Model of Lean tools for the reduction of waste in the manufacture of non-metallic minerals

Published in: Engineering, Integration, and Alliances for a Sustainable Development. Hemispheric Cooperation for Competitiveness and Prosperity on a Knowledge-Based Economy: Proceedings of the 18th LACCEI International Multi-Conference for Engineering, Education and Technology
Date of Conference: July 27-31, 2020
Location of Conference: Virtual
Authors: Piero Abanto (Universidad Peruana de Ciencias Aplicadas, PE)
Carlo Guzmán (Universidad Peruana de Ciencias Aplicadas, PE)
Edgardo Carvallo (Universidad Peruana de Ciencias Aplicadas, PE)
Iliana Macassi (Universidad Peruana de Ciencias Aplicadas, PE)
Christian del Carpio (Universidad Peruana de Ciencias Aplicadas, PE)
Full Paper: #171

Abstract:

The present paper presents a model that combines tools such as SLP (Systematic Layout Planning), 5´s, Standardization of methods and Preventive Maintenance for the reduction of waste in the manufacture of non-metallic minerals. This RMI (Industrial Rocks and Minerals) production sector has a high growth potential. Around 5 to 20 million tons were produced in the 70s, 80s and 90s, and it increased between 25 and 100 million tons annually in the present millennium in Peru. The problem that is sought to attack is the high amount of material that is wasted in the production process in small and medium-sized companies in that sector. With the validation carried out on our model, results of a reduction of material waste from 135.1 tons / year to 55.6 tons / year were obtained. This meant a waste reduction of 58.8%. The implementation of 5's until the standardization stage indirectly impacted the other components. The result obtained with the design redesign model was from 46.1 tons / year to 16.32 tons / year (65%), the redesign reduces the travel distances with material, which generates less waste in transport. In addition, a reduction of 35 tons / year to 10.5 tons / year (70%) is validated with the pilot testing of the definition and standardization of the prior rock breakage method. Also, the preventive maintenance pilot testing to the cyclone dust extractor, reduced the machine stops and validated than waste is reduced from 54 tons / year to 28.8 tons / year (46.7%).