Propuesta de mejora del subproceso de retrabajo y recuperación de llantas verdes y carcasas mediante la integración de AMEF y PHVA

Abstract

Process management plays a fundamental role in the tire manufacturing industry due to its direct influence on operational efficiency, product quality, and compliance with regulatory requirements. The present study aimed to diagnose and analyze the operational risks of the green tire and casing recovery and repair subprocess, leveraging the synergy between Failure Mode and Effects Analysis (FMEA) and the PDCA (Plan–Do–Check–Act) cycle for risk management, stemming from an external audit finding related to traceability and document control of the subprocess. The research was conducted using a non-experimental, cross-sectional design and included a partial, document-level implementation, with a comparative reassessment of risks based on an estimated RPN. Initially, a diagnosis of the subprocess was conducted, identifying 266 operational risks and calculating the Risk Priority Number (RPN). Subsequently, prioritization was carried out based on established organizational criteria, and improvement actions were proposed to reduce the likelihood of occurrence and strengthen detection controls, projecting an estimated RPN as a comparative reference. The results indicated that approximately 86% of the prioritized risks could be placed at NPR values below 100, as an expected effect of potential improvements in Occurrence and Detection. It was concluded that the integration of FMEA-PDCA constituted a useful methodological strategy for structuring operational risk management and strengthening document control and traceability, without validating operational performance through indicators.