Redução do tempo de paradas não programadas: estudo de caso em uma empresa de mineração.

Abstract

Companies are constantly looking for alternatives to increase their profitability and efficiency in the market. For this, it is necessary to have competitive prices and reduce errors, rework, and machine downtime without compromising the company's image or generating high costs. Therefore, the focus is to ensure maximum product quality amidst the growing demand for excellence driven by competition. In this sense, quality is an essential strategy for the survival of organizations. In this context, quality tools enable the organization of the production process, and efficiency in all its stages is an element of competitiveness for contemporary companies. Therefore, this study aimed to reduce the time of unscheduled downtime in the mills of a mining company. To this end, the faults that led to longer downtimes were identified, and measures were proposed to reduce or eliminate them. To this end, the ABC Curve was created to classify the criticality of failures in mill components according to their impact on unscheduled downtime. Next, the Fault Tree (FTA) was created to identify the fundamental causes of Class A failures, and the Failure Mode and Effect Analysis (FMEA) was structured to evaluate the Risk Priority Number and identify the actions necessary to minimize failures. Finally, to resolve the basic root causes researchers create a maintenance plan and apply Standard Operating Procedures. The main results achieved with the suggested improvements were reduced spending on corrective maintenance, increased reliability and availability of equipment, and improved customer service standards.