Improving the Material Loading Process in a Ready-Mix Concrete Production Plant through Industry 4.0 Principles

Carlos Zuñiga Torres J.; Giuvesky Valdivia Yajo S.; Alejandro Vera Mayta C.; Leonor Paredes Aguilar L. · Proceedings of the LACCEI international Multi-conference for Engineering, Education and Technology (2025) · DOI: 10.18687/laccei2025.1.1.2272

Resumen

Urban and infrastructure development implies an increased demand for ready-mix concrete. Small companies producing ready-mix concrete must optimize their operations to improve productivity and meet demand. In this sense, our research applies the principles of Industry 4.0 to process monitoring, automation, and technical assistance to improve the productive efficiency of the material loading process in a ready-mix concrete plant. The methodology includes a literature review, field observation, and interviews with operating personnel. This information allowed the researcher to redesign the materials loading process, integrating monitoring technologies, such as the GPS Logger, to record operating times. In addition, a metal hopper was implemented to automate and facilitate the mixing of materials, and subsequently, employees were trained in the redesigned process using Industry 4.0 technologies. A 15-day pilot test validated the solution, demonstrating a reduction in cement loading time from 9 minutes and 59 seconds to 3 minutes and 33 seconds, with a 3.5% decrease in material waste. The total material loading time was reduced from 42 to 36 minutes per mixer, resulting in a 22% increase in daily production and a 42.6% improvement in operational efficiency. The economic evaluation confirmed the project's feasibility, with an NPV of S/. 23,020.73, a C/B ratio of 1.79 and an IRR of 22.22%, recovering the investment in only five months. These results demonstrate that the proposal optimizes processes and increases the company's competitiveness, paving the way for significant growth in daily production.

Instituciones: Universidad Nacional de San Agustín de Arequipa; Universidad Tecnológica del Perú