INSTITUTO TECNOLGICO Y DE ESTUDIOS

SUPERIORES DE MONTERREY
CAMPUS MORELIA

Final Deliverable Re-engineering of lines and electric and

gas outlets on sheds 2 & 3 of the mechanical workshop of
ANDRITZ HYDRO, S.A. DE C.V.
By:
Jos Ral Ortiz Castillo A01064112
Claudia Janeth De Jess Bruno A01064244
Jess Alberto Labra Andrade A01064603
Agustn Arroyo Cuevas A01064612
Arturo Villagrana Zamudio A01062775
Final Project of Industrial Engineering and Systems
Marco Dasaev Garca Vargas
November 23, 2015

Executive summary
This document corresponds to the proposal of the re-engineering of lines and
electric and gas outlets on the sheds 2 & 3 of the mechanical workshop of Andritz
HYDRO, S. A. DE C. V. which has been formulated as part of the project of the
field of Project of Industrial and Systems Engineering.
Its objective is to establish a solution that help the company to improve its ability to
supply products with features established and regulated and also to ensure
meeting with international standards as are ISO, OHSAS, among others.
The document also describes and establishes the features of the process followed
by the components in each of the stages, including the enabled, pailer, welding,
polishing, machining, assembly and shipment; as well as the various types of
products that are generated as part of the process.
In terms of infrastructure and resources, they have established some guidelines
about the characteristics of the work environments, machinery and equipment
recommended for their production, the provisions of security, protection for workers
and the environment, the guidelines about the competence of the staff and the
provisions relating to the maintenance of infrastructure, machinery, equipment and
auxiliary services of the plant, so our job was to conduct a simulation to observe
ideal behavior of production and also the potential improvements in terms of
controllable variables.
Description of the company
Andritz Hydro S. A. de C. V is a transnational private company which is engaged in
the manufacture of components and electromechanical equipment mainly for
hydroelectric plants. In addition to this, it offers services of installation and
commissioning of the hydraulic units.
Its target market includes Mexico, Central America and the Caribbean, this due to
the closeness that has with the customer, but in recent years has been expanded
to the North American market (USA and Canada).

Its approach to market includes the manufacture of components for new

hydroelectric power stations, or offering a service of maintenance and
modernization for existing plants.
The company was founded in the year 1981 under the name of TEISA (Turbinas y
equipos industrials, S. A. de C. V.) product of the union of business between
Nafinsa, Mexico (70 %) and Escher Wyss, Switzerland (30 %). In 1996 Escher
Wyss was acquired by Sulzer, Switzerland. Toward the year 2000 Sulzer was
acquired this time by VA Tech, Austria. And finally in 2006 VA Tech Hydro became
part of the Group Andritz, since then the company is called Andritz HYDRO S. A.
DE C. V.

Location of the company

Company: Andritz Hydro, S. A. de C. V.
Country: Mexico
Status: Michoacan
Municipality: Morelia
Home: Av Cd. Industrial, 977
C. P. 58200 Morelia, Mich., Mexico (See Image 1)
Tel. 01443-323-1530
Picture 1.- Location of the plant

Customers and Suppliers

Due to the extensive portfolio of customers and suppliers, we will mention only
some what we consider are important:
Customers

Suppliers

* Federal Electricity Commission

* Fundidora Mayran

* Alstom Power

* Fundidora Morelia

* General Electric

* Fronius Mexico

* Precision Machining

* Lincoln Electric

* Andritz Hydro Group World Wide

* Frisa Forged

* Enel Green Power

* Among others.

Main products
The product range on offer is very varied due to the hydraulic units are composed
of thousands of components. In the image below we can see the major
components or larger of which is composed a turbine:

Picture 2.- Major components of a hydraulic turbine.

It should be noted that the components can vary depending on the conditions
where the plan is going to be located, as well as the type of runner, the power
required and some specific specifications of the customer.
Based on historical demand, the company has defined 3 key components or
products:

Picture 3.- Types of runners

Policies of quality management system, hygiene, safety and environment

On the basis of their core competencies fully oriented to the satisfaction of the
customer, the following is a diagram in which the company involves in a general
way how to ensure a successful process through these policies and methodologies
of quality, without forgetting the great influence of contributors:

Image 4.- Quality policies of Andritz Hydro

Currently the company is certified in standards such as ISO 9001 (quality

management system) and 14001 (environmental management system and health)
and OHSAS 18001 (occupational health and safety).
With the reason to reaffirm their commitment to customers, employees and the
environment the company has defined security and environment policies through
which governs their operations.
Environmental Policy
"It's our goal to continually reduce the impact
on the environment through the responsible
consumption of resources and the use of
sustainable goods and services.
We prefer technologies, processes, materials,
and products that help the environment in both
comply with the technical and economic
conditions;

and

the

requirements

of

our

customers".
Health and Safety Policy
"Our goal is to prevent personal
injury and

prevent

damage

to

property; we give to the health and

safety

high

priority in

all

our

activities; our goal is to continuously

improve our performance in health
and safety".

Background (Sources of data or information about the problem we trying to

solve)
The company currently is facing serious economic problems, and a bad image, due
to the low level of productivity, security, order and cleanliness. The conditions of the
mechanical workshop of production are not appropriate because it does not meet
with certain basic aspects of ergonomics.

Picture 5.- current conditions of the mechanical workshop production, areas of welding and pailer.

In the image above we can see the work area that is perceived of the workshop
because of the disorganization of the hoses due to the present arrangement of
electric and gas outlets. As we know this aspect is of the utmost importance as a
company, it can cause the loss of potential customers.
Along with this, the disorganization in the use of lines required for the welding
process increases the probability of occurs an accident in the work area.
Production Process
The mechanical process of production for the manufacturing of components for
hydroelectric turbines, which is the one that we will focus on in this project, is

considered as a pull system because the production is operated with the entry of a
new project / order, which in addition may require conditions of design highly
specific.
The production process consists of 6 main processes, which are a flow already
defined:
1.- Enabled.- Is the initial process in the manufacture of any component, and is
divided into 2 sub-processes: Oxycutting and roll bending machine, depending on
the needs of the component to be manufactured.
The objective of this phase is to enable the raw material based on the drawings or
sketches issued by the department of methods, this in order to facilitate the
subsequent process of assembly of the components.
2.- Pailer.- After getting the different enabled parts that compose a specific
component, it is appropriate to begin with its assembly, this by applying tack weld
in order to fix in a specific shape and position. In order to be sure of the quality of
the assembly, the personnel use extremely precise instruments order to
accomplish with specific tolerances for armed marked on the drawings or sketches.
3.- Welding.- After the component has been completely assembly, it is appropriate
to apply solder to fix by complete the parts of the component.
4.- Polishing.- As its name says, in this process the parts are devastated in specific
areas with the reason of complying with certain measures and surface finish
specified on the drawings. The importance of this process is vital as there are
many points in which the machinery of the machining process cannot reach.
5.- Machining.- At this point of the process, the components are usually assembled
almost in its entirety, but may still have over-material in some sections, or can be
necessary to give a specific finishing on any of them due to the design
requirements. That is why it can goes through lathes, milling machines or drill
machines.

6.- Assembly and shipment.- This is the final process in the manufacture of any
product. Here usually are assembled all the components that constitute the
hydraulic unit and it are tested working in site conditions to ensure that it meets all
the requirements establish on the contract. In addition the parts are prepared
adequately to be sent to its destination by avoiding possible damage to the
components.
Non-destructive testing (NDT)
By the fact that the components that are manufactured in the plant are considered
as components to pressure, it is necessary that during the manufacturing process it
pass through inspections and rigorous testing, following very high standards of
quality worldwide.
The quality control inspections and non-destructive testing (NDT) are carried out in
different parts throughout the manufacturing process, which includes from the
arrival of the raw material at plant until the output of the finished product of the
same.
The main inspections and non-destructive testing that are carried out in Andritz are:
Ultrasound Test: The purpose of this test is to determine whether the material has
inherent defects in its interior, this because of the functionality of the component it
needs to be able to resist high pressures. The benefits of this test is that being
volumetric it shows you all possible defects within a material.
Magnetic particle testing: Your goal is to find defects in the material due to a
discontinuity in the flow of the magnetic field induced in the piece. The goodness of
this test is that it can be carried out quickly, but only applies to materials with
ferromagnetic characteristics and its depth of reach is only 3 mm from the surface
to inside of the material.
Dye penetrant testing: It is used to detect discontinuities present on the surface of
the materials. It is usually for non-ferrous alloys.

Test of rays: It is used to detect internal defects in the material, by passing some
sort of radiation through them.
Dimensional inspection, shape, position, and surface finish: This test consists in
the verification of the measures of the work piec against the marked on the
drawings of manufacture. These inspections require the use of measuring
equipment specially calibrated to thousandths of a millimeter, and require the
experience and knowledge of a qualified and reliable employee. Some of the most
widely used tools are the height and depth gauges, graduated rulers and among
others. In the case of surface finish they use roughness-measuring equipment
calibrated, whose data are compared against exact patterns.
To define the criteria for acceptance in the ultrasound test (UT), magnetic particles
(MT), dye penetrant (PT) and x-rays (RT), the company is governed by regulations
such as CCH-70.- Specification for the inspection of steel foundries of hydraulic
machines.
For dimensional inspections, shape, position, and surface finish, the company is
governed of the drawing of manufacturing that is generated in the area of
Mechanical Engineering or as in most cases the client sends these.

The

process

diagram

flow

Process flow: Enabled PailerMachining Welding Polishing Assembly and shipment

Definition of the problem

Based on the foregoing and the information obtained by the Ing. Alejandro Magaa
(COO of the company), in this project we will focus on the following points:
1.- Redesign of the outlets of gas along the sheds that compose the mechanical
workshop.
This is due to the fact that today the increasing workload, the designated spaces to
carry out the process of welding are not sufficient and also adding that the delivery
times of products are very restricted, the operative personnel continuously decides
to carry out the activities of welding in spaces that are not appropriate for the task,
causing workers to use very long hoses to connect the welding machines to the
outlets of gas, which at the same time generates much disorder in the workshop,
and a great waste of materials (hoses, clamps, etc.).
Description of solution

Symptoms
The set of symptoms that cause the problem is mainly derived from dead times in
in the processes to handle hoses which has a direct impact on the costs of
logistics/operation, waste of material and a poor image of the work area.
Regulations violated
The company is governed under the ISO 9001 standards (standard in quality
management systems (QMS) and ISO 14001 (international standard for
environmental management systems (EMS), which after a brief analysis detected
that would be raped:
By not having an orderly space of hoses, ignore or leave at second plane the
implementation of the quality management system (ISO 9001). This avoid sort,
and systematize processes and documents, as well as effectively control of the
whole process march.
Some simple procedures that apply the employees are based on self-control (e.g.,
cut hoses if they tangle which generates waste and contamination) and that is a
weakness, because there is no culture oriented to the quality and responsibility
with the natural resources (ISO 14001).
To get real results it is important to perform a deeper analysis to know fundamental
information from internal or external sources concerning to these legal and
regulatory requirements about the standards.
Part of our work, as industrial engineers and as part of the quality department, is to
ensure that any statement of compliance a standards, legally and regulatory
requirements, etc., are demonstrated properly by the company Andritz Hydro.
Actions

Initial inspection of the piping and inventory of the items.

Identify materials, fluids, and types of hoses.
Detection of the weak points and that can be changed.
Choice of improvement.
Search for suppliers.
Develop a possible plan of implementation.

Inventory of Manifold (movable)

Location (last
seen)

# Of
identificatio
n

Maintenance

S/N

Maintenance

S/N

Maintenance

S/N

Maintenance
Maintenance
Shed 2 (solder)
Shed 2 (solder)

4
S/N
3
2

Compressed
Air
Compressed
Air
Compressed
Air
LP Gas
LP Gas
LP Gas
LP Gas

Shed 2 (Pailer)

S/N

LP Gas

Type of fluid

Width of
entry

Output width
of

1"

"

1"

"

1"

"

1"
1"
1"
1"

"
"
"
"
"

1"

Shed 2 (Cab 4)
S/N
LP Gas
1"
Shed 2 (Cab
Compressed
S/N
1"
13)
Air
Shed 2 (Cab
1
LP Gas
1"
14)
* Compressed Air: air at a pressure of 1 atm may.
* LP Gas: liquefied petroleum gas (mixture propane-butane)

"
"
"

Inventory of electronic bulletin boards (Movable)

Location (last
seen)
Shed 3 (Pailer)
Shed 2 (thermal
treatment oven)
Shed 2
(Maintenance)
Shed 2 (solder)
Shed 2
(Polished)

# Of
identificatio
n
4

# 110V
connections

# 220V
connections

# 440V
connections

"VA TECH"

S/N

Inventory of Fluids
Fluid

Color

Compressed Air
Argon (Ar)
Carbon dioxide (CO2)
Propane Gas
Mixture Ar and CO2
Oxygen (O2)
LP Gas

White
Coffee
Gray
Yellow
Black
Green
Red

Location in sketch
Location
Fluids
1
Oxygen (O2)
Propane Gas
Compressed Air
Carbon dioxide
(CO2)
Mixture Ar and
CO2
Argon (Ar)
2
Oxygen (O2)
Propane Gas
Compressed Air
Water
3
Compressed Air
4
Compressed Air
5
Argon (Ar)
Compressed Air
Propane Gas
Oxygen (O2)
6
Argon (Ar)
7
Oxygen (O2)
Propane Gas
Mixture Ar and
CO2
Carbon dioxide
(CO2)
Compressed Air
Argon (Ar)
8
Oxygen (O2)
Propane Gas
Compressed Air
Carbon dioxide

Taking
s
1
2
1

Kind of
takes

Hose

2
3
3
1
1
2
2
1
1
3
1
1
1
1
3
3
3
3
5
3
2
3
4
3

Green 0.5 in

Green 0.5 in

Green 0.5 in
Green 0.5 in

Green 0.5 in
Red green line 0.5
in
Black 0.9 in

10

11

(CO2)
Mixture Ar and
CO2
Argon (Ar)
Oxygen (O2)
Compressed Air
Carbon dioxide
(CO2)
Mixture Ar and
CO2
LP Gas
Oxygen (O2)
Compressed Air
Carbon dioxide
(CO2)
Mixture Ar and
CO2
Argon (Ar)
LP Gas
Oxygen (O2)
Compressed Air
Carbon dioxide
(CO2)
Mixture Ar and
CO2
Argon (Ar)
LP Gas

12 (Cab
2)
Argon (Ar)
LP Gas
Compressed Air
Mixture Ar and
CO2
Oxygen (O2)
13 (Cab
4)
Argon (Ar)
LP Gas
Compressed Air
Mixture Ar and
CO2
Oxygen (O2)
14 (Cab
6)
Argon (Ar)
LP Gas

3
3
2
5

Green 0.5 in

3
3
1
1
1

Green 0.5 in

1
1
1
1
1
1

Green 0.5 in
0.95 In Red

1
1
1
1
1 CGA580
1 CGA510
1
1 CGA580
1 CGA540
1 CGA580
1 CGA510
1
1 CGA580
1 CGA540
1 CGA580
1 CGA510

Red 0.8 in
Green 0.5 in

Compressed Air
Mixture Ar and
CO2
Oxygen (O2)
15 (Cab
9)
Argon (Ar)

16
(Booth
11)

17
(Booth
13)

18

19

Green 0.5 in

1 CGA580
1 CGA540
1 CGA580
Green red line 0.5
in
Red 0.9 in

LP Gas
Compressed Air
Mixture Ar and
CO2
Oxygen (O2)

1 CGA510
1

Argon (Ar)
LP Gas
Compressed Air
Mixture Ar and
CO2
Oxygen (O2)

1 CGA580
1 CGA510
1

Argon (Ar)
LP Gas
Compressed Air
Mixture Ar and
CO2
Oxygen (O2)
Mixture Ar and
CO2
Carbon dioxide
(CO2)
Compressed Air

1 CGA580
1 CGA510
1

Propane Gas
Oxygen (O2)
Mixture Ar and
CO2
Carbon dioxide
(CO2)

4
3 F-3000

Red 0.8 in
Red 0.8 in, 0.5 in
Green
Green 0.5 in

Green 0.5 in

Compressed Air
Propane Gas
Oxygen (O2)

5
4
3

1 CGA580
1 CGA540

1 CGA580
1 CGA540

1 CGA580
1 CGA540

Green 0.5 in

3
3
1

4
Red 0.9 in, 0.9 in
blue, red 0.9 in
Green 0.5 in

20

21

Argon (Ar)
Mixture Ar and
CO2
Carbon dioxide
(CO2)
Compressed Air
Propane Gas
Oxygen (O2)
Water
Argon (Ar)

3
4
CGA3203 gate
1
2
2
1
3

Red 0.9 in

Model
First we received information of future parts to be produced, which divide by
families for better results. We broke the whole model down into different sections
so that Arena could manipulate the entities as they flow through the plant. An entity
is just a family of parts which flows through processes, we think of it as a runner or
valve. The three major sections were:
Runners
Valves
Fixed pieces
Process

to

Information to collect (Input data)

model

For input data we used the data schedule for the year of 2015. Arrival rates for all
the models are listed in Exhibit 1, but the control (current) model arrival rates are
listed below:
Component
Pelton runner
Francis runner
Butterfly valve (valves)
Head cover
Bottom ring

Quality inspection processes

Penetrating liquids 1 and ultrasound
Penetrating liquids 1 and ultrasound
Penetrating liquids 2, magnetic particles and ultrasound
Penetrating liquids 2, magnetic particles and ultrasound
Penetrating liquids 2, magnetic particles and ultrasound

Component
Pelton runner
Francis runner
Butterfly valve (valves)
Head cover
Bottom ring

Times of load/unload (hours)

Pessimistic + probable Optimistic
3
1.75
0.5
1.5
1.08
0.667
1.5
1.08
0.667
2.5
1.5
0.75
0.75
0.583
0.416

Possible Occupied Space by piece and work area

References
(2015).

Andritz HYDRO Morelia, Mexico. September 15 2015, Andritz web

site: http://www.andritz.com/es/locations/hy-andritz-hydro-morelia-mexico.htm
Garcia, H. (n.d. ). SELECTION AND SIZING OF HYDRAULIC TURBINES FOR
HIDROELCTRICAS

CENTRAL.

September

15

2015

in

UNAM

web

site: http://www.ingenieria.unam.mx/~deptohidraulica/publicaciones/pdf_publicacio
nes/SELECyDIMENSIONAMIENTOdeTURBINAS.pdf
(s.f.). Selection Criteria. September 15, 2015, School of Engineering of Antioquia
web
site: http://fluidos.eia.edu.co/hidraulica/articuloses/maquinashidraulicas/sel_turbina
s/fondos/criterios.htm