Mejora de la disponibilidad en el mantenimiento de las líneas de producción de papel “línea pp-01” preparación pasta, planta Puente Alto de la empresa Softys Chile

Abstract

The present project addresses the problem of low operational availability in the PP01 pulp preparation line at Softys Chile’s Puente Alto plant. The proposed solution focuses on the implementation of ABB Ability™ Smart Sensors to enable real-time monitoring of critical equipment, aiming to transition from a reactive or corrective maintenance model to a predictive and data-driven strategy aligned with Industry 4.0 principles. Through the identification and prioritization of critical assets, a technical and economic evaluation was conducted to justify the investment in intelligent monitoring technology. The sensors allow for continuous tracking of vibration and temperature variables, enabling early detection of anomalies, reducing emergency maintenance interventions, and improving equipment reliability. The proposal includes the development of a preventive maintenance plan, the application of the Deming cycle (PDCA), and the definition of key performance indicators (KPIs) to monitor the effectiveness of the solution. A cost-benefit analysis was carried out, estimating a 7% increase in line availability and projected annual savings exceeding 590 million CLP, due to avoided unplanned downtimes and optimized maintenance programming. The results demonstrate the technical and economic feasibility of implementing intelligent sensors, establishing a scalable and sustainable framework for improving asset reliability and operational continuity in the production process.