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BAO TR TINH GON

BAO TR TINH GON

(Dung Sau Sigma DMAIC) ----------

Rao can cua tinh gon. Nhng lo lang cua cac nha quan ly. Co giam lng ton kho phu tung c khong ? Co giam chi ph cho ao tao, nhan s, phu tung c khong ? Co nen thue dch vu bao tr t ben ngoai hay khong ?

Van e bao tr

- Hai yeu to chnh la: o tin cay cua may va thi gian hoat ong tot cua may. - Giai phap la tm cac cach thc e loai bo thi gian ngng may khong ke hoach. - Phan ln ngi bao tr eu ngh rang khi nao may ngng th mnh sa no. - Van e la chung ta co the giam sat, o lng, kiem tra, theo doi, bao cao ve tnh trang may, nhng thi gian ngng may se van ton tai neu chung ta khong tm cach loai tr i, ngha la ngan nga e khoi xay ra ngng may.

Mot giai phap (Bao tr Tinh gon)

- e ngan nga ngng may chung ta phai loai tr nhng nguyen nhan gay ra ngng may. - Can co mot phng phap luan bao ve may tnh, cac bo ieu khien, PLC, CNC, cac he thong c kh, thuy lc, kh nen tranh nhng nguyen nhan gay ra van hanh sai va h hong.

@ Phng phap nay c gi la Bao tr tinh gon cho San xuat tinh gon ("Lean Maintenance for Lean Manufacturing). @ Phng phap hieu qua va thc tien nay co the giup ch cho cac doanh nghiep vien thong, y te, c kh, ien t, nha, v.v @ Trong vong 30 ngay ngi ta co the tranh van hanh sai, h hong may, ngng may ngoai ke hoach, phe pham, tai che, l thi han giao hang, v.v.. Va at gan nh la 100% o tin cay, nang suat, thi gian may hoat ong can e san xuat va gia tang li nhuan.

1. Co san phu tung thay the, 2. Sa cha, phuc hoi tai cho cac trng hp h hong, 3. Co san cac ky thuat vien, ky s bao tr, Muc tieu cua bao tr tinh gon la: - Giam 50 % thi gian ngng may cua he thong c kh. - Giam 80 % thi gian ngng may cua he thong thuy lc. - Giam 92 % thi gian ngng may cua he thong ien t.

Chung ta co the tang thi gian lam viec on nh cua may e giam chi ph bang cach am bao:

Chi ph ngng may - Mot gi ngng may mat bao nhieu (trieu ong) ? - Mot gi ngng mot nhom (day chuyen) may mat bao nhieu (trieu ong) ? - Mot gi ngng hoat ong cua toan bo nha may mat bao nhieu (trieu ong) ?

Tong chi ph ngng may (tr. ) = Chi ph cho phu tung h hong + Chi ph cho cac sai sot khi bao tr + (Chi ph mot gi ngng may x so gi ngng may)

Ch khi nao cac ban nam c chi ph ngng may th ban mi xac nh c tam quan trong va tac ong cua cac phng phap bao tr tinh gon (BTTG).

Bao tr tinh gon Phng phap luan

+ Muc tieu chnh cua BTTG la lam cho may moc, thiet b cua cong ty chay on nh 100 % ong thi giam t nhat 50 % chi ph bao tr. + Muon vay can ieu tra va phan tch co he thong tng may va he thong e xac nh nhng nguyen nhan goc re nao gay ra trc trac, h hong cho may, t o vach ra nhng trnh t, giai phap, s o bao ve may tranh khoi cac nguyen nhan nay.

Co ba loai thi gian ngng may: 1. Ngng may do sai sot cua ngi van hanh hoac ngi lap trnh.

2. Ngng may do qui trnh bao tr phong nga khong ung, khng thch hp. 3. Ngng may do h hong gay ra bi cac nguyen nhan nh: nhiet, rung ong, an mon hoa hoc, mai mon c hoc, ong bui, qua ien ap hoac dong ien, nhiem ban bui, nc, acid, tap chat trong he thong thuy lc, v.v..

Sau Sigma, ISO-9000 va TPM thng e cap en hai van e au tien. Con BTTG nhan manh tam quan trong cua ca ba va tap trung vao van e th ba. V du n gian nh sau: Chung ta co the tr nhien lieu au o nhng phai tranh nguon nhiet va oxy. c nh vay th co the tranh b hoa hoan. Tng t nh vay, neu chung ta co the loai tr cac nguyen nhan gay ra h hong trong cong tac bao tr th se khong xay ra van hanh sai, lam lan, khuyet tat, sa cha, phuc hoi va ngng may.

 Cac bc thc hien BTTG - DMAIC

Bc 1: Xac nh van e (Define the problem): May moc la nhng cong nhan co nang suat cao cua mot doanh nghiep. Thng may moc co lng cao hn con ngi. Khi may moc b ngng, doanh nghiep b mat doanh thu va li nhuan. V vay can xac nh ro s viec, van e xay ra.

Bc 2: Giam sat va o lng van e (Monitor & Measure the problem): Giam sat thi gian ngng may va o, tnh chi ph , ton that do ngng may. Neu chung ta co mot he thong Quan ly bao tr bang may tnh CMMS (computerized maintenance management system) hoac mot he thong quan ly cung ng va phieu bao tr tot th co the tnh c tiem nang tiet kiem va li nhuan thu c neu tranh c cac h hong xay ra. Can o va bao cao nhng van e sau ay (trong nam qua):

1. Bao nhieu Phieu yeu cau bao tr cho nhng lan ngng may khong ke hoach ma ban a co trong vai thang qua, trong nam qua ? 2. Bao nhieu gi ngng may khong ke hoach? Bao nhieu gi bao tr c thc hien bi ngi cua nha may hoac cua ben ngoai? Bao nhieu gi ngng may do he thong c kh, thuy lc, ien b h hong ? 3. Bao nhieu ong a c chi cho viec sa cha may moc?

4. Bao nhieu chi ph e sa cha cac bo phan ien t (noi bo va thue ngoai) ? 5. Bao nhieu chi ph e sa cha cac bo phan thuy lc (noi bo va thue ngoai) ? 6. Bao nhieu chi ph cho dau thuy lc ?

7. Bao nhieu chi ph e x ly dau thuy lc phe thai? 8. Co bao nhieu he thong thuy lc? 9. Co bao nhieu may hay he thong ieu khien bang PLC/ may tnh c s dung nha may ?

10. Nhng khu vc hoac cac may moc, thiet b nao can phai het sc quan tam ? 11. Chi ph/ ton that/ thiet hai do mot gi ngng may tai bo phan/ day chuyen/ nha may la bao nhieu? 12. Nhan chi ph moi gi ngng may vi tong so gi ngng may muc 1 va 2. Neu ban loai tr c 70% - 92% muc so 12 th co ang e ban va cong ty quan tam khong?

Bc 3: Phan tch lam the nao e giai quyet hoac loai tr van e nay (Analyze how to solve or eliminate the problem): Ky s bao tr cua cong ty, hoac chuyen gia t van se phan tch va xac nh oi vi moi may, thiet b giai phap bao ve may co hieu qua nhat e tranh cac nguyen nhan neu tren. Nen yeu cau ho viet bao cao chi tiet, theo tng may, cach thc bao ve may, thiet b, dung cu can thiet, nhng ch dan lap at chi tiet, d toan chi ph thc hien. Quyet nh co au t hay khong phu thuoc vao anh gia cua chung ta khi so sanh li ch nh thi gian ngng may giam va li nhuan gia tang nh c e cap muc so 12

 Lap at va thc hien (Install and Implement)

Nhng ch dan lap at neu tren phai chi tiet, cu the e nhan vien bao tr cua chung ta co the lap at de dang va nhanh chong nhng thiet b, phng phap, linh kien, v.v

 Kiem soat d an (Controlling this project)

Kiem soat BTTG khong can nhieu co gang. Cac bc thc hien e tranh van hanh sai he thong thuy lc va thi gian ngng may co the giam trong thc te en 90 % lao ong thc hien cong viec bao tr phong nga va phuc hoi, ong thi keo dai tuoi tho cua may.

 Kinh nghim ca Cong ty Amemco: co the giup trien khai Chngtrnh Bao tr Tinh gon trong vong 30 ngay. Chng trnh au tien mat 5 nam. Lan th hai can 2 nam. Sau o rut xuong con 3 6 thang. Bay gi sau 25 nam kinh nghiem cng ty nay a giup khach hang nang cao en mc toi a thi gian may hoat ong, o tin cay, nang suat va li nhuan trong vong 30 ngay.

 Amemco tien hanh ieu tra va phan tch nha may va thiet b cua khach hang. Chng trnh bat au bang mot hoi thao chuyen e ve Bao tr tinh gon tai nha may trong ba gi cho moi ngi co lien quan t lanh ao bo phan san xuat en cac ky s va ky thuat vien bao tr. Chuyen e nay se trnh bay nhng cang thang do h hong, ngng may gay ra nh the nao va cac phng phap Bao tr tinh gon se loai bo nhng cang thang nay ra sao.

 Moi ngi cung thao luan va xem xet nhng bat thng gay ra ngng may ngoai ke hoach nha may. Nhom cong tac khao sat, ieu tra ve thi gian ngng may, o tin cay cua thiet b trong vong 2 4 ngay, ghi nhan cac so lieu ve may va thiet b, sau o lam bao cao chi tiet khoang 20 - 30 trang ve mot loat cac giai phap bao ve cho moi may va he thong ieu khien.

 Ket luan
Bao tr Tinh gon" nham lam giam ang ke h hong gay ngng may va nh tre san xuat. Bao tr tinh gon nham bao ve may, phong tranh cac nguyen nhan goc re/ thc s gay ngng may ch khong phai ch la trieu chng.

 Ket luan (tt)

Bat ky ky s hoac nha quan ly bao tr nao eu co the bat au Bao tr Tinh gon bang cach bao ve cac thiet b ieu khien, t ong hoa, thuy lc, kh nen, v.v tranh cac nguyen nhan goc re gay ra van hanh sai, h hong, ngng may nh a neu tren. H hong bo mach, he thong thuy lc va van hanh sai sot ch la trieu chng ch khong phai la nguyen nhan nam sau pha di cac hien tng ngng may ngoai ke hoach.

 Bao tr Tinh gon co the c thc hien trong vong 30 ngay thay v phai mat nhieu nam, giup doanh nghiep: 1. Tang li nhuan. 2. am bao gan 100 % thi gian may hoat ong e San xuat tinh gon. 3. Giam ang ke chi ph bao tr trc tiep va gian tiep. 4. Giam s phu thuoc vao dch vu ho tr bao tr ben ngoai.

 Bao tr Tinh gon giup at c toi a thi gian may hoat ong, san lng, nang suat va li nhuan.