Bibliographic citations
Monsefú, L., (2021). Análisis de los procesos de soldadura para mejorar la productividad de fabricación de una viga de alma llena [Trabajo de suficiencia profesional, Universidad Nacional de Ingeniería]. http://hdl.handle.net/20.500.14076/22166
Monsefú, L., Análisis de los procesos de soldadura para mejorar la productividad de fabricación de una viga de alma llena [Trabajo de suficiencia profesional]. PE: Universidad Nacional de Ingeniería; 2021. http://hdl.handle.net/20.500.14076/22166
@misc{renati/267271,
title = "Análisis de los procesos de soldadura para mejorar la productividad de fabricación de una viga de alma llena",
author = "Monsefú Alvarez, Luis Antonio",
publisher = "Universidad Nacional de Ingeniería",
year = "2021"
}
The following research work was developed in order to increase the productivity of metal beam manufacturing that are carried out in metalworking plants by analyzing the welding processes that small companies have, reducing production times and costs in the manufacture of the beams. The welding processes that the companies have implemented were analyzed, as they are small they do not have all the processes, so for this study the processes of coated electrode arc welding (SMAW) and flux-cored arc welding (FCAW). The verification of the welding times of six metal beams, the number of failures, the welding repair time, inspections for penetrating dyes and magnetic particles were carried out in order to quantify the detected welding defects, the manufacturing costs. With this data and analyzing the results, it was decided which process is more profitable, with the lowest manufacturing cost. During the development of the work with the SMAW process, it was obtained that the welding time of three metal beams of 1 010,76 minutes (16,85 hours) with three welders, the inspection of the weld beads was carried out by penetrating liquids and magnetic particles where 8 welding defects were found, the three beams were repaired in a time of 97,60 minutes, then when inspecting the weld beads no welding defect was found. Concluding that for the SMAW process the final manufacturing time (only welding and repair) of the three beams is 1 108,36 minutes, having an average time of 369,45 minutes (6,16 hours); that is, in 6,16 hours, three metal beams were manufactured with three welders performing the welding simultaneously. Continuing with the development of the work, the next welding process to analyze is the FCAW process, with this process the welding of three beams was carried out in a time of 689,10 minutes, the number of defects of 10, the repair time of 109,50 minutes and the final welding time of the beams with the FCAW process is 798,60 minutes, thus reducing the manufacturing time from 1 108,36 to 798,60 minutes, it was reduced by 309,76 minutes which represents a 27,95 %. Concluding that for the FCAW process the final manufacturing time (only welding and repair) of the three beams is 798,60 minutes, having an average time of 266,20 minutes (4,44 hours); that is, in 4,44 hours, three metal beams were manufactured with three welders performing the welding simultaneously. In the economic evaluation, it was obtained that to manufacture 3 metal beams with the SMAW process the cost is US$ 3 362,02 and with the FCAW process it is US$ 3 379,01; the FCAW process is more expensive at US$ 16,99. A comparison was made between the difference in the cost of both processes and the manufacturing time saved between both processes, and the manufacturing time saved equates to a benefit of US$ 105,24; that by subtracting the cost from US$ 16,99, you still get a savings of US$ 88,25 using the FCAW process. Then an extrapolation was carried out with the total number of meters of beams belonging to the project. It was obtained that the manufacturing time of the SMAW process is 186 893,87 minutes and an average time of 62 297,96 minutes, where welders work 8 hours a day and 1 038,29 hours (129,79 days) were obtained; and the FCAW process of 149 072,00 minutes and an average time of 49 690,67 minutes, where welders work 8 hours a day and obtained 828,18 hours (103,52 days) Using the FCAW process, a reduction of 37 821,87 minutes is obtained in the manufacturing time of metal beams; this time represents a cost saving of US$ 12 849,35. Continuing, the cost analysis of the processes was carried out and it was obtained that the FCAW process is superior to the SMAW process by US$ 5 290,56; that by subtracting the time saved, which is equivalent to US$ 12 849,35, a saving of US$ 7 558,79 is obtained. It is concluded that, both in the study sample and in the population, the results are the same, to improve manufacturing productivity the FCAW process should be used with the indicated recommendations.
This item is licensed under a Creative Commons License