15/6/2011

Lp k hoch bo dng cho mt Nh

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Gii php Bo tr Cng nghip

Trang ch Bo Tr Tin tc Thit B C Kh eBook Tin ch iu khin T ng Cng ngh Chuyn Thit b in Ni bt Blog Tm kim Home Lp k hoch, Qun l Bo tr, Qun l Sn xut T vn lp k hoch bo dng cho mt Nh my sn xut ngi lp t ng

T vn lp k hoch bo dng cho mt Nh my sn xut ngi lp t ng

Vit bi Vinamain Editorial on December 3, 2010 8 Bnh lun Knh gi Anh Thanh Sn, Tha Anh, Ti l dn C kh, trc y ti tng tt nghip Trng K Thut Cao Thng, sau ny ti cng c gng hc v tt nghip i hc ti Trng i hc s phm k thut Tp HCM. Ti tng trc tip lm cng nhn bo tr bo dng my mc thit b 12 nm & tip tc lm cng tc qun l bo tr bo dng cho n nay 8 nm. C th anh t hi ti sao ti ni v mnh nhiu th, bn thn ti so vi Anh th c l chng c g ni, v kin thc c kh ca ti so vi Anh cng qu bo. Ti ni v ti nh vy bit rng ti khao kht mun hc hi kin thc v c kh bit dng no. Hin nay, ti ang loay hoay tm phng n lp mt k hoch bo tr bo dng cho mt Nh my t ng sn xut ngi lp, m khng bit phi bt u v kt thc nh th no. Nu c, ti rt mong Anh v cc thn vin Vinamain ch gio. Ti gi n Anh li cm n chn thnh v su sc.Lun chc Anh khe dn dt trnh c kh Vit Nam nhanh chng rt ngn khong cch vi cc nc trong khu vc. Trn trng, Bi Quang Thun.

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Lp k hoch bo dng cho mt Nh

Cm n nhng li ni chn thnh ca anh dnh cho thnh vin ca Vinamain. Cu hi ca anh cng l thc mc ca nhiu bn lm cng tc bo dng cc nh my. y l ch ln nn trong khun kh din n ny cha chc c th gii p ht, Tuy nhin chng ti s c gng a ra nhng chnh bn tham kho: Bn cn cho chng ti bit: Nh my bn vn hnh 24/24 hay ch 8-12 ting mt ngy. Ngng my do h hng c gy thit hi ln khng. iu ny rt quan trng, v n nh hng ti vic chn hnh thc bo dng cho ph hp nhm trnh lng ph thi gian v chi ph. y chng ti a ra cc c bn: 1. Xy dng mc tiu, chin lc Mc tiu cu cng tc bo tr l nhm duy tr tnh trng hot ng tt ca thit b vi chi ph thp nht. Cc nhim v chnh ca cng tc bo tr: Nng cao tin cy. Ti u ha chi ph. An ton v bo v mi trng. Thc hin cc trch nhim x hi. t c mc tiu cc nh my cng nghip phi la chn cc gii php bo tr ng, ph hp vi iu kin sn xut kinh doanh ca doanh nghip. Mi bn c: http://vinamain.com/2010/08/tang-giao-trinh-quan-ly-bao-tri-nha-may-cong-nghiep.html Khi bt u xy dng phng n bn nn xy dng theo mc tiu sn xut ca cty bn t a ra mc tiu bo dng l g ? 2.Chn hnh thc bo dng cho tng loi thit b Bn tin hnh phn loi thit bi: Thit b sng cn (cho an ton, to sn phm, cht lng sn phm). Thit b quan trng (cc thit nh hng ti dy chuyn nhng c d phng, thit b mc tin, vn vt t v.v). Thit b ph tr. Thit b sng cn: Bo dng theo tnh trng (theo di rung ng, nhit , ting n, hay cht lng sn phm) v bo dng nh k (bo dng, thay th chi tit nh k). C cc hnh thc bo dng ch yu sau:

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Lp k hoch bo dng cho mt Nh

Bn tham kho: http://vinamain.com/2010/05/dac-diem-co-ban-cua-4-chien-luoc-bao-tri.html Thit b quan trng: p dng Bo dng theo tnh trng c du hiu h hng th ln k hoch sa cha. i vi cc dng h hng m khng th theo di gim st tnh trng nn tin hnh kim tra khi c iu kin ngng my (hay gi l bo dng c hi) http://vinamain.com/2010/08/mot-so-ky-thuat-giam-sat-tinh-trang.html http://vinamain.com/2010/05/bao-tri-du-doan.html http://vinamain.com/2010/09/bao-duong-co-hoi-nang-cao-do-tin-cay-nha-may.html Thit b ph tr: nhng thit b ny khng quan trng cho vic sn xut bn nn chn hnh thc sa cha phc hi hay h mi sa. (i vi thit b nu h gy tn km ln cho vic SC th bn nn a vo Bo dng nh k). Sa cha ln ton nh my: l thi gian kim nh, bo dng sa cha cc tn ng h hng. Thng thng theo quy nh ca php lut, p dng cho thit b ch sa cha khi ngng nh my nhiu ngy, thit b c ri ro cao ti s hot ng ca nh my (an ton chy n) http://vinamain.com/2010/09/lap-ke-hoach-ngung-may-va-sua-chua-co-hieu-qua.html a cc cng c v gi php h tr hot ng bo dng vo p dng: CMMS: http://vinamain.com/2010/05/he-thong-quan-ly-bao-tri-nh%E1%BB%9D-may-tinh-cmms.html TPM: http://vinamain.com/2009/03/bao-tri-nang-suat-toan-bo-tpm-total-productive-maint.html Kaizen: http://vinamain.com/2009/05/loi-ich-cua-kaizen-va-yeu-to-quyet-dinh-su-thanh-cong-cua-hoat-dongkaizen.html 5S: http://vinamain.com/2009/03/ap-dung-5s-trong-quan-ly-bao-tri.html Lean: http://vinamain.com/2010/12/bao-tri-tinh-gon-lean-maintenance.html 3. C cu t chc V c cu t chc cho hot ng bo dng cng phi m bo cho vic thc thi c tt, c bn cn phi c: 1.B phn lp k hoch (thuc Phng k thut): cc k s c kinh nghim lp k hoch vt t, k hoch bo dng nh k, kim nh thit b, k hoch cho sa cha ton nh my. 2. B phn thc thi: bao gm cc k s cng nhn sa cha bo dng trc tip (c kh, in, t ng ha. Xy dng quy trnh bo dng- sa cha: cc bc trin khai cng vic, ai thc hin, bo co kt qu BD, ai thng k, ai gim st.
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Cch lp k hoch BD nh k:

Lp k hoch bo dng cho mt Nh

Da theo bng phn loi thit b, bn tin hnh lp k hoch cho cc thit b sng cn v quan trng. Bn cng nh ngha cho cc loi hnh BD nh: i tu, trung tu, tiu tu l g? Tn thit b Ni dung Loi hnh Tn sut Ngng bo dng thit/khng ngng c thng tin trn cn da trn c s : S tay vn hnh bo dng my (OMM): nh xut c a ra khuyn co my thng thay du, thay bi, i tu, trung tu S gi chy my, thi gian sa cha ln cui trc Theo tnh trng thc t ca my: mt s my c th tng tn sut bo dng S dng cc cng c RCA (Root Cause Analysis), CBM Condition Based Maintenanace), FMEA (Failure Mode and Effect Analysis), RCM (Reliability Centered Maintenance) phn tch xc nh nhu cu bo dng, ti u ha cng tc lp k hoch.(Ci ny hi cao cp). RCA (Root Cause Analysis): l phng php x l cc vn h hng m mc tiu l tm ra nguyn nhn ct li khc phc v loi b. FMEA (Failure Mode and Effect Analysis): l mt trong cc k thut phn tch ri ro ca RCA, y l phng php mang tnh h thng cho vic xc nh v gim thiu hoc ngn nga cc h hng trong thit b (phn tch cc kiu h hng, nguyn nhn v kt qu ca cc h hng tim tng), sn phm v qu trnh trc khi n xy ra. FMEA s to ra mt bng thng k cc kiu h hng, tn sut h hng, hu qu ca cc thit b quan trng khi n xy ra trong thc t. Ngoi ra bn cn ch vn nhn lc cho bo dng: quyt nh n cht lng cng tc bo dng ca nh my, d k hoch BD c hon ho n u m cht lng tay ngh ca th SC v k s gim st km cng lm cho ph sn k hoch v h hng s pht sinh nhiu hn trc. Nu cn s gip hiu qu hn, chng ti c th n kho st thc t ti nh my ra phng n bo dng hp l cho nh my. Ban qun tr Vinamain mi cc bn tham gia tr li cho cu hi trn trong phn comment. Rt mong cc bn chia s kin cng cng ng bo tr cng nghip Vit Nam. n v S th thc hin Vt t Thi gian HD/ quy trnh

Vit bi: Vinamain Editorial Thnh vin cao cp trong BQT Vinamain. Vinamain cung cp nhng gii php cp bch cho ngnh bo tr cng nghip, qun l bo tr, qun l sn xut, cung cp ti liu k thut bo dng v sa cha c kh, ti liu c kh, in v t ng ho. Din n Cng ng Bo tr Cng nghip Vit Nam.

Bi vit lin quan

Thit k m bo tin cy l g? Bo tr Tin phong (Proactive Maintenance) Lp k hoch v ln lch cng vic cho cng tc bo tr Bo tr: mc tiu v li ch Mt s phng php bo tr thng thng c p dng cc nc u chu
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Bo dng cng nghip Vit Nam: Tt hu 50 nm Biu mu dng trong cng tc bo tr (.ppt) Tng gio trnh Qun L Bo Tr Nh My Cng Nghip M hnh qun l bo tr cc nh my cng nghip Hng dn bo dng sa cha my cng c (ebook) Thit k m bo kh nng bo tr (ebook) Vn hnh v x l s c h thng thy lc Lp k hoch hoch bo tr v theo di tt hn h thng li in vi gii php CBM Lu khi bo dng my cng c Ti ebook:Bo tr nng sut ton din (Total Productive Maintenance)

Lp k hoch bo dng cho mt Nh

T kha: Bo dng Cng nghip, Bo tr Cng nghip, chien luoc bao tri, Gio trnh, Ke hoach, Lp k hoch, Maintenance, Phuong an, Qun l

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8 Nhn xt cho T vn lp k hoch bo dng cho mt Nh my sn xut ngi lp t ng

1. hieu 04.12.2010 y l bi vit rt hay v hu ch cho tt c anh em k s. Thanks Ban qun tr Vinamain. Tt c cc trn theo ti rt vch ra k hoch bo tr bo dng rt tt cho cng ty ri. Theo ti b sung thm 01 vn : cn c thng k chi ph bo tr cho nh my trn n v sn phm sn xut. Chi ph bo tr ny chim bao nhiu % trong gi thnh sn xut. Khi kim sot c chi ph, bn hon ton c th xc nh cn trang b thm thit b my d phng hay thay mi cc thit b my. iu ny s gip bo m hiu sut khai thc my. Reply

2. Vinamain Editorial 06.12.2010

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Cm n bn hieu b sung, l vn o lng hiu hot ng bo dng nh my v:Vic o lng hiu qu thc hin l quan trng v n xc nh khong cch gia kt qu hot ng hin ti v mong mun v cung cp cc tin trnh hng ti gn mc tiu: http://vinamain.com/2010/09/kpi-do-luong-va-quan-ly-chuc-nang-bao-duong-p1.html Reply

Lp k hoch bo dng cho mt Nh

3. hieu 06.12.2010 Theo ti vic lp k hoch bo dng cho hot ng ca nh my cha phi l vn nghim trng. Vn nghim trng nht l nhn lc thc hin, t tay ngh, tinh thn lm vic ca th sa cha n vic gim st ca i ng k s. Chc chn bn khng th kim sot tt c cc cng vic: t thc hin thao tc ng k thut n thi gian hon thnh cng vic. Rt kh ni rng 01 cng vic cn thi gian c th bao nhiu hon thnh. gii quyt c vn ny th cng ty bn phi c chnh sch tin lng rt r rng, c th: ai ng gp nhiu hng nhiu, ng gp t hng t.. hoc ti thiu i ng bo tr bo dng phi c hng lng khon sn phm. Reply

4. thuansam 08.12.2010 Knh gi Ban qun tr Vinamain, Trc ht, ti gi li cm n chn thnh & li chc sc khe n lnh o Ban bin tp cng nh mi thnh vin trong ban bin tp Vinamain. Ti nhn c bi vitT vn lp k hoch bo dng cho mt Nh my sn xut ngi lp t ng ca Vinamain, ti c & nay ti xin gi km mt s thng tin v nh my nh sau: 1/ Phc p cc yu cu ca Vinammain: - Nh my ti l h thit b gn nh hon ton t ng c nhp khu t Hng Rieter c vo nm 2007, v vy ton b dy chuyn sn xut khp kn t khu x l nguyn liu cho n khu ra l nung. y l mt h thit b hin i v c cu thnh t nhiu linh kin lin quan n nhiu lnh vc k thut c truyn & ng i khc nhau: C kh, in in t, kh nn, thy lc & PLC, - c im hot ng ca dy chuyn: L nung sn phm phi hot ng lin tc 24/24; Cc thit b khc hot ng theo sau: T 07 gi sng n 11 gi tra (ngh tra 01 gi), tip tc hot ng t 12 gi n 18h30, (ngh 2gi ri), tip tc hot ng t 21 gi cho n 06 gi sng hm sau (ngh 01 gi) n 07 gi sng hm sau v tip tc lp li nh trn. - Mt gi ngng my th mt ti thiu 50 triu (cha k cc thit hi v hnh khc). - C nhiu thit b m h hng xy ra l do nguyn nhn bo tr bo dng (nu bo tr bo dng tt th n cha h hng, thm ch cn s dng thm c hng vi ba nm na). 2/ Cc vn khc: - V cha c k hoch bo tr ph hp, nn lun phi chi ph cho d phng cc ph tng tn kho cao (do ph tng a s phi nhp ngoi). - Nhn lc bo tr hin nay ang l vn au u, bi: Hu ht nhn lc mi ra trng, cha c kinh nghim lm vic, cha c kin thc & thc bo tr my mc thit b theo hngphng bnh hn cha bnh. - Mc lng: Hu ht cng nhn bo tr th mc c bn 03 triu/thng, nu lm thm gi th c th t 5 triu/thng. K s th nhnh hn cng nhn khong 30%. - Trong cng ty, s ngi c kin thc & t duy bo tr theo hng hin i cng him (c 5% n 7%). - Phng php bo tr bo dng ang p dng cho n hin nay: Hu ht nh gic theo li h u sa ; ph tng thit b d phng thc hin theo li c th thay th, khng c th ngng my bo cp trn, c ngha l ang p dng phng php bo tr & qun l bo tr qu lc hu.
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Cn rt nhiu vn na,ti cha thi gian trnh by, hm nay vit th cm n kp thi bi t vn ca ban bin tp Vinamain. Tht ra, trc khi ti gi th nh Vinamain t vn th ti c gn ht cc bi vit v bo tr bo dng ca Vinamain.com, c bit cc bi vit do anh Thanh Sn vit v ti cng ngi son ln mt chng trnh k hoch bo tr bo dng p dng ph hp ti Nh my ti, nhng th tht cng nh cc anh ni, y l mt ti rng cn phi u t nhiu thi gian v tin bc mi la chn & p dng thu o mt phng php bo tr bo dng thnh cng ti mt Nh my c th. Hin nay, ti cng ang tip tc hnh trnh i tm li gii cho bi ton bo tr bo dng ti Nh my ti, khi son xong k hoch hnh ng c l ti cng phi nh cc Anh Vinamain duyt qua. Ti xin ngng y, lun chc cc anh sc khe tht nhiu gp phn a nn c kh Vit Nam i ln, Trn trng knh cho, Tp HCM, ngy 08/12/2010, Bi Quang Thun. Reply

Lp k hoch bo dng cho mt Nh

5. hieu 09.12.2010 Cho bn Theo nh cc vn bn nu th ti e rng vn nhn lc ca bn l vn rt ln . V vi mc lng bnh qun 3T m tng ca th c kh nng t 5T, chim khong 70% lng. iu ny rt d dn n cc anh em s khng ch tm cng vic trong gi hnh chnh v ko thi gian sa cha ra ngoi gi. Theo kin ti trc ht: + Bn hy xut phng n hng lng sn phm: ngha l lng cng + % t l theo sn phm lm ra hoc lng cng + tin thng sn xut; iu ny ng ngha vi vic my h nhiu s khng c tin sn phm. Hn ch ti a vn tng ca. + Bn cnh bn trin khai cc k hoch bi trn nh k v tng cng cng tc gim st my. Nu bn trin khai c 02 vn trn kh nng s gim bt downtime xung. Reply

6. hoang van giang 01.01.2011 xin cho BQT, chao anh Bi Quang Thun, Em l mt SV nm cui v cng thnh vin mi ca din n, Em c bi vit ca din n v bi vit ca anh v T vn lp k hoch bo dng cho mt Nh my sn xut ngi lp t ng. Em bit chc chn rng Anh bit c li ch to ln ca cng tc bo tr, bo dng mang lai cho nh my, c nhng thng tin anh vit v nh my ca anh thi Em thy thc s bc xc v cng tc bo tr, bo dng trong cng ty. Theo anh th: Mt gi ngng my th mt ti thiu 50 triu (cha k cc thit hi v hnh khc). - C nhiu thit b m h hng xy ra l do nguyn nhn bo tr bo dng (nu bo tr bo dng tt th n cha h hng, thm ch cn s dng thm c hng vi ba nm na). 2/ Cc vn khc: - V cha c k hoch bo tr ph hp, nn lun phi chi ph cho d phng cc ph tng tn kho cao (do ph tng a s phi nhp ngoi). - Nhn lc bo tr hin nay ang l vn au u, bi: Hu ht nhn lc mi ra trng, cha c kinh nghim lm vic, cha c kin thc & thc bo tr my mc thit b theo hngphng bnh hn cha bnh. - Phng php bo tr bo dng ang p dng cho n hin nay: Hu ht nh gic theo li h u sa ; ph tng thit b d phng thc hin theo li c th thay th, khng c th ngng my bo cp trn, c ngha l ang p dng phng php bo tr & qun l bo tr qu lc hu. V KHNG CN PH HP VI TH K 21 NA. theo Em, vic lm u tin l anh nn thng k ra nhng tn tht to ln m cng ty ang phi chiu do cng tc
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bo tr v qun l bo tr yu km mang li. c bit v mt kinh t v trnh ln ngi c quyn hn cao nht trong cng ty. Sau anh trnh by bn k hoch bo tr hin i m anh ang lp v theo l nhng li ch to ln m n mang li. V khng phi v gim c no cng bit c nhng phng php bo tr tin tin, hin i v ang c p dng rng ri trong cc cng ty ln ca Nht v M. ccn phng php nh l: TPM, JIS RCM, 5S, 6 Sigma, Kaizentt nhin khng th p dng hon ton nhng ta c th p dng tng phn ph hp vi cng ty. V lm iu ny th nhn lc l mt vn ln. Anh nn t chc nhng bui ta m, mi cc cng ty chuyn v lnh vc bo tr v ni chuyn v gii thiu v cc phng php bo tr hin i ph hp vi qui m sn xut ca cng ty. (Em tng t chc bui ta m nh th gia SV trong lp vi 1 cng ty ln v lnh vc bo tr ca tp). Tt nhin thc hin c vn iu anh mong mun thi cn rt nhiu vn khc lin quan m ch ngi trong cuc mi bit c. V cn l SV nn rt mong nhn c s gip ca din n. Chc anh thnh cng. Reply

Lp k hoch bo dng cho mt Nh

7. hoanson82 13.03.2011 mi nguoi giup toi voi, toi duoc giao lap ke hoach bao dung, bao tri cho mot nha may thuc pham, nhung thuc te toi lai chua bao gio lam viec nay ca, nen k biet nen bat dau tu dau,lam nhu the nao,tim tai lieu o daunoi tom lai kien thuc ve mang nay cua toi gan nhu bang khong.. Reply

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