúa móvil, garantizando la eficiencia operativa. Desde un punto de vista económico, el análisis de costo-beneficio mostró que: la implementación de grúas estacionarias presenta un Valor Actual Neto (VAN) de $327.647.825, una Tasa Interna de Retorno (TIR) del 108%, y un periodo de recuperación de la inversión de 11 meses. Comparativamente, el costo presente de mantener la grúa móvil es significativamente mayor en 25 años, alcanzando $1.011 millones, mientras que la opción de las grúas estacionarias se estima en $169 millones en valor presente. Esto se traduce en una reducción del Costo Anual Equivalente (CAE) del 84%. El análisis de sensibilidad mediante simulación Montecarlo ratifica la robustez del proyecto, con un VAN promedio de $332 millones y una TIR promedio de 110% bajo escenarios conservadores. En conclusión, la sustitución de la grúa móvil por grúas estacionarias en el El Colorado no solo es técnica y económicamente factible, sino que resulta en una solución altamente rentable que asegura la sostenibilidad operativa a largo plazo.
The forestry sector is a significant economic activity in the Biobío region and presents an opportunity for growth. This project aims to assess the technical and economic feasibility of replacing the use of a mobile crane at Aserradero El Colorado in Arauco. The issue arises from the need to optimize operational costs and considers the availability of stationary cranes after the closure of the Horcones II plant. The methodology involved several stages: first, a study of the current operations was conducted, focusing on analyzing failures in the feeding area. This analysis identified critical functions and existing solutions. Next, each process interruption was recorded in the field with precise timing, and the critical intervention zones within the sawmill were identified. Based on this information, a design was proposed that includes the installation of two stationary cranes in strategic locations, considering a technical analysis covering operational compatibility, crane reach, and space constraints. Additionally, a simulation model was developed in Flexsim to analyze production impacts under different operating scenarios, incorporating key variables such as the adjustment of feeder speed and the probability distribution of interruptions. The technical study results indicate that implementing stationary cranes is feasible, provided the feeder speed is adjusted to 21 logs per minute. The simulation showed that without this adjustment, production could decrease by up to 16%, leading to monthly losses of up to $300 million in scenarios with log diameters ranging from 14 to 20 cm. In contrast, optimizing the feeding speed maintains the same production level as the mobile crane, ensuring operational efficiency. From an economic perspective, the cost-benefit analysis revealed that the implementation of stationary cranes offers a Net Present Value (NPV) of $327,647,825, an Internal Rate of Return (IRR) of 108%, and a payback period of 11 months. In comparison, the present cost of maintaining the mobile crane over 25 years is significantly higher, reaching $1.011 billion, while the stationary crane option is estimated at $169 million in present value. This results in an 84% reduction in the Equivalent Annual Cost (EAC). Sensitivity analysis using Monte Carlo simulation confirms the project’s robustness, with an average NPV of $332 million and an average IRR of 110% under conservative scenarios. In conclusion, replacing the mobile crane with stationary cranes at El Colorado is not only technically and economically feasible but also a highly profitable solution that ensures long-term operational sustainability.
The forestry sector is a significant economic activity in the Biobío region and presents an opportunity for growth. This project aims to assess the technical and economic feasibility of replacing the use of a mobile crane at Aserradero El Colorado in Arauco. The issue arises from the need to optimize operational costs and considers the availability of stationary cranes after the closure of the Horcones II plant. The methodology involved several stages: first, a study of the current operations was conducted, focusing on analyzing failures in the feeding area. This analysis identified critical functions and existing solutions. Next, each process interruption was recorded in the field with precise timing, and the critical intervention zones within the sawmill were identified. Based on this information, a design was proposed that includes the installation of two stationary cranes in strategic locations, considering a technical analysis covering operational compatibility, crane reach, and space constraints. Additionally, a simulation model was developed in Flexsim to analyze production impacts under different operating scenarios, incorporating key variables such as the adjustment of feeder speed and the probability distribution of interruptions. The technical study results indicate that implementing stationary cranes is feasible, provided the feeder speed is adjusted to 21 logs per minute. The simulation showed that without this adjustment, production could decrease by up to 16%, leading to monthly losses of up to $300 million in scenarios with log diameters ranging from 14 to 20 cm. In contrast, optimizing the feeding speed maintains the same production level as the mobile crane, ensuring operational efficiency. From an economic perspective, the cost-benefit analysis revealed that the implementation of stationary cranes offers a Net Present Value (NPV) of $327,647,825, an Internal Rate of Return (IRR) of 108%, and a payback period of 11 months. In comparison, the present cost of maintaining the mobile crane over 25 years is significantly higher, reaching $1.011 billion, while the stationary crane option is estimated at $169 million in present value. This results in an 84% reduction in the Equivalent Annual Cost (EAC). Sensitivity analysis using Monte Carlo simulation confirms the project’s robustness, with an average NPV of $332 million and an average IRR of 110% under conservative scenarios. In conclusion, replacing the mobile crane with stationary cranes at El Colorado is not only technically and economically feasible but also a highly profitable solution that ensures long-term operational sustainability.
Description
Tesis presentada para optar al título de Ingeniero Civil Industrial
Keywords
Aserradores forestales, Estudio de factibilidad, Evaluación económica Investigaciones