Improving the Loading Process in a Ready-Mix Concrete Production Plant Using Industry 4.0 Principles (#2272)

Authors

Valdivia Yajo, Silvie Giuvesky

Vera Mayta, Christian Alejandro

Zuñiga Torres, Juan Carlos

Paredes Aguilar, Lizbeth Leonor

Abstract

Urban and infrastructure development implies an increased demand for ready-mix concrete. Small companies producing ready-mix concrete must optimize their operations to improve productivity and meet demand. In this sense, our research applies the principles of Industry 4.0 to process monitoring, automation, and technical assistance to improve the productive efficiency of the material loading process in a ready-mix concrete plant. The methodology includes a literature review, field observation, and interviews with operating personnel. This information allowed the researcher to redesign the materials loading process, integrating monitoring technologies, such as the GPS Logger, to record operating times. In addition, a metal hopper was implemented to automate and facilitate the mixing of materials, and subsequently, employees were trained in the redesigned process using Industry 4.0 technologies. We validated the solution through a 15-day pilot test, which showed a reduction in cement loading time from 9 minutes and 59 seconds to 3 minutes and 33 seconds, reducing material waste by 3.5%. Reduced the total material loading time from 42 minutes to 36 minutes per mixer, increasing daily production by 22% and improving operating efficiency by 42.6%. The economic evaluation confirmed the project's feasibility, with an NPV of S/. 23,020.73, a C/B ratio of 1.79 and an IRR of 22.22%, recovering the investment in only five months. These results demonstrate that the proposal optimizes processes and increases the company's competitiveness, paving the way for significant growth in daily production.