INTRODUCTION

This work is done in order to put knowledge into practice.

acquired in the subject of Administration and maintenance of the
industrial engineering career and accordingly plan the
maintenance to a company, apply an analysis to achieve a
reliability-centered maintenance and perform a root cause analysis
of a failure.

The company subject of this work "PANADERIA LOS ARBOLITOS" has

opened its doors to our work with our commitment to
to use the images and information collected for purposes
exclusively educational and with no intention of causing any harm
to his good name.

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 OBJECTIVES

Recognize and establish the different methods to carry out a

maintenance plan.
Recognize the criticalities of the assets to develop a plan for
maintenance.
Take into account the procedures and user manuals for
reduce the most common failures in a maintenance plan.
Design and propose an execution plan for maintenance
taking into account and complete clarity the vision, mission, and policy
of the company's quality.
Use the necessary tools to perform a
reliability-centered maintenance.
Use root cause analysis for troubleshooting and achieving
reliability of a team.

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1.- MAINTENANCE PLAN

Through this maintenance plan, it is intended to execute a series of

actions to conserve and improve the productive system of the
BREADSHOP THE LITTLE TREE

1.1 PRODUCTION SYSTEM

The company subject to this maintenance plan is 'BREAD SHOP EL'

"ARBOLITO," whose owner and manager is Mr. Juan Antonio López,
a company with 10 years of experience in the port of Salina Cruz
Oaxaca whose production process is linear, consisting of a
series of machines whose aim is the production of bread and pastries.
This company is framed by:

VISION: To position itself in the local market and be recognized for

its quality and service.

MISSION: Generate employment to improve the quality of life at the local level,
satisfying the needs of the community.

To achieve efficient production, the company has (see annex)

A maid
A roller
A cutter
A blender
Three ovens.

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One of these teams is currently undergoing maintenance.
fault.

1.2 RECORDS.

These records are designed to collect initial information from

the machinery and equipment that the company has, we find them
in annex B.

1.3 MAINTENANCE STRATEGY.

According to the production required by the company "BAKERY THE

"ARBOLITO" the criticality of the machinery has been determined.
next way:

Criticality 1: mixer, cylinder and oven

Mixer: its function is to make the mixture completely.

homogeneous and smooth for pastry. ABSOLUTELY

NECESSARY. Your maintenance strategy will be predictive.
and preventive.
The cylindrical machine: its function is to knead and soften the mixture to

make the bread. ABSOLUTELY NECESSARY. Your strategy

maintenance will be predictive and preventive.
Oven: its function is to bake bread at an appropriate temperature.

ABSOLUTELY NECESSARY. Your strategy of

maintenance will be preventive.
Criticality 2: cutter
Cutter: its function is to cut the dough into equal portions
to ensure production is uniform. NECESSARY. Its
The maintenance strategy will be preventive.

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Criticality 3: wetting agent
oMojadora: its function is to mix the ingredients to make
the mass: NOT ESSENTIAL. Its maintenance strategy
it will be predictive and preventive.

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1.4 MAINTENANCE PLAN

This plan aims to reduce the high probability of failure that

they present the teams found at 75% since in them
evidences the lack of maintenance; as well as reducing costs of
services at 20% as substandard conditions are evident
such connections that are not in optimal conditions, which generates
overcosts in electricity, lack of electrical controls technically
suitable for machines, in addition to working with expensive equipment that fails

what generates unplanned production downtime with its

corresponding downtime and the cost overruns of replacing parts
or the same machines which would represent 60% of the investment
initial in machinery, taking into account its depreciation and service
borrowed.

Executing this maintenance plan requires a firm commitment from

the administration since it requires hiring for work or
contracted work of an electromechanical maintenance technician for
that I carry out the activity on the established days and schedule.

The maintenance strategy, taking into account the parameters and

previously mentioned conditions according to the machinery to
to intervene would be:

Roller machine: it is rated 1 therefore it will be done.

an initial preventive maintenance in which it is necessary
establish minimum operating parameters since it is not
lacks card, plate or manual, in this maintenance it is
necessary

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General and thorough cleaning of the engine casing;
the rollers and the kneading sheets will also be made but
a degreaser will be used that allows for cleaning without leaving

harmful waste for health since they are parts of

contact with food.
Cleaning and lubrication of the engine.

Inspection, replacement, and registration of the engine bearings.

Inspection, change and/or lubrication of the bearings
support points of the rollers (bearings).
Inspection and determination of the useful life of the belt.

Review and isolation of the electric cut mechanism with

recommendation for a change to a command unit type and
control panel with built-in start and stop push button.
Every three months, maintenance of type will be carried out.

estimate in which the variables will be monitored

motor electricals (voltage, current, power), this is
it will be tabulated and sent to the maintenance manager for

determine modifications to the maintenance plan.

Every year predictive maintenance will be carried out on the
an electrical insulation test of the motor will be conducted,
this will be tabulated and sent to the maintenance manager
to determine modifications to the maintenance plan.
Every six months preventive maintenance will be carried out.

grease bearings and moving parts.

Annual preventive maintenance will be carried out with
replacement of parts (bearings, ball bearings, belts,
pulley), this subject to required modifications or
recommended in the predictive maintenance stage.

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1.5STORE

For the realization of this maintenance plan, it is suggested that the

hiring of an electromechanical maintenance technician; for the

the amount of machinery and its limited specialization
recommend keeping a small spare parts inventory with the
next elements.

WAREHOUSE
REPLACEMENT EQUIPMENT MAX.
B90 BELT 2 1 1
BEARING 6205 2 1 1
BEARING 6203 2 1 1
POWER ON/OFF BUTTON 2 1 1
ADJUSTMENT SPRING ACCESSORIES 2 1 1
GAS FLOW REGULATOR KNOB 2 1 1
HOSE CONNECTOR 1/2" 4 2 2
1/2" HOSE FOR GAS OF 2 METERS 4 1 1

ELEMENTS REQUESTED BY UNPLANNED DEMAND:

ELECTRICAL SYSTEM RESET BUTTON

5" PULLEY
2" BEARING

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1.6 EVALUATION

This maintenance plan is subject to modifications and adjustments by

therefore it is not a defined procedure, but a guide subject to improvement.
The adjustments should be made taking into account the data collected.
through the predictive and preventive maintenance carried out and with the
administration authorization.

Reliability-Centered Maintenance

In the pursuit of achieving increased availability and reliability

and the maintainability of the company's productive system BAKERY THE
LITTLE TREE, all this to achieve a significant increase in the
profitability of the company, a strategy has been created to
Reliability-Centered Maintenance in order to identify and
implement policies for managing failure modes that may
cause a functional failure in one of the most critical equipment and
incidence in production such as the Cylinder machine.

1.7 FUNCTION TO ANALYZE

The main function of the machine under this analysis is to knead and
smooth the mixture until a homogeneous dough is obtained for making bread.

through two parallel rollers, within the following parameters:

Voltage between 208 and 220 V.

Speed between 1100 to 1300 rpm.

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 Soft sound from 50 to 70 db.
Mix load of 5 to 20 Kg.
Engine temperature from 50 to 90°C

1.8 FUNCTIONAL FAILURES, MODES AND CAUSES OF FAILURE

Within the analysis conducted in the development of the MCC table (ANNEX C)

It was evident that the possible failures that the equipment may present have
its main reason is electrical failures and lack of maintenance
to the mechanical elements such as bearings.

1.9 Effects of Faults

Among the possible failures analyzed, it was evident that in most cases
they impact production (up to 50%), quality (up to 50%) and
security (20%).

1.10 EVALUATION OF THE CONSEQUENCES.

Possibly, mostly, obvious consequences that when being

assessed affect the operation with high risk (H) in production and the
quality caused by machine stoppage due to electrical damage,
average (M) due to network failure, damage to electrical devices, lack of
lubrication and mechanical damage, low (L) due to mechanical damage and

lack of knowledge in the operation and maintenance of the machine;

health risks were also evaluated and possible ones were found
medium (M) and low (L) risk consequences due to contamination
auditory and electrical risk.

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1.11 TECHNICAL FEASIBILITY OF THE TASK

To achieve Reliability-Centered Maintenance, it is necessary

establish a strategy that includes:

Maintenance based on 'operate until failure' to respond to

network failures, power switch failures, fuse of
open circuit, mechanical overload caused by overload
machine mechanics.
Preventive maintenance every six months consisting of:
Periodic inspection of power supply conductors
machine.
Inspection and lubrication of bearings both from the motor

like the axes of the rollers.

Roller alignment.
Mechanical adjustment of the machine and engine parts to
on its basis.

General cleaning of the machine.

Other tasks aimed at ensuring proper operation of
the machine, consisting of evaluating knowledge of
operator regarding the machine's capabilities and understanding
from the manual, managing to detect the shortcomings and identify the topics

to reinforce.

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 2.- ROOT CAUSE ANALYSIS

At the company Centro Pan, due to the failure of the semi-electric mixer.
An analysis of defect elimination was carried out in the industry.

Using Root Cause Analysis, in search of finding the

resolutions to permanently eliminate their origins, achieving
control them or eliminate them.

2.1RESULTS DEL ACR BLENDER ELECTRIC

SEMIINDUSTRIAL FALLADA

After an analysis of the failure specified in Annex D, it was found

the following:

5% of the problem is caused by loss of electrical power due to

analyze.
3% of the problem is caused by a damaged electric motor due to
analyze.
40% (1.3 + 25.7 + 13.0) has its origin of the problem in the gears
worn out due to lack of maintenance.
14% (10.8 + 3.2) of the problem is caused by gears
worn out by ignorance of the existence of manuals of
the machine.
14.4% of the problem is caused by clogging due to
lack of knowledge about the existence of operating manuals.
3.6% of the problem is caused by foreign particles in the
interior to analyze

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 8% of the problem is caused by overheating in the engine due to
excess load due to ignorance of the operating manuals.
12% (0.6+11.4) of the problem is caused by overheating
of the engine due to lack of maintenance.

2.2 ROOT CAUSE OF THE FAILURE

Having conducted the analysis, the root of the problem is found, mainly
in the absence of implementing a maintenance plan, by correcting this,
the consequences of the failure would be corrected by 52%, represented in
$582,400 of the $1,120,000 in losses caused by the failure.
lack of knowledge of the machine and its technical specifications through
the manual causes losses of 36% amounting to $403,200,
we can correct this by training and evaluating the competencies of
machine operator.

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 CONCLUSION

Awareness is necessary across the entire industry, regardless of its

size, of the need and the benefits of defining a plan of
maintenance under a thorough and technical analysis of the
personal needs.

In modern management, it is necessary to maximize production,

minimizing costs and making it more competitive, profitable and
operational the production processes, being a fundamental pillar for
achieve all this establish a plan that guarantees productivity and
continuous improvement of processes.

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 BIBLIOGRAPHIES

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MAINTENANCE

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 ANNEX A

NUM.
PAN CENTER Electric Roller INVENTORY
TYPE
Code of
TEAM MODEL
MANUFACTURER CRITICALITY
CAPACITY
ACQUISITION PROCESS (HP)
ACQUISITION OBSERVATIONS
DATE N :
(DD/MM/YYYY)INSTALLATION
N
TECHNICAL CHARACTERISTICS
T NOMINAL NOMINAL FREQUENCY WEIGHT
I NOMINAL (A) (V) (RPM) CIA (KG)

MECHANICAL RELATIONSHIP OF
REDUCTION
BELT REFERENCE
DIAMETER OF MOTOR PULLEY
DIAMETER OF PULLEY
ROLLERS
NUMBER.
PAN CENTER MANUAL CUTTER INVENTORY
TYPE
TEAM CODE MODEL
MANUFACTURER CRITICALITY
ACQUISITION PROCESS OBSERVATIONS:
DATE ACQUISITION
(DD/MM/YYYY) INSTALLATION
TECHNICAL CHARACTERISTICS
WEIGHT (KG) HEIGHT LONG. LEVER # CUTS

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 NUMBER
PAN CENTER blender INVENTORY
TYPE
CODE OF
TEAM MODEL
MANUFACTURER CRITICITY
ACQUISITION PROCESS CAPACITY (HP)
ACQUISITION OBSERVATIONS:
DATE N
(DD/MM/YYYY)INSTALLATION
N
TECHNICAL CHARACTERISTICS
VEL FREQUENCY WEIGHT
I NOMINAL T NOMINAL NOMINAL A (KG)

NUMBER
PAN CENTER Wetland INVENTORY
TYPE
CODE DEL
TEAM MODEL
MANUFACTURER CRITICITY
ACQUISITION PROCESS CAPACITY (HP)
ACQUISITION OBSERVACIONES:
DATE N
(DD/MM/YYYY)INSTALLATION
N
TECHNICAL FEATURES
VEL FREQUENCY CURRENCY
I NOMINAL T NOMINAL NOMINAL A (KG)

INVENTORY NUMBER
PAN CENTER GAS OVEN
TYPE
TEAM CODE MODEL
MANUFACTURER CRITICALITY
ACQUISITION PROCESS OBSERVATIONS:
ACQUISITION
DATE (DD/MM/YYYY)
INSTALLATION
TECHNICAL CHARACTERISTICS

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ANNEX B

Roller machine Machine roller motor

Cutting machine Wet machine

Mixer machine Ovens.

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3