02. Chien Luoc Bao Duong Nm Dpm
Transcript of 02. Chien Luoc Bao Duong Nm Dpm
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CHIN LC BO DNG CA NH MY M PH M
Trnh by: Nguyn Thanh Sn, Ph Phng K Thut, Nh my m Ph M
www.dpm.vn 1 Bo co chin lc bo dng Nh my m Ph M
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GII THIU V NH MY M PH M 1
CC HOT NG BO DNG TRN TH GII
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M HNH CHIN LC BO DNG CA NH MY M PH M
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KT QU GHI NHN 4
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GII THIU V NH MY M PH M 1
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GII THIU V NH MY M PH M
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Nh my m Ph M a ch: KCN Ph M 1, H. Tn Thnh, Tnh B Ra Vng Tu. Ch u t: Tng cng ty Du Kh Vit Nam. Cng ngh: an Mch & Italia Nguyn liu u vo: Kh ng hnh m Bch H, kh thin nhin t bn trng cn Nam sn v cc b khc thuc thm lc a pha Nam.
Sn phm chnh ca Nh my: -NH3: khong 1,350 tn/ngy (cng ngh Haldor Topsoe an Mch). -Urea: khong 2,385 tn/ngy (Cng ngh SnamProgetti Italia). -in: 21MW.
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CC HOT NG BO DNG TRN TH GII 2
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Th h th 3: Bo dng ngn nga, d on: da theo tin cy, ti u ha vic lp k hoch Cc cng c v k thut bo dng: RCM, RBI, CBM,
FMEA, RCA,
1940 1950 1960 1970 1980 1990 2000 2010
Gia
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hi
u q
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Th h th 2: Bo dng nh k: bo dng theo thi gian, thay th chi tit theo khuyn co Vendor Th h th nht:
Sa cha khi c h hng
Cao
Tru
ng b
nh
Thp
LCH S PHT TRIN HOT NG BO DNG TRN TH GII
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Mc tiu chnh ca
RCM?
Gim chi ph bo dng bng cch tp trung vo cc chc nng quan trng ca cc h thng, nhm loi b cc hnh ng bo dng khng cn thit.
RCM phn loi cc thit b c hnh thc bo dng hp l
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RCM (Reliability Centered Maintenance)
RCM l mt qu trnh c s dng xc nh cc cng vic cn phi lm m bo thit b lun vn hnh iu kin mong mun ca ngi s dng
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RCM (Reliability Centered Maintenance)
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lm tt RCM cn gii quyt 7 cu hi c bn:
Cc chc nng v tiu chun hot ng ca thit b khi vn hnh l g?
Bng cch no dn n thit b h hng cc chc nng ca n?
Cc nguyn nhn gy ra cc h hng ?
iu g xy ra khi h hng xy ra?
Cch thc xy ra cc h hng?
Cn lm g d on v ngn nga h hng?
Cn phi lm g nu khng th tm ra nguyn nhn loi tr?
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PMO (Planed Maintenance Optimization)
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PMO thu thp cc dng h hng (Failure Mode) bit t chng trnh bo dng hin ti, a ra nh gi cc Failure Mode, nh gi nh hng cho tng dng h hng v la chn hnh thc bo dng ph hp.
PMO gip ci thin cng tc lp k hoch bo dng theo cch sau:
iu chnh li ni dung, tn sut cng vic bo dng.
Loi b cng vic trng lp
Tin ti hnh thc bo dng theo tnh trng.
B sung cng vic cn thit ngn nga cc h hng c th xy ra (trong lch s xy ra).
Phn b khi lng cng vic cho cc ngun lc bo dng v vn hnh.
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RBI (Risk Based Inspection)
RBI l mt phng php da trn mc ri ro kim tra nh gi thit b theo API 580&581.
Phng php ny nhm phn loi mc ri ro ca thit b ra k hoch v phng php kim tra tnh trng thit b.
RBI s dng cho thit b tnh, ng ng v van an ton da theo mc quan trng ca thit b trong h thng.
Ma trn xp loi ri ro
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RCA (Root Cause Analysis)
RCA l phng php x l cc vn h hng m mc tiu l tm ra nguyn nhn gc r khc phc v loi b.
RCA thng c coi l mt qu trnh lp v thng c xem nh mt cng c ca ci tin lin tc.
RCA tr thnh mt phng php chuyn nghip ch ng, RCA c th d bo kh nng xy ra mt s kin, ngay c trc khi n c th xy ra.
RCA p dng trong mi lnh vc: phn tch h hng, an ton, sc kho, cht lng sn xut...
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RCA (Root Cause Analysis)
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FMEA (Failure Mode and Effect Analysis)
FMEA l mt cng c dng phn tch cc nguyn nhn gy ra cc dng h hng, tn sut h hng, hu qu h hng ca cc thit b quan trng c th xy ra trong thc t. T a ra hnh ng khc phc trong tng lai.
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CBM (Condition Based Maintenance)
CBM l hnh thc bo dng da trn vic gim st s thay i tnh trng ca thit b.
C th kim sot thng trc (on line), hoc nh k xc nh tnh trng my.
Ch ln k hoch dng my x l sau khi chn on chnh xc tnh trng my.
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Chc nng chnh ca CMMS l
qun l thit b v tn kho.
My tinh hoa qun l cng
vic bo dng
Cc cng vic bo dng c sp xp v ln lch nhm ti
u hoa vt t ph tng,
ngun lao ng v cng c. Cung cp thng
tin v c tinh ky thut ca thit b
Cng vic c qun l tp
trung (cng vic, con ngi, thit
b )
T ng xut ra k hoch bo
dng nh k
CMMS (Computerized Maintenance Management System)
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CMMS l
mt phn mm lu tr c s d liu v cc thng
tin ca hot ng cng tc
bo dng ca Nh my.
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M HNH CHIN LC BO DNG CA NH MY M PH M
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M HNH CHIN LC BO DNG ANG C P DNG TI NH MY PM
PM/PdM
WORK ORDER
CMMS
FIELD
CBM
RCM/PMO
RBI
RCA FMEA
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a CMMS vo hot ng tt trong thc hin ti a cc chc nng ca CMMS, vi tnh ha cng tc qun l bo dng thit b nh my.
Duy tr v nng cao hiu qu ca h thng MMS system1, ng thi nghin cu a cc cng c, k thut khc vo cng tc theo di tnh trng thit b in v TH (CBM).
p dng RCA trong vic tm nguyn nhn cc h hng ca cc thit b quan trng ca nh my.
p dng RBI trong vic theo di, kim tra v chn on tnh trng thit b tnh.
p dng FMEA vo nh gi ri ro kh nng gy ra h hng v a ra bin php nhm lm gim v loi tr h hng.
Ti u ha vic lp k hoch v la chn hnh thc bo dng hp l nh thc hin PMO/RCM
MC TIU THC HIN
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L TRNH THC HIN
Giai on Cng vic trin khai Giai
on
I Chun b
Xc nh thc trng cng tc bo dng nh my.
Xc nh yu cu v mc tiu thc hin La chn m hnh chin lc bo dng sa
cha
2 nm (2010-
2012)
II
Hon
thin CMMS.
Xy
dng RBI
Xc nh ngun lc (ngn sch, thi gian v nhn lc).
Duy tr khai thc v hon thin cc chc nng CMMS
Duy tr khai thc h thng MMS (CBM). Duy tr phn tch RCA (iu tra s c, h hng
lp li). Xy dng RBI Xc nh hnh thc bo dng hp l Cp nht ni dung v tn sut BD Ci tin lin tc qua KPIs.
2 nm (2012-
2013)
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L TRNH THC HIN
Giai on Cng vic trin khai Giai
on
III
Phn
tch
PMO
Duy tr khai thc v hon thinCMMS
Duy tr khai thc MMS (CBM).
Duy tr khai thc RBI
Phn tch PMO
Xc nh li hnh thc bo dng hp l
Ti u ha ni dung v tn sut BD
Ci tin lin tc qua KPIs.
3 nm
(2014-
2016)
IV
Phn
tch
RCM
Phn tch FMEA
Thu thp d liu phn tch t RBI, CBM, FMEA,
RCA, CMMS
Xc nh li hnh thc bo dng hp l
Ti u ha ni dung v tn sut BD
Ci tin lin tc qua o lng KPIs.
5 nm
(sau
2016)
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SCH LC BO DNG
Cn c vo chin lc bo dng ra, Nh my ban hnh sch lc bo dng nh my m Ph M: Nhm cung cp cc thng tin cn thit xy dng mt
chng trnh bo dng an ton, t hiu qu v mt kinh t v k thut.
t c mc ich trn, sch lc bo dng m t cch thc qun l cc hot ng bo dng nhm m bo an ton, sc kho cho con ngi; quan tm n mi trng; bo ton s nguyn vn cho h thng v thit b; duy tr s vn hnh n nh, hiu qu.
Sch lc bo dng cng m t cch thc qun l cc thit b, quy nh vai tr v trch nhim ca cc c nhn tham gia qun l cng tc bo dng, m bo s ph hp vi cc quy nh ca cng ty, quy nh ca nh nc, cc iu kin thc t, cc tiu chun k thut.
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Stt Lnh vc cng nhn
D kin 2015-2020
1 o Lng T ng Ha 6 7
2 Cng Ngh 3 4
3 in 1 3
4 KTTB, C Kh 4 6
O TO NHN LC
Nhm nng cao nng lc ca khi BD, PVFCCo trin khai mt s bc: - y mnh cng tc o to ni b - o to trong nc v nc ngoi, u tin v tr quy hoch - nh k t chc thi kim tra kin thc khi bo dng - Xy dng v pht trin i ng chuyn gia cho cng tc bo
dng trong cc lnh vc (nm 2014 c 14 chuyn gia c cng nhn).
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KT QU GHI NHN 4
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KPI O LNG HOT NG BO DNG
STT Ch s KPI nm 2013 VT Kt qu Ch tiu
1 % hng mc sa cha khn cp % 0.03% < 5%
2 % hng mc BDSC c k hoch thc hin
% 85.3% > 80%
3 % hng mc BDSC theo KH thc hin so vi k hoch
% 98.5% > 90%
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Tng s gi ngng nh my tr so vi k hoch (BDTT, SC ngn hn)
Ngy -1.5 3-5 Tun
5 % ngun nhn lc bo dng c o to hng nm
% 70.6% >5%
6 Kh nng sn sng cho thit b critical nh my
% 99% >96%
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Trn trng cm n!
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