Reducción del tiempo de ciclo del subensamble de motores de una empresa automotriz de la ciudad de Quito

Abstract

The automotive industry is very important within the economy of Ecuador, for this reason the Ecuadorian government launches the "Popular Truck" program which consists of exempting the tax on Special Consumption (ICE) when acquiring trucks at cheaper prices and assembled in the country. This project focuses on the quantitative analysis of 40.1% of the variable time that contains waste and activities that do not add value to the product in the operations of assembling an engine, thus reducing the cycle time in the motor subassembly section. of the company General Motors - Ómnibus BB. In order to meet the challenge posed, the use of lean manufacturing and continuous improvement tools was proposed to determine all operations that do not add value, associated waste and that are those that cause low productivity, high costs and reduce competitiveness. Through the implementation of action plans, it was possible to meet the main objective, to improve the initial cycle time from 2474.59 to 2084.54 seconds, which represents a 15.76% improvement. In addition, a new Actual Takt Time (ATT) of 246 seconds was established, which allows the engine production capacity to be increased by 2 units, achieving a significant improvement in productivity from 0.85 to 0.46 man-hours per unit corresponding to the 54.55% improvement in this metric. This helped in the reduction of 11.2 percentage points of waste and activities that do not add value to the motor sub-assembly, which represents a 27.93% improvement. In short, due to the actions taken, a reduction of $ 5.35 dollars per unit produced was achieved, which represents an 18.67% improvement in the cost per unit, which multiplied by the number of units produced will result in a saving of $ 91,662. $ 19 a year, this represents a lower structural price for the area, since it ranges from $ 28.68 to $ 23.33 for each unit manufactured.