Estudio de viabilidad de una instalación automática de suministro de componentes para una línea de ensamblaje

Abstract

Este Trabajo Final de Máster aborda el diseño y la planificación de una instalación automática destinada a optimizar el proceso logístico de suministro en una línea de montaje de automóviles, sustituyendo un modelo altamente manual por una solución más eficiente y segura. El proyecto se desarrolla a partir del análisis del estado inicial, la evaluación de alternativas y la definición progresiva de una solución automatizada validada mediante pruebas FAT, SAT y ABE. Los resultados estimados muestran una reducción del orden del 80 % en las operaciones manuales de manipulación directa y una disminución significativa de incidencias logísticas, junto con una mejora ergonómica relevante. El análisis económico confirma la viabilidad del proyecto, con un periodo de retorno de la inversión estimado en 1,75 años. La solución se concibe además como una base escalable para futuras fases de automatización logística.

This Master’s Thesis focuses on the design and planning of an automated installation, together with the auxiliary equipment required for its integration into an automotive assembly line, aiming to replace a highly manual logistics process with a more stable, efficient, and safe solution. The project is developed in a production environment where sequenced supply of large components plays a critical role in maintaining line continuity and avoiding production disruptions. The work begins with a detailed assessment of the initial state of the line, identifying bottlenecks, operational constraints, and tasks with a high ergonomic and organizational impact. Based on this analysis, several alternative supply concepts were evaluated. During this stage, some initially viable options were ruled out due to their inability to ensure cycle time stability and process repeatability under real operating conditions. The selected solution was progressively defined through layout development, technical specifications, and logistics flow simulations, allowing its performance and integration capacity to be assessed prior to manufacturing. The implementation plan was structured around clearly defined milestones, including factory acceptance tests (FAT), site acceptance tests (SAT), and final validation by end users (ABE). At the time of writing, the project is in the manufacturing phase of the installation and its auxiliary equipment, with final testing and commissioning activities already scheduled. The projected results indicate substantial improvements compared to the initial situation, including an estimated reduction of approximately 80% in direct manual handling operations associated with the supply process, together with a decrease of around 30% in logisticsrelated incidents. In addition, a positive impact on operator ergonomics is expected, contributing to safer and more stable working conditions. From an economic standpoint, the investment analysis estimates a payback period of approximately 1.76 years, driven by annual operating cost savings equivalent to the optimization of two logistics operators working across three shifts. Overall, the proposed solution demonstrates technical and economic feasibility and has been designed with scalability in mind, enabling future extensions to other logistics flows or production lines. The project illustrates a structured and pragmatic approach to logistics optimization in complex industrial environments and supports the ongoing transition towards more automated and competitive production systems.