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Amcor Flexibles Production System

Capacitación OEE -Operaciones


OEE Tracking ‘Blueprint’ owner Issue date 09/10/2017
AFPS 2.03 Marie-Pierre Jasinski Version v.1.0

List of Amcor experts List of training/implementation material List of audit/template material


• Marie-Pierre Jasinski • OEE Calculation template
• Fabian Boensch
• Andreas Brieler
Objetivo del ‘blueprint’: Visualizar qué tan efectivamente se está utilizando un equipo, qué tipos de pérdidas hay y qué
tan grandes son

Detailed description

1 Cómo funciona? Qués es? Cuándo usarlo?


Cuándo usarlo: Cómo: Ejecute un diagnóstico OEE y
– Bottleneck (Cuello de botella), Máquina que es limitante de capacidad en el defina el camino para la mejora
flujo productivo para cumplir con la necesidades del cliente.
– Equipo de alto costo: Dónde se debe incrementar la utilizaicón.
– Competitividad, cuando el foco debe de ser en función del costo variable
reduciendo sobretiempos y/o mejorando la productividad.
– Sistema de gestion del Performance para revisar el actual nivel de
performance
Qué es?
– OEE muestra en general el alcance total de las pérdidas de producción
– OEE (cascada), comienza desde el tiempo total y calcula cada pérdida de
tiempo desde allí, lo que ayuda a priorizar los esfuerzos de mejora

2 Aprendizajes clave: ¿Cuáles son los beneficios y las limitaciones?

El cálculo de OEE puede variar mucho de días a semanas. En un sistema de gestión del rendimiento, use OEE como un KPI
semanal/mensual a nivel de gestión Cuando faltan datos, puede tomar mucho tiempo estimar una caída de agua OEE.

Draft/Privileged and Confidential/Prepared for Counsel 2


OEE Tracking ‘Blueprint’ owner Issue date 09/10/2017
AFPS 2.03 Marie-Pierre Jasinski Version v.1.0

List of Amcor experts List of training/implementation material List of audit/template material


• Marie-Pierre Jasinski • OEE Calculation template
• Fabian Boensch
• Andreas Brieler
Objective of the ‘blueprint’: To visualize how effectively an equipment is being used, what types of losses there are and how big
they are

Revisión Histórica

Número Fecha de Cambio de razón Revisado por Aprobado por


de Revisión
Revisión
1.0 09/10/2017 Primer problema Marie-Pierre Alan Saxon
Jasinski

Draft/Privileged and Confidential/Prepared for Counsel 3


OEE es una medida de productividad

OEE Mide la relación entre la producción Cuanto mayor sea la medida OEE,
buena real y la producción posible más producto bueno por turno
produce una máquina o línea, lo
que da como resultado costos más
OEE muestra la imagen general de dónde bajos por unidad producida y
se pierde tiempo productivo; categoriza ayuda a que las operaciones sean
las pérdidas de tiempos con el fin de más competitivas
realizar mejoras focalizadas.

When to use?

• OEE debe ser usado como soporte de los objetivos comerciales, cuando existe una
nacesidad clara, por ejemplo:
– Bottleneck (Cuello de botella), Máquina que es limitante de capacidad en el flujo
productivo para cumplir con la necesidades del cliente.
– Equipo de alto costo: Dónde se debe incrementar la utilización.
– Competitividad, cuando el foco debe de ser en función del costo variable
reduciendo sobretiempos y/o mejorando la productividad.
– Sistema de gestion del Performance para revisar el actual nivel de performance

Draft/Privileged and Confidential/Prepared for Counsel 4


Niveles de Estandarización

Marca Description

• Adoptado por todos los sitios


• Sin discusiones, sin excusas
OBLIGATORIO
• Sirve como solución estándar y 'ir a’
• Se permite ligera modificación
POR DEFECTO • Requiere aprobación para
cambio/desviación
• Sirve como buena práctica codificada
• Modificaciones permitidas sin aprobación
FLEXIBLE adiciona

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Table of Contents

Qué es el Overall Equipment Effectiveness (OEE)

Cómo se contruye la cascada OEE para entender las


pérdidas

Ejemplos de los cálculos OEE de Rorschach y Lugo

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OEE identifica las principales pérdidas que pueden
reducir la eficacia de una máquina
Ejemplos. . .
Non working time ( Tiempo no trabajado)
Problemas con . . . Puede liderar a . . .
Paradas programadas: Mantenimiento preventivo> 1 turno

Set-Up time (tiempos de configuración)

Pérdidas de Production DownTime


Disponibilidad
tiempo Breakdowns
Trial time ( Tiempo de prueba)

Pérdidas de Paradas menores


Rendimiento velocidad
Velocidades reducidas

Pérdidas de Set-Up & Run waste


Calidad
calidad NCI and customer claim

Width
Width efficiency capacity loss Actual width vs max machine width

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OEE calculation
Ratio que considera de el tiempo de
Availability máquina produciendo sin involucrar e:
Setup, Downtime, Breakdown y Trials.

Ratio que considera las horas perdidas


OEE is calculated by
Performance por las que la máquina no logró correr a
multiplying 3 factors su máxima capacidad establecida.
expressed as percentages

Ratio que considera las horas de


Quality producción de material declarado como
scrap.

Width
Width capacity
Ratio of the actual used width to the max
efficiency loss
machine nominal width

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Understand OEE with a road-trip example
Road-trip time-loss waterfall
Hours per day
24,0

12,0

17%
12,0
2,0
0.5 8,5
1.0 33%
2,5
5,0
1.0 0 4,0
1.0

Total Non Tiempo Gasolina Cena Llanta Tiempo Semáf Tráfico Startup Tiempo Extraviarse Effective
time working de viaje Baja dentro oros loss de time
time del carro manejo

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Understand OEE1
Equipment time-loss waterfall
Hours per week

160 168,0 48,0


140
120
120 8,0
100 112,0 30
44.6%
80
12
60 5,0 1,0 64 4 8,0
40 52 2,0 50 5
45
20
0
Total Available Occupation Run Effective Effective Effective
time time Time Time Runtime Time Time &
Non Planned Set-up Produc- Break- Trials Micro- Speed Waste +
Width
Width
working prev tion down stoppage loss NCI + utilization
time maint > DownTime Customer
1shift claim
Width
Quality
OEE1 = Availability rate
Performance rate
rate
efficiency
rate

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Existe diversas maneras de mostrar el OEE

0 20 40 60 80 100 120 140 160

Total time
Non working time
Available time
Planned prev maint > 1shift
OEE 2  AFEMEA OEE

Occupation Time
Set-up
Production DownTime
Break-down
OEE 1 – AF Lima

Trials
Run Time
Micro-stoppage
Speed loss
Effective Runtime
Waste
Effective Time
Width utilization
Effective Time & width

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Cuándo usar OEE1 vs OEE2?
Cuando hay un cuello de botella que restringe el Cuando es necesario utilizar equipos de alto
rendimiento,
costo de capital a su máxima capacidad
Cuando se debe hacer un enfoque de competitividad
en el costo variable mediante la reducción de horas  use OEE2
extras y/o la mejora de la productividad laboral,
 usar OEE1

Focus: ¿La máquina está trabajando en su


Focus: ¿Está optimizada la utilización de la
tiempo de ciclo estándar?
máquina?

Bottleneck

Es necesario un análisis de OEE para optimizar la


utilización de las máquinas
Es necesario un análisis del OEE del cuello de
botella para optimizar su productividad y
aumentar el rendimiento de la línea

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Las diferentes pérdidas:
1 Occupation Time  Total time

This measures time percent


lost for

• Non working time:


F1: Horas no programadas por
Sistema de turnos
E1: Falta de trabajo
F5: Proyecto.

• Mantenimiento preventivos
planeados
F2: Mantenimiento preventivo
Total Non Available Planned Occupation F4: Mantenimiento correctivo
Time working Time preventive Time programado
Time maintenanc
e > 1shift D7: Limpieza de máquina - TPM

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1 Losses: What is a “Non Working Time”?

Definition Counter measures

For a bottleneck equipment, it is very important to


The Equipment is not running e.g.
have the machine working all the time
weekends, holidays, no shift scheduled/no
order, Town Hall meeting, plant stoppage, • For holidays, use temporary workers, develop
engineering work multi-skills workers
• Organize the plant to work during week-ends
• Plan the engineering work on a 24h/24h
Pitfalls schedule, run preventive maintenance at the
same time
If Set-Up and/or Breakdowns are very long,
production people sometimes consider a part of them
as Non working Time. As a rule,
▪ All Set-Up Hours should be booked in Set-up
▪ All breakdowns hours should be booked as
breakdown on the machine until the machine is
either back to production or ready for new incoming
orders

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Losses: What is a
2 “Planned Preventive Maintenance > 1 shift”?

Definition Counter measures

The equipment is idle because teams are • Calculate the total cost of a Planned Preventive
doing periodical maintenance Maintenance to create a cost awareness,
▪ Periodic checks need to be done to • Limit the stoppage duration by improving the
ensure proper machine operating scheduling of all requested tasks
conditions
▪ Worn parts need to be replaced to avoid • Have one person responsible for the Total
stoppage time and related cost
major breakdowns going forward
• Develop Predictive Maintenance
Pitfalls
▪ Some managers consider the Planned Prev.
Maint. cost as being the hours spent by the
maintenance team (internal or external) and the
cost of the replaced parts.
▪ The real cost of a Planned Preventive
Maintenance is the cost of non producing during
the full stoppage of the machine. The stoppage
time includes the time needed for the
maintenance tasks, the time needed by the
production people (e.g. cleaning) and any idle
time from last good material to new set-up.

Draft/Privileged and Confidential/Prepared for Counsel 15


Las diferentes pérdidas:
Run Time  Occupation time

Ejemplos de códigos de actividad por


Bucket.
• Set-up:
A2: Cambio de trabajo
A3: Arranque – Calibración, etc.
• Production Downtime:
D3: Falta de personal
B7: Limpieza
B4: Cambio de bobinas
D8: Reunión
B5: Refrigerio, etc.
• Breakdown:
C1: Falla de máquina
C3: Falla de suministros
Occupation Set-Up Production Break Trials Run C4: Falla/Falta de Accesorios
Time DownTime down Time • Trials:
D1: Fabricación de muestra, etc .

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3 Losses: What is a “Set-Up”?

Definition Counter measures

• Run SMED workshop


Time lost due to Set-Up, calculated from the
last good part to the first new good part • Implement Performance Board at machine level
produced at Run speed to compare actual Set-up time with standard Set-
It includes the time : up Time after SMED.
•to make the machine ready for the production of a new job
• to match the quality requirements :
- colour, cold seal, register etc. for conversion
• RCPS (Root Cause Problem Solving) for
- optical, physical properties etc. for extrusion. deviation
•to set the machine at run speed

Pitfalls
Sometimes losses due to Set-Up are not totally
recorded:
▪ All Set-Up time, including change-over time
between different product families, must be
recorded in Set-Up
▪ If some cleaning tasks are required to set a new
order, this time should be included in Set-Up not in
Production downtime for cleaning.

Draft/Privileged and Confidential/Prepared for Counsel 17


4 Losses: What is a “Production DownTime”?

Definition
For ta Counter measures

• Implement Performance Board at machine level


Time lost due to a stoppage else than a to highlight deviation
breakdown
Production DownTime covers : • Use a Pareto to classify the Production
▪ Cleaning, waiting, DownTime
▪ stoppage due to : an input problem, a
change of a defective tool, process • Have unambiguous and distinct Production
problems, DownTime reason codes in the MES shop-floor
▪ no manning vs scheduled manning, system to fine-tune the Pareto
▪ Planned downtime such as meeting,
training, preventive maintenance <1shift • RCPS (Root Cause Problem Solving)

Pitfalls
Some plants are booking time to reprocess a
defective material as Production DownTime. The
time to reprocess a defective material should be
booked with a specific order and a adequate hours
booking (set-up/run/Breakdown ..). A system must in
place to track these specific orders for tracability and
efficiency improvement.

Draft/Privileged and Confidential/Prepared for Counsel 18


5 Losses: What is a “breakdown”?
Definition Countermeasures

Time lost due to machine breakdown. • Implement Performance Board at machine level
Breakdown time should be recorded from the to highlight deviation
minute the machine is stopped until the machine is
given back to production. • Use a Pareto to classify the Breakdown
▪ Small maintenance work during set up time are not
recorded on condition that this maintenance work • Have unambiguous and distinct Breakdown
does not disturb the set up activities reason codes in the CMMS (computerized
▪ this does not include maintenance time in the
Maintenance Management System) and/or in
periods that the machine is not manned
the MES shop-floor system to fine-tune the
▪ After a breakdown, some cleaning or set-up
activities maybe needed. These activities should be Pareto
booked under Production Downtime even-though
they are a consequence of the breakdown. This • RCPS (Root Cause Problem Solving)
split allows a good overview of the maintenance
efficiency through MTTR calculation (Mean Time To • Review the Preventive Maintenance plan
Repair)
• Develop Autonomous Maintenance
Pitfalls
If Breakdowns are very long, production people sometimes
consider a part of them as Non working Time. As a rule,
• All breakdowns hours should be booked as breakdown on
the machine until the machine is either back to production
or ready for new incoming orders

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6 Losses: What is a “trial”?

Definition
For ta Countermeasures

All time related to the processing of trial • For long trial, calculate the total cost to create a
orders cost awareness,
▪ trials are identified by separate order series • Limit the stoppage duration by improving the
▪ trials are tests of new raw material or new scheduling of all requested tasks
process
▪ can be paid or non-paid by the customer • Have one person responsible for the Total
▪ different departments can initiate trials stoppage time and related cost

Pitfalls
• Some managers consider the Trial cost as being
the hours spent by the process team (internal or
external) and the cost of the raw materials.
• The real cost of a Trial is the cost of non producing
during the use of the machine. The use time
includes the time needed for the process tasks, the
time needed by the production people (e.g.
cleaning) and any idle time from last good material
to new set-up.

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Las diferentes pérdidas: Effective Running
Time Running time

Perfor-
mance %
The performance ratio
measures time percent
lost for
• Micro Stop
B10: Bobinas en el árbol
• Reduced speed (RS)

Running
time
Micro
stops
Reduced
speed
Effective
running (
𝑅𝑆= 1 −
𝑉 𝑂𝐸𝐸)
𝑉 𝑟𝑒𝑎𝑙
∗ 𝐻𝑟𝑠( 𝐴 1)

time

Draft/Privileged and Confidential/Prepared for Counsel 21


7 Losses: What is a “minor stoppage”?

Definition Countermeasures

• Strong presence of the Team Leader on the shop


Time lost due to unplanned stops other than
floor to make production hours respected
Set-Up, Production Down-Time, Breakdown
• Continuous or hourly follow up of the production
to show any deviation from the standard
Operators pause to "tweak" equipment • Recording of all the short stops
(e.g. prevent jamming , vibration, overflowing …
• It is possible to record unplanned stops with a
computer linked to the machine and to ask
Pitfalls people to fill in the reason of the stoppage
Most of the time, unplanned stops are not recorded: • RCPS (Root Cause Problem Solving)
• The level of recording of unplanned stops
depends strongly of the level of performance Recording of short stops
management and repeatability of the process. Example and root causes
• When there is a computer on the machine, they
are often reported under a false reason (Ex:
Other stoppage)
• Unplanned stops also take into account late
start/early finish of the shifts

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Qué es la máxima velocidad referencia de
8 máquina para Amcor?
Definition

La velocidad máxima del equipo es la velocidad mecánica máxima dada por:


• la placa de velocidad del proveedor de la máquina,
cuando los datos no están disponibles, es la velocidad mecánica máxima del controlador principal
• Para extrusión soplado y plano, es la suma de la salida máxima de cada tornillo en LDPE

No se debe tener en cuenta ninguna limitación de velocidad debida al proceso (p. ej., capacidad de
laminación, capacidad de secado, alcance del LEL...), debido a la combinación de productos o a
una modificación de ingeniería (p. ej., sistema de frenado...).

Tips & tricks


La velocidad máxima del equipo es en muchos casos un tema delicado que se puede discutir. Por lo tanto, la alineación es
imperativa.
Al rastrear la pérdida de velocidad, se recomienda:
Para observar inicialmente la pérdida entre la velocidad real y la velocidad más rápida a la que el equipo podría funcionar
produciendo una buena calidad.
Y luego, busque la pérdida de velocidad adicional en comparación con la velocidad mecánica máxima

La velocidad más rápida a la que el equipo podría funcionar con buena calidad debe reflejarse en las Condiciones de
funcionamiento estándar (SOC) de la máquina.
El SOC debe ser desafiado regularmente para alcanzar la velocidad mecánica máxima de manera regular.

Draft/Privileged and Confidential/Prepared for Counsel 23


Cuando usar: Max. velocidad mecánica o “La máxima velocidad que el
equipo puede alcanzar con producción buena”

Cuando hay una diferencia entre la Cuando no hay diferencia entre la velocidad
velocidad real de la máquina y las real de la máquina y las condiciones de
Condiciones de operación estándar operación estándar publicadas en la
publicadas en la máquina, máquina,

• Calcular la pérdida de OEE versus “la • Calcular la pérdida de OEE versus “la
velocidad más rápida a la que el equipo velocidad mecánica máxima.
podría funcionar con buena calidad”
(SOC) • Configure los proyectos para aprovechar
la velocidad para alcanzar la velocidad
• Establecer la revisión de desempeño mecánica máxima
con el equipo en base a esta referencia
de velocidad

Draft/Privileged and Confidential/Prepared for Counsel 24


When to use : Max mechanical speed or “ the fastest speed that the
equipment could possibly run with good quality”

Shift performance review at Plant performance review and


machine level AFEMEA reporting

Availability ratio : Availability ratio :

Availability losses are limited to the one All availability losses are taken into
that the team can influence  OEE1 account  OEE2

Performance ratio :
Performance ratio :
Performance ratio is calculated with “
the fastest speed that the equipment Performance ratio is calculated with
could possibly run with good quality” “the max mechanical speed of the
machine”
These speeds are validated and
displayed in the Standard Operating
Conditions on the machine – the team
can influence them at machine level

Draft/Privileged and Confidential/Prepared for Counsel 25


8 Losses: What is a “reduced speed”?

Definition Countermeasures

•Implement Performance Board at machine level to


highlight deviation
Time losses due to the machine working at a lower •Reduce the gap to standard speed through RCPS
speed than the max equipment speed (Root Cause Problem Solving)
Machine runs slower than its max because of :
•Check physically with a stopwatch the actual speed
▪ bottleneck down the line of the machine. It may be higher than the standard
▪ Speed lost for ramp up speed given by production

Losses can be counted versus :


▪ Max Mechanical speed : see definition former Reduced speed recorded by
slides Example the machine computer
▪ The fastest speed that the equipment could 3,5
Observation
possibly run producing good quality 3

2,5

1,5
Pitfalls 1

• It is often difficult to separate losses from reduce 0,5

speed and losses from unplanned short stops 0

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The different losses: Quality rate is defined as
Effective Time over Effective Run Time

The quality ratio


measures time percent
lost for
Quality rate %
• El impacto del scrap
contabilizado en horas.

Effective Set-up & Customer Effective Time


Run Time Run Waste claim and
NCI

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Losses: What is “Set-up & Run Waste”?

Definition Countermeasures

• Implement Performance Board at machine level


Time lost producing parts out of specifications to highlight deviation
which are rejected at the end of the process
or later • Set Waste standards that reflect the scheduling
pattern

Pitfalls • Use a Pareto to classify the Waste cause


• Waste defects should also include defects found
later on other lines, • Have unambiguous and distinct Waste reason
• Defects attributed to another process should not codes in the MES shop-floor system to fine-tune
be recorded the Pareto

• In theory, the waste losses should be limited to • RCPS (Root Cause Problem Solving)
Run Waste. Set-up Waste are produced during
Set-Up Hours and are already previously counted
as a loss in OEE. To ease the data collection, Set-
Up & Run Waste can be aggregated.

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Losses: What is “NCI and customer claim”?

Definition Countermeasures

Time lost producing parts out of specifications


which are :
• Considered as good but rejected later in
the process
• Considered as good and sold but rejected
in the customer process

These losses are not taken into account in the


Amcor OEE :
• because of the time lag between the
creation of the loss and its reporting
• Quality KPIs are already tracking NCI and
customer claims

Pitfalls

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The different losses: Width efficiency rate is defined
as Effective Time over Effective Time & Width

Width efficiency rate %

The width efficiency


ratio measures time
percent lost for
• Not using the nominal
width of the machine

Effective Time Effective Time


& width

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Losses: What is a “width efficiency”?

Definition Countermeasures

Time lost for not using the nominal


width of the equipment

Pitfalls

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OEE en el Power BI

https://app.powerbi.com/links/
fB31o9roFC?ctid=fe9c207f-da30-4226-
82b5-
bff6ef031c8c&pbi_source=linkShare

Draft/Privileged and Confidential/Prepared for Counsel 32


OEE en el Power BI – Waterfall OEE1
Seleccionemos (1) Proceso/Familia, (2) Rango de fechas del mes actual (3) El rango de fecha del
mes Referencia

3
1
2

Ratios del rango de


fechas seleccionado

Ratios Referencia
del rango de fechas
seleccionado

Draft/Privileged and Confidential/Prepared for Counsel 33


OEE en el Power BI – OEE1 x Fecha
Seleccionemos (1) Proceso/Familia, (2) Rango de fechas del mes actual (3) El rango de fecha del
mes Referencia

Aquí podemos observar la evolución del OEE1 en el tiempo

Draft/Privileged and Confidential/Prepared for Counsel 34


OEE en el Power BI – Principales Sugerencias

Set-up • Implementar el SMED


• Implemente el tablero de seguimiento a nivel de máquina para comparar el tiempo de setup real con el
tiempo de setup estándar después de SMED.
• RCPS (Resolución de Problemas de Causa Raíz) para desviación

Production • Implementar Performance Board a nivel de máquina para resaltar la desviación


Downtime • Use un Pareto para clasificar los principales tipos de actividad y su impacto.
Tener códigos de motivo de tiempo de inactividad de producción inequívocos y distintos en el sistema intgral
para ajustar el Pareto
• RCPS (resolución de problemas de causa raíz)

Breakdown • Implementar Performance Board a nivel de máquina para resaltar la desviación


• Use un Pareto para clasificar el desglose
• Tener códigos de motivo de avería inequívocos y distintos en el CMMS (Sistema de gestión de
mantenimiento computarizado) y/o en el sistema Integral para ajustar el Pareto
• RCPS (resolución de problemas de causa raíz)
• Revisar el plan de Mantenimiento Preventivo
• Desarrollar Mantenimiento Autónomo

Draft/Privileged and Confidential/Prepared for Counsel 35


OEE en el Power BI – Principales Sugerencias

Trials • Para una muestra larga, calcule el costo total para crear una conciencia de costos
• Limite la duración de la parada mejorando la programación de todas las tareas solicitadas
• Tener una persona responsable del tiempo total de parada y el costo relacionado
Reduce Speed • Implementar Performance Board a nivel de máquina para resaltar la desviación
• Reduzca la brecha a la velocidad estándar a través de RCPS (Resolución de problemas de causa raíz)
• Compruebe físicamente con un cronómetro la velocidad real de la máquina. Puede ser superior a la
velocidad estándar dada por la producción
Deffect Losses • Establecer estándares de Scrap que reflejen el programa de producción
• Use un Pareto para clasificar la causa del Scrap
Tenga códigos de motivo de desperdicio inequívocos y distintos en el sistema de piso de producción MES para
afinar el Pareto
• RCPS (resolución de problemas de causa raíz)

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