NGUYN HNG LONG L TH THY DNG

VNCPC

S TAY BO DNG CNG NGHIP TIN TIN

1

MC LC

LI CM N..................................................................................................6 CCH S DNG CUN S TAY BO DNG.................................7 PHN 1. CC KIN THC C BN V BO DNG....................8 I. 1.1. 1.2. 1.3. 1.4. II. 2.1. 2.2. 2.3 III. 3.1. 3.2. 3.3. 3.4. BO DNG CNG NGHIP TIN TIN L G?.................9 nh ngha Bo dng..................................................................9 Bo dng Tin tin khc vi Bo dng truyn thng nh th no?.....................................................................11 Cc loi hnh Bo dng Cng nghip Tin tin trn th gii..............................................................................................11 M hnh bo dng xut cho Vit Nam.........................18 TI SAO CN P DNG BO DNG CNG NGHIP TIN TIN?.....................................................................19 Cc li ch ca Bo dng Cng nghip Tin Tin............19 Cc iu kin m bo s kh thi p dng Bo dng Cng nghip Tin tin Vit Nam...........................20 Cc in hnh p dng................................................................28 BT U NH TH NO?.........................................................32 Kim ton Bo dng Bn ang u?............................33 Trin khai h thng c s h tng cn thit cho Bo dng Cng nghip Tin tin..................................................33 Tch hp bo dng cng nghip tin tin vo hot ng qun l hng ngy ca doanh nghip......................33 TPM v Kaizen................................................................................34

S TAY BO DNG CNG NGHIP TIN TIN

PHN 2. CC TI LIU CHUYN SU...............................................................36 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 5S trong bo dng cng nghip...........................................................37 Bn cht hot ng v qu trnh hng ca thit b..........................40 Bo dng sa cha (bo dng hng my).....................................54 Bo dng phng nga.............................................................................61 Bo dng da trn tnh trng (ti liu cho cn b qun l bo dng)......................................................................................................79 Bo dng da trn tnh trng (ti liu cho cn b k thut bo dng)....................................................................................88 Mt v d v la chn thit b chn on tnh trng ti Trung tm Sn xut Sch Vit Nam......................................................102 H thng trao i thng tin...................................................................111 Hiu sut tng th (GER)..........................................................................122 Cu trc h s k thut.............................................................................134 Cu trc h s thit b...............................................................................141 Xy dng h s thit b v c s d liu bo dng......................163 Cp nht ti liu bo dng...................................................................169 T kim ton bo dng..........................................................................173 L thuyt phn tch chc nng..............................................................183 Qun l ti chnh bo dng da trn tnh trng...........................195 T chc bo dng....................................................................................204 H thng Gim st v chn on tnh trng thit b bng k thut dao ng my.................................................................229 V d ng dng v trin khai TPM cng ty giy Bi Bng..................................................................................................266 Khi nim v cc ni dung c bn ca TPM......................................269 L thuyt TPM v hng dn trin khai TPM....................................290 Qun l thit b............................................................................................326 Bo dng sn xut v an ton.............................................................330 Gim st tnh trng thit b.....................................................................334 Ch gii giao din phn mm k ton bo dng.........................371 Kaizen..............................................................................................................387

LI CM N
Trung tm Sn xut Sch Vit Nam (VNCPC) xin chn thnh cm n Phi on WallonieBruxelles ti Vit Nam (Dlgation Wallonie-Bruxelles) ti tr cho d n Xy dng nng lc v Trnh din K thut Bo dng Cng nghip Tin tin, cng nh cho vic bin son v in n b ti liu ny. VNCPC cng trn trng by t s cm n i vi t chc chc Le FOREM h tr k thut cho d n. S thnh cng, cc kt qu v kinh nghim thu c trong sut qu trnh thc hin d n gip VNCPC pht trin mt cng c mi trong gi dch v Sn xut Sch hn Tin tin- CP+, l t vn trin khai Bo dng Cng nghip Tin tin cho cc doanh nghip va v nh Vit Nam. VNCPC cng tri n cc nh t vn v cc cn b trong v ngoi nc, nhng ngi vn cn lm vic ti VNCPC hay chuyn cng tc khc, v nhng n lc to ln trong vic xy dng b ti liu S tay Bo dng Cng nghip Tin tin qua nhiu phin bn khc nhau hnh thnh ti liu chnh thc: ng Nguyn Hng Long, chuyn gia Sn xut Sch hn v Bo dng Cng nghip ca VNCPC, ngi tham gia thc hin D n, ng thi l tc gi vit v bin son phn ln ni dung cun S tay ny. ng Bertrand Collignon, chuyn gia Sn xut Sch hn v Bo dng Cng nghip, ngi chu trch nhim qun l D n Xy dng nng lc v Trnh din K thut Bo dng Cng nghip Tin tin. ng cng l ngi c cng ln trong vic xc tin v xy dng mi quan h hp tc tt p gia Phi on Wallonie-Bruxelles vi VNCPC. PGS.TS.Trn Vn Nhn, gim c VNCPC, ngi tham gia xy dng cu trc ca S tay. C L Th Thy Dng, ngi bin son phn ti liu chuyn su v Kaizen, cng nh bi tr v kim li cc bn tho. ng Phm Sinh Thnh, chuyn gia Sn xut Sch hn tham gia vo D n trin khai ti Cng ty Detech. ng Nh Qu Th, chuyn gia c kh v t ng ha, nghin cu sinh trng i hc Cng ngh Delft H Lan, ngi cung cp cc kin xy dng cho S tay v kim li bn tho cui cng. B L Thu H, chuyn gia Sn xut Sch hn, ngi tham gia phn bin v kim li cc bn tho ca S tay. Chng ti cng xin ghi nhn ng gp to ln ca Vin Nghin cu C kh (Narime) l n v cung cp cc thng tin v ti liu v mt s kin thc chuyn su cho S tay, cng nh o to tc gi ca n - ng Nguyn Hng Long cc kin thc ban u v Bo dng Cng nghip. Do nhng hn ch v ngun lc, thi gian v chuyn mn nn cun S tay ny chc chn cn nhiu thiu st. Nhng VNCPC vn mnh dn gii thiu ti c gi vi nim tin rng, vi t cch l mt ti liu thc hnh chuyn su bng ting Vit u tin trong lnh vc bo dng, y s l ngun tham kho v h tr c lc cho cc chuyn gia v nht l cc cng ty va v nh trong cng tc bo dng cng nghip. Chng ti rt mong nhn c cc kin ng gp, ph bnh v xy dng tip tc hon thin hn cun S tay Bo dng Cng nghip Tin tin ny. Thay mt VNCPC v Nhm tc gi PGS.TS.Trn Vn Nhn

CCH S DNG CUN S TAY

Cun S tay Bo dng Cng nghip Tin tin c vit phc v cc i tng: 1Cc nh lnh o v qun l doanh nghip (cp cao): 2Cc cn b qun l bo dng (cp qun l trung gian) 3Cc cn b k thut bo dng hoc sn xut- bo dng (cp qun l trung gian) y l ba nhm i tng quyt nh i vi trin khai Bo dng Cng nghip Tin tin ti cc doanh nghip. Ngoi ra, cc cn b ging dy, cc nh nghin cu, t vn v cc nh thit k thit b cng c th tham kho cc phn lin quan n chuyn mn ca mnh. Trong 3 nhm ngi c chnh, nhu cu kin thc v cc vn cn gii quyt khc nhau ng k. V vy chng ti cu trc cun S tay theo hai lp: (1) lp c bn v nguyn l; (2) lp kin thc chuyn su cung cp c s l thuyt cho qun l v k thut bo dng. Lp kin thc th nht c trnh by trong phn I Cc kin thc c bn v Bo dng. Phn ny dnh cho tt c cc i tng. c bit vi cc nh lnh o v qun l doanh nghip thng khng c nhiu thi gian v ch cn nm cc vn bn cht v nh hng th phn I p ng c yu cu ny. Tuy nhin, cc i tng cn li cng cn c k v hiu thu o. Phn I gm 26 trang, ng vai tr h thng ha kin thc nh mt bn t duy, vi cc kt ni v ch dn ti cc phn kin thc chuyn su trong phn II. Nu khng c k v hiu phn ny th ngi c rt d b ngp trc s lng kin thc s v cm thy b cc cun sch l kh hiu. Lp kin thc th hai c trnh by trong phn II Cc ti liu chuyn su. Do lng kin thc cn thit cho vic trin khai Bo dng Tin tin l rt bao qut v gn kt vi nhau nn khi c phn II phi hiu r phn I v lun duy tr c tm nhn bao qut ton b bc tranh v bo dng. Khng nn c tun t cun sch ny t u n cui v lm nh vy l khng ng vi logic cu trc v t duy ca n. Nu qu v c nhng ng gp v chia s nng cao cht lng cun sch ny, xin lin h vi tc gi qua email: long.nh@vncpc.org hay nghglong@gmail.com Trn trng!

I.

BO DNG CNG NGHIP TIN TIN L G?

1.1. nh ngha Bo dng Tiu chun AFNOR x 60-010 nh ngha Bo dng nh sau :

PHN 1.

L MI VIC LM C TH NHM DUY TR HOC KHI PHC MT THIT B TI MT IU KIN XC NH C TH TO RA SN PHM MONG MUN Theo quan im thc hnh BO DNG l vic thc hin cc tc v gip bo tn nng lc thit b, qua m bo tnh lin tc v cht lng ca sn xut. BO DNG din ra trong ton b thi gian s dng (tui th) ca thit b. (c thm v vng i v tui th thit b trang 45) BO DNG TT l m bo t c hot ng MC CHI PH TI U TNG QUT. T Bo dng - maintenance - trong ting Anh xut pht t ng t maintain, c ngha l duy tr. iu ny c ngha l duy tr kh nng lm ra sn phm ca my mc thit b. Hin nay, tuy c nhiu nh ngha khc nhau, nhng cch hiu thng dng nht v Bo dng Cng nghip ( Vit tt l bo dng) l duy tr hay khi phc kh nng ca my mc thit b nhm to ra sn phm c cc c tnh yu cu, trong thi gian cn n chng, vi chi ph tng qut thp nht. Ngy nay, cng vi nhng thay i cng ngh, hin tng ton cu ho kinh t, s ti c cu lin tc cng nh ci tin phng tin sn xut, cc cng ty chu p lc cnh tranh ln hn bao gi ht. Nhim v sng cn ca mi cng ty tn ti v pht trin l phi s dng ti u c s vt cht v thit b mnh c th ch ng k hoch sn xut theo nhu cu ca khch hng. Cc nhu cu m sn xut cn phi p ng c: 1. Lng d tr ti thiu: p dng cc phng php sn xut kp thi vi thi gian sn xut (thi gian tnh t u vo l nguyn liu n u ra l sn phm) rt ngn, 2. Cht lng khng ch cao hn m cn phi n nh v c th c kim sot trong sut qu trnh sn xut, 3. Sn phm phi tho mn c nhu cu ca khch hng, v.v... 4. T chc sn xut theo nhu cu th trng, tc l theo m hnh ko, ch khng phi l theo nng lc sn xut (m hnh y truyn thng). y chnh l xu hng mi, c t tn l sn xut tinh gn (Lean manufacturing).

CC KIN THC C BN V BO DNG

Cc yu cu ny i hi phi c mt cch tip cn hon ton mi v vai tr ca vic s dng hiu qu thit b, (tc l bo dng cng nghip), cng nh v quan h sn xut - bo dng. Rt nhiu cng ty vn cn t chc b my hot ng theo th t chiu dc li thi ngha l bo dng t di s kim sot ca sn xut. Vic chuyn sang c cu t chc hng ngang vi bo dng v sn xut l ngang hng l rt cn thit, gip cho tt c cc cng vic lin quan n sn xut c kt ni vi nhau. iu ny khng ch nng cao hiu qu kim sot c s vt cht v thit b sn xut m cn ci thin kim sot ti chnh vi cc chi ph bo dng (trc tip v gin tip), cng nh thc y nng lc trin khai chin lc Bo dng i km vi chin lc pht trin ca cng ty. gii quyt cc yu cu ny cn phi m rng lnh vc kim sot Bo dng, bao gm: 1. quan nim v sn phm, 2. quan nim v thit b theo cch nhn nhn ca sn xut, 3. mua sm thit b mi mt cch c phng php, 4. cch a thit b vo hot ng. M rng hn l cch qun l s dng thit b theo quan im nhn nhn ton b vng i ca chng mt cch hiu qu nht v kinh t, an ton v mi trng v m bo tnh trch nhim vi ngi s dng chng. (c thm v vng i thit b trang 45) R rng l b phn Bo dng khng cn gi vai tr th yu na m phi l mt b phn ngang hng v gn kt vi sn xut. Qun l b phn Bo dng gi y khng ch mc k thut c kh truyn thng m cn phi a vo thm cc yu t: 1. tnh phc tp ngy cng cao ca cng ngh, 2. s tch hp ca cc cng ngh mi (cng ngh thng tin, vt liu mi,..) 3. s t do ha v ton cu ha kinh t, 4. s pht trin ca tm l con ngi, 5. quy lut t chc con ngi v h thng. hon thnh c nhim v ca mnh, Bo dng cn phi p ng ba yu cu c ngha sng cn, l: 1. k nng, 2. phng tin, 3. ch ca t chc (cng ty).

Tm li, cc mc ch chnh ca Bo dng c th c tm tt nh sau :

CC MC CH BO DNG

NHN BIT QU KH

KIM SOT HIN TI

LP K HOCH CHO TNG LAI

Hnh 1.2: S mc ch chnh ca Bo dng 1.2. Bo dng Tin tin khc vi Bo dng Truyn thng nh th no? Bo dng Truyn thng quan tm n duy tr hoc phc hi kh nng lm vic ca my mc thit b vo bt c thi im no, khng xt n yu t chi ph v c lp vi sn xut. Trong khi , Bo dng Tin tin tnh ti sn sng v cht lng ca thit b trong mi quan h vi chi ph v k hoch sn xut. Ni cch khc, b phn Bo dng Truyn thng phi tr li cu hi: - Lm th no thit b lun sn sng hot ng? Cn b phn thc hin Bo dng Tin tin phi tr li cc cu hi: - Lm th no thit b sn sng hot ng vo lc cn thit? - Vi chi ph (hiu theo ngha rng) thp nht? - Nguyn nhn no lm hng thit b v gim cht lng sn phm lin quan n cch vn hnh v khai thc thit b? 1.3. Cc loi hnh Bo dng Cng nghip Tin tin trn th gii Nhu cu v bo dng my mc xut hin k t khi loi ngi bt u s dng chng trong sn xut. K t , ngnh bo dng tri qua cc bc pht trin t thp n cao, t b ng n ch ng. Di y l cc loi hnh bo dng v ang c p dng trn th gii: 1.3.1. Phng php Bo dng Sa cha (Bo dng Hng my - Breakdown Maintenance)

K NNG = O TO

NHIM V HON THNH

CH = NG LC TRN NN TNG NHN THC MI

PHNG TIN = U T

y l phng php bo dng lc hu nht. Thc cht lch bo dng c quyt nh khi my mc b hng v con ngi hon ton b ng. Khi my hng, sn xut b ngng li v cng tc bo dng mi c thc hin. Phng php bo dng ny c rt nhiu nhc im nh: gy dng my bt thng, khng ngn nga c s xung cp ca thit b, c th ko theo s h hng ca cc my mc lin quan v gy tai

Hnh 1.1: S cc yu cu Bo dng phi p ng

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nn, lm cho cc nh qun l sn xut b ng trong vic ln k hoch sn xut, nh hng n kh nng cung ng sn phm trn th trng, gim tnh cnh tranh ca sn phm. Do thi im xy ra cc hng hc thng ngu nhin, bt ng nn cc nh qun l bo dng lun b ng trong vic chun b cc chi tit thay th, b tr cc cng tc sa cha lm ko di thi gian dng my gy chi ph ln. Trong mt s trng hp, thm ch chun b rt nhiu cc chi tit thay th nhng do tnh a dng v kh d on ca cc h hng nn khi lng cc chi tit vn rt ln gy tn km; hn na mt ca cc loi h hng thay i lin tc nn c chi tit thay th lun b thiu trong khi cc chi tit khc nm trong kho hng chc nm m khng c dng ti. Mt khuyt im khc ca phng php ny l cc h hng mt cm my mc no do khng kp ngn chn c th gy h hng dy chuyn lm nguy him n cc b phn my khc hoc gy tai nn cho ngi s dng. Do cc hn ch nu trn, chi ph cho bo dng theo phng php ny rt ln v vy cho n nay n hu nh khng cn c p dng trong cc dy chuyn sn xut cng nghip cc nc tin tin na. c thm v bo dng Sa cha ( Bo dng hng my trang 49) 1.3.2. Bo dng Phng nga 1.3.2.1. Bo dng Phng nga theo thi gian (Preventive Maintenance - Time Based Maintenance). (Phng php ny cn c gi n gin l Bo dng Phng nga) y l phng php bo dng hin c p dng trong hu ht cc nh my, dy chuyn sn xut Vit Nam (tr mt s t cc nh my mi xy dng). Trn th gii, phng php ny c pht trin v ph bin t nhng nm 1950. Ni dung ch yu ca phng php ny l cc my mc thit b trong dy chuyn sn xut s c sa cha, thay th nh k theo thi gian. V d c mi thng mt ln s dng dy chuyn cho sa cha nh v khong mt nm mt ln dng dy chuyn thc hin cc sa cha ln. Thc t phn ln cc dy chuyn sn xut dng bo dng mi nm 2 ln. Mi khi dng my nh k sa cha, bo dng, cc b phn, chi tit my s c kim tra, cn chnh, phc hi, nu cn thit s c thay th. Sau mi t sa cha nh vy ton b cc thit b my mc trong dy chuyn c coi nh sn sng cho t sn xut mi. V mt l thuyt, dng nh y l phng php kh l tng. Tuy nhin, trong thc t phng php ny vn bc l kh nhiu nhc im: Th nht l vic xc nh cc chu k thi gian dng my. Do phn b ca cc h hng theo thi gian rt khc nhau nn vic xc nh cc chu k sa cha thch hp cho ton b dy chuyn rt kh. Nu khong thi gian gia hai ln dng my di, cc h hng c th xut hin gia hai ln dng my gy ra ngng sn xut bt thng. Nu khong thi gian gia hai ln dng my ngn, khi lng sa cha thay th ln, mt s chi tit vn cn dng c nhng n thi hn vn phi thay th gy lng ph. Th hai, do chng loi my mc thit b c th h hng cn sa cha bo dng trong mi t dng my ca nh my thng rt a dng, khi lng chi tit thay th, b tr nhn lc, vt lc cho mi ln dng my l rt ln nhng thc t cc chi tit cn thay th sa cha li khng nhiu gy lng ph. Th ba, cc my mc thit b c th b h hng do s bt cn ca cng nhn trong qu trnh kim tra, bo dng. Mt s loi my d b hng, mn hay gim tui th do b tho ra lp vo nhiu ln. Thut ng trong ngnh bo dng gi hin tng ny l bo dng qu mc. (c thm v Bo dng Phng nga theo thi gian trang 57) 1.3.2.2. Bo dng Phng nga theo tnh trng thit b (Preventive Maintenance - Condition Based Maintenance). (Cn gi l Bo dng theo tnh trng) y l phng php bo dng phng nga tin tin c pht trin t Bo dng Phng nga theo thi gian, v c p dng trong cc ngnh cng nghip khong t gia nhng nm 1950. Ni dung chnh ca phng php ny l: trng thi v cc thng s lm vic ca cc my mc thit b hot ng trong dy chuyn s c gim st bi mt h thng gim st v chn on tnh trng thit b. H thng gim st s chu trch nhim gim st cc hin tng xut hin trong qu trnh lm vic ca thit b nh ting n, rung, nhit ...,kim tra tnh trng thc t ca thit b, pht hin cc trng thi bt thng ca thit b, qua xc nh chnh xc xu hng h hng ca thit b.

H thng gim st s chu trch nhim gim st cc hin tng xut hin trong qu trnh lm vic ca thit b nh ting n, rung, nhit ...,kim tra tnh trng thc t ca thit b, pht hin cc trng thi bt thng ca thit b, qua xc nh chnh xc xu hng h hng ca thit b. H thng phn tch v chn on tnh trng thit b s chu trch nhim phn tch cc kt qu thu c t h thng gim st, thng bo chnh xc v tr, mc h hng gip ngi s dng kp thi iu chnh hoc thay th cc phn h hng, trnh cc h hng theo dy chuyn. H thng ny cn cho php xy dng mt b h s d liu v thit b (l lch my). T c th chn on cc nguyn nhn gy hng thng gp v h tr tm cch khc phc, ngn nga. Trong phng php ny, thay v sa cha, bo dng theo chu k thi gian, ngi s dng s gim st tnh trng ca cc thit b thng qua cc php o v kim tra theo chu k thi gian. Tu theo tnh trng hot ng, mc phc tp v quan trng ca thit b ngi ta xc nh cc khong thi gian o ph hp v nh vy ngi bo dng c th gim st cht ch tt c cc thit b cn thit. V d i vi cc tua bin th o v gim st lin tc, vi cc qu l, ln cc php o s c thc hin hng ngy, cn vi ng c in th ch cn o 2 ln trong thng l . Vic qun l cht ch tnh trng cc thit b cn cho php ch ng trong lch bo dng, k hoch sn xut v sn sng hn trong vic tip nhn cc n hng ln. V chi ph cho cng vic thc hin cc php o v phn tch nh hn rt nhiu so vi vi cng vic sa cha; an ton v tin cy ca dy chuyn rt cao (do c gim st cht ch) nn phng php bo dng ny c coi l gii php k thut u vit cho vic qun l bo dng nh my v cc dy chuyn cng nghip. (c thm v Bo dng thit b cho Cn b qun l bo dng trang 75) (c thm v Bo dng thi b cho Cn b k thut Bo dng trang 84)

BO DNG NH K (Bo dng theo thi gian) BO DNG PHNG NGA BO DNG D ON (Bo dng theo tnh trng thit b)

CHU K C NH

CHU K KHNG C NH

Hnh 1.3: Quan h gia bo dng Phng nga theo thi gian vi bo dng Phng nga theo tnh trng thit b

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Ghi ch:

o Bo dng D bo: l mt phng php bo dng gn tng t nh bo dng da trn tnh trng thit b cng c pht trin song song. V bn cht, loi hnh ny da trn c s d liu bo dng v s dng cc phn mm chuyn bit s dng cc k thut v hoc cc chuyn gia bo dng d bo v tnh trng hin thi ca thit b, xc sut hng ca thit b (hay kh nng sn sng ca thit b) cc thi im cn bit trong tng lai. K thut bo dng ny khng yu cu u t ln nhng ph thuc rt nhiu vo trnh chuyn gia v c bit l h thng c s d liu bo dng phi rt y , tin cy v c thu thp trong thi gian di, thm ch ti hng chc nm. Do cc yu t ny kh hi t cc doanh nghip Vit Nam nn chng ti khng tp trung gii thiu Bo dng D bo trong ti liu ny. o Bo dng C hi: v bn cht, Bo dng C hi l vic thc hin cng tc bo dng, sa cha vi cc h hng khng c trong k hoch khi dy chuyn hay thit b phi dng v mt nguyn nhn no : hng t ngt mt b phn khc, mt in, ht n hng. Mt s quan im khng coi y thc s l mt phng php bo dng. Tuy nhin, Bo dng C hi c ngha tng i ln trong vic gim chi ph v thi gian bo dng. N cng c th p dng tt vi Bo dng Phng nga theo tnh trng thit b.

PHN LOI CC HNH THC BO DNG

Bo dng phng nga

Bo dng hng my - sa cha

Bo dng nh k

Bo dng cn c vo tnh trng

Bo dng d bo

Khc phc tm thi

Bo dng sa cha

Hng

Kim tra

Kim sot

Thm khm

Sa cha tm thi

Nng cp phn mn hng, xung cp

Hnh 1.4: Phn loi cc hnh thc Bo dng

LU : CC CP BO DNG THEO NHM CHC NNG

M t v cc cp Bo dng xc nh s phc tp ca vic bo dng c quyt nh bi mc phc tp ca cc bc quy trnh v/hoc phc tp ca vic s dng hay trin khai cc thit b h tr cn thit. Khng nn nhm ln mc phc tp ny vi phc tp ca thit k hoc mc quan trng ca thit b h tr. S phn loi theo cp Bo dng c quy chun ho trong tiu chun AFNOR X 60-010 v c dng nh mt hng dn v cng c phn nh. ng dng ca n ch c hiu gia cc bn thng nht v nh ngha c p dng cho cc thit b cn bo dng. Bo dng Hiu nng (Productive maintenance PM) hay Bo dng Hiu qu Vo cui nhng nm 1950 hng Genegal Electric a vo p dng Bo dng Hiu nng - tc l Bo dng nhm nng cao nng sut v hiu qu. Xut pht t quan im khc phc nhc im ca Bo dng Phng nga l bo dng qu mc, Bo dng Hiu nng va lm gim ti thiu thit hi do thit b xung cp va tit kim cc chi ph bo dng thit b. (Xem H.1.5) Bo dng hiu nng c nh ngha nh sau: Bo dng hiu nng l loi hnh bo dng nng cao hiu sut ca doanh nghip nh gim cc chi ph do my mc thit b t chi ph vn hnh, chi ph bo dng n cc thit hi do thit b xung cp

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Hot ng bo dng

Sa cha

S kin

Lch bo dng

Cc ngng xc nh trc

Cc cp d bo

Khi n im bo dng

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Chi ph

BNG 1.1 TM TT CC CP BO DNG

Chi ph thp nht

CP 1

HNH NG + Lm sch, v sinh my + Cc cn chnh my n gin + Bi trn + Thay cc b phn mn hng

+ Thay cc chi tit

NGI CAN THIP

+ Ngi vn hnh

TI LIU
+ Hng dn bo

GHI CH
+ Khng cn dng c hay dng c n gin + Gim lng ph tng thay th

(my mc thit b)

dng

ch h ip Ch

ng t hi ph C

th
ng

C h i ph

b ng

Trnh bo dng

+ B phn bo tiu chun ha n dng. gin + Cn b k thut c + Kim tra mch thm quyn in + Bm m + Cc sa cha + B phn bo

+ Hng dn v Bo

dng phng nga.

+ Cc dng c cm tay + Cc ph tng c th mang vc c

Hnh 1.5: Bo dng Hiu nng Bo dng hiu nng pht trin qua cc giai on Bo dng Hiu chnh (Corrective Maintenance), Phng nga Bo dng (Maintenance Prevention) v Bo dng Hiu nng hin i. Cn lu rng Bo dng Hiu nng chnh l bc k tip ca Bo dng da trn tnh trng thit b. Nu khng c cc c s h tng cn thit v Bo dng da trn tnh trng vn cha c doanh nghip thc s lm ch th khng th chuyn sang Bo dng Hiu nng c. Chi tit v trin khai Bo dng Hiu nng c trnh by trong mc III Bt u nh th no? Bo dng Hiu nng Tng th (Bo dng hiu nng vi s tham gia ca tt c cc b phn -TPM): Total productive maintenance TPM c th c nh ngha nh sau: TPM l bc pht trin tip theo ca PM, thng qua cc hot ng t gic ca cc nhm nh (hot ng JK) tt c cc b phn nhm xy dng mt h thng bao qut ton b chu k s dng thit b nhm mc ch t c hiu sut s dng thit b ti a. * Cc hot ng JK: l cc hot ng hon thin quy trnh vn hnh ca mt nhm nh cng nhn v tm ra phng php gii quyt cc vn trong vn hnh v bo dng my mt cch t nguyn. V ngi vn hnh hiu r tnh trng thit b nht nn cc hot ng ny rt c hiu qu. Chi tit v trin khai Bo dng Hiu nng Tng th c trnh by trong Mc 3.4 TPM v Kaizen. Vo nm 1976 khi TPM c pht minh Nht,th Anh ngi ta cng a ra khi nim Terotechnology c cng mc ch vi TPM: Terotechnology c nh ngha l cng ngh s dng cc gii php thc tin ton din v bao qut nh: qun l, ti chnh, cng ngh.. p dng vi nhng ti sn hu hnh (thit b v cng trnh) nhm t c chi ph chu k s dng kinh t. C th ni Terotechnology l k thut qun l tng th nh my, n ng ngha vi qun l nh my hiu theo ngha rng bao gm c qun l chu k s dng thit b. Xt v mc ch TPM v Terotechnology l ging nhau nhng c mt khc bit ln l TPM c thc hin bi ngi s dng thit b, cn Terotechnology lin quan ti c ngi sn xut ln ngi qun l v vn hnh thit b. Tuy nhin, s trao i tin tin gia nh sn xut, ngi s dng v thit b khng hiu qu do khc bit v li ch . y cng l nguyn nhn dn n tht bi ca Terotechnology. Tht bi ny l mt gi v s cn thit xem xt cc tin kh thi ca khi nim hin i v rng hn l sn xut v tiu dng bn vng.

v thay th i hi phi tho lp chuyn dng

dng + Cn b k thut c thm quyn

+ Hng dn Bo

dng: - phng nga - sa cha

+ Cc dng c chuyn dng + Cc thit b o + Bn kim + Ph tng thay th + Cn nhiu dng c chuyn dng + Cc ph tng thay th chuyn dng, phi tiu chun

+ Bo dng quan

trng: - phng nga - sa cha

+ B phn bo

+ Hng dn bo dng dng. + Cng ty bo dng chuyn nghip + Nhm bo dng chuyn ngnh + Nh sn xut. + Cng ty bo + C th theo hng

+ Nng cp cng

ngh. + Phc hi/ ti thit

dng.

dn ca nh sn xut thit b.

+ Nhiu dng c khc nhau

Khi nim v chi ph chu k s dng kinh t ln u tin c B Quc phng M a ra. H tin hnh mt cuc iu tra v gi mua thit b quc phng v chi ph vn hnh, bo dng chng trong 5 nm. Kt qu iu tra cho thy chi ph vn hnh v bo dng ln gp 10 ln chi ph mua sm ban u.

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17

1.4. M hnh Bo dng xut cho Vit Nam Ngy nay, sn xut cng nghip th gii ang i theo xu hng c nhn ha, linh hot, thi gian giao hng ngn v nhanh chng i mi sn phm nh ng dng rng ri cc thnh tu trong t ng ha v cng ngh thng tin cho tt c cc khu ca qu trnh sn xut. Cng v vy m cc dy chuyn sn xut v thit b ngy cng phc tp, vi s kt hp nhng thnh tu ca cc lnh vc k thut khc nhau. Vic s dng mt cch hiu qu thit b s quyt nh kh nng cnh tranh ca doanh nghip. Trong bi cnh , bo dng vt ra khi quan nim c in l bo tr, duy tu v sa cha my mc tr thnh mt trong nhng yu t quyt nh hiu qu u ra ca sn xut: t nng sut, cht lng, gi thnh, thi gian giao hng n an ton sn xut v bo v mi trng. cc nc cng nghip pht trin, bo dng pht trin thnh cng cng ngh Bo dng hiu nng Tng th TPM (Total Productive Maintenance) hoc mt hnh thc tng t p dng Cng ng Chu u l Terotechnology (K thut Qun l nh my Tng th) t thp k 70 ca th k trc. y chnh l mt trong nhng bin php hu hiu gp phn gip cc nc ny vut qua hai cuc khng hong du la v cnh tranh thnh cng trn th trng quc t. Trong thi k hi nhp, cc doanh nghip Vit Nam cn khn trng nng cao nng lc sn xut v kh nng cnh tranh c th ng vng v thnh cng khi m cc bin php thu quan bo v sn xut trong nc hon ton b d b, sau khi vo WTO. t c mc tiu ny, bn cnh vic u t nng cp, i mi thit b v cng ngh, vic s dng mt cch hiu qu cc ngun lc sn c mang tm quan trng sng cn. Hin nay, ngnh bo dng hu ht cc c s trong nc u kh lc hu v khng c nh gi ng tm quan trng ca n nn hiu qu s dng my mc, thit b ca chng ta vn cn thp. Do , mt yu cu cp thit t ra t c hiu qu s dng trang thit b ti a l nhanh chng trin khai ng dng cc cng ngh v k thut bo dng hin i trong cc doanh nghip. Vit Nam, phng php bo dng ph bin vn l bo dng phng nga theo thi gian (bo dng nh k). Mt vi nh my hin i mi ng dng phng php bo dng theo tnh trng thit b. Hn na, do trnh pht trin cng nghip cn thp v khng ng u, cc trang b my mc c xut x a dng, theo nhiu h tiu chun khc nhau gy nhiu kh khn cho cng tc qun l bo dng. Do vy hiu qu s dng thit b thp, cc h hng t ngt v tai nn vn xy ra. iu ny lm gim ng k kh nng cnh tranh ca cc doanh nghip sn xut nc ta. khc phc tnh trng ny, mt yu cu t ra ht sc bc xc hin nay l nhanh chng trin khai cng ngh bo dng tin tin PM (Bo dng Hiu nng hay Bo dng da trn Hiu qu) v tin ti l TPM (Bo dng Hiu qu Tng th hoc Bo dng Hiu nng Tng th) vo cc ngnh cng nghip trong nc. Mt trong nhng yu cu cp bch hin nay l trin khai v ng dng TPM mt cch thch hp v hiu qu Vit Nam, trnh tt hu qu xa v trnh bo dng. Khng c mt m hnh bo dng no duy nht ng cho cc doanh nghip. Vic la chn m hnh bo dng ph hp cho tng cng ty ph thuc vo cc yu t: Quy m sn xut c th ngnh/ a phng (v d sn xut quanh nm hay theo ma, cc kiu hng thng gp hay kh hu c trng) S sn c v cht lng, trnh ca cc dch v bo dng sa cha c th thu ngoi Nng lc lm ch thit b ca cng ty Yu cu v cht lng v thi gian giao hng Chin lc ca cng ty

Tuy nhin, theo kinh nghim ca chng ti, nu mt cng ty sn xut lin tc v c chi ph tng th lin quan n bo dng ln th m hnh PM l kh thi cho hin ti trong khi TPM l mc tiu tt yu cho tng lai. Do vy, ti liu ny c bit tp trung vo din gii cc kin thc c s trin khai Bo dng Hiu nng (PM) trong hin ti v Bo dng Hiu nng Tng th TPM trong tng lai cho doanh nghip. Vi cch tip cn nh vy, chng ti s dng thut ng Bo dng Cng nghip Tin tin trong ti liu ny ch Bo dng Hiu nng (PM), vi t cch l loi hnh bo dng kh thi v l tin cho TPM.

II. TI SAO CN P DNG BO DNG CNG NGHIP TIN TIN?

2.1. Cc li ch ca Bo dng Cng nghip Tin Tin Li ch ca vic p dng thnh cng Bo dng Cng nghip Tin tin l hin nhin, th hin qua s hi lng lu di ca khch hng, nhn vin cng ty v cng ng a phng. Thng thng, li ch s c d dng nhn thy thng qua cc ch s (thng c gi l cc ch s PQCDSM): Tng sn lng (P- productivity): Khi cc thit b sn sng hot ng vo lc cn thit vi cht lng thc hin cng vic tt th sn xut m bo lin tc vi cng sut cao. Bo dng tt thm ch c th gia tng cng sut thit b so vi cng sut thit k; Nng cao cht lng (Q - quality): Thit b tnh trng tt s cho sn phm cht lng cao. Ngoi ra, do Bo dng Tin tin hng ti vic tm ra cch vn hnh ti u cho c thit b ln sn phm, cht lng ca c hai m bo c nng ln ng thi; Gim chi ph sn xut (C- cost): nh mc tiu th nng lng, nguyn vt liu v nhn cng gim i, thit b tnh trng tt v ngi vn hnh thng xuyn phi lu n cc thng s nh mc ca mnh. Mt yu t quan trng khc ng gp vo vic gim chi ph l tui th thit b thng tng ng k v chi ph trc tip cho vic sa cha khi cc vn c chn on v pht hin t sm gim i kh nhiu. Song song vi gim chi ph, tc ng mi trng ca hot ng sn xut cng c gim thiu m bo thi gian giao hng (D- delivery): trong mt lot lnh vc nh ng tu hay cung cp hng tiu dng cho Ging Sinh, thi gian giao hng ng vai tr rt quan trng. Vic nm vng tnh trng thit b v ch ng k hoch sn xut chnh l b quyt m bo thi gian giao hng. An ton (S- safety): Thc t sn xut v cc nghin cu u ch ra rng c mt mi quan h trc tip gia tnh trng thit b, cch thao tc vn hnh vi xc sut xy ra tai nn trong sn xut. Mi trng lm vic (M-morale): Bo dng Tin tin da trn s tn trng quyn lm ch v s pht huy sng to ca mi nhn vin, nht l cc cng nhn lm vic trc tip. S thoi mi v mi trng lm vic thn thin cng l mt biu hin ca vic p dng Bo dng Tin tin.

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19

2.2. Cc iu kin m bo s kh thi khi p dng Bo dng Cng nghip Tin tin Vit Nam 2.2.1. Cc iu kin tin quyt cho p dng thnh cng Bo dng Cng nghip Tin tin Tm nhn ca lnh o doanh nghip: Thc s thc c tm quan trng ca Bo dng Cng nghip i vi cng ty mnh v bit cn phi lm g, vo lc no. S nht qun: Bo dng Cng nghip Tin tin khng i hi qu nhiu vn so vi tng u t ca doanh nghip, nhng n i hi s n lc thng xuyn v nng cao trnh lin tc. Vic dnh ngun lc, nht l nhn lc, mt cch lin tc cho bo dng l yu t quan trng bc nht. Gn ging vi vic hc ngoi ng, b quyt nm cc hot ng thng xuyn v mi s gin on hay ti khi ng u thu hp c hi thnh cng. Dm ti cu trc: Hu ht cc doanh nghip Vit Nam khng c cu trc hp l lm Bo dng Tin tin. iu ny l do nhn thc lc hu v vai tr Bo dng v mi quan h ca n vi sn xut cng nh vi nng lc cnh tranh ca doanh nghip. Ch khi bo dng c t chc ngang hng v gn b hu c vi sn xut th n mi c th thc s gi l Tin tin c. Nng lc con ngi: Thng th khi khi ng thc hin Bo dng Tin tin, cc kin thc v k nng khng sn c trong i ng ca cng ty. iu quan trng l cc cn b k thut nng ct ca cng ty v bo dng c kh nng tip thu v ng dng cc kin thc cng nh tch ly c cc k nng cn thit. Kh nng s dng ngoi ng, nht l ting Anh, cng l mtyu t quan trng, nhng khng quyt nh m ch mang tnh xc tc Xy dng h thng c s d liu bo dng: S liu bo dng v cc thng tin rt ra t ngha quan trng nh tin bc v chnh l tin bc. T cc s liu v thng tin , cng ty c th a ra cc quyt nh v t chc, qun l hay ti chnh gip ci thin cc ch s PQCDSM. H thng c s d liu c th c coi nh l mt iu kin k thut, nhng t kinh nghim ca chng ti, y nn c coi l mt iu kin Qun l v Hnh chnh bo dng. u t: trong giai on u tin, cc cng ty ch phi u t rt nh t c hiu qu ban u. Nhng khi bc sang giai on pht trin, hiu qu bo dng ph thuc nhiu vo cc khon u t cn thit, chng hn cho cc thit b o, thu thp s liu bo dng v x l chng

a. Phn tch Chc nng C th ni rng, l thuyt Phn tch chc nng c nhng ng gp rt ng k cho vic nng cao hiu qu bo dng v pht trin cc phn ngnh ca n. Phn tch chc nng bao gm nghin cu mt h thng thng qua vic phn chia n thnh cc b phn chc nng c th thay th c. B phn ny s khng c ln hn b phn thay th tiu chun. Ngoi ra, cng cn lu n trnh t sp xp v kt cu, khng lin quan hon ton n cc mi lin h v chc nng. Trnh t y l trnh t v v tr khng gian, ch khng phi v thi gian. N khng th hin chu trnh thi gian ca qu trnh hot ng. Phn tch chc nng cho php a ra cc mc tiu cho cng tc bo dng. 1. i vi mt k thut vin, ngi c trong tay cc cng c h tr hiu qu s c th kim tra bt k h thng phc tp no, anh ta c th lt qua cc b phn ca thit b v xc nh rt nhanh chng tnh trng lm vic ca cc b phn chc nng khc nhau, cng nh ton b h thng lm vic ca thit b. i vi nhn vin chu trch nhim bo dng, ngi c trang b cc cng c hiu qu cho vic t chc cng vic k thut ca mnh, anh ta phi c kh nng qun l chi ph r rng v cht ch cho cng vic.

2.

Do vy vic phn tch chc nng cho php: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Thit lp cc iu kin lm vic ti u cho thit b. Tm ra nhng b phn hao mn ca cc thit b. a ra c cc ch bo gip cho vic theo di qu trnh tin trin cc h hng ca thit b. Xc nh cc dng v phng php bo dng cn p dng cho mi b phn ca thit b. a ra c k hoch bo dng. Phn loi cc h s ti liu bo dng v cch tra cu khi cn thit. Pht trin mt k hoch bo dng tt hn thng qua cc h s lu tr. Xc nh trnh v k nng cn c cho vic bo dng cc thit b my mc. Xc nh v h thng ha ton b h thng my mc ca n v hin c. Phn tch v tnh ton cc chi ph cho cng tc bo dng. Quyt nh ngn qu cho nguyn vt liu phc v cng tc bo dng v theo di vic s dng chng.

2.2.2. C s h tng cn thit cho Bo dng Cng nghip Tin tin Xy dng cc c s h tng di y chnh l cc iu kin trin khai thnh cng Bo dng Cng nghip Tin tin. 2.2.2.1. iu kin 1: Qun l Bo dng Qun l Bo dng Tin tin c th coi l Qun l Bo dng truyn thng kt hp vi bn yu t hin i: (1) Phn tch Chc nng; (2) Hiu sut Tng th; (3) Trao i thng tin bo dng, nht l ng dng ICT; (4) Qun l Ti chnh Bo dng.

(c thm v l thuyt phn tch chc nng trang 179)

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21

b.

Hiu sut Tng th

Qun l bo dng l mt phn ca qun l nh my. Quan im qun l bo dng hin i da trn khi nim v hiu sut tng th. y l khi nim a ra nh gi hiu qu thc s ca vic qun l v s dng thit b. Su loi tn tht thi gian s dng thit b c a ra v phn loi di y. 1. 2. Tn tht thi gian do cc s c: iu ny c th c kim sot bi cng tc bo dng hiu qu v s tham gia ca b phn sn xut. Thi gian cn cho thay i sn phm: Khi cn thi gian iu chnh li thit b cng nh thay th cc dng c my mc. iu ny c th c kim sot bi khu t chc sn xut tt hn v chnh sch ci tin thit b my mc sn xut. Tn tht thi gian do nhng ln ngng my ngn: V sinh thit b, cung cp ph gia v cc nguyn liu ph, Tn tht thi gian do ch lm chm li: Sn xut cc sn phm c bit, s xung cp ca mt b phn my mc, Tn tht thi gian do li cht lng. y l kt qu t vic iu chnh thit b, cc qui trnh lin quan n kim sot cht lng hoc iu khin thit b. Tn tht thi gian khi khi ng. Trong giai on ny d xut hin cc sn phm khng t yu cu.

Thng tin = s tm hiu = cc gic quan Quyt nh = s phn tch = tr no Hnh ng = s can thip = s tham gia

THNG TIN

MNH LNH

NGI CUNG CP THNG TIN

NGI RA QUYT NH

NGI VN HNH

3. 4. 5. 6.

GHI CHP

PHN HI

Hnh 1.6: Trao i thng tin bo dng S trao i thng tin c th di mt s dng: 1. 2. 3. Dng truyn ming thc cht d b tht lc, c th b thay i, v d b sai lch, Dng vn bn v/hoc biu , Dng khng chnh thc.

( c thm v Hiu sut tng th GER trang 118) c. Trao i thng tin Bo dng

Qun l Bo dng cn phi m bo s trao i thng tin bo dng hiu qu trong doanh nghip. Vic trao i thng tin trong ni b cng ty thng b xem nh v b st. Chng thng b chuyn thnh dng bo co ming. Mc d vy, n c chc nng quan trng trong qun l cng tc bo dng. Trao i thng tin l si dy kt ni thit yu gia thng tin, ra quyt nh v hnh ng.

Nhn vin bo dng c thin hng khng thch trao i thng tin di dng vn bn. iu gip cho h d lng trnh hiu lc thi hnh v d dng bin minh cho tnh hnh. Tt c mi ngi cn phi hiu rng s khng c s can thip no c thc hin thnh cng nu cc cu hi sau y khng c tr li: U? CI G? NH TH NO? KHI NO? AI? BNG CI G ? CHI PH G? Cng vic cn phi c thc hin l u? Nhn bit thit b. Cng vic cn phi thc hin l g? Nhn bit cc nhim v cn hon thnh. Cng vic s c gii quyt nh th no? a ra quy trnh v quy nh k thut cho vic thc hin. Khi no th phi tin hnh cng vic? Lp k hoch cho cc nhim v phi thc hin. Ai s gii quyt cng vic ny? Xc nh ngun nhn lc, k nng yu cu v.v Cng vic s c gii quyt cng vi nhng g? Ch ra ngun cung ng, cc dng c, ph tng thay th v.v. Bao gm nhng g? Cn phi xem xt chi ph mua ph tng, thit b v chi ph nhn cng.

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Chnh nhng iu ny lm nn s khc bit ca cng tc bo dng. 7. By cu hi v tr li cho thy r rng dng trao i thng tin bng ming l khng thch hp. Dng trao i bng vn bn, c hon thin bi cc biu c rt nhiu u im: 1. 2. 3. 4. 5. Gip cho ngi tham gia nhn bit c cc trch nhim ca mnh. Gip trnh c cc sai lch v thng tin, b st thng tin, cc thay i khng cn thit, cng nh cc nguyn nhn dn n nhiu hnh ng tri ngc. Gip phng trnh nhng s c c th xy ra. Lu tr tra cu v sau. Gim s lng thng tin cn trao i i vi cc hot ng lp i lp li theo chu trnh.

Vic phn tch ti chnh c th phn nh c lp nhng mc ch v tiu ch ca mi cng ty. Tuy nhin, khi khng tnh n phng php phn tch, vic phn tch ti chnh s th hin nhng c im chung sau y: - Cc kt qu phi o lng v nh lng c. - Cc chi ph v c tnh cn phi c cc bn lin quan thng nht. - Cc kt qu ti chnh cn phi c trnh ln ban qun l bng nhng thut ng d hiu. - Lp h s theo nh k v ngun thu ti chnh phi l mt b phn khng th tch ri ca chng trnh bo dng. Nhng c im ny c cp mt cch chi tit nh sau: Cc kt qu phi o lng v nh lng c. iu c ngha l cc ch s ROI, NPV hay thi gian hon vn l nhng ch s cn c s dng v nh gi. ( c thm v Qun l Ti chnh Bo dng da trn tnh trng thit b cho cc cn b qun l bo dng v k thut bo dng trang 75 v trang 84) Song song vi qun l ti chnh da trn tnh trng, vic nh gi hiu qu u t cho cc gii php k thut lin quan n bo dng cng rt quan trng v l c th ca qun l ti chnh bo dng. ( V d v phn tch u t k thut bo dng cho lnh o cng ty v cn b k thut bo dng trang 100) 2.2.2.2. iu kin 2: Hnh chnh v hu cn bo dng Cc cng tc Hnh chnh v Hu cn Bo dng tuy khng i hi nhiu hm lng k thut hay u t ln, nhng chng thc s ng vai tr ht sc quan trng v to ra rt nhiu gi tr gia tng cho hot ng bo dng. a. (1) Cc cng tc Hnh chnh Bo dng tp trung vo cc ni dung: Quy nh vai tr v trch nhim c th ca cc phng, ban lin quan n chc nng bo dng trong cng ty, cch thc trao i thng tin, s dng v chia s ngun lc, cch thc ra cc quyt nh lin quan n k hoch v can thip bo dng, cch tin hnh u t thit b v k thut bo dng... Thit lp, cp nht, phn tch v s dng hiu qu h thng c s d liu bo dng: ICT hay truyn thng, cch nh m s, ti liu ha, thit lp v cp nht h thng c s d liu, qun l c s d liu, phn tch chuyn mn v h chuyn gia o to v xy dng nng lc bo dng, bao gm o to cc k nng thc a, vn hnh, cung cp l thuyt, trao i kinh nghim v khuyn khch cc sng kin t cp cng nhn vn hnh

Nhm ti u ha nhng u im ny v to iu kin cho nhng ngi s dng, cc ti liu phi tha mn cc iu kin: 1. 2. 3. 4. 5. Ph hp vi cng ty-tham kho nhng ti liu ca cc cng ty khc S lng vn bn phi ph hp Trnh s dng qu nhiu vn bn v biu mu, trch trng lp. Cn c xy dng theo hng thun tin cho x l cc d liu, Phn bit c cc loi thng tin thu c. Cn r rng, d c, logic v d s dng.

( c thm v h thng trao i thng tin trang 107) d. Qun l Ti chnh Bo dng

Qun l Bo dng khng th thiu qun l ti chnh bo dng. C th ni rng nhng tin b ca ngnh bo dng c khi ngun t vic ngi ta thay i cch nhn nhn v cc chi ph cho bo dng, c bit l v cc chi ph gin tip. Khi trin khai Bo dng Tin tin, vic qun l chi ph da trn tnh trng thit b chnh l c s nh gi cc ch s hiu qu PQCDSM, cng nh a ra cc quyt nh quan trng lin quan n chin lc bo dng v sn xut. C nhiu cch nh gi tc ng ti chnh khc nhau cho hot ng bo dng my mc da trn hin trng. Nhiu cng ty pht hin ra nhng vn v thit b c xc nh bng nhng thit b bo dng da trn tnh trng ngay trong thi gian dng my thng thng. H so snh chi ph sa cha nhng trc trc ny vi chi ph vn hnh ca chnh c my y trong thi gian trc . Nhng cng ty khc hng ti so snh thng tin v chi ph sa cha vi chi ph ca cc chng trnh bo dng da trn tnh trng c p dng cho cc my mc t mang tnh then cht hn.

(2)

(3)

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25

( c thm v h s v c s d liu trang 159) ( c thm v cp nht ti liu bo dng trang 165) ( c thm v cu trc H s K thut trang 130) ( c thm v cu trc H s Thit b trang 137) b. Hu cn Bo dng

Cng tc ny tp trung vo qun l kho thit b v ph tng d tr, cc b phn mau mn chng hng, cc thit b v dng c chn on, ghi chp s liu.. Cc k thut c p dng ph bin l FIFO (vo trc ra trc), 5S v ICT. Mt s phn mm chuyn dng hay gii php ICT trn gi cho cng tc qun l bo dng, vi trung tm l qun l hu cn bo dng, c a vo ng dng t nhng nm 1990. Trong ng k nht l cc phn mm qun l tch hp c chuyn bit ha theo nhu cu khch hng ca hng SAP, c. ( c thm v 5S trong bo dng cng nghip trang 33) 2.2.2.3. iu kin 3: T chc Bo dng Khng c c cu l tng no cho mi b phn bo dng. c im cc cng ty rt khc nhau, chnh v l m khng th p dng mt m hnh cho mi cng ty. Mt s im khc nhau gia cc cng ty nh: 1. 2. 3. 4. 5. Quy m Trang thit b Phng thc sn xut S tham gia ca b phn sn xut vo cng vic bo dng Cc iu kin sn c nh: Ngun nhn lc, hu cn,...

thc y vic kt hp cc b phn vi nhau th tt c cc b phn chnh ca cng ty cn phi c t ngang hng nhau. B phn bo dng phi c mi lin h trc tip vi ban lnh o cng ty. iu ny khng trit tiu mu thun v xung t gia cc b phn. N ph thuc vo vic liu ban lnh o cng ty c to c mt mi trng ph hp cc b phn hp tc cht ch vi nhau hay khng. iu ny c th t c nh vic t chc cc cuc hp thng bo cho mi ngi bit c nhng hn ch, mc tiu v phng php loi b nhng mu thun . Cc cuc hp ny phi l mt knh i thoi gn gi, thng xuyn gia cc b phn vi nhau. ( c thm v t chc Bo dng trang 200) 2.2.2.4. iu kin 4: C s K thut cho Bo dng Tin tin Cng ging nh mi loi hnh p dng thnh tu khoa hc cng ngh khc, bn thn s tin tin ca cng ngh khng m bo cho s thnh cng ca doanh nghip. Cc doanh nghip thnh cng v bo dng hu ht u l cc n v khai thc hiu qu cc k thut bo dng hin i bn cnh vic s dng cc phng php truyn thng. Cc k thut bo dng hin i cho php gim st, chn on tnh trng thit b v a ra cc nh gi v nguyn nhn v cch khc phc hay phng nga, bao gm: a. Cc k thut quan trc bng gic quan ca ngi vn hnh v cn b k thut bo dng. y l phn n gin nht ca cc k thut o khng ph hy, ch s dng gic quan ca con ngi vi cc dng c h tr (tai nghe, knh chuyn dng...). Nh nhng kin thc v k nng thch hp, mt cng ty c th qun l kh tt tnh trng thit b ca mnh m hu nh khng phi u t g. y cng l cch tip cn khn ngoan v hiu qu nht i vi cc cng ty va v nh. Vi cc k thut ny, u t ln nht l v o to kin thc v k nng chn on cho cc cn b k thut bo dng. K thut o v phn tch s liu v dao ng my: L k thut p dng ph bin nht hin nay.Khong 90% chng loi thit b c th c gim st v nh gi bng k thut ny. Thit b o dao ng my cng c nhiu loi, t nhng my a nng cm tay c gi khong 20.000USD n nhng thit b trc tuyn (online) theo thi gian thc c kt ni vi h iu khin t ng c gi n hng triu la. V bn cht, cc thit b ny o cc rung ng sinh ra t s quay ca my (dao ng my) pht hin cc vn nh mt cn bng lch trc, li vng bi, li ng c hay cng hng. Vic chuyn i tn hiu dao ng t min thi gian sang min tn s, cng vi cc phn mm ci t theo my o cho php x l cc d liu dao ng kh n gin nhng rt hiu qu. Thng th vic u t cc thit b o v gim st ny hon vn sau vi thng u t vi cc doanh nghip c va. K thut quan trc v phn tch hng ngoi: L k thut rt hiu qu trong vic pht hin ra cc li k thut v nhit, in v bi trn. Thit b quan trc chnh l camera hng ngoi. Cc camera ny cng thng c kh nng chp nh trong di tn s kh kin, do vy cho php quan st v chp hai loi nh ng thi (hng ngoi v kh kin). Nh vic pht hin v nh v khu vc hng rt d dng. K thut siu m v m thanh: Rt hiu qu trong vic pht hin cc li hng v r r kh hay cht lng hoc cc r r do chnh lch p sut. Nguyn l ca cc thit b o ny l pht hin ra cc r r nh khuych i cc tn s c trng ca r r. y l k thut ng vai tr rt quan trng trong vic bo m an ton, nht l chng r r cc loi kh c khng mu sc v bnh thng kh pht hin. K thut phn tch du bi trn: V bn cht, y l cc k thut phn tch mc hng ca du bi trn, cc cht xm nhim v cc ht mi mn c trong du. Cc kt qu phn tch cho

b.

Trc khi tnh ton mt c cu bo dng ti u th nht thit phi xem xt din bin ca mi quan h gia sn xut v bo dng. Theo kinh nghim tin hnh bo dng, i tc chnh l b phn sn xut. Trc y, b phn vn hnh buc phi chp nhn mt s hn ch sn xut ngn hoc trung hn. B phn Sn xut chp nhn mt s can thip x l li nh gy t im bt li (nh: bi trn, thay i u lc...). H t nhiu cng chp nhn cc ln dng my do s c hng xy ra. Nhng h nht quyt phn i bt c chng trnh bo dng theo k hoch no gy cn tr vic kim sot cng c sn xut ca h. c.

d.

e.

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bit hng (ch yu l mi mn do ma st) pht sinh u, mc mn n u, cc vn v bi trn, ma st v nhit. K thut ny i hi phi ly mu du ng cch v a i phn tch ti phng th nghim. Hin k thut ny Vit Nam vn cha ph bin. Tuy nhin, ro cn chnh nm kh nng lm ch k thut ch khng phi chi ph u t. f. K thut o v gim st cc thng s vn hnh h thng: in p, cng dng in, lu lng, nhit , dn in, o mc cc loi, khi lng, tc Cc k thut ny thng kt hp vi cng ngh iu khin bn t ng hay t ng. c im ca cc h thng ny l nhng thng s vn hnh ri rc ca h thng, c o bi cc thit b khc nhau ti cc v tr khc nhau c kt hp li a ra bc tranh tng th v sc khe ca c h thng, cng nh ca tng thit b. Mt khc, cc thng s ny c dng phc v v vic can thip vn hnh hay vn hnh t ng h thng. c im ca h thng ny l khng c s phn chia r rng gia sn xut v bo dng. Mt cch s dng k thut o v gim st thng s h thng l u t cc thit b o tng i r, khng kt ni vo mt h thng iu khin trung tm. Cc thng s o c lu tr v phn tch phc v cc mc ch khc nhau v ty thuc nhiu vo trnh chuyn mn v h thng qun l ca doanh nghip. Cch ny gim thiu chi ph u t ban u, nhng cng hn ch hiu qu ng k v lm tng s l thuc vo con ngi. Trong cun S tay ny, tng quan v c s l thuyt ca cc k thut ni trn u c m t y . ( Tm hiu v cc k thut cho Bo dng tin tin trang ) (c v h thng gim st v chun on tnh trng thit b bng dao ng my trang 225) 2.3. Cc in hnh p dng Do Vit Nam cha c mt tm nhn quc gia hay mt chin lc chung pht trin bo dng cng nghip nn trnh ca ngnh ny thp hn cc nc tin tin khong 50 nm. Ngoi mt s doanh nghip c vn nc ngoi v mt s cng ty ln trong nc, hu ht cc n v sn xut ca ta p dng chin lc bo dng hng my hoc bo dng nh k theo thi gian. Tnh trng thiu nh hng, thiu c s h tng k thut, thiu chia s kinh nghim v hp tc, thiu cc nh cung cp dch v chuyn nghip c nguy c lm ngnh bo dng tt hu xa hn na v lm suy gim nng lc cnh tranh ca cng nghip Vit Nam. D n Xy dng nng lc v Trnh din K thut Bo dng Cng nghip Tin tin do Vng WalloniaBruxxelles ti tr l mt trong nhng n lc u tin tm v m nhm ng dng bo dng cng nghip tin tin Vit Nam. Trong thi gian thc hin t thng 4/ 2007 n thng 5/2008 D n chn 3 cng ty c va trong 3 ngnh tiu biu l vt liu xy dng, c kh v ni tht trin khai trnh din k thut. Kt qu thc hin ht sc kh quan cho thy tnh kh thi ca vic p dng bo dng cng nghip tin tin vi cc doanh nghip trong nc c va tr ln. Ba doanh nghip c chn l Cng ty C phn Xi mng Kin Kh, Cng ty C phn xe my Detech v Cng ty Xun Ha. Cc tiu ch la chn n v trnh din k thut l: 1- Cc cng ty va v nh c tnh in hnh ca ngnh, thun li cho vic ph bin kinh nghim v nhn rng ti cc doanh nghip cng ngnh khc 2- Nhn thc ca lnh o v vai tr ca bo dng cng nghip, t quyt nh s cam kt trong vic dnh thi gian v ngun lc cho vic thc hin cc gii php bo dng cng nghip 3- Kh nng trin khai cc gii php c t vn ca n v ph trch bo dng (thng l phng k thut) v cc cn b ph trch sn xut trc tip ti cc b phn trin khai th im Cc kinh nghim v bi hc rt ra t qu trnh trin khai bo dng cng nghip tin tin ti cc doanh nghip Xun Ha v Kin Kh c trnh by di y. Do kh khn trong vic tng kt s liu nn trong phn ny cha trnh by v cng ty Detech. A. Cng ty Xun Ha

Qu trnh trin khai bo dng cng nghip tin tin Xun Ha bt u vi vic thnh lp nhm ci tin Bo dng gm 10 ngi, trong c 1 iu phi vin l gim c nhn s Cng ty, trng phng k thut, 2 cn b ph trch thit b, 2 cn b ph trch bo dng ti xng v cc qun c xng. Cc hot ng v kt qu ca nhm c bo co nh k ti Ph Tng gim c ph trch sn xut Cng ty. 3 trong s 10 ngi trong nhm c c i tham gia cc kha hc do D n t chc. Nhm chn dy chuyn m t ng 3, nhm my hn v nhm my un lm trng tm thc hin ci tin bo dng. L do ca vic la chn ny l tnh trng hng t ngt thng xuyn cng nh hiu qu lm vic ca cc nhm my ny. ng thi, vic la chn mt dy chuyn sn xut th im c k vng s mang li cc kinh nghim qu cho cc dy chuyn khc. Vi mi trng tm, cc nhm nh li c thnh lp vi nng ct l Nhm Ci tin Bo dng ca Cng ty. Vn u tin Nhm nhn thy l v c cu t chc bo dng ca Cng ty. Vic phng K thut ch qun l v quy trnh v quy nh k thut, trong khi nhn s v thit b li do cc Phn xng qun l to ra mt s thiu ng b v nht qun, gim tui th v hiu qu s dng thit b. Mt xut thay i c cu c Nhm son tho v trnh ln Ban Gim c cng ty. Trong xut ny, cc cn b v nhn vin trc tip lm bo dng ti cc Phn xng c tch thnh cc t thuc qun l ca phng K thut. S thay i ny cho php nng cao trnh cn b, thun li trong chia s cc s liu bo dng, nm vng c tnh trng v mc sn sng ca cc thit b trong cc phn xng. Nh vy, cht lng v hiu qu bo dng s nng cao ng k. Trong lc ch quyt nh ca lnh o Cng ty, cc b phn c chn lm trng tm c p dng th nghim m hnh ny.

Biu pareto s li xy ra trong sn xut DC T3

12 11 10 9 8 7 6 5 4 3 2 1 0 7 1 16 3 4 9 11 15 10 5 6 13 8 14 2 12 100.0% 80.0% 60.0% 40.0% 20.0% 0.0%

S li

Loi li
Hnh 1.7: Biu Pareto s li xy ra

Xun Ha l mt in hnh v p dng Sn xut Sch hn v cc k thut qun l mi trong cng nghip. Nh c tm nhn tt ca lnh o cng ty v mt i ng cn b qun l cp trung gian nng ng, tch cc, chi ph sn xut ca Xun Ha lin tc c hp l ha trong khi cht lng sn phm c nng cao. Chnh s nhy bn vi nhng ci mi l ng lc chnh thc y cng ty tham gia D n.

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Tip theo, cc s liu bo dng sn c trong ghi chp theo quy nh ISO ca Cng ty c thu thp v sng lc mt cch c h thng s dng nh l c s d liu bo dng ban u. Nhm my hn v my un tp hp cc s liu t 2006, trong khi dy chuyn m t ng tp hp c cc s liu t 2003. S dng k thut Pareto, cc nhm phn tch cc s liu thng k hng my theo tn sut, thi gian dng my v chi ph khc phc li. Mc d cn c mt s lng tng trong vic xc nh chnh xc chi ph khc phc, c bit l chi ph gin tip, nhng cc thnh vin ca Nhm hc hi c nhiu kinh nghim qu v c ci nhn khc v cng tc ghi chp, tng hp v phn tch s liu phc v bo dng.

700,000,000 600,000,000 500,000,000

400,000,000 300,000,000 200,000,000 100,000,000 0

100.0% 90.0% 80.0% 70.0% 60.0% 50.0% 40.0% 30.0% 20.0% 10.0% 0.0% 15 1 7 14 4 3 16 11 5 6 10 8 9 13 2 12

S li xy ra

S li xy ra

Chi ph

Hnh 1.9: Biu Pareto theo chi ph khc phc B. Cng ty C phn Xi mng Kin Kh Cng ty C phn Xi mng Kin Kh nm trn a bn huyn Kin Kh, H Nam. y l mt cng ty xi mng loi nh, thay i cng ngh t l ng sang l quay vo nm 2004. Vic ng dng Bo dng Cng nghip Tin tin din ra ng vo thi im Cng ty ang n lc lm ch thit b pht huy ht u im ca cng ngh l quay. Do cc hn ch v trnh k thut v nhn s, chng trnh Bo dng Cng nghip ca Cng ty kh c th ni l ton din v h thng. Tuy nhin, y cng l mt kinh nghim tt cho cc cng ty c va c nng lc hn ch nhng bit tp trung nng lc ng trng tm, nh thu c hiu qu rt ng k.

16

11 15 10

13 8

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Loi li li Loi Hnh 1.8: Biu Pareto theo thi gian sa cha li Trn cc hnh1.7, 1.8, 1.9 (s th t ca hnh) l biu Pareto th hin cc li xy ra nhiu nht, cc li gy tn tht v thi gian nhiu nht, v cc li gy thit hi kinh t ln nht xy ra cho dy chuyn m in t ng s 3. C th thy rng cc i tng khc nhau quan tm n cc s liu khc nhau: ngi ng my quan tm n my ca mnh, b phn bo dng v k hoch sn xut quan tm n li no gy mt thi gian x l nht, cn b phn qun l ch n kha cnh kinh t nhiu nht. Sau khi c cc s liu phn tch v cc li ni bt v tn sut hng, thi gian dng my v chi ph gy ra, bc tip theo l phn tch cc nguyn nhn gy ra li. K thut Ishikawa (cn gi l xng c) t ra l cng c hu hiu gip tm cc nguyn nhn gc ca cc li. T y, cc bin php x l c nu ra, tho lun la chn v ln k hoch thc hin. Cc gii php hiu qu nht ha ra li kh n gin, chng hn ch l tng cng kim tra, v sinh b pht hin sm cc vt nt, ci tin thit k b gim nguy c r r, hay trang b thm b d phng cha tm dung dch m khi x l hay v sinh b. Kt thc thi gian trin khai d n ti Xun Ha vi s h tr ca chuyn gia, cc li ch trc tip thu c c gi tr 578.436.000 ng/nm. Tuy nhin, cc li ch gin tip khng th hin c bng s li c ngha quan trng hn. l Cng ty nm c cch lin tc ci tin v p dng Bo dng Cng nghip Tin tin cp 1 v 2, quan im v qun l thit b thay i t dng my nh k sang qun l tnh trng, v mi quan h gia bo dng- sn xut c thay i v cht. Vo bui hp cui ca d n, Cng ty cho bit s ti t chc li h thng sn xut- bo dng. Cc li ch khc c ghi nhn l gim t l sn phm hng, ko di tui th thit b, ci thin iu kin lm vic v gim tai nn

Tit kim s dng ti nguyn khng ti to v cc kt qu khc 2006 2007 Sn lng, tn xi mng PCB30 Chnh lch sn lng cng k, tn xi mng PCB30 Chnh lch doanh s cng k, quy theo gi bn 2006, tm tnh theo gi bn 2006, VND 90,905 105,756 14,851 7,425,500,000

Tng gim pht thi CO2, tn

Tng tit kim s dng ti nguyn khng ti to, ng

13,309 2,397,599,865

Cn lu rng cc kt qu trnh by trn y l kt qu tng hp ca nhiu n lc ci tin khng ngng ca doanh nghip trong nhiu mt, v vy kh c th tch ring kt qu ca chng trnh Bo dng Cng nghip (v iu ny cng khng cn thit).

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 trin khai chng trnh, Cng ty thnh lp i Ci tin Bo dng gm 11 cn b ph trch cc khi sn xut, kho v ti chnh. Cng ty c 4 cn b theo hc 3 kha o to v Bo dng Cng nghip Tin tin do D n t chc. Chng trnh Bo dng Cng nghip, vi s h tr ca TTSXSVN v chuyn gia quc t, c thc hin T thng 4/2007 n thng 5/2008. Trong thi gian ny, chuyn gia ca D n v Trung tm Sn xut Sch n lm vic v h tr Cng ty 9 ln. Cc bn cng nhau thit lp c s cho vic trin khai bo dng ti Cng ty, tm ra cc im yu v vn chnh, phn tch nguyn nhn gc v tm ra cc gii php hiu qu nht thch hp vi iu kin thc t trin khai. Can thip ln nht ca d n tp trung vo vic ti u ha cc thng s vn hnh ca l quay. Mc d l thit b trung tm, cc thng s u vo v vn hnh ca l cha c gim st y v phi hp tt vi nhau. Cc thng s v lng d tr nguyn liu, t l trn chnh xc, m, cht lng v thnh phn cc phi liu, cng nh cht lng clinker u c o c nhng li khng c cung cp kp thi cho b phn vn hnh l m gi li cc b phn trc tip. Nhit v l khng c gim st, trong khi cc thng s m men xon (tnh gin tip t cng dng in ng c dn), lu lng gi, nhit cc zone khc nhau.. tuy c gim st nhng li thiu chnh xc do bo dng km. Ring vic khng gim st c nhit v l dn n chy v bin dng v l, gy thit hi tng cng (trc tip v gin tip) cho cng ty ln ti 7 t ng. Trong khi mt thit b o nhit laser cm tay n gin ch c gi 7 triu ng (Trung Quc sn xut). Ngay khi bt tay vo d n, vic u tin Cng ty thc hin l mua my o nhit v l. Tip l phi hp cc thng tin u vo v vn hnh mt cch kp thi gip ngi vn hnh c th ra quyt nh kp thi. Cc sensor o cng c bo tr v kim nh li m bo chnh xc. Phng vn hnh c thay knh ca s v sa ca ra vo hai lp m bo cch ly khi bi v nhit bn ngoi. Hnh v th gim st cc thng s hot ng Cc gii php khc Cng ty thc hin: Xy mi kho ph tng bo dng. i Ci tin Bo dng hp thng xuyn vi tn sut trung bnh 2 tun/ ln. C h thng ghi chp s liu bo dng mi, h thng m s cho thit b, c cc biu mu bo dng mi tng thch vi h thng ISO ca Cng ty. p dng cng c h tr qun l bo dng v sn xut cho l bng my tnh.

3.1. Kim ton Bo dng Bn ang u? Ch sau khi doanh nghip chc chn rng hi t cc iu kin cn thit trong mc 2.2.1 v hiu c ni dung trong 2.2.2 th vic trin khai Bo dng Tin tin (xin php nhc li l Bo dng Tin tin y ng ngha vi Bo dng Hiu nng) mi c th thnh cng. u t ban u cho bo dng khng ln, nhng quan trng l phi ng cch v sau mt thi gian trin khai, phi t c cc mc tiu c th v mt h thng qun l, hnh chnh-hu cn, t chc v k thut bo dng ph hp vi cng ty v c kh nng t vn hnh. t c iu ny, cc mc tiu t ra phi c th, c khung thi gian r rng, c cc ngun lc yu cu cn thit v s gim st cht lng v tin hiu lc. Vic u tin m doanh nghip cn lm l t thc hin Kim ton Bo dng bit mnh ang u trn con ng xy dng h thng qun l, hnh chnh, t chc v k thut bo dng nu trn. Cng tc t kim ton cng cn c thc hin sau mi khong thi gian nht nh tip tc nh gi trnh v cc vn v bo dng ca doanh nghip, cng nh ch ra hng i tip theo v chin lc bo dng. Cng vi cun S tay ny, chng ti cung cp cho Qu v mt phn mm t ng nh gi trnh trong bo dng ca doanh nghip. ( c thm v T kim ton Bo dng trang 169) 3.2. Trin khai h thng c s h tng cn thit cho Bo dng Cng nghip Tin tin C nhiu cch hiu v mt h thng c s h tng cn thit cho trin khai bo dng tin tin trong cng mt doanh nghip. Tng t nh vy, h thng c s h tng cn thit ny s rt khc nhau vi cc doanh nghip, ngnh ngh v quy m khc nhau. Vic la chn kt cu v cc c im ca c s h tng bo dng l mt bi ton m doanh nghip cn t gii, c th vi s h tr ca cc chuyn gia Bo dng (chng hn ca Trung tm Sn xut Sch Vit Nam). hiu r v vn ny v ra quyt nh ng, lnh o doanh nghip v cc cn b qun l k thut bo dng cn nghin cu k phn 2.2.2 Cc iu kin m bo s kh thi p dng Bo dng Cng nghip Tin tin. 3.3. Tch hp bo dng cng nghip tin tin vo hot ng qun l hng ngy ca doanh nghip Vic khi ng mt chng trnh bo dng ti doanh nghip khng phi l iu kh. Th thch ln nht l lm th no duy tr cc hot ng bo dng c t chc v qun l tt trong sut thi gian sau , nh chnh bn cht ca Bo dng (trong ting Anh, maintain va c ngha l duy tr, va ngha l bo dng). Do mi quan h qua li cht ch gia cc hot ng qun l khc nhau trong doanh nghip, nht l mi quan h bo dng sn xut (s c phn tch k trong phn sau), v vy hiu qu nht l p dng mt h thng qun l tch hp. Hng SAP ca c cung cp dch v thit k cc phn mm qun l tch hp theo yu cu ca khch hng, trong c cc hng mc lin quan n qun l bo dng: Qun l kho, qun l nhn s, k hoch mua ph tng, k hoch bo dng, k hoch s dng thit b (lin quan n k hoch sn xut)

III. BT U NH TH NO?
C nhiu l trnh kh thi cho vic p dng Bo dng Cng nghip Tin tin. Tuy nhin, cng ging nh vic gii quyt mi vn hc ba ca cuc sng, p n tt nht l cu tr li m doanh nghip t tm cho mnh. Theo chng ti, cho d doanh nghip i theo l trnh no th cng phi qua v lm ch cc giai on sau: 1234Bit mnh ang u v cc vn hin ti: Kim ton bo dng Trin khai h thng c s h tng cn thit cho bo dng Tch hp cc hot ng bo dng vo hot ng hng ngy ca doanh nghip: bt u vi qun l Hng ti tng lai: TPM v Kaizen

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Vi cc doanh nghip va v nh Vit Nam, vic pht trin mt phn mm tch hp nh vy l khng thc t. Tuy nhin, xy dng mt h thng qun l tch hp trn c s cng ngh tin hc cho ring n v mnh l kh thi, nht l vi cc cng ty c hoc ang trin khai ISO 9000 hoc 14000. Mt h thng qun l tch hp ca doanh nghip sn xut nn bao gm cc cu phn sau: - Qun l nhn s v hnh chnh - Qun l bo dng: . . . . . . Kho thit b v ph tng d tr Tnh trng v mc sn sng ca thit b K hoch bo dng H thng thng tin bo dng H thng c s d liu bo dng o to cc k nng bo dng

gii php sng to c a ra t nhng ngi hiu vn nht v hng ngy i mt vi chng. Trin khai TPM cng l chun b iu kin cn thit cho Kaizen- i mi lin tc. Trong bi cnh mi trng cnh tranh thay i lin tc theo hng ngy cng khc nghit, vng i sn phm ngy cng ngn, cc k thut mi lin tc xut hin, cc i th a quc gia ngy cng ln sn th i mi lin tc l cch duy nht doanh nghip tn ti v pht trin. Kaizen c ngha l ci tin lin tc, c ngun gc t ting Nht, trong kai c ngha l thay i v zen mang ngha l tt. y l mt h thng cc phng php tp trung vo vic ci tin lin tc cc quy trnh sn xut, k thut, kinh doanh, v qun l. Kaizen ln u tin c p dng ti Hoa K, bi cc gio vin v qun l. Sau n bt u ph bin trong nn kinh t Nht Bn t sau th chin th II. Ngy nay, Kaizen c ph bin rng ri trn th gii. Kaizen khng phi l hot ng nh k mt thng hay mt nm mt ln, m n l mt hot ng lin tc. Ti cc cng ty ni ting ca Nht Bn, nh Toyota v Canon, trung bnh mi nhn vin a ra 60 n 70 tng mi nm, nhng tng ny c trnh by di dng vn bn mi ngi cng nhau chia s v nu kh thi, s c thc hin. Hu ht cc tng khng phi l nhng thay i ln lao. Kaizen da trn nhng thay i nh vi nguyn tc c bn: lun lun ci thin nng sut, an ton v hiu qu, ng thi gim thiu rc thi. ( c thm v TPM cho lnh o doanh nghip trang 286 ) ( c thm v TPM cho Cn b qun l Bo dng v Cn b k thut Bo dng trang 286) ( c thm v Kaizen trang 387)

- Qun l sn xut - Qun l cht lng - Qun l mi trng - An ton sn xut ( c thm v mi quan h gia Bo dng sn xut v an ton trang 326) Xy dng thnh cng mt h thng qun l tch hp nh vy i hi mt qu trnh n lc theo kiu th-sai lin tc. Nhng khi c mt h thng nh vy, doanh nghip t nng tm ca mnh ln mt trnh mi, gim thiu s ph thuc vo cc c nhn v c u th r rt v nng lc cnh tranh so vi cc n v khc, th hin c th trong cc ch s PQCDSM. 3.4. TPM v Kaizen S thnh cng hin ti i khi li hn ch thnh cng ni tip. Khi doanh nghip xy dng c mt h thng qun l tch hp, trong c phn qun l bo dng, v ang hng li t h thng th thng s ngi thay i ln. Tuy nhin, giai on cao hn ca Bo dng Hiu nng- TPM- li i hi mt s thay i kh ton din v t chc v vn ha doanh nghip. y l kh khn ln nht vi cc doanh nghip Vit Nam v n i hi phi nhn thc li vai tr ca tt c cc thnh vin trong cng ty: - Vi lnh o: Chuyn t lnh o l trung tm sang lnh o phc v, lun sn sng lng nghe v trao quyn, ci m vi cc tng thay i, nhn trch nhim gii trnh, tn trng cc nguyn tc dn ch v minh bch thng tin - Vi nhn vin: Chuyn t th ng sang ch ng, t lng nghe v chp hnh sang t chu trch nhim, t tun th cht ch sang thc hin sng to. Tm li, vi TPM, ton b vn ha doanh nghip v nhn thc v vai tr ca mi thnh vin u phi thay i. Gi tr gia tng ln nht cho t chc c thc hin bng khi c v tri tim nhiu hn bn tay v i vai. Thng tin khng ch i mt chiu t trn xung m theo c hai chiu, trong thng tin t di ln, ng vai tr rt quan trng. iu ny cho php s tht c ni ln v tn trng, cc

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35

PHN 2.

CC TI LIU CHUYN SU

1. 5S TRONG BO DNG CNG NGHIP

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37

K LUT LAO NG nhm t chc BO DNG T QUN tt hn c th t c nh p

dng 5 nguyn tc: 5 nguyn tc ny c bit n nh l trit l 5 S:

2. SNG LC Mi cng nhn vn hnh sn xut v k thut vin phi th hin tinh thn t gic v n lc t cc thit b hoc cng c ti ng ch ca chng: C CH CHO MI VT DNG V MI VT DNG U T NG CH

SEITKETSU SEIRI SEISSO SEITON SHITSUKE

1. SCH S

SCH S SNG LC SN SC SP XP SN SNG

Bc ny phi c h tr bng vic theo ui tnh hiu qu trong cng vic, c th l cc yu t h tr hoc thit b ct tr cho cc chi tit sn xut c nh. Cc thit b ph tr cn thit s phi c a vo phn xng. 3. SN SC: THIT LP TIU CHUN I VI VIC LM SCH V TRA DU M Nhn vin k thut ph trch bo dng phi thit lp cc tiu chun v hng dn thao tc, cng nh nhng ti liu m ngi vn hnh v cng nhn k thut s phi c. Nhng ngi ny s phi tun th cc hng dn m h nhn c lin quan n vic lm sch v tra du m cng nh l pht hin v sa cha nhng li n gin v c kh, in. H phi ch nhng kh nng c th ci tin da trn nhng bi hc rt ra c t nhng s c v nhng hin tng xung cp quan st c. T chc sn xut phi kt hp nhng ln can thip cn thit cng nh ch n cc nhn xt c lin quan ca nhng k thut vin v cng nhn vn hnh sn xut. 4. SP XP V PHNG PHP Tt c mi ngi phi gn gng trong cng vic ca mnh v thc hin cng vic theo phng php nghim ngt. Cc dng c cn thit cho cng vic phi trong tnh trng tt v sn sng s dng. 5. SN SNG: K LUT/ GIO DC O C/ TN TRNG NGI KHC Nhng quy nh ny c th c vit trong cc iu khon hot ng. H s my khng phi l quy tc ng x tt. Tuy nhin n c th dn dt chng ta n nhng quy nh phng nga (v.d. tai nn) mt cch ht sc c th.

Mi quan tm i vi ngi vn hnh v nhn vin k thut l lm th no nhng vt r r du m, lng ai c, hoc s bin tnh dn dn ca mt chi tit c th d dng pht hin ra trong khi lm sch thit b. Hn na tc can thip cng nh ng lc ca cc k thut vin thc hin vic can thip bo dng cng tng ln. Mt can thip phng nga c th pht hin: 1. 2. S tch t ca mt st, du m, cht cn b c th gy ra hng thit b hoc thm ch c th gy dng sn xut. Trong mt mi trng ngn np v sch s, nu nh mt vt no b rt xung nn, chng c th d dng c tm thy v nht ln, gip nng cao tnh an ton.

Bo dng t qun phi c thit lp mi cp . 1. Lm sch ban u Cng vic ny gm c vic loi b bi bn mt cch trit khi cc thit b trong phn xng. Chng ta s tn dng li th ca bc ny x l nhng li n gin c pht hin. Bc ny s c thc hin mt cch hi ha nu nh chng ta lp k hoch trn tng thit b mt, vi s h tr ca cc k thut vin v cng nhn vn hnh. Nhng bt thng c pht hin v c sp xp s c ghi li trong s ghi chp bo dng. 2. Loi b bi bn y l vic lm ci thin tnh trng trong khi vn gim c thi gian dnh cho vic lau chi. Chng ta c th thc hin vic ny bng cch: loi b s r r ca du bi trn v/hoc nc lm mt, s dng mng chn bo v trnh s vung vi ca cc mt st hay loi b cc ngun pht sinh bi, lm sch cc tm lc ng hn, dnh thi gian tm ngng my cho cc hot ng lau chi v qut dn.

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39

1. Cc chc nng v mc lm vic Chc nng bo dng bao gm vic duy tr thit b trng thi nh ban u. Nh , n c th tip tc m bo cc chc nng yu cu. Vic bo dng ch c th thc hin c khi chng ta hon ton hiu k cc chc nng ca thit b. xy dng v a ra c phng php bo dng th trc ht chng ta cn phi hiu thu o v xem xt mt cch chi tit cc chc nng hot ng ca thit b. Kh nng hot ng mong mun lin quan n cc chc nng yu cu. Mi lin quan ny phi c xc nh mt cch chnh xc. Phng cch xc nh cc chc nng yu cu ph thuc vo mi trng v cch s dng thit b. Cng tc sn xut, cht lng sn phm, dch v khch hng, tnh ton vn ca mi trng sinh thi, ton b chi ph vn hnh v chi ph m bo an ton phi c a vo xem xt trong qu trnh xc nh.

2. BN CHT HOT NG V QU TRNH HNG CA THIT B

Cc h hng chc nng Vic kim sot v gim s c i hi chng ta phi thc hin cng tc qun l s c mt cch hiu qu. iu l gii ti sao qun l mt cch hp l cc thit b i hi phi ch ra c cc h hng d xy ra, nhng ri ro m chng gy ra khi xut hin cng nh mc nh hng . Do vy cn phi bit: 1. 2. Cc chc nng lm vic ca thit b b hng hc nh th no? Nguyn nhn gy ra cc hng hc.

Vic ch ra c cc dng h hng khc nhau gip chng ta c th sa cha mt cch ph hp v khng b nhm ln trong qu trnh xem xt cc triu chng hng hc. Tip sau , xem xt tc ng ca mi dng hng hc. Nu s c xy ra, cc hu qu ca n s l g ? Theo cch , chng ta c th nh lng c nh hng ca mi loi h hng. 2. Cc hu qu do cc s c gy ra 2.1. Cc hu qu v mt an ton Mt trc trc c th gy nguy hi n an ton cho con ngi. Nu nh hng ny l nghim trng, th kha cnh ny phi c u tin v iu kin so vi cc yu t v ti sn cng nh hot ng sn xut. Dng h hng ny phi c nh gi v mc cng nh v kh nng xy ra ri ro. 2.2. Cc hu qu v mi trng Nhng h hng gy hu qu n mi trng nu n vi phm nhng qui nh php l ang c hiu lc thi hnh hoc vi phm cc qui nh ca cng ty. Cc hu qu trm trng v mi trng c th lin quan n con ngi, n k thut v ti chnh. Vic nh gi mc nguy hi ca chng tng ng nh cc h hng lin quan n an ton.

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41

2.3. Cc hu qu v hot ng y l nhng h hng gy bt li cho cng tc sn xut, nh hng n cht lng sn phm, v nh hng n dch v khch hng. Sau y l chi tit tnh ton chi ph: 1. Cc chi ph trc tip, bao gm tt c cc chi ph cho vic khi phc hot ng ca thit b nh trng thi ban u. 2. Cc chi ph gin tip, bao gm tt c cc hu qu lin quan n qu trnh sn xut. Tng chi ph s c a vo ngn sch trong mc c ton chi ph cho cc h hng v kinh ph khc phc. U MC 1 2 3 4 5 6 7 8 TN GI S c

BNG 2.1 BNG PHN LOI S C NGHA

H hi, bo li, h hng, ngng hot ng, Xung cp S c tng phn Tng cc s c H hng ln S c ngu nhin S c do hao mn S c ngy mt tng Gy nh hng n s hot ng Gy ngng hot ng t ngt v ngng hon ton Tn sut xy ra l khng d on c Tn sut xy ra s c tng dn

2.4. Cc hu qu khng lin quan n hot ng sn xut Cc hu qu ny lin quan n cc h hng khng phi l an ton, mi trng cng nh hot ng sn xut. Chng ch gy pht sinh chi ph trc tip. 3. Nhng cu hi chnh yu Chng ta lun lun cn phi bit cc hu qu ln ca mi loi h hng v ri ro c th c. Cu tr li s gip xc nh xem cn p dng loi hnh bo dng no. Nhm mc nh xc nh c hnh ng cn thit phi tin hnh, nhng cu hi sau cn c nu ra v tr li : 1. 2. 3. 4. 5. 6. Cc chc nng cn thit v cc yu cu lm vic ca thit b l g? Lm th no chng ta loi b c cc h hng? Nguyn nhn ca cc hng hc l g? Hu qu ca cc hng hc l g? Chng ta c th lp k hoch cho cho vic qun l v phng nga cc h hng khng? Chng ta c th lm g nu cu tr li cho cu hi s 5 l khng?

4.2. Cc hnh ng can thip Sa cha tm thi ch c ngha tm khi phc hot ng trc khi tin hnh sa cha chnh thc. Dng can thip ny cn phi c thc hin theo nhng tiu ch cht ch: 1. Phi lu tm n an ton v ngi v cc thit b. 2. m bo cht lng sn phm. 3. Gii php tm thi cho php tm ngng hot ng. 4. Gii php x l tm thi khng nn gy ra s xung cp ca cc b phn thit b/hoc sn phm,

4. Cc nh ngha & khi nim theo tiu chun 4.1. H hng Tun theo tiu chun AFNOR X 60-011 : S C L S XUNG CP HAY NGNG TR CA CC CHC NNG YU CU.

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43

Sa cha l s can thip cui cng trong mt thi hn ngng sn xut c th chp nhn c. Nu thi hn cht cho sa cha khng th t c ng nh yu cu, cn cn nhc mt s kh nng: 1. 2. 3. Sa cha tm thi. Chuyn sang s dng thit b khc. Lm hp ng vi thu ph.

Thit b 1

Chu k: 285 ngy + 14 ngy + 1 ngy = 300 ngy = 3000 ngy 300 ngy = 10

Tng thi gian bt my Chu k lm vic

Thi gian i (cp) ph tng + Thi gian sa cha = ( 14 ngy + 1 ngy) x 10 = 150 ngy Tnh sn sng: (3000 ngy-150 ngy) 3000 ngy x 100 = 95%

Mt s thit b v h thng c thit k trong mt s trng hp s c vn cho php t mt ch lm vic, c bit trong mt khong thi gian nht nh trc khi buc phi ngng hot ng. 5. Phn tch s c Vic phn tch s c, s ln xy ra s c v hng hc chc nng i khi rt kh khn. Mt yu t quan trng cn phi bit l khi no th chc nng hot ng c khi phc. Trong bt k tnh hung can thip no, iu quan trng l gim ti a thi gian cn thc hin cng vic. y xut hin khi nim tnh cha sn sng hot ng. Mt khi nim khc cng c a ra l : M.T.B.F. (khong thi gian trung bnh gia cc ln xy ra s c) M.T.B.F. c hiu nh l khong thi gian trung bnh gia cc ln h hng, v s phi c cng vi thi gian cung cp b sung thit b v thi gian sa cha h hng. Cc thi gian ring bit khc cng cn phi c nu ra. Tuy nhin, n gin vn , trong phm vi trnh by y, ta ch tp trung cp n 3 loi thi gian nu trn. V d Sau y l s liu cho hai chi tit ca hai thit b, c cng chc nng nh nhau v qui trnh sa cha l ging ht nhau:

Thit b 2

Chu k : 485 ngy + 14 ngy + 1 ngy = 500 ngy = 3000 ngy 500 ngy = 6

Tng thi gian bt my Chu k lm vic

Thi gian i (cp) ph tng + Thi gian sa cha = ( 14 ngy + 1 ngy) x 6 = 90 ngy Tnh sn sng: (3000 ngy-90 ngy) 3000 ngy x 100 = 97%

V d ny cho thy r rng rng thi gian cung cp b sung l rt ng ch . Nu trong c hai trng hp thi gian cp b c a v s khng, chng ta thu c kt qu cho kh nng sn sng l 99% cho thit b u tin, v 99,8% cho thit b th hai. Nu nh tnh sn sng tng thm 2% th bn thn n cha ni ln c g nhiu, hy lm mt tnh ton v sn lng do mt n v thit b c s dng to ra, sau lin h vi doanh thu. Tr i chi ph khu hao thit b, chi ph khng trc tip lin quan n sn xut, chi ph cho sn phm khng ph hp v.v chng ta s phi quan tm n vn ny.

CC THNG S M.T.B.F. Thi gian cp ph tng Thi gian sa cha Chu k Thi gian hot ng

THIT B 1 285 ngy 14 ngy 1 ngy 300 ngy 3,000 ngy

THIT B 2 485 ngy 14 ngy 1 ngy 500 ngy 3,000 ngy

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5.1.1.1. Lit k cc s c THI GIAN NGNG HOT NG T.A.F. THI GIAN NGNG HOT NG THC T T.A. Theo tiu chun AFNOR X 60-011, cc s c c th c xc nh nh sau: Thit b c th hot ng c nhng khng th vn hnh do nhng l do bn ngoi nh: ngi vn hnh, nguyn liu, nng lng

S C TNG PHN

S C TON MY (Ton phn)

Thit b c th p ng chc nng yu cu.

S xung cp ca mt thit b v chc nng

S C

S ngng tr hot ng ca mt thit b do s c chc nng

SA CHA (Bo dng sa cha)

SA CHA TM THI (Bo dng khc phc)

THI GIAN YU CU T.O.

Bo dng cui cng v gii hn sau khi h hng

Hnh ng khc phc cho mt thit b nhm khi phc hot ng tm thi trc khi sa cha chnh thc

Hnh 2.1: Lit k cc s c Nh vy, chng ta hiu v khi nim, v nh chng ta c th xc nh c thi gian lin quan n cng tc bo dng vi ba thng s cn thit cho Cng tc bo dng hiu qu (AF X 60-015). Thi gian ngng hot ng T.A.F. s nh hng n qu trnh sn xut, trong khi thi gian ngng c bit T.A.M. s nh hng n cng tc bo dng v kinh ph i km. THI GIAN BT MY THC T

Thit b c th p ng chc nng yu cu

46

Thit b p ng c chc nng yu cu

THI GIAN HOT NG T.B.F.

Thit b c th hot ng c nhng khng i hi phi lm

THI GIAN CH CH T.A.F.

Hnh 2.2 : Cc trng thi ca thit b t gc qun l

Ngi s dng mong mun thit b trng thi hot ng theo ng yu cu chc nng.

THI GIAN NGNG C BIT T.A.M.

Thit b khng th hot ng c do s c hoc ang trong thi gian bo dng thng

47

Cc thng tin v cng vic bo dng thit b cn phi c ghi chp li. iu ny c thc hin thng qua 2 dng: 1. 2. Bng phn tch s c h hng cung cp cc thng tin v cht lng; Cc bng tng hp cung cp nhng thng tin c th v nh lng nh : thi gian sa cha, cc chi ph, ngy thng ..

5.2. Phn tch s c h hng: Biu pareto % Tn sut xut hin

Nu cc ti liu bng biu khng c, thng tin c th c tp hp thng qua phn tch lnh yu cu cng vic nhng s rt kh khn. Khi cc s c v h hng c lit k, chng phi c ng k v h thng ha, ri c nhm li theo cc tnh cht hot ng, d l thuc mt b phn ca thit b hay mt thit b ring l (D.C. ng c in). Tiu chun AFNOR X 60-510 phn loi cc dng s c thnh hai nhm: 1. Cc s c ph bin, 2. Cc dng s c theo nhm. Cc dng s c ph bin Hot ng sm hn thi gian qui nh Khng hot ng theo ng thi gian nh Khng dng theo ng thi gian nh S c trong khi ang hot ng A B C D E F K dng s c

Hnh 2.3: Biu Pareto Vic biu din bng dng biu gip chng ta c th phn tch c s liu mt cch nhanh chng. Nhng phn tch u tin gip chng ta rt ra c nhng h hng c gi l bn ngoi v khng thc cht. Chng s c sa cha v iu chnh li nu c th, nhng s khng c tnh n trong phn tch tin cy. Chng lin quan ti cc li iu khin, do ha hon, do ngp lt,i vi nhng s c bn trong v thc cht , cn tin hnh phn tch nhm quyt nh xem c phi thc hin bo dng hay khng? Phn tch ny s da trn ba biu Pareto: 1. 2. 3. Pareto n xc nh tin cy. Pareto t xc nh mc bo dng. Pareto (n.t ) xc nh kh nng bo dng c th .

BNG 2.2 CC DNG S C THEO NHM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 S c v kt cu (hng hc) B tc vng Qu rung lc Khng nm ng v tr Khng m c Khng ng c S c v tr m S c v tr ng R r bn trong R r bn ngoi Vt qu gii hn trn cho php Thp hn gii hn di cho php Hot ng khng theo ng lch trnh thi gian nh Hot ng khng lin tc v n nh Hot ng khng bnh thng a ra cc ch bo sai Lung nguyn vt liu b suy gim Khi ng khng ng Khng ngng c 34 24 25 26 27 28 29 30 31 32 33 20 21 22 23 Khng khi ng c Khng o mch c Hot ng sm Hot ng mun hn thi gian d kin u vo sai lch (b tng ln) u vo sai lch (b gim i) u ra sai lch (b tng ln) u ra sai lch (b gim i) Tn tht u vo Tn tht u ra on mch Mch h (in) R r (in) Cc trng hp s c ngoi l khc ph thuc vo c im ca h thng, cc iu kin vn hnh v cc tr ngi trong vn hnh Thc mc nu ra thm nu c

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5.1.1.3. Vng i ca thit b Tn sut xy ra s c l mt hm ca thi gian v s tin trin ca n c biu din bng ng cong bn tm ni ting, hay n gin gi l qui lut Weibull S lng s c 100% S c im ti hn

3. Giai on lo ha Giai on ny s c phn nh bi tn sut h hng khng chp nhn c i vi cng ty. Trong hon cnh ny cn phi c mt quyt nh:

. .

Gim cp thit b. Phc hi tng th cho thit b.

tin cy cho hot ng ph thuc vo tt c cc s c k thut cng nh vo cc yu t bn trong v bn ngoi cng ty. Biu Ishikawa cho php c th tin hnh cc phn tch cn thit. a. o lng mt phn m.t.b.f. (v do t l xy ra s c) (t) = 1 M.T.B.F

INTERVENTION

T l hng hc cho php nh gi tin cy, phn nh s ln xy ra s c trong sut thi gian vn hnh. u mc cc s c cha bao gm cc hng hc chc nng do: 1. 2. Vng i thit b Cc li iu khin do nguyn nhn ngu nhin hoc do khng tun th cht ch cc quy trnh kim sot, Cc s c tc ng t bn ngoi nh ha hon, ngp lt, Nhng s c ny c coi l khng c bn i trong phn tch h thng.

im bo ng

(t) = S lng cc s c n v s dng V mt thng k, t l xy ra s c l kh nng xy ra s c c iu kin trong mt khong thi gian t cho. T l xy ra s c l mt hm nghch bin cho thy quan h gia xu hng xy ra cc s c v tc xut hin cc s c. C hai trng hp xy ra: 1. 2. Cc b phn hng hc c thay th hoc c sa cha trong khong thi gian t . Cc b phn hng hc khng c thay th hoc sa cha trong khong thi t .

Khi ng

G b

Giai on trc khi xy ra s c

Gian on m tn sut xy ra s c l khng i

Pht hin

Cc kim tra giai on

Kim tra thng xuyn

Giai on h hng do thit b c

Hnh 2.4: Biu quy lut Weibull ng cong Weibull ch ra ba giai on trong vng i ca mt thit b. 1. Giai on trc s c c bt u t lc khi ng i vi nhng thit b cng nghip. i vi cc thit b in ngi ta s dng k thut lo ha. Nhng i vi hu ht cc thit b, qu trnh ny c theo di ti hin trng bi nhng ngi s dng v c rt theo cc iu kin c th ca chnh cng ty. Giai on n nh.

2.

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51

* Cc b phn hng hc c thay th hoc sa cha trong khong thi gian t NS ( t ) N

O

NO 0 50

NS ( t ) 50 33

NS ( t + t ) 60 27

t ( t )
< <

t + t

t (Thit b s dng) (t)= 33 van 27 van NS ( t ) - NS( t + t ) = NS ( t ) . t 33 van.10 gi

4

C ( t )

( t ) = 1,8 .10 N = s lng ban u ca cc thit b NS ( t ) = s lng thit b cn hot ng ti thi im T NS ( t + t) = s lng thit b cn hot ng ti thi im T + t C ( t ) = s lng cc s c trong khong thi gian t C ( t ) = NS ( t ) - NS ( t + t)
O

h hng / gi = 3,78.10 5 h hng / ln

(t) =

33 van -27 van 33 van.8 ln.600

K t thi im thit b hng c thay th, chng ta thu c NS ( t ) = N . T l s c trung bnh trong khong thi gian t c tnh:
O

Nu cc van hng c thay th: (t)= 33 van -27 van 50 van.10 gi = 6 h hng 50.10 gi = 12. 10
3

(t) =

C ( t ) N0 . t )

h hng / gi

* CC B PHN HNG HC KHNG C THAY TH HOC SA CHA TRONG KHONG THI GIAN t Trong trng hp ny NS ( t ) s khc vi N . T l s c trung bnh s bng:
O

b.

M.T.B.F. v vic s dng n

( t ) =

NS( t ) - NS ( t + t) NS( t ) . t

Khong tin cy ca M.T.B.F. Theo qui lut s m, s d dng trc tip suy ra c M.T.B.F. t t l h hng ca mt n v thit b hoc mt b phn thit b ang hot ng. Chng ta nhc li rng M.T.B.F. l thi gian trung bnh gia cc ln hng. N khng phi l mt khong thi gian c nh. T khng th cn c vo M.T.B.F. thit lp mt yu cu thay th thit b mt cch h thng theo chu k cho cc hot ng bo dng phng nga. Chu k ny s hoc l qu ngn hoc l qu di. Trong mi trng hp n s lm tng chi ph. iu gii thch ti sao cn phi xc nh khong thi gian tin cy cho M.T.B.F., chng hn, cho thi im nh nht i v thi im ln nht S l c nh. Theo cch , kh nng M.T.B.F. nm gia i v S c thit lp. Tip cn xc nh cc h s nhn gi cho hai thi im trn l c nh. i M.T.B.F. S T

V d 1. Cc b phn hng c thay th hoc sa cha. Mt i xe c 70 chic, gi thit c 41 b hng trong giai on ng h ch cy s t ti gia 80,000 v 90,000 km. T l xy ra h hng l bao nhiu? t = 90,000 km - 80,000 km = 10,000 km (t) = 41 s c h hng 5 = 5.85.10 h hng. / km 70 phng tin.10.000 km

2. Cc b phn b hng khng c thay th v sa cha. Mt nhm 50 van in c vi 8 ln y trn pht. Vo cui gi th 50, cn 33 chic lm vic. Vo cui gi th 60, 27 chic cn lm vic. T l xy ra h hng l bao nhiu trn mt gi? Trn mt ln y?

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GII THIU
Bn cht Bo dng sa cha l b ng. Nhng n c th l mt la chn trong mt s trng hp. Chng ti c gng gii thiu cc phng php ti a ha tnh ch ng khi chn phng php ny. Cc phng php qun l bo dng mi ch yu nhm kim sot v gim thiu mc bo dng Sa cha. lm c vic ny, vic lp h s bo dng thit b l rt quan trng. Trong mi loi hnh bo dng, thng tin chnh l ti sn qu nht m cc b phn bo dng ca cng ty s hu, l cha kha i n s ti u ha s dng thit b trong cng ty.

3. BO DNG SA CHA (BO DNG HNG MY)

Khng ging vi cc loi hnh bo dng khc, Bo dng Sa cha lun l cc yu cu khn cp, i hi thi hn hon thnh sm v thiu nhiu thng tin cn thit bt tay vo cng vic sa cha. Do vy, cc ngun lc v vt cht v con ngi cn cho can thip sa cha kh c th xc nh chnh xc ngay t u. Vic thc hin phn tch ban u l hu ch. Nhn vin vn hnh thit b nn l ngi lm cng vic ny v h l ngi r nht v c tnh k thut ca thit b cng nh tnh trng ca n trc khi hng. Cc kin v kt qu phn tch ca ngi vn hnh c chuyn cho k thut vin bo dng, nh k thut vin s xc nh loi dng c v ti liu bo dng cn thit. Cng vic tip theo l chn on ti ch. C hai tnh hung c th xy ra : 1. Nu h hng c nh gi l nh. K thut vin t x l tnh hung bng cc dng c, ph tng v vt t sn c. Sau anh ta cn vit mt bo co can thip sa cha (hay cn gi l bo co can thip), bo co ny s c lu trong h s cc can thip thc hin. Cc bo co ny s l thng tin c b sung vo h s Bo dng Sa cha. Nu chn on pht hin ra nguyn nhn cn n nhng ngun lc con ngi v k thut ln: K thut vin phi vit v trnh cc yu cu v ngun lc cn thit, ng thi nghin cu thit lp cc quy trnh sa cha phc hi hay khc phc tm thi. K thut vin phi a ra bn Yu cu Sa cha Tm thi vi nhng thng tin c th v: Ngun nhn lc. Phng tin k thut. Thi gian (thi lng) cn cho can thip. Thi gian hon thnh, v.v...

2.

Cc thng tin ny phi c nh gi li trc khi tin hnh can thip bo dng v s c iu chnh cho ng thc t trong bo co can thip gi l bo co nh gi hon tt (c ngha l bo co v cc cng vic can thip bo dng hon tt). Bn bo co nh gi hon tt ny s kt hp: 1. 2. 3. Cc quy trnh tho v lp thit b. Cc quy trnh m bo an ton. Tc k ghi li cc sa cha tm thi, v.v...

Bn Yu cu Sa cha tm thi c th c xem nh mt ti liu hng dn. Khi kt thc vic can thip, ngi tin hnh can thip s hon thnh v chnh sa bo co ny thnh Bo co nh gi hon tt. Ty theo quy m ca cng ty v mc phc tp ca h thng thit b m cc bo co ny c th c mc chi tit khc nhau. iu quan trng l cng ty phi gii quyt c hai yu cu tri ngc:

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55

ti thiu ha lng ghi chp ti hin trng v ti a ha tnh chnh xc, chi tit ca cc thng tin bo co. Thng th hai bn bo co ny c lp theo mu (phiu) trong cng mt t giy A4 hay A5 nhn vin k thut v ngi vn hnh (hoc nhng ngi lin quan khc, ty theo cc t chc ca tng ni) c th ghi chp ti ch thun tin. Nu s nh gi ca ngi vn hnh c lp bng vn bn chnh thc ring bit, vn bn s phi c a vo cng vi bo co nh gi hon tt ca k thut vin v lu vo h s Bo dng Sa cha. Nh cp, hiu qu ca vic khai thc thit b ph thuc vo kh nng kim sot v gim thiu cc s c hng, dng my, ni cch khc l kim sot v gim thiu Bo dng Sa cha. t c mc tiu ny, nu ch c cc h s bo co can thip khng thi th cha . Nht thit phi tin hnh phn tch hng hc v ghi chp li cc hin tng, nguyn nhn hng vo mt bn ghi chp ti hin trng. Thng tin c ghi li phi c c gii php xut nhm ngn chn h hng ti din v xc nh: 1. 2. Nhng kh nng xung cp v hnh c th dn ti nhng h hng khc. Cc thit b tng t c th c nguy c gp h hng cng loi.

QUY TRNH SA CHA TM THI

CC VN BN GHI CHP LIN QUAN

Li

nh gi

Chn on Bo co nh gi c Li nh khng Yu cu cng vic Sa cha Bo co nh gi hon tt

Hnh 2.5 l s can thip Bo dng Sa cha song song vi cc vn bn ghi chp c lin quan. Bng 2.4 v 2.6 l cc v d v cc mu ghi chp dng trong ton b qu trnh bo dng sa cha.

HNG DN THC HIN

Yu cu sa cha tm thi (cc yu t d on)

Sa cha tm thi

Kim tra & kim sot

Kt qu tt c Tr li sn xut

khng Bo co nh gi hon tt Yu cu sa cha tm thi hon tt

Phiu phn tch li hng Kt thc Hnh 2.5: S khi quy trnh sa cha tm thi

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57

Bng 2.3 PHIU GHI CHP BO DNG SA CHA M loi hnh BD: ...................... TN MY: ..................................................................................................................... M my ......................................... ............................................................. Phiu yu cu bo dng s: Mc khn cp PHN 1 BO CO NH GI M:............................................................. ...........................................................................................

Bng 2.4 PHIU GHI CHP BO DNG SA CHA M loi hnh BD: ...................... PHN 2 Ph tng cn dng ??? STT Tn M hiu D kin S dng Thc t PHIU YU CU SA CHA TM THI M thit b ...................

M T S C HNG C kh

in Li khc .......................................................................... M t ngn gn: .................................................................................................................................................................. .................................................................................................................................................................................................... Phiu nh gi hng s: .................................. Thit b xy ra hng khi no: Khi ng

Thy lc
in t

Kh nn

ang ngng sn xut Hin tng: ........................................................................................................................................................................... .................................................................................................................................................................................................... nh gi v s c hng: ................................................................................................................................................... .................................................................................................................................................................................................... Nguyn nhn c th: ......................................................................................................................................................... .................................................................................................................................................................................................... Gii php xut: Li hng nh: ....................................................................................................................................................................... .................................................................................................................................................................................................... Thc hin sa cha C Khng Li hng nghim trng: ................................................................................................................................................... .................................................................................................................................................................................................... ngh can thip bo dng: C Khng Cc quan st khc: Bnh lun ca ngi vn hnh: Cc iu kin lm vic ca my(nhit , m, vv.): Loi sn phm ang c sn xut Quan st khc: Ngi vn hnh Ngi chu trch nhim Tn Du Thi gian nh gi Bt u Kt thc Ngy S t:

ang vn hnh

Dng c Ti liu tham kho Cc dng c/ vt t phc v bo dng: ................................................................................................ ................................................................................................................................................................................................... ................................................................................................................................................................................................... Thi gian d kin........................................................... Thi gian s dng................................................................ Ghi nhn: ............................................................................................................................................................................... ................................................................................................................................................................................................... ................................................................................................................................................................................................... ................................................................................................................................................................................................... ................................................................................................................................................................................................... ................................................................................................................................................................................................... ................................................................................................................................................................................................... Ngi chu trch nhim Tn:........................................................ Du: Ngy Trang

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Bng 2.5 PHIU GHI CHP BO DNG SA CHA M loi hnh BD: ...................... TN MY: ....................................................................................... Phiu yu cu bo dng s: Mc khn cp PHN 3 PHN TCH S C HNG M my ..........................................................

........................................................................................... ........................................................................................... M:........................................

Tm tt nh gi v sa cha tm thi - M t h hng ................................................................................................................................................................................................ ................................................................................................................................................................................................ ................................................................................................................................................................................................ - M t tnh trng din ra ................................................................................................................................................................................................ ................................................................................................................................................................................................ ................................................................................................................................................................................................ - Quy trnh sa cha tm thi c s dng ................................................................................................................................................................................................ ................................................................................................................................................................................................ ................................................................................................................................................................................................ Mc v tc xy ra Tip din t ngt Chn on - S c - Li vn hnh - Mi trng khng ph hp - Khng tun th hng dn - Li bo dng ln trc - Lm sch my khng tt - Nguyn nhn bn ngoi khc ..................................................................... ..................................................................... .....................................................................

4. BO DNG PHNG NGA

Cc b Ton b

- Nhn thc sai - Li sn xut - Li lp rp - Mn c hc

Xung cp t ngt Nguyn nhn bn trong

Nguyn nhn bn ngoi

- n mn ha hc - Hng do mi - Nguyn nhn bn trong khc .............................................................. .............................................................. ..............................................................

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61

1. Gii thiu Cng tc Bo dng cng nh hot ng sn xut ca cng ty thng th b ng khi nhng s c hng thit b xy ra. Hng thit b t ngt thng gy ra nhng thit hi: 1. 2. 3. 4. 5. Gin on sn xut, c th lm tr hon thi gian giao hng. Tng tiu hao nguyn, vt liu v nng lng do tng nh mc tiu th v do t l sn phm hng tng, tng chi ph sn xut. Gim cht lng sn phm. Tng cc nguy c v tai nn lao ng v lm gim cht lng mi trng lm vic. Nguy c phi thay mi thit b, thm ch l dy chuyn sn xut. MC TIU BO DNG PHNG NGA L GIM THIU T L H HNG VI MC CHI PH TI THIU. Nh c Bo dng Phng nga m cng tc bo dng c th chuyn c sang th cng ngc hn vi Bo dng Sa cha. Bo dng Phng nga gm: 1. 2. Cc hot ng bo dng gp phn ko di tui th ca thit b, Cc thng s k thut thit b o c v ghi chp c gip theo di tin trin ca cc mn hng ca my mc trong qu trnh hot ng lp k hoch can thip trong kp thi (trong khong thi gian m s mn hng c th phc hi hay kim sot c).

3. 4.

Mc sn sng ca cc dng c bo dng chuyn dng, Mc sn sng ca ngun nhn lc bo dng, Xc nh tn sut kim tra v cc hot ng Bo dng Phng nga khc nh vo biu histogram, c xy dng da trn phn tch nhng ln can thip bo dng trc. Xc nh cc loi dng c bo dng thch hp v cn thit cho cng tc Bo dng Phng nga.

2. Cc mc tiu ca bo dng phng nga Cng ty no cng c mong mun SN XUT RA SN PHM TT NHT VI MC GI TI U Bo dng v c th hn l Bo dng Phng nga cn phi gn lin vi mc tiu ny. t c iu ny, Bo dng Phng nga phi t t ra cho mnh cc mc tiu sau: 1. 2. 3. 4. 5. 6. 7. 8. Tng tnh tin cy cho thit b, Gim s ln can thip bo dng do xy ra cc s c hng khng lng trc, Ko di tui th ca thit b, Nng cao cht lng sn phm, m bo lch v k hoch lm vic, Gim tn sut can thip bo dng, Nng cao tnh an ton cho ngi v thit b, Ci thin iu kin lm vic v c quan h lm vic (gia b phn sn xut v bo dng) trong cng ty.

Bo dng Phng nga cn: 1. 2. 3. 4. 5. Cc cuc kim tra nh k c t chc tt, Thay th cc ph tng mt cch c h thng, Chuyn mn su, Ch thay th cc b phn sau khi phn tch, nh gi, Bo dng da vo tnh trng thit b.

3. K hoch bo dng phng nga Vic trin khai k hoch Bo dng Phng nga i hi: 1. 2. 3. Kin thc v cu to v chc nng ca thit b, Nhn thc v cc iu kin hot ng ti u ca thit b, Nm c cc thng s s dng thit b kt hp vi b phn sn xut (thi gian sn xut, s gi sn xut tch ly theo s sn phm lm ra, thi gian dnh cho can thip bo dng ty theo mc xung cp ca thit b, cc n v sn xut,)

Do vy, Bo dng Phng nga bao gm cc cng tc: 1. 2. Theo st s pht trin qu trnh mn, hng ca thit b d on s c, Lp k hoch bo dng, tnh n cc yu t: D bo thi im xy ra hng, Mc sn sng cho sn xut ca thit b, Thi gian nhn c ph tng thay th,

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2.

Phn tch tm quan trng ca thit b. Thit b no khi hng s lm ton b qu trnh sn xut b gin on. Thit b no khi hng s lm gim sn lng hay lm gim cht lng sn phm. Thit b no khi hng s lm tng chi ph bo dng. Thit b no khng cn n Bo dng Phng nga. S phn tch nh tnh v thit b.

Phn tch iu kin s dng

1.

Phn tch cc s liu bo dng thu thp c.

4. S l-gic bo dng phng nga S bao gm: 1. Vic phn chia theo cu trc v chc nng nh nu trong cc chng trc. Phn tch chc nng xc nh ra thit b hoc b phn cn p dng Bo dng Phng nga. Cn phn tch theo cu trc l lp danh sch cc ph tng thay th cn d tr trong kho. 2. 3. 4. Bn k hoch Bo dng Phng nga nu chi tit tt c cc hot ng cn thc hin trn mi b phn ca cc thit b cn n Bo dng Phng nga. Bn K hoch Bo dng da trn tnh trng nu tn mi thit b cn p dng loi bo dng ny cng nh cc thng s, ch s cn o c, ghi chp v theo di. Cc t kim tra c tn sut kim tra thp hn k hoch (v d 1 tun/ln, 1 thng/ln). Tn sut ny ti mi cng ty v vi mi thit b l khc nhau. Cc t kim tra ny c th nm trong lnh bo dng thng xuyn v c biu mu hnh chnh ring. Lm nh vy s gim ti cho cng tc qun l hnh chnh bo dng v gim tiu th giy. Cc t kim tra c tn sut cao hn k hoch: Kim tra li quy nh v thi gian gia cc ln kim tra. Cc ln dng sn xut theo k hoch hoc khng theo k hoch cho php thc hin cng vic bo dng Phn tch kiu hng

Tn xut bng hay thp hn x

Gi tr cc thng s k thut quyt nh cng tc Kim tra v BD

Bo dng ngoi gi sn xut

Dng my

Bo dng Phng nga khng th p dng cho tt c cc thit b my mc trong cng ty. V vy cn c la chn khn ngoan v hp l. Vic la chn thit b cn p dng Bo dng Phng nga cn da vo cc tiu ch k thut sau:

B phn BD tin hnh kim tra & bo dng

5. 6.

Phn tch chc nng

Bo dng trong gi sn xut

Phn tch h s BD

Bo dng da vo tnh trng thit b

64

Bo dng d bo

B phn SX tin hnh kim tra & bo dng

Tn xut > x

Hnh 2.6: ng i gia cc blocks

K hoch bo dng phng nga

65

5. Cc phiu bo dng phng nga PHIU BO DNG PHNG NGA S: KHU VC B PHN: CC GI TR HOT NG BO DNG THAM KHO NG SAI NHN LC VT LC THIT B: TN THNG S THEO DI: NGUN LC TN SUT h/NGY TRUNG TM CHU TRCH NHIM: Bng ch: TRNG THI CA N V SX Dng sn xut Chy khng Sn xut

Ghi ch:

Cng ty:

Ngi lp:

Ngy cp nht:
Hnh 2.7: Cc phiu bo dng phng nga

Trang s: /

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V D PHIU BO DNG PHNG NGA S: 26 KHU VC B PHN: U NI DO CC GI TR HOT NG BO DNG THAM KHO Kim tra ng trc Kim tra tnh trng b phn nha Kim tra tnh trng b phn kim loi Kim tra gi ca b phn kim loi Ghi ch: dy > DUNG SAI NHN LC 1 th c kh 1 th c kh 1 th c kh 1 th c kh VT LC THIT B: NHM THY LC TRUNG TM CHU TRCH NHIM:

TN THNG S THEO DI: K HOCH (NGY SX) NGUN LC TN SUT h/NGY TRNG THI CA N V SX Dng sn xut c c c c Chy khng Sn xut

Thc ngm 300 h hoc ng h so panme

Cng ty:

Ngi lp:

Ngy cp nht:

Trang s: /

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V D PHIU BO DNG PHNG NGA S: 27 KHU VC B PHN: ng c lng sc khng ng b CC GI TR HOT NG BO DNG THAM KHO Kim tra tnh trng nhit Kim tra nhit than my Kim tra lp sn v sch ca v thn my Kim tra np thng hi Kim tra rung khi my quay* Kim tra cc hp lm kn ti cc u cc Kim tra cht ca cc u ni Kim tra in tr ca cun dy Kim tra cch in ca cun dy Bo dng tng th ** NHN XT: CNG TY: * xem tiu chun ISO 2372 ** xem quy trnh s .. NGI LP: NGY CP NHT: PAGE N: / 9 ohm 0,28 mm/s RMS > 0,71 mm/s RMS A.T. + 55 C A.T. + 55 C DUNG SAI 10 C 10 C NHN LC 1 th in 1 th in 1 th in 1 th my 1 th my 1 th in 1 th in 1 th in 1 th in 1 th in 1 th c kh bridge of Westhone insulation controller Bt rung VT LC Nhit k in t Nhit k in t THIT B: NHM THY LC TN THNG S THEO DI: k hoch (ngy sx) NGUN LC TN SUT h/NGY Hng ngy Hng ngy Hng ngy Hng ngy Hng ngy daily 3,000 h 3,000 h 3,000 h 8,000 h c c c c TRUNG TM CHU TRCH NHIM: Bng ch: TRNG THI CA N V SX Dng sn xut Chy khng Sn xut c c c c c c

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6. Phiu quy trnh v m t chi tit k thut QUY TRNH S TRUNG TM PH TRCH: BC S BO DNG B PHN: HOT NG THIT B: M: DNG C KHU VC GI TR 1 2 3 4 5 6 7 CNG TY: NGI LP: NGY CP NHT: Tr. / 8 9

QUY TRNH S TRUNG TM PH TRCH: BC S

BO DNG B PHN: HOT NG

THIT B: M: DNG C KHU VC GI TR

Khi ng r le nhit t QD11 Treo bin Cm bt my, ghi r tn cng nhn thc hin v cng vic bo dng ang tin hnh. Kha t in. M hp trn cc in cc Kim tra xem in cung cp cho cc ng c tt cha. Xc nh dy ni ca hp trn cc in cc Ngt cp dn in Tho vt bo hnh (3 vt 6 cnh M6). Kim tra thng hng Kim tra v tr cc bnh ai so vi cc u trc Kim tra v tr bnh ai dn ng v puli b dn Kim tra v tr ca gi b phn dn ng so vi khung Tho bu-lng c nh b phn dn ng (4 bu-lng 6 cnh u 8). Ni lng dy cu-roa (2 vt 6 cnh M8) Tho dy curoa Kim tra tnh trng dy curoa. Tham kho bng s c/ nguyn nhn/gii php phiu s:.. Tho bnh ai (kiu lp cn tiu chun) Kim tra tnh trng bnh ai C nh cc v tr gi trc Tho cc c ca bulng gi hp gim tc (4 c M8) Tip tc tho hp gim tc C-l 8 Mc treo 50 kg v pallet vn chuyn C-l 5 v 6 ng h So C= Mn < 0,8 mm Pan-me 2 c-l 8 C-l 8 Cha kha s:.. Tuc n vt u 6 ng h o in Cc nh du tham kho Tuc n vt u 8 C l 6 Thanh chn 500 mm < 1/4 Pan-me

10 11 12 13 14 15 16 17 18 19 20 21

22 23 CNG TY:

Tp hp cc b phn khc nhau v mang n xng trung tm Dn dp ni lm vic NGI LP: NGY CP NHT: Tr. /

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7. Cc hot ng bo dng phng nga nh trc Do tnh cht c ln k hoch trc, cc d liu ny hon thnh h s thit b d dng nht. V th cc thng tin thu thp c c th trc tip cho vo ti liu m t hot ng Bo dng hoc vo mt trang trong phn ph lc. Ti liu c s dng s dng mt mu ph hp thun tin cho cc k thut vin hon thnh theo cc tiu ch t ra sng lc cc thng tin. Mt ngi khng c nn tng k thut cng phi c kh nng kim tra d liu (v d: nhn vin th tc hnh chnh). Thut ng Bo dng nh trc c hiu l: 1. 2. 3. 4. Kim tra. Bi trn. iu chnh. Bo dng xc nh trc.

7.3. Phiu bi trn theo vng

PHIU KIM TRA THEO VNG S lnh cng vic Tn vng kim tra (m) Tn xut vng Ngy thc hin Cp bo dng S ngi thc hin/ngi c thm quyn Ngi chu trch nhim chnh Thi gian can thip d tnh MY 1 Tn my (t tn) M can thip Cc thng s ghi chp ............................................. ............................................. ............................................. ............................................. ............................................. ............................................. Cc yu t kim sot Thi gian s dng Nhn xt My 2, 3,... (xem phn trn) Du ca ngi chu trch nhim Nhn xt thm: Ngy Gi tr danh ngha ................................... ................................... ................................... ................................... ................................... ................................... Rep. Bnh thng

7.1. Kim tra Cc cuc kim tra thng b gii hn bi cc gi tr ghi nhn c ca cc thng s la chn. Tuy nhin cc cuc kim tra ny c th c hp l ha bng cch tm hiu mt vng cho php chuyn mt cch t nhin t mt chi tit ca thit b sang chi tit khc. Vng kim tra c phn nh trong phiu kim tra m trn lit k ng th t m cc thit b c kim tra v cc thng s cn xem xt. Nu cc d liu c thu thp vo c s d liu th cc chc nng xut hin trn ca s phi c hin th theo ng trnh t nh trn phiu. V d v phiu kim tra cho thy thng tin c th c thu thp. Vng kim tra c th c ti u ha nu k thut vin thc hin cc hot ng bo dng nh trong qu trnh kim tra (kim tra trng thi hot ng ng ca h thng thot nc hoc hi nc, c ng h nng lng, thay mng lc, v.v...). 7.2. Bi trn Cng vic bi trn l cng vic trong k hoch mang tnh h thng c ln lch sn t trc. Cng vic ny khng nn qun l theo tng thit b m cn phi c qun l bng mt nhm thit b ging nhau v tn xut bi trn v yu cu v khong gii hn cht bi trn. Trong vng kim tra, vic bi trn c th c t chc theo t l ca chu k cho trc. Phiu bi trn c th c cc nhn xt nh trng thi ca giong pht, cc vt du hoc m, ghi chp trng thi nhit , v.v... H s sn xut thng c nhng hng dn chnh xc c th gip xy dng k hoch bi trn. Ta nn lp h s cc vng bi trn theo tn xut (theo tun, thng...)

Gi tr quan trc ............................... ............................... ............................... ............................... ............................... ............................... Pht hin cc li nh

Trang

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7.4. iu chnh Thut ng iu chnh khng m ch cc hng dn hot ng v cc iu chnh do ngi vn hnh qun l. Thut ng ny mun m ch cc iu chnh Bo dng chng hn nh: 1. 2. 3. Lung chy hoc p sut cht lng (hi nc, nc, thy lc, v.v...) Nhit ca mt vng hi nc, Tc lc ca trm lm sch,...

Phiu iu chnh Vic iu chnh p sut khng kh c thc hin nh sau: 1. 2. 3. 4. 5. Rt ai hm Ko con ln c rng kha tho Chnh p sut theo mong mun v i n khi p sut c n nh: Ni c tng p sut, Sit c gim p sut. y con ln rng ca kha hm Lp ai hm cht kha b phn.

Nhm mc ch kim tra v bi trn, cc cuc kim tra c t chc theo vng v kho thit b a ra cc iu chnh cc thit b c bn cht v tn sut tng t. Cc phiu theo di iu chnh nu r cc thit b cng bng cc thng s iu chnh v dung sai theo quy nh. Nu c th c, chng phi bao gm cc gi tr quan st c trc v sau khi iu chnh. Nu khng lm c iu ny, k thut vin cn phi tin hnh nh gi. nh gi ny cn c vo bng tham kho ging nh khi thc hin cc cng vic can thip khc. V nhng cng vic ny l phc v cho mc ch kim tra v bi trn nn vic nh du thit b cn phi c thc hin theo nh k. S liu di y a ra hai v d v phiu iu chnh dng cho khu vc 1 trong nh my nh.

iu chnh Chnh p sut s dng Kim sot u ra c thc hin bng cch sit cht hoc ni lng tip xc iu chnh t b mt. Chnh chun: 1git cho mi b phn. Thit b iu chnh cht bi trn 8. Bo dng xc nh trc Vic kim tra, bi trn v iu chnh, khng b qua cc b phn quan trng, a ra lng thng tin t hn yu cu ca cc hot ng Bo dng xc nh trc. Do cc cng vic ny c qun l theo kho thit b. Quy m ca Bo dng Xc nh trc l mt vn hon ton khc. H s kt qu thu c cng nhiu lp mt h s ring v n. Cc hng dn ca Bo dng xc nh trc c xc nh, v d nh, cc thit b tiu hao s dng, cc b phn c thay th thc t, cc ln can thip cng nh thng tin khc cn thit phc v cho vic tin hnh can thip mt cch sun s. H s lu tr khng cn phi l bn sao c xc nhn ca h s Bo dng xc nh trc. S liu lin quan vi phn trc cn phi c trch ra t phn sau. Nu cn thm thng tin, th c th tham chiu ti phiu Bo dng xc nh trc. iu ny cng p dng tng t cho cng tc kim tra, bi trn, v cc vng iu chnh. S liu sau y l mt v d v phiu ghi chp Bo dng xc nh trc. Thit b iu chnh

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PHIU BO DNG XC NH TRC

M:....................

Tn my:..................................................................................................................... NIF:.................................................... S Lnh lm vic Tn sut S tun/thng Cp bo dng Ngi chu trch nhim chnh Thi gian d tnh Sa/M .................................................................................................. .................................................................................................. .................................................................................................. .................................................................................................. .................................................................................................. ..................................................................................................

S cng nhn vn hnh/ ngi c thm quyn ..................................................................................................

5. BO DNG DA TRN TNH TRNG

(TI LIU CHO CN B QUN L BO DNG)

Tn........................................................................................................................................................... Nhn xt:

Sa/M

Tn........................................................................................................................................................... Nhn xt:

Sa/M

Tn........................................................................................................................................................... Nhn xt:

Ghi chp v cc n v s dng .................................................................................................................................... Thi gian s dng My dng Nhn xt c bit Trng hp bt ng Nhng kh khn gp phi ....................................................................................................................................... ....................................................................................................................................... Bt u............................................. Kt thc ......................................................... .......................................................................................................................................

Ph kin v dng c khng lng trc c ..................................................................................................... Du ca ngi chu trch nhim: Nhn xt ph: Ngy: Trang

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I. Bo dng 1. nh ngha: Tiu chun NF X 060-0610 nh ngha bo dng l tt c cc hnh ng c th duy tr hoc khi phc mt chi tit tr v mt iu kin c th hoc gn nh th n c th thc hin c nhng chc nng vn c ca n. Tnh trng xc nh: hot ng c ngi s dng quy nh . 2. Bo dng v vng i thit b 1. Mc tiu Mc tiu ca mt chng trnh bo dng khng ch nhm ch ra thi im khi no my mc khng hot ng c na hoc cn phi sa cha m cn phi duy tr tt c my mc lun trong tnh trng hot ng tt nht bng cch hn ch ti mc thp nht thi gian v ch v m bo hiu qu s dng mt cch ti a. Hot ng bo dng cn phi c tin hnh trong sut thi gian tn ti ca my mc. Nhiu hot ng din ra ngay trong thit k thit b:

II.

HNH THC BO DNG NO?

HOT NG HNG HC CHP NHN C SAI S GIA TNG H HI C TH O LNG C NG BO DNG PHNG NGA C TNH KINH T? SAI NG

BO DNG SA CHA

NGN NGA XC NH TRC

SAI NG S NGN NGA DA TRN TNH TRNG

tin cy n nh Tnh sn sng hot ng An ton Bo dng sa cha Bo dng phng nga CC HNH THC BO DNG

t c cc mc tiu bo dng ny, c ba yu t cn phi c quan tm:

Yu t k thut Yu t ti chnh Yu t con ngi Bo dng xc nh trc Bo dng da trn tnh trng

2. Chm ngn v bo dng VIC SA CHA KHNG C NGHA G, TA PHI BO DNG KP THI. VIC SA CHA L DO THIU KIM SOT. VIC BO DNG CHNH L VIC KIM SOT.

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III. -

BO DNG SA CHA N c tin hnh sau khi my mc b hng. Trng hp ny cng c th c gi l cha bnh. N cng bao gm mt s cc hot ng nht nh nhm loi b hoc gim thiu cc li hng v s bt thng tng tui th cho thit b, s chun ho cc thnh phn v ci thin tnh bn. BO DNG PHNG NGA

VI.

NHNG THNG S C S DNG

RUNG NG (dao ng) NHIT P SUT Bo dng phng nga LU LNG CNG IN NNG S PHN TCH DU M V...V...

IV.

4.1. Cc hot ng gim st Cc vng gim st Khc phc nhng hng hc n gin (cp 1)

4.2. nh k thm khm Nu tui th ca cc b phn hay cc thnh phn my mc b b qua khng ch n, cc chuyn thm kim tra ny thng i km vi cc cng tc bo dng c quyt nh tc thi v cng vic mang tnh cp bch hoc cng c th theo k hoch. 1. Bo dng xc nh trc c t chc khi bit r tui th ca cc thnh phn khc nhau hay mt s thit b phi qun l theo lut nh. 2. Bo dng da trn tnh trng c t chc khi nhng nguyn nhn v cc dng hng hc c c bit r mt mc va v s biu hin ca chng c th c mi tng quan vi cc hin tng vt l m c th ghi nhn c bng cc thit b cm bin. V. NHNG MC TIU CA BO DNG DA TRN TNH TRNG. Ti a nng lc sn xut ca thit b ko di m khng gy nguy hi khong thi gian gia nhng ln i tu. hn ch ti a nhng ln i tu. nng cao cht lng cc ln sa cha (C.M.M.S.). Tng tui th thit b. Ci thin vic lp k hoch lm vic. Nng cao cht lng sn phm. Gim cc chi ph sn xut v chi ph bo dng. Tng tnh an ton trong khi khai thc thit b. Hnh 2.8: Phn tch cc thng s CC K THUT KHC NHAU CA BO DNG PHNG NGA K thut phn tch rung ng K thut nhit ph K thut ni soi K thut X quang K thut m thanh K thut phn tch du m K thut siu m, v...v...

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VII. VIII. -

MT VI V D Nhit ph (Vng bi ca ng c) Nhit ph (Nhng mi ni in tip xc km) Phn tch du m (Thnh phn st ln trong du) m thanh (Ph m thanh) m thanh (Biu n) PHN TCH DAO NG Mt trong s nhng cng c khc ca bo dng da trn tnh trng. Mt cng c bt buc phi ng dng: Yu cu o to lin tc cho ngi s dng, Hiu v nhng hn ch cng ngh ca thit b v phn mm ca chng.

X.

X L TN HIU

H thng o c ghi chp tng qut tn hiu thi gian. thun tin cho vic phn tch cc tn hiu c ly ra ny, cc tn hiu s c chuyn i sang dng tn hiu tn s bng hm chuyn i (Khai trin nhanh Fourier). Cc tn hiu nhn c theo cch ny s cho php phn tch nhng hin tng rung ng khc nhau o c bi thit b cm bin. XI. CC V D V O C V TN HIU.

NG CONG XU HNG DIN TIN ng cong m t v phng on xu hng din tin tip theo trong tng lai ca mc dao ng (rung) 1. Tn hiu thi gian (hng s) Tn hiu c thu nhn bi u cm bin. 2. Ph ca tn hiu 2 Ph ca mt tn hiu thi gian thng thng. 3. Tn hiu thi gian ( hiu chnh) Tn hiu c thu nhn bi u cm bin. Trong trng hp ny, hai my c t bn cnh nhau c s khc nhau rt t v tc . 4. Ph ca tn hiu 4 Ph ca tn hiu thi gian trc. 5. S phng i ca tn hiu thi gian 4 S khuch i ca tn hiu thi gian hiu chnh. 6. Ph khuch i Ph (s khuch i) ca tn hiu thi gian trc. XII. CC KIU THIT B O C

NGUYN L Mt u cm bin (o vn tc, o gia tc bin p) thng c t trn vng bi. Nhng rung ng pht ra t thit b c thu nhn bi mt u cm bin v truyn v rt nhiu loi thit b h tr (thanh nam chm, thit b phn tch tn s xch tay, b phn theo di c nh). (Ph lc 6) IX. NHNG HNH THC O C

THI GIAN: Tn hiu c o c trong mt khong thi gian. TNG TH: Ch ra mt dng thng s c chn trong mt mt mc di tn xc nh, Cho php v mt ng cong biu th xu hng. TN S: Ch ra hnh dng ph nhng thnh phn thng xuyn xut hin ca tn hiu trong mt di tn nht nh.

I VI CC O C TNG TH: Thit b xch tay c hoc khng c s lu tr cc gi tr o c. Cc thit b c nh (quan trc) vi s iu chnh ca cc ngng bo ng.

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1. XIII.

i vi cc php o ph: Thit b xch tay. Thit b c nh (quan trc) vi s iu chnh ca cc ngng bo ng. CC LOI PHN MM

XV.

PHN TCH, NGHIN CU IN HNH V TC NG CA VNG BI LN MT THIT B LM SCH (UI KH)

Nghin cu in hnh ny s nhn mnh cc yu t cn thit thc hin mt chun on tng i chnh xc v mt vn hng hc. GHI CHP HNG HC Khch hng nhn thy rng trong mt s iu kin vn hnh, vng bi ca mt thit b lm sch (kh) rung v pht ra nhng ting n khc thng. 1. 2. a. Cc bc tun theo Nghin cu ng hc ca my (S vng quay, kiu vng bi, v.v...). Ghi chp mt lot cc im o c trn my vi cc thng s khc nhau (tn sut, kiu o c,v.v...). Phn tch cc o c. Gi mt bo co can thip cho khch hng. ng hc Cc iu kin vn hnh: Nhng thay i ti trng ln vng bi do nhng thay i lin tc ca lng vt cht cha trong thng cha. b. 3. Phn tch cc thng s: (xem ph phn tch hnh 2.8) Vit mt bo co can thip. Kt qu phn tch: v vng bi. Phi c thay th ngay lp tc.

i vi cc o c tng th: th d liu lu tr to thnh cc ng cong xu hng din tin cho thy mt cch trc quan tin trin ca cc gi tr o sau mt khong thi gian v xc nh ngng ca cc cp bo ng. 1. i vi cc php o ph:

th d liu lu tr minh ha tin trin tng th v cc vch ph c th c xc nh theo thi gian. Bng cch ny, tin trin ca cc cc s liu thiu ht cng c d kin c. 2. Cc phn mm h chuyn gia

a ra cc chn on t ng da trn c s cc d liu lu tr v ng lc ca my mc. XIV. THC HIN CC PHN TCH RUNG NG

S O C NH K t c cc kt qu tt v vn ny, bn cn phi: 1. Bit rt r cng ngh, thit b o c, phn mm, phn tch ph, phn tch tn hiu, C mi thng thng tin v ng hc ca thit b gim st. Khai thc cc php o nh th no?

Nguyn l nh hng ca bo dng phng nga theo phn tch rung ng nm : 2. S tin trin d kin ng quy lut ca cc gi tr vt l ca dao ng (ph, tng th, tm thi) da trn c s trng thi thc S xc nh cc ngng bo ng quyt nh thi im can thip. Cc kiu bo ng Da vo cp tng th Da vo ph tham kho (ng bao) Da vo cc di tn

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1. Gii thiu Mt chng trnh bo dng my mc khng ch nhm vo vic ch ra thi im khi mt c my s cn phi sa cha m cn nhm vo vic duy tr tt c my mc lun trong tnh trng hot ng tt nht bng cch hn ch ti mc thp nht thi gian v ch v m bo hiu qu s dng mt cch ti a.

6. BO DNG DA TRN TNH TRNG

(TI LIU DNH CHO CN B K THUT BO DNG)

Mc ch Mc ch ca chng ny l gii thiu vi cc bn mt khi nim mi v theo di tnh trng/ bo dng da trn tnh trng ca l cc thit b v phng php s dng chng. Phn ny bao gm: Nhng im chnh v li th lin quan n vic thit lp mt chng trnh bo dng da trn tnh trng. Gii thiu v cc thng s tnh trng my mc. Gii thiu v cc phng php v cc h thng thu thp s liu. Cc nguyn l c bn ca cc thng s dao ng. Gii thiu v cc thit b o rung ( dao ng my). Gii thiu v mt s k thut phn tch rung. S tc ng ti chnh ca bo dng da trn tnh trng.

2. Bo dng da trn tnh trng l g? Trong iu kin l tng, mi b phn ca mi my mc s thch ng vi cc c tnh k thut ca nh thit k. i vi nh sn xut, cc b phn chnh xc s phi c sn xut ng theo yu cu k thut kht khe, c o kim v th nghim. Khi a vo s dng, cc b phn ca my phi c lp t, s dng v bo tr mt cch ng n. V th, cc chi tit chuyn ng s hot ng bn b nu nh n c sn xut, lp t mt cch chnh xc theo ng chc nng thit k, c bo dng v bi trn ng cch. Tuy nhin, trn thc t, nhng hng dn quan trng li thng b b qua, mt c tnh cho thy 80% cc chi tit chuyn ng b hng trc khi t c tui th thit k. Cc phn tch my mc v bo dng c thc hin ngay t khi my mc ra i. V mt k thut, hnh thi bo dng pht trin t: Bo dng sa cha sau pht trin ln Bo dng phng nga v cui cng l tin ln bo dng Da trn tnh trng 4. Bo dng sa cha (Bo dng hng my) l mt hot ng cn thit khc phc nhng vn gy ra t mt li my. Hnh thc Bo dng sa cha thng gy ra nhng thit hi th cp nghim trng. l nhng tn tht ti chnh do thi gian ngng my v bo dng.

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5. Bo dng Phng nga (Bo dng nh k theo thi gian) Khi mt c my hoc mt chi tit ca n c i tu vo thi im nh k m khng quan tm n tnh trng ca thit b. Mc d iu ny l tt hn Bo dng sa cha, nhng Bo dng phng nga bc l ra l rt tn km do qu lng ph thi gian ngng my dnh cho s i tu khng cn thit v nhng chi ph tn km cho nhng ph tng mi thay th cho nhng chi tit b hao mn. 6. Bo dng da trn tnh trng y l mt quy trnh c dng xc nh tnh trng hot ng ca my mc nhm a ra c mt k hoch thi gian sa cha nhng b phn sao cho hiu qu v hp l nht trc khi hng hc xy ra. Bo dng da trn tnh trng khng ch gip cho cng nhn ca nh my phng nga nhng hng hc ng tic trc khi chng xy ra m cn cho php t hng trc nhng ph tng thay th, d kin trc nhn lc, v ln k hoch sa cha ng thi nhiu b phn trong thi gian ngng my. Bo dng da trn tnh trng ca my mc gm c 2 mu phn tch: Phn tch d bo, Phn tch chn on.

Ko di thi gian gia nhng ln i tu m khng h nguy hi g. Bo dng da trn tnh trng cung cp thng tin cho php bn lp k hoch bo dng da trn c s yu cu thc t. Hn ch thp nht s ln i tu thng thng nh l m, kim tra, v sa cha nu cn thit. Bo dng da trn tnh trng ci thin hiu qu bo dng do c th ch dn cho cc hot ng bo dng, i tu mt cch c th cho tng loi s c hng hc. Ci thin thi gian sa cha. Do bn c th ln k hoch thi gian bo dng my mc, thi gian bo dng, sa cha thc t s nhanh hn v thng xuyn hn. Nng cao tui th ca my mc. Mt c my c bo dng tt c tui th lu hn so vi thit b cng loi khc c bo dng ti. Gip cho vic lp k hoch s dng nhn cng cho vic sa cha v gim lngn t hng ph tng thay th. Lp k hoch bo dng da trn tnh trng ng gp vo vic ct gim thi gian cn thit: pht hin ra li, xc nh tnh trng hng, chuyn ti cc k thut vin ph hp (rt nhiu tai nan xy ra bi v mt c nhn khng c kinh nghim chn gii php n gin v c gng sa cha) c c cc ti liu chnh xc v my mc v c c cc ph tng tt, dng c tt v cc th khc cn thit cho vic tin hnh sa cha. Nng cao cht lng sn phm. Kt qu chung ca chnh sch bo dng dn n ci thin cht lng sn phm. V d, trong cc nh my giy, rung ca thit b c tc ng trc tip ln cht lng ca giy c sn xut ra. Tit kim ng k tng chi ph bo dng. Nhiu cng ty ang tit kim t 250,000 USD n 2,000,000 USD tng chi ph bo dng mi nm. Gim chi ph sn xut. Gim thiu thi gian dng my, gim cc chi ph sa cha v tng khong cch thi gian gia nhng ln i tu gp phn vo vic gim cc chi ph sn xut. Hn na, nh c bo dng da vo tnh trng bn c th nng cao sn lng hoc tng tc vn hnh ca my mc dn ti chi ph vn hnh gim xung.

6.1. Phn tch d bo Ghi chp v phn tch cc c tnh ca my da trn c s d bo. Nhng thng tin ny phc v cho vic ch ra tnh trng ca my hot ng nh th no sau mt khong thi gian hot ng. ch ra tnh trng ca my mc nh th no, cho php pht hin cc vn sm hn (trc khi chng t im ti hn) v c dng lp k hoch thi gian hp l nht v hn ch ti a chi ph thi gian sa mt chi tit c bit ca my mc cn phi i tu. 6.2. Phn tch chn on c dng xc nh, tm hiu v sa cha nhng nguyn nhn ca nhng vn c lin quan n my mc v hn ch cc hng hc. Phn tch chn on cng c dng ci thin nng sut ca nhng my mc cn tt, kim tra tnh trng ca chng v thc hin s tinh chnh hon ho cho nhng my mi nhm ti u ho nng sut ca chng. Mc tiu chnh ca bo dng da trn tnh trang l ti a ho thi gian hot ng tt ca my mc v hn ch ti mc thp nht nhng hng hc. N ng gp vo vic ct gim thi gian ngng my v cc chi ph bo dng ln. V n c p dng cho tt c cc my mc (khng ch ring vi i tng my mc hot ng bt thng hay gp trc trc), bo dng da trn tnh trng nng cao tnh trng hot ng ca my mc ln mc ti u thng thng vt qua cc c tnh ban u ca my mc. 6.3. Nhng u im ca chng trnh bo dng da trn tnh trng. Thi gian ngng my ca cc doanh nghip sn xut c va chu u c th tn km t 6.000 USD n 9.000 USD mi gi. Kinh nghim cho thy, cc nh my p dng chng trnh bo dng da trn tnh trng c th: Ti a ho nng sut ca my mc. Nh c bo dng da trn tnh trng bn c th hn ch ngay t khi lp k hoch lm vic bt c thi gian ngng my no do cc hng hc khng lng trc ca my mc xy ra.

7. Cn c cc o c no? Bo dng da trn tnh trng l mt quy trnh o c cc c tnh vt l ca mt c my khi ang hot ng. Kt qa rt ra t cc php o ny cho thy s chuyn bin tnh trng ca my mc sau mt thi gian hot ng. S phn tch kt qu ca cc php o ny phc ho nn mt bc tranh khi qut v tnh trng ca my mc v ch ra nhng b phn s b mn hoc h hng.

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 kim tra ng cch tnh trng ca my mc, bn cn c mt ngi hiu bit r v cc php o cn p dng cng nh cch thc v thi gian thc hin. Cc u o cm ng c t ti cc im chin lc trn my mc nhm kim sot tnh trng ca my. u o cm ng l mt thit b c kh nng cm nhn v chuyn i c nng thnh cc tnh hiu in t m c th phn tch, hin th, ghi li v o c c. Di y l cc c tnh vt l cn o c. DAO NG Dao ng c xem nh l thng s vn hnh tt nht nh gi cc iu kin nng ng nh cn bng, n nh ca vng bi v cng ca cc b phn. S chuyn ng c kh ca thit b, ting n vang cu trc, khng c nh, khng thng hng, cong r-to, hoc mt cnh r-to c cng c th o c c bng cc php o dao ng thit b. V tr ca mt trc quay c xc nh bng cch so snh vi cc thnh phn c nh m bo khng c nhng x dch c th dn n nhng va chm gy h hi thit b. o c rung ng tng th ca my mc, ca mt roto truyn ng trong my hoc cu trc ca n v so snh kt qu o c ny vi nhng thng s bnh thng (tiu chun) s rt ra c kt lun v tnh trng kho mnh ca my mc. NHIT o c nhit l mt ch s thng thng xc nh tnh trng c kh hay ti c p dng cho mt chi tit c th, v d sc cng ca vng bi. Ging nh mt khuyt tt ca vng bi, ma st l nguyn nhn lm nhit tng ln.

M HC Mt tn s rt cao, s lan truyn m thanh bi cc rung ng, c o c vi mt cm bin in p tn s cao. u cm bin ny cng hng vi cc sng p c sinh ra do tip xc ca kim loi vi kim loi v bi kim loi nu nh n gy s h hi c kh. Cc tn hiu m thanh khi pht hin ra mt ch hng c a vo b bin i tn hiu u ra c th o c di dng cc gi tr bng con s. Cc o c ny c dng nh gi tnh trng chung ca mt vng bi cng nh l nh gi cc v tr b h hi. K thut ny rt c hiu qu trong vic pht hin sm cc khuyt tt ca vng bi hay vic thiu cht bi trn. CC THNG S KHC V HIU SUT MY MC. Thng tin sn c trong mt h thng kim sot my mc, nh p sut, dng chy, tc vng quay hay bt k mt ch s no khc, c th c th hin trong chng trnh bo dng da trn iu kin ca bn a ra nh gi nhng ghi chp v nhn nh v xu hng. Nhng s liu b sung ny c th gip bn trong vic phn tch tnh trng ca my mc. em so snh cc thng s hiu sut mt cch c lp vi s kim sot ca h thng my mc cng gp phn vo cng c thm h thng kim sot ca bn v cung cp thm nhng tn hiu cnh bo v cc bo co kim sot.

BIU XU HNG

NHIT PH Qu trnh ny c thc hin thng qua vic s dng mt thit b qut hng ngoi, tng t nh mt my quay phim, thit b ny c th pht hin s khc nhau v nhit trn b mt v vch ra phc nhng s khc nhau ny bng cch hin th chng trn mn hnh tivi mu hay tivi en trng. Nhng hnh nh ny c th chp li hoc ghi vo bng video v c dng phn tch biu nhit tn tht hay nhit hu ch. Tuy nhin ph nhit ch dng o c nhit b mt. PHN TCH DU BI TRN (T PH) Kim tra thnh phn c tnh ca du ngn nga s gia tng cc tp cht ngoi lai, nh l nc, thnh phn c th lm suy gim cc c tnh ca du bi trn v c th l nguyn nhn n n hng vng bi. iu ny cng c th gip pht hin ra s xut hin ca cc ht kim loi b a vo du. Cc ht kim loi ny c phn tch xc nh b phn no ca my mc gp nguy hi v mc no. T ph l s nghin cu v phn tch cc ht nm ln trong du bi trn. Thnh phn, kch thc v s lng tng i ca cc ht c th c ghi chp xc nh xu hng v c phn tch ct gim nhng s c lin quan n s mi mn v tp cht. THI GIAN Hnh 2.9: Biu xu hng 8. La chn my mc v cc kha cnh o lng. Trc y, nhn vin bo dng kim tra bng mt v bng tay theo nh k da vo vic tm kim cc triu chng r rng ca cc s c my mc chng hn s r r du m, du bn, nhng rung ng qu mc, ting n, v.v... Cng ngh hin nay a ra cc thit b kim tra my mc rt a dng, chng c th o c mt cch chnh xc hn tnh trng ca my mc mt cch lin tc hoc nh k. Bn c th thy c rng cc cng ngh mi khng thay th cc phng php phn tch hin c m chng l yu t b tr cho cc phng php . Kim tra bng mt l v cng quan trng v s tip tc c hiu qu min l cc nh gi v thng s my c thu thp.

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BIN

Lp t mt u o cm ng nhit v bao ca mt vng bi v o c s thay i ca nhit bn trong vng bi hoc ca m bi trn cho php bn xc nh c nhng vn sm hn v ln k hoch bo dng trc khi cc hng hc nghim trng v tn km hn xy ra.

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Bo dng lin tc nghin cu cc o c c thc hin mt cch lin tc. l mt h thng t ng thu thp s liu ghi li cc o c t nhng u o c lp t c nh. Bo dng lin tc i hi mt khon chi ph ban u tng i ln. Tuy nhin, mt khi n c lp t, chi ph vn hnh li thp. Bo dng nh k da trn nhng o c c thc hin gia nhng khong thi gian u n. Cc o c ni chung c thc hin th cng vi cc dng c o c di ng. Bo dng nh k c chi ph ban u thp nhng yu cu chi ph nhn lc cao. V th chi ph ca n l tng i cao sau mt thi gian vn hnh di. MT CHNG TRNH BO DNG DA TRN TNH TRNG TT NHT V HIU QU NHT BAO GM S KT HP GIA BO DNG LIN TC/ HOC NH K VI KIM SOT BNG MT THNG V THAY TH CC PH TNG THEO K HOCH THI GIAN. 9. La chn v phn loi my mc Trin khai mt chng trnh bo dng da trn tnh trng mt cch hiu qu i hi mt nghin cu chi tit v cc nhu cu ca cng ty. N cn thit bit c hot ng ca tng c my trong cc iu kin lm vic thay i khc nhau. Cn phi p dng bin php bo dng lin tc cho cc my mc quan trng d xy ra cc s c hoc c th dn n cc S c. C th din ra nhanh chng v gy ra nhng hu qu nghim trng v ti chnh hoc thit b, cc hng hc c th gy nguy hi cho cc nhn vin. Thng ta p dng bin php quan trc nh k i vi cc thit b t quan trng hn.i vi cc thit b ny ch cn c mt h thng cnh bo sm tnh trng hng hc l c th a ra quyt nh tin hnh cng vic sa cha trc khi s c hng hc nghim trng xy ra. Bo dng thit b bt buc phi c thc hin theo mt trnh t u tin. Nhng my c u tin hng u trong chng trnh bo dng da trn tnh trng phi l nhng my m s c ca n bit trc hoc l c nhng ghi chp v nhng s c tng xy ra vi chng. Cc kha cnh khc cn phi cn nhc khi phn loi thit b l: S an ton ca nhn vin. Nu thit b l nhng dng c th cng nguy him th cn phi c kim sot cht ch. Nguy c xy ra s c. Thit b hot ng ti cc ti hn xc nh v/hoc thit b gy nguy him cho cc thao tc th cng th bt buc phi c gim st mt cch st sao hn l nhng thit b thng thng. Cp kim sot. Liu c ngi lin tc gim st thit b hay khng hay thit b vn hnh ti mt ni bit lp m khng c bt k mt s gim st no? Tnh hung c th xy ra sau cng ny yu cu cn phi p dng bin php bo dng lin tc. Chi ph v hu qu ca s c hng hocngng my. Nu l chi ph cao v hu qu ln th bo dng da trn tnh trng c th d dng tnh ton c.

Cc php o rung ng v nhit l cc ch s tt nht th hin tnh trng chuyn bin ca cc my mc c c cu quay. S kim tra du m cng thng c s dng. p sut, nhit v dng chy l cc yu t cn thit nh gi hiu sut. Trong mt s trng hp, c th ch ra tnh trng c kh ca my mc. Trc tin, thit lp cc thng s tiu chun phn nh tnh trng tt nht ca thit b la chn. Sau , la chn khong thi gian gia cc ln o c. Rt nhiu qu trnh v s phn tch tng t c dng chn cc my mc v cc thng s tiu chun li c dng chn khong thi gian cho cc ln o c. V d, mt thit b m cc hng hc ca n c th xy ra rt nhanh v gy ra nhng mi nguy him trn phm vi rt rng th cn c theo di lin tc vi tn xut thi gian rt ngn (trong khong 1 giy). Kinh nghim s cho ta c c nhng ch s tt nht lin quan n vic chn tn sut o c. Nhng my mc xy ra nhng s c trc y hoc c ghi nhn cc s c xy ra rt nhanh cn phi c o c thng xuyn vi tn sut thi gian rt ngn. i vi nhng my mc, nhng ghi chp cho thy l chc chn, v ng tin cy th tn sut o c c th di hn. 11. Cc h thng v phng php thu nhn s liu Sau khi thit lp cc yu cu ca my mc lin quan n bo dng da trn tnh trng, bc tip theo l chn la thit b bo dng da trn tnh trng p ng cc yu cu mt cch tt nht. Cc tu chn l: o c v phn tch th cng. Cc thit b thu thp v phn tch di ng. Mt phn mm qun l c s d liu/phn tch dao ng. Thit b thu nhn v phn tch lin tc s liu.

12. Cc thit b o c v phn tch th cng Mt thit b o rung th cng l mt dng c o r tin v n gin c th l mt phn ca bt c t bo dng v dao ng no. Cc dng c o c v phn tch th cng c cung cp bi nhn vin bo dng. Khi nhng dng c ny tip xc vi nhng my mc rung, chng hin th mt di cc s liu rung ng (hoc xung, hoc s). Tn hiu ny ngay lp tc c nh gi xc nh tnh trng rung ca my l bnh thng hay bt bnh thng. (Hnh 2.10).

10. La chn cc bin php o c v khong thi gian gia cc ln o c. Mt khi my mc c la chn a vo bo dng, nhim v tip theo l quyt nh cc bin php o c cn thc hin c th phn nh c tt nht tnh trng ca my mc. B quyt thnh cng ca bo dng da trn l khu chn cc thng s o c tnh trng xc nh hon ton v/hoc mt phn ng k vo thc t tnh trng ca my mc. giai on ny, nhng suy on tt s gip bn gt hi nhng li ch rt ln.

Hnh 2.10: V d v mt thit b o c th cng.

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Cc dng c o c bng tay in hnh c cung cp nng lng t pin v s dng mt cm bin o gia tc. Cc dng c o rung ng cng nh nh cng tt v phi c bo v chc chn m bo chng sc mt cch hiu qu nht. Nhng u im ca dng c o rung ng cm tay l tnh thc tin v linh hot ca n khi s dng. Tuy nhin, hn ch ca n l ch ph hp vi mt s dng o lng nht nh v khng c kh nng lu tr s liu. khc phc nhng hn ch ny, nhng dng c o c mi hin nay kt hp kch thc nh gn vi kh nng lu tr s liu v l im khi u hnh thnh nn mt chng trnh bo dng da trn tnh trng nh k r tin.

Vi cc thit b thu thp v phn tch s liu di ng, d liu c thu thp nhanh chng v chnh xc. Vic thu thp s liu c thc hin ti mt s v tr o c c xc nh trc theo mt vng nht nh. Vng v cc im thu thp c xc nh trc nhm mc ch xc nh quy trnh hiu qu nht i vi nh my. S thu thp s liu c thc hin ti tng im o c bi mt ngi vn hnh v cc thng s dao ng c ghi li bng mt thit b d c t c nh tm thi hoc cc u cm ng t c nh trn my mc. Cc thng s khc nh p sut, nhit v p lc dng chy c th c c t cc thit b v c gi cho thit b thu thp s liu bng bn phm. Cc quan st bng mt thng nh r r v du bn cng c th c chuyn i thng qua bn phm. Cc o c tin hnh trn my c hin th trn mn hnh ca thit b thu thp s liu xch tay v c th c phn tch trc tip hoc khi kt thc mt vng o c, ngi vn hnh c th kt ni d liu vi mt my ch v truyn cc s liu v cc quan st vo phn mm qun l d liu phn tch. Cc thit b phn tch v thu thp s liu t ra l nhng thit b hiu qu v c sc mnh trong vic phn tch dao ng thit b lin quan n bo dng nh k da trn tnh trng. y l cc u th ca chng: Thu thp s liu theo trnh t thi gian, Mt phn mm giao din qun l c s d liu/ phn tch rung ng, Mt di cc phn tch rung ng, Truyn ti t ng cc thng s theo nhng gii hn c thit lp t trc.

Hnh 2.11: Mt dng c o c cm tay vi cc kh nng lu tr 13. Cc thit b thu thp v phn tch s liu Cc thit b phn tch v thu thp t s liu di ng thu thp v ghi li d liu rung ng lin quan n my mc v hin th ph c phn gii cao tn s FFT v thi gian di dng sng trn mt mn hnh tinh th lng.Cc thit b thu thp v phn tch s liu di ng a ra tt c cc chc nng cn thit cho mt chng trnh kim sot my mc nh k. Cc thng s dao ng thu thp c c th c phn tch trc tip hoc ti vo mt chng trnh qun l d liu ca mt my ch phc v cho cc phn tch di hn v xu hng.

14. Phn mm qun l c s d liu/ phn tch rung ng Nh cp t trc, phn mm qun l c s d liu/ phn tch rung ng c th gip bn thu thp, qun l v phn tch d liu lin quan n my mc ca bn. Cc chng trnh qun l d liu ny c thit k vic bo dng my lu gi s liu v tin hnh cc so snh gia cc thng s o c hin ti, qu kh v cc gii hn c xc nh trc cho cc im cnh bo xc nh.
M8840 Universol Doto Display Version 2.01 File Plots Display Upsets STEAM TURBINE T1B1 3X/3Y Tine 5 MILS 01/16/92 09:54:37 (H863)
Dple 9 (Gr) -1.42 MILS 0.000098 RPM: 2768

Help

STEAM TURBINE T1B1 3X/3Y FFT 01/16/92 09:55:28 (H863)

10 MILS (PK)

Dple 9 (Gr) 0.04 MILS 2.00 Hz RPM: 3042 A Phose:

0.0

0 0.0

Hz

400

-5 MILS 0.0

Seconds

0.05

Hnh 2.12: Thit b thu thp s liu di ng.

Hnh 2.13: Mn hnh ca phn mm phn tch rung ng hin th ph rung ng: Ph F.F.T. v sng thi gian

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Cc thng s o c c ti vo phn mm phn tch rung ng c hin th nhanh chng trn mn hnh bt u cc iu kin bnh thng. thc hin mt cch nhanh chng, ph thi gian v F.F.T. c to ra gip bn xc nh, nh v v phn tch cc bin i rung ng. Cc t s c hin th ra pht hin cc my mc, cc cp rung ng vt qu cc im cnh bo cho php. Mt d kin hin ti c so snh vi s liu nn phn tch. Vi cch lm ny, nhng thay i v tnh trng ca my mc sau mt thi gian hot ng cng nh l xu hng thay i ca n s c bc l. Cc ng bin thin cho chng ta nhng cnh bo sm hn v nhng s c ca my mc v c tham kho lp nn k hoch khong thi gian sa cha tt nht. Phn mm phn tch rung ng cng c dng nh dng v kim sot s thu thp s liu lin quan n my mc, hoc l t cc thit b thu thp d liu xch tay (v.d: t chc nhng vng mi) hoc t cc thit b c thit k thu thp v phn tch s liu lin tc. 15. S thu thp v phn tch s liu lin tc. Cn phi p dng ch bo dng lin tc i vi nhng my mc chnh d xy ra s c hoc c th dn n nhng s c c din bin rt nhanh v gy hu qu kinh t rt nghim trng, hoc nhng my mc m nhng hng hc ca n tim n nhng mi nguy him cho cng nhn. Bo dng lin tc c thc hin thng qua cc thit b c thit k thu thp v phn tch s liu mt cch lin tc. Cc thit b cm bin c kt ni c nh vi cc im o c trng yu ca my. Nhng thit b cm bin ny c kt ni vi thit b c thit k thu thp v phn tch d liu mt cch lin tc (cc n v bo dng cc b). Cc o c c thc hin mt cch t ng v c th c hin th v phn tch trn mt thit b bo dng cc b hoc c lu tr trong mt my ch v trn mt phn mm qun l d liu phn tch. V thit b bo dng c kt ni c nh vi mt thit b cm bin, khong thi gian ngh gia nhng ln o c c th ngn n mc coi nh l lin tc.

Trong nhng u im c th hin bi vic thu thp v phn tch s liu lin tc ca thit b th mt nguyn tc vng xc nh l kh nng lin tc gim st tnh trng ca my mc. Bo dng lin tc m bo pht hin v a ra hnh ng bo v sm ng ph vi cc c xy ra i vi cc thit b quan trng. Hnh ng bo v c hiu trong trng hp ny bao gm hot ng bo ng cnh bo nhn vin bo dng my v mt s c, hot ng ca cc r le c kh nng t ng dng my khi mt nguy c hng hc nghim trng sp sa xy ra.
M8840 File Plots Display Upsets Universol Doto D isplay Version 2.01 Help STEAM TURBINE T1B1 3X/3Y FFT

STEAM TURBINE T1B1 D1sp1026 c10

Overall Value (HBOOA Trend) 5.00 MILS

3.12 MILS 01/16/92 10: 32: 23

01/16/92 10:47:32 (MA63) 10

Dp109 (Gr) 0.00 MILS 2.00 HZ RPH: 3016 A Phanet

MILS (PK)

0.00 01/16/92

10:32:23

0.0

Hz

400

01/16/92 10:46:19 5 MILS

(MB63)
Dplc9 (Gr) -1.88 MIL 0.000976 RPM: 3024

0.25 MILS (Div)

0.0

-5 MILS 0.0 Seconds 0.50 RPM: 3024

Thit b 2 Thit b 1

Hnh 2.15: Mn hnh ca mt phn mm hin th ph rung ng: bin thin ca ph F.F.T., sng thi gian v qu o Truyn ti thng tin vo mt my ch v mt phn mm phn tch rung ng/ qun l c s d liu chnh l kh nng ni bt ca thit b thu thp v phn tch s liu lin tc. Vi vic lp t hng lot cc n v bo dng cc b bn trong mt my ch, chng ta c th kim tra mt im no ca my mc t rt nhiu cc v tr khc nhau. Hn na, thng tin c th c truyn t my ch ti cc thit b bo dng cc b bm bo s kim sot thit b bo dng mt cch d dng hn. Phn mm qun l d liu/phn tch rung ng cng c th dng nh mt mng kt ni nhiu my tnh s dng mng LAN, hoc mng WAN cho php rt nhiu ngi cng d dng gim st tnh trng hot ng ca my mc.

Cc n v gim st ti ch

My tnh ch Hnh 2.14: Thit b thu nhn v phn tch s liu lin tc

16. H thng thng tin da trn kin thc Ngi ta s dng mt c s kin thc c my tnh ho da trn kinh nghim ca cc chuyn gia rung ng v tch hp thng tin trn bn v v cc c tnh ca my mc, t tnh trng ca my c th c phn tch mt cch t ng v c xc nh. Mt khi thng tin c chi tit, phn mm da trn kin thc v tnh trng ca my s chn on cc vn ca my mc theo trnh t mc quan trng v gi cc gii php. Cch tip cn ny yu cn c ngay kin v kinh nghim ca mt chuyn gia.

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Thng c nhc n nh l cc h chuyn gia, h thng thng tin da trn kin thc ph thuc nhng thng tin trn my c em phn tch. Nhng h thng trc y yu cu ngi vn hnh tr li v thit k v cc c tnh ca my cho n khi loi b c mt chun on c kh nng no . Khi khng th loi b c mt chun on no th n s c coi nh l gii php kh d nht. Quy trnh hi/ p ny t ra phin h v tn nhiu thi gian. Nhng h thng gn y nht cho php ngi vn hnh xc nh c cc c tnh ch o ca my mc nh s gim st. Mu my c lu tr v s dng bi h thng da trn nn tng kin thc, h thng ny thu thp v phn tch mt cch t ng cc s liu hin ti ca my m phng triu chng, chn on v nhng khuyn co nhanh chng theo cc thng s tin cy v mc u tin.

H thng thng tin da vo kin thc phn tch s liu hin ti ca my mc v so snh chng vi s liu ghi chp nh gi nhng thay i. Phn mm xc nh r tnh nghim trng ca nhng thay i ln bng cch dng gii hn thng k, ngng tuyt i v s tnh ton v s nhng ln thay i. Sau cc quy lut c chng minh (c s nhn bit) c p dng vo d liu. Cui cng, tt c mi vi phm quy lut c kt hp xc nh xc sut m mt s chun on l chnh xc.

Hnh 2.16: Nhng v d v bo co c a ra t mt h thng da vo kin thc

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1. S b v h thng chn on tnh trng thit b da trn tn hiu dao ng my v ng dng

7. MT V D V LA CHN THIT B CHN ON TNH TRNG TI TRUNG TM SN XUT SCH VIT NAM

1.1 Gii thiu h thng chn on tnh trng thit b H thng chn on tnh trng thit b bng dao ng hot ng da trn nguyn l phn tch cc thng tin dao ng my. Tt c cc my quay u pht ra dao ng c chu k cc tn s v cng no . Cc dao ng ny ph thuc vo tnh trng ca thit b. Thng thng, khi my ang trng thi tt, cc dao ng c cng thp v hn ch mt s tn s nht nh lin quan n tc lm vic ca my. Lc ny ch cc thit b o nhy mi ghi nhn c dao ng my. Khi my xung cp, cng ca cc dao ng tng dn cng vi s xut hin dao ng cc tn s khc. S tng cng ca dao ng din bin tuyn tnh trong mt thi gian di, chim hu ht tui th lm vic ca my. Sau , khi t n mt bin nht nh, gi l ngng, cng dao ng tng theo hm m cho ti khi my b ph hy. Khi cng mnh, cc dao ng tr thnh nhng rung ng con ngi c th cm nhn c. i khi, cc rung ng mnh n ni c th ph hy cc thit b v cng trnh xung quanh. Trong mt c s cng nghip in hnh, khong 70% s hng hc v s c lin quan n cc my quay nh: ng c, my gia cng, qut, bm, my nn, cc thit b cng ngh. Khong 90% cc li v s c ca my quay c c th d bo trc bng cng ngh phn tch dao ng my. Cc loi hng in hnh lun i cng vi cc c im ni bt v dao ng: tn s, pha v bin . Nh phn tch cc thng s dao ng ca mt my, kt hp vi cc ghi chp bo dng khc, ngi ta c th nh gi c: - Tnh trng sc khe ca my v cc b phn my. V d: my ang hot ng rt tt hay ang c mt s hng hc pht trin trong my, nu khng kp thi x l, my s xung cp nhanh chng. - Cc li ch to v lp t ca mt my mi hay cc li cn tn ti ca my sau i tu. V d: trc ng c v trc bm lp lch nhau hay mng my yu. - Cc hng hc ang pht trin v b phn my ang b hng. V d: Vng ngoi ca vng bi s 2 c mt vt nt hay trc my b un cong. - Cc nguyn nhn no gy ra cc hng hc . V d: Vt nt ti vng bi s 2 l do thiu bi trn hay lc cng dy cua-roa qu ln, gy un cong trc. - tin cy (sn sng) ca thit b, hay xc sut hng thit b ti mt thi im no trong tng lai. V d: vi din bin ca bin dao ng ti tn s 1X nh hin nay, sn sng ca t my pht in s 2 vo ma kh nm 2007 l 85%. - Tui th cn li ca thit b hay b phn my. V d: Nu khng c can thip no v duy tr vn hnh n nh, thi gian phc v cn li (cho ti khi phi dng sa cha) ca qut l 2250 gi, vi xc sut ng l 90%, hoc tui th cn li ca giong chn bi l 150 gi, vi xc sut ng l 95%. Nguyn l gim st v chn on tnh trng thit b da trn dao ng my c t lu. Nhng phi ti khi cc cng c o, chuyn i v phn tch d liu dao ng mnh x l lng thng tin rt ln v dao ng, k thut ny mi tr nn kh thi v c ph bin. Hin nay cc h thng ny rt a dng v chng loi, gi c v ng dng. Nhng thit b quan trng v t tin nh turbine pht in, h thng gim st tnh trng on-line c tch hp vi h thng iu khin. Vi cc thit b r, t quan trng nhng c s lng ln, chng hn nh cc ng c nh, ngi ta s dng cc h thng vn nng off-line c lp. Cc h thng ny cho php gim st din bin tnh trng thit b bng cc php o ri rc cch nhau t vi tun n vi thng vi chi ph thp m vn m bo cht lng bo tr tt.

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Do s lng ln cc thit b trong cng nghip l my quay, hin nay cc h thng chn on tnh trng thit b bng dao ng chim khong 60% th phn cc cng ngh v k thut phc v bo dng. Cc k thut gim st v chn on tnh trng thit b khc: siu m, m thanh, hng ngoi, phn tch du bi trn, phn tch thng s vn hnh (p sut, nhit , in p, cng dng in..), k thut kim tra khng ph hy, phn tch li sn phm.. chim 40% th phn cn li. 1.2. ng dng H thng chn on tnh trng thit b trong cng nghip Cc h thng gim st v chn on tnh trng c ng dng rng ri trong cng nghip. cc nc cng nghip pht trin, hu ht cc thit b quan trng u c p dng cng ngh bo dng d bo (cc quyt nh bo dng c a ra trn c s d bo trc din bin tnh trng thit b). Cc cng ngh ny cho php gim cc chi ph bo dng trc tip v cc chi ph sinh ra do bo dng km nh tai nn, thit hi do ngng my... Theo thng k trong ngnh cng nghip Hoa K, chi ph cho bo dng d bo l 6-8 USD/ Kw cng sut thit b lp t, trong khi chi ph trc tip cho bo dng hng my (chi ph sa cha my) l 17-18 USD/kw cng sut thit b lp t. l cha k ti cc chi ph gin tip khc nh dng my hay tai nn. Cc thit b cng nghip c th ng dng hiu qu h thng gim st v chn on tnh trng da trn phn tch dao ng l: ng c: bao gm tt c cc loi ng c in, ng c nhit, ng c kh nn v ng c thu lc c chuyn ng quay, mt s ng c c chuyn ng kh hi. My Bm: bm ly tm, bm hng trc, bm pit-tng cc loi. Qut: Qut ly tm, hng trc, qut cao p Cc thit b cng ngh: Tt c cc my c chuyn ng quay: my gia cng (tin, phay, mi, gia cng bnh rng..), sy, nghin, p, ct, dp, khoan, xeo, khuy, phi liu, cun, ko si.. Cc thit b vn ti: bng ti, trc ti, gu ti, vt ti, bng ti st Cc thit b nng h: cu trc, cn trc, cn cu My nn: trc vt, rto, cnh gt

Cng hng: l hin tng tn s dao ng ring ca my trng vi tn s dao ng kch thch(thng l ca ng c dn). Cng hng gy hng cc chi tit my, kt cu v mng my. Hng vng bi: dng hng c th ch xy ra cho vng bi, bao gm v, nt vng trong hoc vng ngoi; v, m con ln; mn ng ln; v vng chn du. Hng bnh rng: bao gm v, m, trc lan, mn b mt rng. Hng b truyn ng ai: ai trt, bnh ai qu mn, lc cng ai qu ln hoc qu nh, mt ma-st. Xm thc: hin tng sinh bt trong lng cht lng trong bung bm nhit thng do tc b lc u vo hoc ct p ht qu ln. Mng my yu: cc dao ng mnh mng my do mng qu yu, ni lng bu-lng mng hoc vt liu lm mng my khng thch hp. Dao ng lan truyn: hin tng my, thit b hoc cng trnh b hng do dao ng t cc ngunkhc truyn sang qua cc trung gian: mng my, ng ng.

- - - - - -

2. V d v la chn h thng chn on tnh trng thit b ph hp vi ng dng ca Trung tm 2.1 Chn loi H thng chn on tnh trng thit b Nh trnh by trn, trn th trng hin c rt nhiu loi thit b chn on da trn nguyn l dao ng my vi gi c v ng dng rt a dng. B thit b chn on ca trung tm cn p ng cc tiu ch sau: Thn thin ngi dng: Cc tnh nng ca thit b: pht hin li, lu tr v trao i d liu, th vin, h tr ra quyt nh, cn bng my ti hin trng cn c khai thc mt cch d dng. Qu trnh o to ngi s dng v chuyn giao khng phc tp, khng i hi chuyn mn su. Tin cy v n nh : thit b phi lm vic tin cy, cc thng s o phi chnh xc v n nh. Tnh nng: thit b chn on phi l loi a nng, c th pht hin c tt c cc li dao ng tt c cc loi thit b cng nghip ph bin. Khng dng cc thit b chn on chuyn dng cho mt loi thit b. Gi bn: gi thit b chn on bng dao ng my rt a dng, t gn 10.000 n hng triu USD. Vi ng dng ca Trung tm ch yu trong trnh din k thut v tch hp vi nh gi SXSH, gi thit b ch nn trong khong di 30.000 USD. Bo tr thun li: khi c s c, thit b chn on phi c bo tr kp thi, d dng, vi thi gian v chi ph hp l. Cc nng cp phn mm (nu c) c th thc hin thun li- tt nht l qua mng Internet. D mang vc: do c im s dng ca trung tm l phi o nhiu nh my khc nhau, phi vn chuyn nhiu trong v ngoi nh my nn thit b phi gn nh. H tr khch hng: bao gm chia s kinh nghim, cp nht thng tin, nng cp phn mm.

Tm li, tt c cc thit b c chuyn ng quay v mt s chuyn ng tnh tin u c th c chn on tnh trng v pht hin li bng h thng da trn dao ng ny. Ngoi ra, h thng chn on dao ng cn c kh nng pht hin mt s khuyt tt v dng hng ca nn mng, kt cu v h thng ng ng. S d h thng gim st v chn on tnh trng da trn phn tch dao ng c ng dng rng ri l nh kh nng pht hin cc dng hng c bn ca cc my quay. Cc dng hng c th pht hin gm c: Mt cn bng: hin tng trng tm ca my lch khi trc quay, gy ra dao ng bng tn s quay ca my do tc ng ca lc ly tm. Mt cn bng lm cong, gy trc, hng trc, vng bi, v v my v c th gy tai nn. Lch trc: thng l hin tng lch gia trc ng c v trc ca thit b c dn ng. Lch trc lm hng khp ni, cc trc dn v truyn ng, vng bi, gim tui th ca ton my.

Mt cn bng v lch trc c coi l nguyn nhn ch yu trong s cc dng hng ca my quay. Chng chim ti 70% cc s c v hng thit b trong cc c s cng nghip in hnh.

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Tng thch: cc phn mm ng dng, th vin in t i km phi tng thch vi cc my tnh, laptop ang c s dng ca Trung tm, khng i hi cu hnh qu cao.

Tiu ch Gi, USD- cha VAT 16.410

SKF Microlog MX 27.600

SKF Microlog GX Giao din tt, c th s dng c lp. Tuy nhin thn thin khng cao do thiu phn mm h tr ra quyt nh v khng c th vin vng bi

Vi cc tiu ch trn, h thng thit b chn on thch hp nht l loi off-line, a nng v nh (portable), c gi t 15.000 - 30.000 USD ton b (phn cng, phn mm, o to s dng). Tuy nhin thit b c gi di 20.000 USD l loi cu hnh c bn, khng c h tr ra quyt nh v cn bng ti hin trng nn kh s dng v tnh nng b hn ch. 2.2 Chn nh cung cp h thng chn on tnh trng thit b Cc yu cu cung cp thit b ca Trung tm c gi ti 4 nh cung cp thit b: GE-Bently Nevada (M), SKF (Thy in), Bruel&Kjar (an mch), Columbia Research Labs. Inc. (M). Tuy nhin n nay ch nhn c thng tin t GE-Bently Nevada v SKF. L do Bruel&Kjar khng tr li c th v h khng thnh cng trong bn hng Vit Nam (truc y cng ty Thng Li v Vin Nghin cu C kh l nh cung cp thit b ca h ti Vit Nam, thit b ca B&K cng bn c cho Cng ty Giy Bi Bng v Nhit in Ph Li). B&K l cng ty nh nn khng u t mnh trong phn mm, do vy h tr ra quyt nh v giao din khng bng cc hng khc. Th trng chnh ca B&K l Chu u, M v Hn Quc nn h tp trung h tr khch hng cc th trng . Vi Columbia Research Labs. Inc., l do c l v Vit Nam l th trng nh v h cha c mng li Vit Nam nn cha quan tm. Cho hng ca Cng ty SKF: SKF nm trong s cc cng ty hng u v bo dng v k thut duy tr tin cy (reliability engineering) do Cng ty ny bt u t sn xut vng bi- sn phm i hi tin cy cao v chn on phc tp. SKF kinh doanh vng bi Vit Nam khong 15 nm nay. Gn y h trin khai thm mng bo dng, bao gm o to, dch v bo tr cng nghip v thit b chn on bo dng. n nay SKF bn c khong 10 b thit b bo dng dng Microlog ti Vit Nam. SKF cho hai loi thit b chn on l SKF Microlog MX v Microlog GX vi cc thng tin nh sau:

Thn thin ngi dng Giao din tt, c th s dng c lp. Tuy nhin thn thin khng cao do thiu phn mm h tr ra quyt nh v khng c th vin vng bi tin cy Tnh nng (a nng) Tng i tt Cc tnh nng o dao ng c bn, kh nng pht hin mt s li c bn, knh o hp v cn bng ng 2 mt phng, mn hnh TFT, b nh trong 64MB, c khe cm b nh ngoi.

Cc tnh nng o dao ng y , kh nng pht hin tt c cc li dao ng ph bin, knh o rng, h thng phn mm hon chnh v cn bng ng a mt phng, mn hnh LCD, b nh trong 64MB, c khe cm b nh ngoi.

Bo tr

Thi gian bo tr 12 thng, thi gian sa cha hoc calip 2 tun Sa cha ti Singapore hoc Vit Nam. Chi ph calip (2-3 nm/ln) l 1.000 USD/ln Tng thch vi cc phn cng v phn mm thng dng Vit Nam SKF c h thng h tr khch hng ring ngay ti Vit Nam, c pht trin trn c s h thng h tr k thut vng bi- bi trn. So vi cc hng khc Vit Nam th y l u im ni tri. Thi gian o to hng dn s dng: 1,5 ngy Kch thc DxR: 186 x 93 mm Trng lng: 700 g C dy eo tay v qung vai Kch thc DxR: 186 x 93 mm Trng lng: 715 g C dy eo tay v qung vai

Tnh tng thch H tr khch hng

Gn nh

* Lu : Mt s thng tin: s u o vn tc, tachometer, proximity sensor v stereo plug adapter cha c th cn c xc nh thm.

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Cho hng ca Cng ty Bently-Nevada: Bently Nevada mi c vn phng i din Vit Nam v bn hng qua cng ty i l l Viettech. n nay Cng ty cha c ghi nhn v bn hng Vit Nam. Cng ty cng cha c h thng h tr khch hng ring. Tuy nhin, Bently Nevada l hng rt ni ting th gii v cng ngh bo dng ni chung v dao ng my ni ring. Gi Tiu ch Bently Nevada Snapshot 32.520 TM Thn thin ngi dng tin cy Tnh nng (a nng) Bo tr Tnh tng thch H tr khch hng Gn nh Giao din trung bnh, mn hnh n sc nn hin th khng nt, cc phm chc nng khng nhiu nn thao tc khng thun li. Tng i tt Cc tnh nng o dao ng rng, kh nng pht hin tt c cc li dao ng ph bin, knh o rng v cn bng ng 2 mt phng, mn hnh TFT, b nh trong 32MB, c khe cm b nh ngoi. Thi gian bo tr 12 thng, thi gian sa cha hoc calip 2 tun. Sa cha ti Singapore. Chi ph calip (2-3 nm/ln) cha r. Tng thch vi cc phn cng v phn mm thng dng Vit Nam Bently Nevada cha c h thng h tr khch hng ring Vit Nam. Thi gian o to hng dn s dng: 2 ngy Kch thc DxRxC: 250 x 163 x 60 mm Trng lng: cha r C dy eo ngang hng v qung vai Bently Nevada Snapshot TM

BNG 2.6 BNG SO SNH SKF Microlog GX im 8 8 Bnh lun C gi thp hn vi cu hnh cao hn Mn hnh mu, phm chc nng y , c th vin vng bi. Tng i tt: mt s h thng bn t nm 1999 n nay vn hot ng tt (Cng ty ng Ngh An) C th chn on c hu ht cc li dao ng c bn nhng nhy hn ch nn kh nng pht hin sm khng cao Thi gian bo tr 12 thng. Sa cha ti Vit Nam hoc Singapore Tng thch vi my tnh v phn mm ph bin Vit Nam H tr trc tuyn qua website ring. C din n trao i kinh nghim. C h thng h tr k thut ti Vit Nam Thun tin mang vc 6 6 Bently Nevada Snapshot TM im Bnh lun Gi cao nhng cu hnh thp hn i th Mn hnh n sc, phm chc nng t (khng c phm s), khng c th vin vng bi Hin cha c thng tin no t khch hng Vit Nam

Tiu ch

Thn thin ngi dng tin cy

n/a,

Tnh nng (a nng)

Tng t ca SKF

Bo tr

Thi gian bo tr 12 thng. Sa cha ti Singapore Tng thch vi my tnh v phn mm ph bin Vit Nam H tr trc tuyn qua website ring. C din n trao i kinh nghim v tp ch bo dng on-line. Cha c h thng h tr k thut ti Vit Nam Thun tin mang vc, kch thc hi ln hn sn phm SKF nhng khng ng k.

Tnh tng thch

H tr khch hng

So snh hai thit b cu hnh tng ng theo cho hng ca SKF v Bently Nevada c trnh by trong bng di y. Gn nh 8

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Kt lun: Cn c vo cc thng tin do nh cung cp a ra v da trn cc tiu ch i vi h thng thit b chn on dao ng ca trung tm, chng ti a n kt lun nh sau: SKF chuyn su hn v vng bi, tuy nhin Bently-Nevada ni ting v cc ng dng rng trong cng nghip. Tuy nhin hin cha c nh gi so snh c th no gia sn phm ca cc Cng ty ny vi nhau. H thng ca SKF c u im hn v tnh nng v gi c cng nh v chm sc sau bn hng.(Cn ly thm thng tin v s u o vn tc, tachometer, proximity sensor v stereo plug adapter)

Kin ngh: Vic mua mt h thng h tr chn on tnh trng thit b v lu di rt c ch cho hot ng ca trung tm, c trong tch hp bo dng vo gi dch v nh gi SXSH ln trong cung cp cc dch v h tr bo dng c lp. Tuy nhin, do chi ph mua sm thit b ln nn cn cn nhc k. Trc mt trung tm s t chc kha o to v bo dng nn c th mi cc nh cung cp n trnh din thit b kt hp vi ni dung ging dy (cc cng ty ny u cung cp cc kha hc c bn v bo dng). Qua c th hiu r hn v thit b v kh nng ng dng vo hot ng ca Trung tm. Ngoi ra cng c th tham kho thm kin ca cc chuyn gia Php ging dy cho CFMI thng 4-2006.

8. H THNG TRAO I THNG TIN

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1. Gii thiu Vic trao i thng tin trong ni b cng ty thng b xem nh v b st. Chng thng b chuyn thnh dng bo co ming. Mc d vy, n c chc nng quan trng trong qun l cng tc bo dng. Trao i thng tin l si dy kt ni thit yu gia thng tin, ra quyt nh v hnh ng. Thng tin Quyt nh Hnh ng = = = s tm hiu s phn tch s can thip = = = cc gic quan tr no s tham gia

Chnh nhng iu ny lm nn s khc bit ca cng tc bo dng. By cu hi v tr li cho thy r rng dng trao i thng tin bng ming l khng thch hp . Dng trao i bng vn bn, c hon thin bi cc biu c rt nhiu u im: _ Gip cho ngi tham gia nhn bit c cc trch nhim ca anh ta. _ Gip trnh c cc sai lch v thng tin, b st thng tin, cc thay i khng cn thit, cng nh cc nguyn nhn dn n nhiu hnh ng tri ngc. _ Gip phng trnh nhng s c c th xy ra. _ Lu tr tra cu v sau. _ Gim s lng thng tin cn trao i i vi cc hot ng lp i lp li theo chu trnh. Nhm ti u ha nhng u im ny v to iu kin cho nhng ngi s dng, cc ti liu phi: _ Ph hp vi cng ty-tham kho nhng ti liu ca cc cng ty khc. _ S lng vn bn phi ph hp: Trnh s dng qu nhiu vn bn v biu mu, trnh trng lp. _ Cn c xy dng theo hng thun tin cho x l cc d liu. _ Phn bit c cc loi thng tin thu c. _ Cn r rng, d c, logic v d s dng.

THNG TIN

MNH LNH

NGI CUNG CP THNG TIN

NGI RA QUYT NH

NGI VN HNH

GHI CHP

PHN HI

Vic trao i thng tin vn phi c hiu lc khi ngi ph trch vng mt. H thng thng tin c tip tc c thc hin bnh thng khng? Nu c, y l mt h thng trao i thng tin tt. Nu khng, n cn phi c xem xt li, xem c ph hp vi c cu bo dng khng. H thng trao i thng tin s v ch nu n khng th s dng c v khng c s dng. H thng lu tr h s phi cho php tra cu nhanh v d dng. Khi la chn thng tin tp hp cn phi xt xem chng c ch v ph hp vi nhau hay khng. 3. La chn nhng thng tin cn thit H thng trao i thng tin phi gip cho cc lung thng tin c thng thong, nh chng c th phc v cho cng tc qun l chung (v k thut v ti chnh) trong dch v bo dng. t c iu ny, vic cu trc cc lung thng tin, xc nh cc knh thng tin v nhng ngi s dng l rt quan trng, qua gip cho cc s liu c th c khai thc v s dng.. Cc thng tin hu ch cho cng tc bo dng cn c cng b. N lin quan n cc hot ng khc nhau: Cc yu cu cng vic. Cc cng tc c thc hin. Cc h s bo dng. Qun l tn kho. Danh mc ng k. Cc ti liu lin quan: Ti liu ni b, Ti liu bn ngoi, Cng tc qun l ti chnh v k thut. Lung thng tin khng th b gin on cng nh b lm sai lch bi vic thay i nhn s. Do vy cn thit phi p dng ng thi quy trnh ca ISO 9000 v ISO 9002 .

Hnh 2.17: S trao i thng tin 2. Cc knh trao i thng tin S trao i thng tin c th di mt s dng: Dng truyn ming thc cht d b tht lc, c th b thay i, v d b sai lch, Dng vn bn v/hoc biu , Dng khng chnh thc. Nhn vin bo dng c thin hng khng thch trao i thng tin di dng vn bn. iu gip cho h d lng trnh hiu lc thi hnh v d dng bin minh cho tnh hnh. Tt c mi ngi cn phi hiu rng s khng c s can thip no c thc hin thnh cng nu cc cu hi sau y khng c tr li: U? CI G? NH TH NO? KHI NO? AI? BNG CI G ? CHI PH G? Cng vic cn phi c thc hin l u? Nhn bit thit b. Cng vic cn phi thc hin l g? Nhn bit cc nhim v cn hon thnh. Cng vic s c gii quyt nh th no? a ra quy trnh v quy nh k thut cho vic thc hin. Khi no th phi tin hnh cng vic? Lp k hoch cho cc nhim v phi thc hin. Ai s gii quyt cng vic ny? Xc nh ngun nhn lc, k nng yu cu v.v Cng vic s c gii quyt cng vi nhng g? Ch ra ngun cung ng, cc dng c, ph tng thay th v.v. Chi ph cho cng vic l g? Cn phi xem xt chi ph mua ph tng, thit b v chi ph nhn cng

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 phc v cho cng tc bo dng, nhng vic cn phi lm l: Cc yu cu cng vic c a ra bi b phn sn xut hoc bo dng cho thu ph- v cc yu cu mua sm, c a chung vo trong mt bn hp ng mua ph tng thay th, nguyn vt liu cho vic thc hin cng vic v dch v; H thng trao i thng tin thng qua yu cu cng vic (W.R.), qun l tn kho, cc h s bo dng v.v; S hiu qu ca cng tc bo dng thng qua vic kim sot cc cng tc bo dng c thc hin bi chnh cc nhn vin trong cng ty v bn th ba, kt qu thu c cui cng trong cng vic, vic kim sot s ph hp ca cc ph tng c cung cp; Nhng ci thin c nhn thy thng qua cc phn tch h hng (M.T.T.R., M.T.B.F., ); Vic qun l cc h s k thut: Kh nng truy cp v tra cu, s cp nht, cc quy trnh Khng phi bn ci khi ni rng vic la chn cc thng tin cn thit cng mt lc ch c th t c nu chng ta nh r: Thit b v vic s dng chng, cc c tnh k thut. Nhng thng s v qun l cn thit cho vic thit lp cc s qun l, bn thn chng c ly ra t k hoch qun l, c xc nh bi tng gim c iu hnh.. CC NGUN THNG TIN V CC MC TIU 1. Thc hin cc nhim v Yu cu cng vic (W.R.) phi c kt hp vi lnh bo dng (W.O.). Cng tc chun b. Lnh bo dng phi lin quan n cng tc chun b v yu cu cng vic. Bo co thc hin c chuyn cho cc bn s dng khc nhau (b phn lp bin php thc hin, b phn k ton, lu tr h s k thut, b phn a ra lnh bo dng). 2. Thit lp h s bo dng Cng vic cn thc hin kt thc vi vic lm bo co thc hin. Bo co ny l c s lm h s bo dng. Bc thc hin hon thin h s bo dng ny phi p ng c nhng yu cu mc tiu sau:: Qun l ti chnh thng qua phn tch chi ph trn tng hng mc cng vic ln, tng danh mc thit b Mc tiu qun l k thut mt mt phi gip cho k thut vin c th s dng c cc c s d liu cho vic thc hin cc can thip v k thut ca mnh, mt khc gip cho Phng k thut bo dng trong vic phn tch cc hng hc (F.M.D.S. v G.E.R.). t c iu ny, cc thng tin cn tp hp s lin quan ti: Bn cht ca vic sa cha, L do phi c hnh ng can thip sa cha, Cc b phn cn thay th, Thi gian cn thit cho vic can thip sa cha, Thi gian thit b phi ngng hot ng. Thi gian lm vic ca thit b, Nhn vin thc hin cng vic sa cha (chc nng v s lng).

Nhng thng tin trn s to iu kin cho vic t c cng vic ra l qun l chi ph v qun l k thut. T , chi ph v vic theo di tip theo s c nh gi thng qua thi gian lm vic ca nhn cng, tiu tn v nguyn vt liu, ph tng thay th, chi ph gin tip v...v... Vic qun l tn kho cng c th c thc hin thng qua: Quay vng tn kho B sung hng trong kho. Gi tr hng tn kho, Vic qun l thu ph c thc hin v lin quan ti : Ngun lc bn trong v bn ngoi. Cc kim ton hp php. Cc h tr v k thut. Cc hp ng bo dng. Nhn vin tm thi/hay nhn s c tr lng theo tng gi dch v cung cp, Chi ph nhn cng phi bao gm: Tin lng v cc chi ph cho vic tuyn ngi. Chi ph lm thm gi, chi ph bo him, Bo him x hi, Chi ph o to (cho trong v ngoi cng ty), Qun l nhn cng c thc hin thng qua 3 h thng: Thi gian sa cha c nu trong bo co thc hin, Bng chm cng hay h thng thit b chm cng t ng, Phn tch h s thanh ton. Thi gian tham gia ca nhn lc khng gy ra vn g c bit do c s h tr ca cc k thut ng tin cy hin nay. Mc d vy thi gian sa cha c th s l vn . Rt nhiu ngi cho rng cn phi xt n thi gian c mt ca h nh my. iu ny l gii ti sao h i hi thi gian lm vic tm gi trong ngy trnh nhng sai lch trong vic thu thp cc s liu. Tt c cc nhn vin tham gia cn c thng bo mc tiu cng vic cn hon thnh, v nhn thc c tm quan trng ca thi hn hon thnh. iu ny cho thy s quan trng ca bo co cng vic sa cha v yu cu v tnh chnh xc.. Cc chi ph gin tip cng c tnh thm vo: Chi ph b sung cc thit b ph hp cho bo dng. Cc dng c bng my. Cc dng c cm tay. Cc thit b th nghim v.v.... Cc ngun lc c s dng cho vic bo dng, Tin bo him, Mi trnh t cng vic tng ng vi mt loi chi ph chnh. Mi thng tin phn tch s tng ng vi chi ph nhn cng. Cn lu rng thi gian tnh chi ph khng nht thit tng ng vi tng thi gian lm vic. C mi thng th h s sau y c th c tnh nh sau: Thi gian tnh cng S gi lm vic

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Phn tch chi ph c th c lm theo cc tiu ch cp di y: Thit b, Loi ngh nghip, Tnh cht ca cng vic sa cha, Cng vic sa cha c tin hnh trong gi hay ngoi gi lm vic chnh thc, Mt bng so snh gia kinh ph theo k hoch v kinh ph u t thc t s c lm. 3. Cc ti liu lin quan n thu thp thng tin Khng nn tng s lng ti liu mt cch khng cn thit. Mt bo co cng vic c th bao hm c bo co sa cha. Nu khng a thng tin sa cha vo, n c th cp n vic tham kho W.R. v I.R. i vi nhng ti liu lin quan-cc k hoch, cc qui trnh, cc hng dn an ton, v.v- chng c th c hp l ha. Mi ti liu bao gm cc chi ph: chi ph son tho v xy dng ti liu, chi ph in n, chi ph v mi trng v.v..cc ti liu lin quan n cc quy trnh c th lm mng gn cc k thut vin c th s dng.

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CC S LIU TRONG QU KH
BNG 2.7 GHI CHP CNG TC BO DNG

TN NH SN XUT

BO M

S KIM K

S GI HOT NG NM 1996 1997 1998 1999 2000 2001 CNG VIC BO NG C THC HIN CC L DO NGNG HOT NG THNG THNG 1 2 THNG 3 THNG 4 THNG 5 THNG 6 THNG 7 THNG 8 THNG 9 THNG 10 THNG THNG 11 12

CHI PH S X RI. NM SN XUT YU CU CNG VIC S.

NGY BT U HOT NG NGY NGNG HOT NG C BO DNG BI NGY

LOI(*)

NGY THNG V THI GIAN BO DNG

THI GIAN NGNG HOT NG

(*) P = phng nga; TR = sa cha tm thi; O = i tu; R = sa cha

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119

BNG 2.8 LCH YU CU CNG VIC THNG BA 1998

TRANG S TNG S TRANG

S THAM KHO

W.F. No.

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

AE1306 AE1306 AE1306 AE1306 PR1205 PR1205 PR1205 PR1205 HD1456 HD1456 HD1456 HD1456

2123/98 2223/98 2153/98 2135/98 2343/98 2126/98 2363/98 2332/98 2145/98 2199/98 2266/98 2148/98

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1. Phn tch thi gian o lng G.E.R. c s dng cho vic tnh ton hiu sut lp t v s dng my mc. G.E.R. thu c bng vic phn tch thi gian theo hnh v di y.

Thi gian bt my

9. HIU SUT TNG TH (G.E.R.)

E1 E2 E3

Tng thi gian hot ng

Thi gian hot ng thc

Thi gian hu ch

S C THAY TH PH TNG

THI GIAN TRNG TRONG QU TRNH HOT NG

KHNG T CHT LNG X, PH THI , SA CHA LI CHO T

HIU SUT = E1 * E2 * E3
Hiu sut tng th thu c t ba yu t: 1. Tng thi gian hot ng. 2. Thi gian hot ng thc. 3. Thi gian hot ng hiu qu (thi gian hu ch).

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A. V d Mt xe but mun ti mt khu du lch Ty Ban Nha. Chuyn i mt 20 gi, bao gm: 1. cc s c 1h 5% 2. nc lm mt 0.5 h 2.5% 3. i chm 2h 10% 4. tc ng 2h 10% 5. chuyn s khng hp l 1h 5% 6. i sai ng 2h 10% Nh vy c th ni hiu sut l 100% - 42,5% = 57,5% Tnh ton ny ng xc nh chnh xc thi gian tn tht. Chng c th c phn loi nh sau: 1. Nhng ln dng theo ng lch trnh, 2. Nhng ln dng khng theo lch trnh. Vic o lng cc thng s ny i hi s thng nht ca tt c nhng ngi tham gia v phn nh c th ring ca cng ty. Mt bui tp hun i khi l cn thit nhm m bo rng nhng nhn vin c nhim v o lng s tin hnh cng vic mt cch nht qun v lin tc. HIU SUT TNG TH L MT CH BO K THUT V KH NNG LM VIC. CHC NNG CA N L NHM CHO THY BT C S THIU NHT QUN NO. NH CHO PHP PHN LOI V PHN CP CC TN THT V THEO DI TIN TRNH THC HIN. N PHI C A VO TRONG S QUN L CNG TC BO DNG. KHI LN U TIN G.E.R. C TNH TON, N GY RA S NGC NHIN V I KHI GY RA CM GIC THIU TIN TNG TRONG MT B PHN NHNG NGI LM CNG TC BO DNG. KINH NGHIM CHO THY N THNG NM TRONG KHONG T 40% N 60%. 2. o lng G.E.R. 1. 2. Nhm tnh ton tng thi gian lm vic, chng ta phi cn nhc: Thi gian s dng thit b sn xut, Thi gian ngng hot ng do: Cc s c. Thay i sn phm.

2.

Thi gian cn cho thay i sn phm, khi cn thi gian iu chnh li thit b cng nh thay th cc dng c my mc: iu ny c th c kim sot bi khu t chc sn xut tt hn v chnh sch ci tin thit b my mc sn xut. Tn tht thi gian do nhng ln ngng my ngn: V sinh thit b, Cung cp ph gia v cc nguyn liu ph, Tn tht thi gian do ch lm chm li: Sn xut cc sn phm c bit, S xung cp ca mt b phn my mc, Tn tht thi gian do li cht lng. y l kt qu t vic iu chnh thit b, cc qui trnh lin quan n kim sot cht lng hoc iu khin thit b. Tn tht thi gian khi khi ng. Trong giai on ny d xut hin cc sn phm khng t yu cu

3.

4.

5. 6.

4. Tnh ton ba mc hiu sut Mc sn sng 1. 2. Xc nh tng thi gian hot ng. Xc nh tng thi gian bt my. E1 = T L SN SNG = TNG THI GIAN HOT NG TNG THI GIAN BT MY

Mc lm vic 1. 2. Xc nh thi gian lm vic thc. Xc nh tng thi gian lm vic. E2 = T L MC LM VIC = THI GIAN LM VIC THC TNG THI GIAN LM VIC

Nhm tnh ton hiu sut chng ta phi xt n: 1. Thi gian hot ng thc, 2. Thi gian sn xut thc ca mt n v thit b. 3. Sn lng t c. Nhm tnh ton t l t cht lng chng ta phi xem xt: 1. S lng sn phm b loi b. 2. S lng sn phm phi sa cha. 3. Phng php lun Xc nh thi gian Cn phi xc nh cc tn tht sn lng chnh ca cc thit b sn xut. Su loi tn tht thi gian c a ra v phn loi di y. 1. Tn tht thi gian do cc s c: iu ny c th c kim sot bi cng tc bo dng hiu qu v s tham gia ca b phn sn xut.

Mc cht lng 1. 2. Xc nh thi gian lm vic hu ch. Xc nh thi gian bt my. E3 = T L CHT LNG = THI GIAN LM VIC HU CH TNG THI GIAN BT MY

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125

Tnh ton Cng thc:

= E1 * E2 * E3 = TxSS. * TxLV. * TxCL

4.

Tnh ton Hiu sut tng th

g

= E1 * E2 * E3 = (0.631 * 0.767 * 0.966) * 100 = 46.7% = THI GIAN HU CH *100 = THI GIAN BT MY 318h 680h *100 = 46.7%

Thi gian hiu ch

g

Thi gian bt my 5. % 1 Theo di G.E.R

A. Bi tp a. Cc gi thit Mt my cn c cc s liu thi gian sau:

MC LM VIC DNG THI GIAN Thi gian bt my Thi gian ch ng dng my Thay i dng c thit b Cc s c Dng ngn Thi gian chy chm Thi gian tiu ph cho sn phm khng t yu cu THI GIAN 680 h 16 h 102 h 133 h 55 h 45 h 11 h

THNG B. Li gii 1. Tnh ton mc sn sng Tng thi gian hot ng: 680 h - (16 h + 102 h + 133 h) = 429 h E1= 2. 429h 680h *100 = 63.1%

% 1 MC HOT NG TNG CNG

Tnh ton mc lm vic Thi gian hot ng thc: 429 h - (55 h + 45 h) = 329 h E2= 329h 429h *100 = 76.7%

3.

Tnh ton cht lng Thi gian hu ch: 329 h - 11 h = 318 h E3= 318h 329h *100 = 96.6%

THNG

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127

% 1 T L CHT LNG CH BO V K HOCH P= 480 - 43 * 100 480 91.04%

CH BO V MC SN SNG A= 437- 10 100 437 * 97.71%

CH BO V MC SN SNG V= 2,800 3,000 * 100 93.33%

CH BO V MC SN SNG Q= THNG 6. Kt qu kim sot G.E.R. Cc nhn vin vn hnh cn phi hiu rng h s nng cao c gi tr vai tr ca mnh bng thay i nhn thc t vic ch n nt sang kim sot. Ph b s phn chia bng cch hp nht cc cng vic bo dng v sn xut vo lm mt t ti cng mt mc tiu. C mt phng php lun cht ch cho vic thit lp cc k hoch nng cao nng sut. t c s hp l ha trong cc chi ph v bo dng. Tng c nng sut s gim bt chi ph u t cho my mc thit b. Gim tn kho sn phm v tng cng kim sot cc khu cng vic. 2,800 - 150 * 100 2,800 94.64%

GER = A*V*Q = 97.71*93.33*94.64 SN LNG U RA GER*P = 86.30 * 91.04

86.30% 78.57%

1. S dng s qun l V d: Cng ty MANRO Xc nh thi gian C.T. = Thi gian theo lch cho ca lm vic 8 ting V.D.T. = Thi gian chm do ch TNG V.D.T. = C.T. THI GIAN NGNG HOT NG

7. V d tnh ton G.E.R B. iu kin cho NH MY GIY LIN HP THNG: GING THI GIAN BT MY THI GIAN NGNG KHNG C YU CU CNG VIC BO DNG NH K THAY I SN PHM TNG THI GIAN HOT NG THI GIAN NGNG NGOI D KIN BO DNG SA CHA CC LI TRONG LM VIC THI GIAN HOT NG THC SN XUT SN LNG THEO K HOCH SN LNG T C CHNH LC KHNG T CHT LNG S NGY: 20 NGY 480 h 0h 35 h 8h 437 h 8h 2h 427 h 3,000 t 2,800 t 200 t 150 t

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129

N.I.T. = Thi gian ch ng ngng (induced time). Thi gian ngng do thiu nguyn liu, lng thnh phm tn kho qu ln, . T.O. = Thi gian bt my T.O. = C.T. THI GIAN NGNG MY - N.I.T. P.D.T. = Thi gian ngng sn xut do s c G.T. = Tng thi gian sn xut G.T. = T.O. - P.D.T. T.A.F. = Thi gian khi ng li sau khi ngng my T.A.E. = Thi gian quy i tng ng vi s lng ph phm N.P.T. = Thi gian sn xut thc N.P.T. = G.T. - T.A.F. - T.A.E.

KH NNG SN SNG = TNG THI GIAN SN XUT THC (NPT) TNG THI GIAN BT MY

HIU SUT =

TNG THI GIAN SN XUT THC (NPT) TNG THI GIAN BT MY

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131

BNG 2.9 BO CO SULPHONATION 1997 S GI THI GIAN THEO LCH C.T. THI GIAN NGNG MY Bo dng nh k Cng vic mi nh cng TNG v.d.T. THI GIAN CH NG NGNG ( N.I.T). THI GIAN BT MY O.T. THI GIAN NGNG DO HNG CHC NNG SO3 THIT B LC IN CHEMITHON BALESTRA HN LONG EN RNS CC NGUYN NHN KHC TNG P.d.t. TNG THI GIAN SN XUT G.T. NON-IDENTIFIED THI GIAN KHI NG LI SAU KHI TT MY TAF THI GIAN CHO SN XUT CC SN PHM S.B. HAL ETHERSULPHATES SULPHATES TNG T.P. PH PHM (%) THI GIAN QUI I T.A.E. THI GIAN SN XUT THC N.P.T. S SN SNG (%) HIU SUT(%) Thng 1 744 27.5 716.5 Thng 2 672 Thng 3 743 44 699 Thng 4 720 Thng 5 744 Thng 6 720 43.25 676.75 4.5 716.5 672 699 720 744 672.25 Thng 7 744 Thng 8 744 Thng 9 720 Thng 10 744 103.25 640.75 Thng 11 720 Thng 12 744 Tng 8,759 218 8,541 5.25 720 640.75 720 744 8,535.75

672

720

744

744 0.5 743.5

744 0.25 743.75

720

720

744

5.25

8.25

13 1.25 10.25

38.25

4.75 6.5

83

1 47.25 43.25 2.5

1.75 21.5 695 12 7 692 7.25 7 713 1 8.25 735.75

672

24.5 647.75 2

38.25 705.25 3.25

743.75 1.5

11.25 708.75 2.25

83 557.75 10.75

48.25 671.75 22.75

45.75 698.25

294.75 8,241 62.75

61 352.25 189 109.75 712 2 13.70 671.05 98.99 96 3 21.36 690.64 99.03 95.92

484.5 182 69.25 735.75 1.8 13.24 722.51 98.89 97.11

10.25 355.25 228.5 51.75 645.75 7.4 47.78 597.97 96.05 88.95

451 201 50 702 3.96 27.79 674.21 94.42 90.68

77.75 358.75 275.5 30.25 742.25 3.1 23.01 719.24 100 96.7

50 415.5 160.75 80.25 706.5 12.6 82.02 617.48 98.43 85.78

51.25 223 252 20.75 547 16.9 94.44 454.56 85.34 70.94

208.75 284.50 81.5 74.25 649 16.13 104.68 544.32 93.29 75.6

48.5 392.25 231.5 26 698.25 10.64 74.29 623.96 93.85 83.86

8,178.25

69.66 613.34 95.99 85.60

27.42 644.58 100 95.92

604.39 7,573.86 96.54 88.73

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133

1. Hiu khi nim thit b Trong ti liu ny, thut ng thit b cp ti mt tng th k thut c mt chc nng no v thng c kt cu phc tp, tc l c thit k v sn xut thc hin mt nhim v (mt hot ng hoc chc nng) xc nh. V d: mt thit b nghin, mt my p, mt thit b sn hoc l x l b mt, bm, cu trc, v.v... 2. Hiu khi nim h s k thut v h s thit b

10. CU TRC H S K THUT

Khi nim h s thit b hoc h s k thut ca thit b i khi cha ng nhiu thc t khc nhau tu theo tc gi. Trong quan im ca chng ti, h s k thut thng coi nh mt h s trc s dng (ngha l trc khi thi gian s dng ca thit b bt u). V th, i vi chng ti h s thit b l h s qu trnh s dng. H s ny s do b phn bo dng s dng. Trong s c bao gm h s trc s dng t thm dn cc vn bn do qu trnh s dng thit b to ra. I. NGUN GC V MC TIU CA H S THIT B

H s thit b s c xy dng theo thi gian. 1. H s trc s dng H s ny do nh sn xut thit b cung cp v thuc v trch nhim ca n v ny. H s phi c cc thng tin hu ch v s dng v bo dng ng cch i vi thit b. Cc d liu c rt ra t cc giai on lin quan thit k v sn xut ra thit b. 2. H s qu trnh s dng H s ny s hnh thnh bi ngi s dng c s phi hp mt phn vi nh sn xut v cc vn lin quan ti khu trc s dng. H s phi c ton b cc thng tin hu ch c thu thp t thi im mua, lp t, vn hnh v bo dng thit b. V th cc d liu phi c xut pht t cc giai on lin quan ti vic mua, lp t, vn hnh v bo dng. Phn qu trnh s dng trong h s thit b thuc trch nhim ca duy nht ngi s dng. Hnh 2.18 di y s tm tt cc ngun thng tin ca h s thit b.

NH SN XUT

THIT K & SN XUT

TRC S DNG

K THUT

MUA V LP T

NGI S DNG

VN HNH V BO DNG

QU TRNH S DNG

Hnh 2.18: Dng thng tin xy dng mt h s thit b

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135

II.

CU TRC CA H S THIT B

2. Cc ti liu lin quan ti vic mua v lp t thit b Cc ti liu ny l nhng yu t ch cht ca h s thit b v cha ng ton b cc thng tin k thut v ti chnh thuc giai on trc s dng v i km vi chng nhn mua thit b. khng b b st bt c thng tin no trong phn ny ca h s thit b, ngi ta thng lm theo logic v qu trnh mua thit b c minh chng v tnh hu hiu. V vy, chng ta s tm: Cc ti liu lin quan ti t vn t pha nh cung ng. Cc ti liu lin quan ti quy trnh mua thit b. Cc ti liu thng tin k thut. Cc ti liu lin quan ti lp t thit b.

Mt h s thit b hon chnh phi c cc thng tin sau y: 1. Thng tin xc nh v kt cu thit b. 2. 3. 4. 5. 6. Cc ti liu lin quan ti vic mua v lp t. Cc hng dn. Cc yu cu bo dng. Catalogue v cc khon mc tiu hao v ph tng. Thng tin v s dng. H s. S liu thng k.

3. Cc ti liu lin quan ti s dng Phn ny trong h s thit b cn c ton b cc thng tin cn thit s dng thit b ng cch. Chng ta thng thng s tm: Cc c tnh mang tnh khi nim v chc nng ca thit b/ Quy trnh khi ng v tt. Cc quy tc ng x. Cc s c c th xy ra trong khi s dng thit b. Cc ch dn v sinh v an ton. Cc ch dn bo dng.

1. Thng tin xc nh thit b Vic xc nh v kim k cho tng thit b l rt quan trng. R rng l khng th qun l c thit b nu khng c ti liu chi tit i vi tng thit b hin l cng c sn xut. Tc nghip u tin l xy dng mt danh mc kim k hon chnh v ti sn vt l l cc thit b (cc loi v s lng) ca cng ty. Mt danh mc n gin khng phi lc no cng c th s dng c bi v vic kim k chi tit v tng hng mc c th ko di v gy chn nn. V th, ngi ta cn phi phn loi cc thit b xc nh tng thit b trong s theo mt phng thc c tnh chc chn. Cha ch trng ti cc chi tit ca phn Lm nh th no?, hy chng ti m t cc giai on cn i qua trong Hnh 2.19.

4. Cc yu cu v bo dng Phn ny l phn quan trng nht v thng di nht trong h s thit b. Ngun thng tin s do nh sn xut cung cp, nhng ngi dng cng s c vai tr rt quan trng bi l cc thng tin cn c s dng thit b mt cch hp l v ti u. (xem cc ngun v chi ph G.E.R.). Cc ti liu trong phn Cc yu cu v bo dng phi gm c: Ti liu gip ta HIU V THIT B, Ti liu gip BO DNG THIT B.

NGUYN TC XC NH MT THIT B

LIT K TT C CC THIT B TRONG CNG TY

5. Catalogue v nhng khon mc tiu hao v ph tng Khng i su thm vo chi tit, chng ti ch n gin l s nhc li vi cc bn rng nhng khon mc tiu hao l nhng chi tit s c thay th bi s tiu hao trong qu trnh s dng thit b c nhng chi tit ny. Ph tng ni chung c s dng khi c s gim st ln v chc nng do s c hoc x l thit b khng ng cch. Do cc hot ng bo dng nhm mc ti u ho kh nng ca thit b, nn iu ti quan trng l cc ph tng cn thit phi lun c sn khi cn n v mc gi chp nhn c. Do i hi phi c mt cch thc qun l thch hp i vi cc loi ph tng (c cc khon mc tiu hao v cc ph tng). H S THIT B L MT CNG C THIT YU.

PHN LOI

M HO

THNG TIN XC NH

V THIT B

V H S THIT B

Hnh 2.19: Cc bc m ho mt thit b

136

137

 t c mc tiu c m t tm tt trn, cn phi tm sn cc thng tin di y: Thng tin xc nh cc ph tng. La chn cc chi tit cn lu kho. M ho cc chi tit trong kho. B sung nhng chi tit trong kho, S kho, Li ra ca kho, Kim sot gi tr hng lu kho. Ch 3 thng tin u tin cp trn l cn phi tnh n a vo h s thit b.
(1) Mt vi tc gi khc gi c hai loi ny bng thut ng ph tng.

Phn ny trong h s thit b c gi l Thng tin lin quan ti s dng, gm nhng thng tin v cng c qun l cho tt c cc hng mc mang tnh vn hnh ca hot ng bo dng. Phn ny s truyn ti chnh sch ca cng ty v bo dng. Ti liu h s phi gm c: Yu cu cng vic (W.R) do nhn vin sn xut hoc dch v bo dng a ra nm trong k hoch bo dng phng nga, Lnh bo dng W.O. pht hnh da trn c s W.R. y l phiu lm vic ca k thut vin bo dng. Cc ph tng v/hoc vt liu cn thit khc c chun b trc . Thit b cng phi c t trong tnh trng sn sng. Bo co hnh ng can thip (I.R.) cho php k thut vin ghi chp li nhng quan st ca mnh, m t hnh ng c tin hnh v cp ti cc b phn v/hoc vt liu s dng. Thm cc thng tin v chi ph hon chnh I.R. Cc thng tin ny s c ch cho ngi vn hnh thit b v cho phng k ton ti chnh ca cng ty.

6. Thng tin lin quan ti vn hnh thit b Thng tin lin quan ti qu trnh s dng thit b gm 2 nhm sau: 1. 2. Cc thng tin lin quan ti h s, Cc d liu thng k.

a. H s Thut ng h s cp ti tt c cc ti liu m t cc hot ng bo dng i vi thit b theo trnh t thi gian k t khi bt u a vo hot ng. H s cng cn bao gm c kt qu ca cc hot ng bo dng ny. Bo dng l mt h thng chu trnh do con ngi kim sot. Cc hng dn u vo ca h thng c m t trong h s thit b v yu t chu trnh y chnh l s can thip v bo dng. iu ny c minh ho Hnh 2.20. Nguyn tc hot ng bo dng.

Tt c cc thng tin trn c thu thp theo trnh t thi gian. Cc thng tin gip chng ta nhn thc c s thay i ca thit b v mc k thut, nhng cng cho bit c v phng din qun l k thut v ti chnh ca vn k thut (tnh ton , T.R.S., M.T.B.F., M.T.T.R., v.v). Mi thng tin trn u c c gi nht nh lin quan ti nhng tr ngi v dch v. Cn trnh mi loi tng l thuyt tn km v phi ly cc s liu c v phng din k thut v kinh t. Quy trnh bo dng khng th thit lp bi cc iu lut, vic thc hin v iu chnh quy trnh bo dng l mt qu trnh bin i u n. Hnh 2.21: Chu trnh iu chnh lin tc cc quy trnh bo dng, sau y c minh ho bng chu trnh DEMING nhn c s nh gi cao ca nhng ngi t cht lng lm mc tiu. S ca chu trnh ny c m t di y:

VO

Vn hnh theo h s thit b

RA

Lp k hoch nh ngha v quy trnh ny

Khc phc Hnh ng bo dng iu chnh

Chu trnh ci tin Cc quy trnh bo dng

Thc hin Cc hot ng bo dng

Hnh 2.20: Nguyn tc hot ng bo dng

Kim sot Lu tr cc phn tch Hnh 2.21: Chu trnh lin tc iu chnh cc quy trnh bo dng

138

139

b. D liu thng k V cc d liu thng k, nh trong nh ngha v ni dung ca cc ti liu lin quan ti h s, th iu cn phi lm l gii hn cc vn bn mc hu hiu v c s dng n. Trong s nhiu d liu thng k theo di, chng ta c th tm c: Cc ch s M.T.B.F. v M.T.T.R. Tnh sn c ca cc thit b, phi ph hp vi k hoch sn xut; Kim sot chi ph, mt cch hu hiu l bc tch chi ph theo tng kiu bo dng s p dng; Qun l cc tc nghip bo dng; Cc ch s qun l i vi ph tng; Cc ch s qun l v nhn lc bo dng; Din bin chi ph. 7. Tm tt

11. CU TRC H S THIT B

H s k thut b bao gm tt c cc phn di y H S K THUT TRC S DNG CC TI LIU LIN QUAN N XC NH THIT B Phn loi M ho Nhn din Kt cu CC TI LIU LIN QUAN TI VIC MUA THIT B Ti liu v Nh cung cp Ti liu v Qu trnh mua thit b Cc ti liu thng tin k thut ban u CC TI LIU LIN QUAN TI LP T V S DNG Ti liu v vic lp t Ti liu lin quan ti qu trnh s dng thit b CC TI LIU LIN QUAN TI BO DNG CATALOGUE V CC PH TNG TRONG QU TRNH S DNG SCH VN HNH H S V CC GHI CHP c im k thut v vn khai thc H S THNG K c im k thut v vn ti chnh

140

141

I.

KHI LC

c. nh gi cng vic lp t Nghin cu kh thi phi bao gm: Cng vic trc khi lp t. Chi ph v thi gian lp t. Tc ng mang tnh t chc. d. Chun b ti liu v cc thng s k thut Ti liu v cc thng s k thut phi trnh by cc nhu cu thc t ca cng ty mt cch hon chnh v t m. Ti liu ny phi bao trm cc nhu cu ngn hn v trung hn. iu cn thit l phi p ng yu cu m khng phng i quy m. Thc t l theo ui s vn hnh bt hp l s c th gy tn km. Mt ti liu v cc thng s k thut hon chnh phi tr li c cc cu hi sau: AI? CI G? TI SAO? NH TH NO? BAO NHIU? CHO AI? LM G? Tr li cc cu hi ny s dn ti vic xc nh mt phng n sn xut hoc dch v nhm p ng nhu cu m R.O.I ca phng n ny s tho mn c cc tiu ch ca cng ty. Cu hi sau cng cng s phn tch xem liu gii php a ra c ph hp vi chin lc v chnh sch ca cng ty khng. Mt ti liu thng s k thut c tnh ti mt lot cc thng s nh vy s c hon thin v gi ti cc nh cung cp tim nng. Tt nhin kt qu thu c khng th bng phng thc n thng c m m i hi s tham vn v phn tch s b. TI LIU THNG S K THUT PHI CP CHI TIT TRONG VN BN V L MT PHN KHNG TH THIU TRONG KHU CUNG CP THIT B Hnh 2.22 di y s tng hp cc bc cn thit hon thin mt ti liu thng s k thut.

1. Gii thiu Tnh hu dng v hiu qu ca mt h s thit b ph thuc vo ni dung thng s k thut v hiu qu hot ng, khai thc thit b trong sut vng i. dy mng ca mt h s thit b khng nht thit l s m bo cho cht lng ca h s . iu quan trng y l cch lm cho h s ny c hnh thnh nh th no, cng nh cn tnh n cc phng php trnh by s liu v khuyn ngh. Vic trnh by cc phn khc nhau ca h s thit b s c iu chnh vi cc i tng s dng. Trc khi xy dng h s thit b, cn phi a ra 4 quy tc t chc ct yu sau y. Vic xy dng mt h s thit b l mt chc nng y trong phm vi t chc v vn bo dng (i vi bt k quy m no ca t chc). Trch nhim lin quan trong chc nng ny phi c ghi nhn v khng th b xo b. Chc nng ny phi c ghi nhn cp cao nht trong cng ty tip s b tr cc phng tin cn thit (nhn lc, vt liu, v...v...). Cng tc bo dng c nhim v bo m h s thit b (k c cc s liu ghi chp) l y v cp nht. Trong trng hp lm ht kh nng ri, b phn bo dng c th thu thu ph i vi mt vi phn ca h s thit b. Tuy nhin trch nhim vi nhng phn vn thuc v b phn bo dng. Trong thc tin, ngi chu trch nhim v h s thit b phi iu phi vic thu thp cc thng tin cn thit t cc i tc ph hp gm: Nh cung cp, B phn mua bn, B phn k thut bo dng v sn xut, B phn sc kho v v sinh cng nghip. Xng sn xut. B phn k ton. B phn qun l. Da trn c s nhng thng tin trc th r rng rng vic xy dng h s thit b va tn km va phi tp trung tinh thn cam kt cao ca tt c cc b phn. 2. Chun b u t Phn th nht s bao gm tt c cc ti liu lin quan ti khu chun b u t: a. Phn tch nhu cu Tnh trng cng ngh trong phm vi vn phi i din. Nghin cu tnh kh thi k thut. nh gi u t v cc mt: mua hng, cng vic, v...v... Li ch cho cng ty quyt nh u t. b. S t vn ca nh cung cp Tm ra cc ti liu lin quan ti s t vn t pha nh cung cp v cc bin bn hp v k thut v ti chnh. Bn cnh cc ti liu cp trn, kt qu nghin cu so snh cc phng n k thut l mt loi ti liu cn c. Nghin cu ny s do k thut vin ca b phn bo dng thc hin kt hp cht ch vi xng sn xut. Mt li khuyn l nn nhn bit tng ti liu bng cch thm ch s thi gian vo s hiu ca h s u t v iu chnh mc lc ca h s ny.

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CHUN B TI LIU THNG S K THUT Xc nh nhu cu

2. Th tc mua Cc dng vn bn lin quan n th tc mua c lit k t trc. a. Cho hng Kh nng chn la m nh cung cp a ra phi ph hp hon ton vi cc iu khon trong ti liu thng s k thut. N thit lp mt bn cam kt trn vn bn v trn hp ng.

Tham kho th trng nh gi cng vic chun b Ci tin cc chi tit k thut

b. t mua Vic t mua bao gm: Cc iu khon khc nhau xc nh y i tng c t mua. Ti liu k thut chi tit. Ti liu lp t chi tit. Cc k hn v khong thi gian chuyn giao nguyn liu v ti liu. Cc loi chng ch khc nhau m vt liu phi tun theo, Cc iu kin vn chuyn v cc iu kin c chp nhn, Gi c, Cc iu kin ha n v thanh ton. Hp ng mua phi ghi r rng ti liu lp t phi c cung cp trc khi chuyn giao thit b. Danh sch k hoch v ti liu lin quan n vic lp t v iu khin thit b phi sn sng cho n v bo dng nhm gip h tm hiu, t k hoch v hon thnh cng vic chun b trc khi lp t my. Vic t mua phi ghi r thi hn cui cng. c. Ha n v s lng Ha n s lng cho php chng ta kim tra xem liu tt c c chuyn giao v bao b cn nguyn vn hay khng. N c ghi li trong bin bn. d. Ha n v cht lng Ha n cht lng ni r s ph hp ca nguyn liu nhn c v nhng s khc bit c th xy ra. N c ghi li trong bin bn e. Khi ng Khi ng v nhng th nghim tun theo s vn hnh lin quan ti vic lp t v iu chnh. iu ny xc nhn trng thi vn hnh tt ca my, s ph hp vi hiu sut v nhng sai s cho php. C nhng cch thc c trng c th tin hnh thnh cng cc qu trnh hot ng ng thi gim thiu nhng ri ro ca tranh chp lin quan n cc th nghim v phng thc c p dng. iu ny c ghi li trong bin bn. f. Ha n tm thi Ha n tm thi cho php chng ta kim tra liu thit b c ph hp vi sai s cho php qui nh bi nh sn xut v cc yu cu ca ti liu thng s k thut hay khng. Bn bo co phi chp nhn ha n tm thi. Nu cn, n cho bit nhng bt thng c ghi nhn hoc s t hng t khch hng. C bn l thit b phi t nhng tiu chun an ton hp php. Phn bo dng mang tnh quyt nh trong tt c qu trnh. K thut vin phi chc chn rng khng c s khc bit gia yu cu v ni dung ca n t hng. Khi nhn thit b, trong trng hp cn thit, h phi ghi li r rng nhng s t trc thng l. Hnh 2.23 di y tm lc cc bc chnh ca vic mua.

Thm d ngn sch

Ti liu thng s k thut chi tit

Kim nghim so snh

Mi thu hn ch

La chn nh cung cp

Hnh 2.22: Cc bc hon thin mt ti liu thng s k thut

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CC BC CA QU TRNH MUA

3. Cc ti liu thng tin k thut u tin Danh sch ca nhng ti liu ny c ghi r trn.

Thu nhn ti liu lin quan n vic lp t

a. Bn ghi k hiu tiu chun Hnh 2.24 di y l mt v d v bn ghi k hiu tiu chun. N tm tt cc c im ch to v hiu sut chnh. Thng i cng vi mt bc nh hoc hnh v phc tho.

Cng vic s b

Ha n s lng v ghi nhn

Lp t

Khi ng v cc th nghim v hiu sut Chp nhn ha n v cc iu khon thanh ton

Giy chng nhn

Ha n tm thi

Thanh ton theo cc iu khon ca ha n

CEMIMO62/3

Hnh 2.23: Cc bc c bn ca qu trnh mua

Hnh 2.24: V d v mt bn ghi k hiu tiu chun Ngun : Technofluid

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b. Bn ghi k thut Bn ghi k thut cung cp tt c thng tin cn thit cho vic la chn b phn v vic lp t n. N hon thin hn bn ghi k hiu tiu chun. Hnh 2.25 di y cho ta mt v d v bn ghi k thut.

Hnh 2.26: V d v bn ghi k thut Ngun : Technofluid S xc nh v tr cc s b phn l r rng. Chng ta coi nh cc s b phn nn c t trong thit b ti v tr m nh sn xut d on trc hoc nu khng th cng phi gn. Trong mt vi cng ty, cc s nhnh c phng v thit k m nhn nhanh chng. Vi trng hp ny, mt bn sao ca cc s phi i cng h s thit b. Hnh 2.25: Bng ghi k thut (Ngun: Technofluid)

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4. Cc ti liu lp t Lm th no chng ta c th s dng cc ti liu ny mt cch tt nht? Chng ta phi chc chn rng cng vic chun b s c tin hnh trong khong thi gian cn thit m bo s ng b tt nht gia thi im kt thc cng vic v thi im tip nhn thit b. Cng vic ny c th bao gm s chun b cc kha hc, di di cht thi, vic cung ng khng kh nn, in nng, nc ..v..vVi k thut bo dng th l s chun b cc s , ti liu cng nh Lnh bo dng (W.O) bt u cho vic cung cp. Danh sch cc k hoch lp t, x l v ti liu phi sn sng cho dch v bo dng ca cng ty nhm gip h tm hiu, t k hoch v hon tt cng vic chun b trc khi lp t my. K thut bo dng c th chun b mt vi k hoch chi tit lin quan ti vic hp nht thit b vi mi trng mi ca n. II. CC TI LIU LIN QUAN N VIC S DNG

Ch ! Vi cc my mc iu khin s, cc yu t xc nh ca bng c sp xp khc so vi cch sp xp chng trn my tiu chun. Nhp d liu cho vic kim tra lch di (ty chn). Khi ng vic kim tra lch di. Cc b iu khin c khi ng v ng h o (b phn bo hiu s sn sng s dng). B phn bo hiu s nhiu lon. B phn ngng hot ng khn cp. Nm iu khin vi trc trc/sau (ty chn). Nm iu khin di ng tt/m (ty chn). My ca tt, ko my ca li. M kp II (truyn ti) tt/m.. Nt n t ng . Truyn ti (m kp II) trc /sau. Nt n ct n v . My kp (m kp I) tt/m. Chn trc s lng ming ct. Chn trc s lng nguyn liu cung cp. Ngt mch chnh.

1. Cho ngi s dng thit b Mt phn ln ca hng dn s dng nhm vo ngi s dng. Trong thc hnh, bn ghi k thut, phn tch chc nng v cc s nhn chung khng c s dng trc tip bi ngi vn hnh. Cc k thut vin bo dng s pht trin ti liu Hng dn bo qun cho ngi s dng. Ti liu ny phi miu t cc thao tc bo qun cp 1. Cng nh vy p dng cho thng tin nm trong cc phn mc khc ca ti liu thit b. Chng ti ngh rng k thut bo dng gii quyt vic sp t cc th tc s dng n gin. Cc th tc ny phi bao gm mt chng Cc cnh bo v ngha ca chng . Ngoi ra chng phi ghi r cc gii hn hot ng ca thit b (vi mt ch thch v nguy him trong trng hp lm dng). Tt c nhng ti liu dnh cho ngi s dng thit b phi tp hp li trong mt ti liu gi l ti liu s dng thit b . Mc d c s dng trong thc tin, n phi c tch hp vo trong ti liu thit b. Nhng ti liu ny s c cp nht theo s pht trin ca thit b. Mt vi nh sn xut khuyn khch vic t cc ghi ch k thut bn cnh thit b. Trong mc thnh phn ca cc ti liu s dng dnh cho ngi s dng, chng ta s tm thy : ng dng c trng ca 5S hn thng l phi l mt phn ca vn ha doanh nghip ; Lm th no s dng thit b mt cch an ton nht . Danh sch kim tra nh k (km hnh nh nu c th) cho bit cc a im kim tra, cc bin s kim tra v cc bin php x l ng n. Cc iu chnh / sa cha n gin : trng thi t nhin, tn sut, gi tr + sai s, cc bin php sa cha (km theo hnh nh nu c th). Bi trn (cc loi du, s lng, tn sut, ..vv..vv..) 2. Cc v d a. Thao tc khi ng v tt my Thao tc c thit lp bi nh sn xut Bc tranh ton th II (Bng iu khin) S 01456628

Trong mt vi trng hp, vic bo dng phi thch nghi vi ngi vn hnh sn xut. b. M iu khin M iu khin c cung cp bi nh sn xut i khi khng d dng s dng i vi ngi vn hnh. V vy nn tng kt mt s m hoc s dng ch tng hnh d hiu ngay c khi ch nhn lt qua. c. Cc s c c th xy ra Mt li ch l nn t gn thit b mt danh sch cc s c c th xy ra v nhng bin php sa cha c a ra. Cc nh sn xut thng cng b loi danh sch ny.

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d. Hng dn v v sinh v an ton Hu ht cc nh sn xut ch ra rng nhng v tr tng ng, cc hng dn v an ton phi ph hp vi php lut c hiu lc. Tuy nhin nhng ch dn ny thng khng y . Ghi ch v vy bao gm mt danh sch cc tham kho b sung. e. Hng dn bo dng Nhng ti liu ny lit k cc hot ng bo dng c thc hin bi ngi vn hnh sn xut. Trong s c th cp n hng dn 5S . Chng ta c th b sung thm cc hng dn bo dng n gin nh kim tra nh k theo quy m nh, cc thao tc bi trn v thay th n gin. 3. Dnh cho k thut vin bo dng i ng k thut vin bo dng phi nm c thng tin lin quan n cc cch thc s dng thit b. iu ny tr nn d dng hn khi h gp phn pht trin nhng g cp trn. Chng s hng dn cc k thut vin bo dng trong vic hnh thnh cng thc s dng dnh cho ngi s dng. Thng tin ny s gip h hiu c cc du hiu hot ng khng tt v xc nh nguyn nhn (chun on). Ti liu cho php h xc nh c cc b phn hng hc v xem xt vic thay th ng thi/hoc sa cha chng. Nhng kha cnh rt quan trng ny s c tip tc trin khai sau. III. CC YU CU V BO DNG Sa cha Phi hp

Ln k hoch nh ngha cc thao tc

Chu trnh ci tin ca cc phng thc bo dng

Hot ng Cc cng vic bo dng

Kim tra Phn tch h s

Hnh 2.27: Nguyn l hot ng bo dng bin son chng Bo dng thit b trong h s thit b, chng ta phi tun theo cc chnh sch bo dng lu hnh trong cng ty. Nhng chnh sch ny s hng dn chng ta trong vic hnh thnh nn tng ca cc yu cu v bo dng. Nhng chnh sch ny c th c sa cha thch ng vi cc tnh hung thay i trong thc tin sn xut. D nhin tt c cc ti liu ny xut pht t cng mt ngun : nh sn xut. Tuy nhin vic t chc v trnh by cc ti liu s phi thay i ty theo nhn vin bo dng. Hu ht cc ti liu phc v cho cng vic bo dng s c son tho t trong cng ty. Vic s dng hp ng ph cc cp bo dng khc nhau s i hi mt cu trc ph hp ca h s thit b. Hnh 2.28 minh ha cu trc h s thit b.

Phn Cc yu cu v bo dng phi bao gm : S thit b. Hng ph hp vi nhng quy nh. M t cc cng tc bo dng. M t cc cch thc vn hnh. M t cc dng c. Sa cha, kim tra v cc th nghim.

xy dng h s v cc yu cu bo dng, chng ta ch nn lu tm n cng vic bo dng. iu ny c th tm lc li nh sau: BO DNG LIN QUAN N TT C CC HOT NG C TH BO QUN HOC PHC HI MT B PHN TR V MT TRNG THI XC NH HOC CNG C TH L CC HOT NG CUNG CP MT DCH V C TH. (FNOR X60-010) iu ny hm khi nim v s HIU BIT thit b, khi nim v DUY TR hiu sut v khi nim v cc quy tc QUN L trong mi quan h vi mc tiu k thut i cng kinh t. Hnh 2.27 di y tng kt li vai tr ca bo dng.

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1. S thit b Trong mt h s thit b k thut, mt s hoc bn sao ca n phi c xc nh bi : Ti liu bo dng hon chnh Dch v chm sc sau khi bn hng ca nh sn xut Tn loi chnh xc ca n, m s v ngy i tu, Ti liu tham kho ca nh sn xut, Ti liu tham kho ca dch v bo dng (v d nh trong trng hp mt s chi tit), H s ha v tham kho cc b ca s gc.

Nh sn xut thit b

Hp ng ph vi cng ty bo dng

Hnh 2.28: V d v phn loi cc ti liu lin quan n h s thit b (c cng b vi s ng ca Gio s R.LEENAERTS)

Ti liu bo dng rt gn

Cc s c ngun gc bn ngoi (nh sn xut) v ngun gc bn trong (ban k thut v thit k, dch v bo dng). Vn chnh l cp nht lin tc danh sch kim k ca cc s ca tt c cc thit b. Danh sch kim k ny l mt loi bn nm trong s cc ti sn ca cng ty. Theo quan im vn hnh, n tip tc t bng iu tra nghin cu c cp n. Khi xy dng cu trc, chng ta hng ti vic to ra mt phin bn h s k thut ph hp c th s dng bt c lc no. 2. Thao tc lp rp v tho d Nh sn xut khng nht thit phi cung cp cc chi tit ca thao tc tho d v lp rp li. Cc k thut vin bo dng dn dn s cung cp chng ty theo nhu cu. Cng vic ny v vy khng phi hon thnh mt cch k lng (v l do chi ph). Cc thao tc phi n gin v c ngha. iu cn thit l phi s dng ti a cc bn phc tho cng vi/hoc hnh nh gii thch thao tc hot ng. Mi s tho d cc b c th ng nht vi mt qu trnh ring bit m c th tm thy v tr ca n trong mt cu trc chung. Mi qu trnh tho d phi da trn s sp xp th t vt liu, iu cho php minh ha s phn chia v sp xp cc b phn theo mi quan h ca chng (v d b phn b mn hoc ph tng thay th). Trong nhng qu trnh lin tip ny, cc chi tit khng c bit n s c tm thy. iu quan trng l m t s vn hnh trong nhng iu kin s dng thc t (cc ch , dng c v thit b). Tt c cc hot ng vn hnh khng c miu t chi tit v chng qu n gin hoc gi thit rng chng c bit n.

Ti liu bo dng chn lc

Ti liu bo dng c bn

Ti liu bo dng chi tit

154

Ti liu chung ca cng ty

Dch v bo dng ca cng ty

Hp ng ph vi cng ty bo dng

Dch v bo dng ca cng ty

155

IV.

TI LIU V CC PH KIN S DNG V PH TNG THAY TH

V.

THNG TIN BO DNG

Chng ta tho lun mt cch tng qut ni dung ca h s thit b lin quan n ph tng thay th. Lm th no tin hnh trong thc tin? 1. Xc nh ph tng thay th nh ngha phn ny trong h s thit b, tt nht l da theo logic ca th t vt liu c m ta trn. V vy chng ta da vo cc s v bn v c cung cp t nh sn xut. Nu cn thit, k thut bo dng s pht trin cc bn v chi tit, bn v phng to, sp xp th t hnh nh, vv... Vic xc nh ph tng thay th s tr nn kh thi khi cng on ny hon tt. Mc ch l gip cho mi k thut vin bo dng xc nh c r rng v nhanh chng v tr cc ph tng khi cn. Xc nh ph tng thay th cho php : Xc nh bt k ph tng thay th no ca bt c my no. Xc nh ph tng thay th c dng cho my no. Ton quyn s dng ti liu tham kho mt cch nhanh chng cn thit cho vic t hng. Bit nhng kh nng tng ng (nu c) v nhng ngi c cung cp chng.

1.Cc thng tin lin quan ti h s Cc thng tin lin quan ti h s cp ti tt c cc thng tin theo thi gian m t cc kt qu ca cng tc bo dng i vi thit b k t khi thit b c a vo hot ng. H s ch cung cp nhng s liu bt buc phi s dng. Chng ta khng nn b qua bt c iu g nhng cng cn phi c s cn nhc hp l v cch thu thp s liu. nh lut PARETO c th rt hu ch khi chn phng thc thu thp v x l s liu. Mt phn tch F.M.E.C. (kiu li, hiu ng v tnh thit yu) c th, trong mt vi trng hp, s gip ch rt nhiu. Hnh 2.29 minh ha s dng v cc ti liu chnh ca tc nghip bo dng. Tt c cc ti liu ny u gp phn to nn phn qu trnh s dng trong h s thit b.

S TC NGHIP CC TI LIU CA HOT NG BO DNG

Yu cu bo dng (W.R.)

Ch s xc nh dng trong h thng k hiu ca cc chi tit phi ging nh khi s dng trong h s, s . 2. D tr ph tng iu l tng hng ti l lun lun c ton quyn s dng ng lc, ng dng c. l s thch thc c v k thut ln kinh t. D tr cc b phn b hao mn c th c nh r mt cch d dng. Tht vy, nh sn xut xc nh danh sch v s lng phi c nh gi v tnh ton li theo tc hao mn xut pht t vic s dng thit b. y l mt vn kinh in trong qun l d tr. S kh khn nm vic cung cp cc chi tit ri ro c s dng trong trng hp Bo dng Sa cha. V vy, khi thit b sn xut gp s c phi x l nhanh chng khc phc. Khi ph tng lin quan c gi thnh thp hoc c th mua d dng th khng phi lo lng v vn ny. Vn s kh x l hn khi gi thnh ca ph tng cao ng thi/hoc thi gian giao hng ko di. Trong tnh hung ny, tt hn l cp n trong h s thit b (v d nh trong cu trc hnh cy). Vi trng hp ny th cch gii quyt cn li nm vic tnh ton s ti u gia chi ph lu gi thit b v chi ph ri ro. Vic tnh ton ny khng h n gin. N i hi phi p dng nh lut WEIBULL. Ch bng cch s dng my tnh mi c th gii quyt loi vn ny mt cch n gin. Cc tham s nh hng ti vic d tr l: Chi ph lu gi thit b trong kho bi CP c tnh bng % ca gi thnh ph tng, Ch s hng hc hng nm () ca ph tng, Thi gian giao hng, Gi thnh ph tng, Chi ph ri ro CD. Hnh 2.29: Minh ha lu cc d liu tc nghip
Hch ton chi ph Th tc hnh chnh v dch v bo dng t mua, Chun b, Bt u trin khai (O.P.S.)

Phng K hoch Bo dng (O.M.)

Kho ph tng (S.P.)

Lnh bo dng (W .O.)

Thc hin

Bo co thc hin (I.R.)

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a. Cc loi thng tin bo dng v vn s dng I. Bo dng khai thc Cc ti liu ny do k thut vin bo dng lp ra cho ngi vn hnh sn xut khng bao gi c trong h s v cc kt qu l tun theo cc tiu chun d kin. Thng tin v cc hot ng ny c lu trong h s sn xut. II. Bo dng nh trc Cc hot ng bo dng loi ny c lp k hoch v chun b theo kiu cc th cho tng loi tc nghip, ngha l: Kim tra, Bi trn, Bo dng nh k, iu chnh.

VI. Th h s Nhng th ny s tm tt tt c cc thng tin thu thp c trong cc ti liu c phn tch. 1. Bn theo di bo dng Ti liu ny cp ti: Ngy thc hin bo dng, S hiu W.O., Lit k nhng u vo s dng (s gi, ph tng), Tn hi c ghi nhn (bn cht, nguyn nhn, hu qu, bin php), Cng vic c thc hin (ch nh, ngi vn hnh thit b, mc bo dng, thi gian), kin nhn xt.

2. Bng theo di thi gian dng my y l hot ng phn tch thi gian dng my: Ch i, Sa cha, S tng ln trong sn xut.

Nhng tc nghip ny s c lu h s theo trnh t thi gian. Nu khng c g bo co, h s ny s ch quan tm ti vic thc hin k hoch bo dng nh trc. III. Bo dng da vo tnh trng iu trc tin cn phi lm l xem cc ch s o lng c th nm c nhu cu v hot ng bo dng. Khi nhng ngi pht hin t ng truyn kt qu o lng hoc tn hiu cnh bo, cc s liu ny s c nhp trc tip vo h s thit b. Khi vic c kt qu l th cng, chng ta cn s dng mt ti liu c trng gip bt u tin hnh mt W.R. nu cu v s a vo h s. IV. Bo dng sa cha Bo dng khc phc l im quan trng nht i vi h s v cc li khng c tr nh trc (thm ch c khi li c th d bo) Cc giai on ca hot ng ny gm: Quan st v phn tch kin v hot ng ca ngi s dng thit b. Chn on. Tm gii php ti u nht (lin quan ti kha cnh sn xut, s sn c, v.v...). Yu cu Bo dng (W.R), Lnh bo dng (W.O), lp k hoch, ph tng v ngi vn hnh. Sa cha tm thi. R.O.I.

3. Bng kim sot chi ph C mt vi cch chi tit ha cc cng c c thit k theo di chi ph bo dng. Hnh 2.31 cho thy mt v d v bng kim sot chi ph. I.L. = lao ng ni b. E.L. = lao ng thu ngoi. I.I.N. = s hiu nhn bit ni b. y l s liu nhn bit ca thit b ang c xem xt.

V. Bo dng ci thin y l hot ng bo dng cn thit. C rt nhiu nguyn nhn dn n can thip bo dng loi ny. Cc hot ng bo dng ny s c xem nh nhng can thip bo dng khc phc m khng c bt k du hiu khn cp no, ngha l bng cch lp k hoch cho bo dng ci thin. Vic lu tr cc s liu ny trong h s thit b s c thc hin bng cch tham chiu ti nhng g lm khi bo dng khc phc. Thng thng yu t sn sng khng chu tc ng ca cc can thip ny.

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159

2. S liu thng k Bng thut ng hn lm ny, chng ti mun cp ti vic khai thc cc s liu c ghi chp trong h s thit b. V th, ngha ca thut ng ny lin quan ti trng hp ca mt thit b n l ang c vn cng nh lin quan ti nhiu phn tch hn trn phm vi chung v ton b hoc phn no ca ton b c s thit b. Hn th na, nhng phn tch nh th c th khng lin quan ti cc thit b nhng li lin quan nhiu ti loi hnh bo dng hoc cc hnh ng ca t chc do cp qun l sn xut hoc bo dng quyt nh. Nguyn tc ca bt k ng dng thng k i vi cc s liu lin quan ti lch s l phi ci tin lin tc cc th tc bo dng v iu chnh chnh sch bo dng theo tin trnh ca thit b. Chi tit Pices Pices M-OE M-OE M-OE Tng M-OI M-OI Total Total Mc tiu cui cng l: SN XUT TT VI CHI PH HP L NHT V th, k thut bo dng lun lun l thch thc vt hn ln nhng g t c. hon thnh cc nhim v th cn o lng cc thng s nh: Tnh SN SNG, Kim sot CHI PH.

Nm ................ ................ ......

Tng

Cng dn

I.I.N......................................................

BD ci thin

M-O

Hnh 2.30 V d v bng kim sot chi ph bo dng. (c cng b di s cho php ca gio s R. LEENAERTS)

Chi tit

Pices

Pices

M-OE

M-OE

M-OE

Tng

M-OI

M-OI

Total

M-O

Total

3. Tnh sn sng Tnh sn sng ca thit b l t s (%) o thi gian s dng thit b vi thi gian tim nng. Gi T l thi gian tim nng (ni chung y l yu t c nh). Gi T.P. l t s (%) gia thi gian sn xut v thi gian tim nng T. Gi T.A.T. l t s (%) gia tng thi gian dng my v thi gian tim nng T. Ta c th vit: Chnh xc hn D > T.P. + T.A.T. D= T - T .A. T. T

BNG KIM SOT CHI PH

BD khc phc

c tnh ngn sch nm.................................................................................................

CH NH THIT B.....................................................................................

Bo co qu

Chi tit

Pices

Pices

M-OE

M-OE

Chi ph bo dng hiu qu trc tip

BD c iu kin

Chi tit

Pices

Pices

M-OE M-OE

Tng

M-OI

M-OI M-OI

Total

M-O

M-OE

M-OE

Tng

M-OI

Total

M-O

Total

Total

BD nh trc

Ta s tm thy g T.A.T.? Ta s tm ra thi gian dng my do sn xut v do bo dng T.A.M. Qun l bo dng phi nhn thy gim gi tr ca T.A.M. trong khi qun l sn xut phi nhn thy gim gi tr ca T.A.P. a. Kim sot CHI PH Vic a vo s dng nhng cng c kim sot chi ph ng rng cn phi cn nhc n mt s yu t quan trng. c th d on im kt thc tui th c tnh kinh t ca thit b. Mt phng php n gin l quan trc bin ng M.T.B.F. ca mt loi thit b theo thi gian. Phi c mt s cng c cho php qun l ng cch kho ph tng. Mt cch tt thc hin l so snh chi ph cho tht bi vi cc chi ph mua ph tng.

Chi tit

Pices

Pices

M-OE

M-OE

160

Ngy

S hiu W.O

M-OE

Tng

M-OI

M-OI

Total

Total

M-O

161

Khng b sa ly vo qu nhiu cng c. l nguyn nhn v sao tt hn ht l ch chn mt s lng nh cc ch s v CP NHT THNG XUYN. a. V d I. Cc ch s chung TNG CHI PH BO DNG HANG NM CA MT THIT B GI MUA THIT B TNG CHI PH BO DNG NH TRC TNG CHI PH BO DNG TNG CHI PH BO DNG KHC PHC TNG CHI PH BO DNG CHI TIU BO DNG NGN SCH BO DNG II. Cc ch s lin quan ti qun l cc ph tng TNG CHI PH CHO CC PH TNG S DNG GI TR TRUNG BNH CA KHO PH TNG

12. XY DNG H S THIT B V C S D LIU BO DNG

TNG CHI PH CA CC PH TNG S DNG TNG CHI PH BO DNG III. Cc ch s lin quan ti qun l nhn cng

THI GIAN CAN THIP BO DNG CA MI K THUT VIN QU THI GIAN LM VIC

S LN CAN THIP NGOI D KIN S LN CAN THIP

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163

1. Gii thiu Trong qu trnh iu chnh, vic nh gi nhng bin php sa i c kim sot so vi ch dn gip ngi iu chnh c th tin hnh mt s thay i cn thit my c th hot ng n nh. Trong bo dng, nhng thay i ny l kt qu ca hot ng bo dng: Tnh hung xy ra bt ng, Bo dng sa cha, Ci tin.

2.3. Lin quan n chi ph 1. 2. 3. Nhm nh hng tt hn cho k thut thit k. Nhm a ra tiu chun trang thit b mt cch chnh xc hn. Nhm xc nh cc thit b qu t a ra cc gii php thch hp nht trong nhng trng hp: Thay th my mc. Thay i thit b,

Tt c s iu chnh ny cng vi kt qu ca qu trnh vn hnh so vi nhng mc tiu ra cho php xc nh tnh trng hot ng tt ca thit b. Cc quyt nh phi c lin tc a ra nhm t c nhng mc tiu . Cng tc lp h s thit b da trn tt c nhng d liu k thut ni trn. Vic s dng nhng thng tin ny gip xc nh bn cht ca cc s liu lin quan cn c. V vy, chnh sch bo dng ca cng ty c quyt nh bi ni dung ca nhng thng tin ghi trong h s. Vic khai thc nhng thng tin trong h s cn phi quan tm n ton b qu trnh qun l bo dng: Bo dng k thut, Qun l ti chnh, Qun l ngun nhn lc.

3. Thu thp d liu Vic t chc thc hin cc hot ng bo dng ph thuc vo cc loi hnh bo dng: sa cha, ci tin, bo dng da vo iu kin v mang tnh h thng. S l hp l nu nhng loi hnh bo dng trn tun theo nhng thng s lit k v phn loi. Chnh nh c s kt hp cc bin php bo dng m chng ta c th c mt dch v bo dng c s lin kt cht ch v chc nng v c cu, y chnh l yu t m bo tnh hiu qu ca cng tc bo dng. Xt c v mc tiu hiu qu v chi ph th h thng x l d liu h s cn phi ph hp vi nhu cu ca cng tc bo dng. Nh chng ta bit, vic lu tr h s d liu s l ngha nu chng khng c s dng. D l nh my hay ti dy chuyn sn xut th tm quan trng ca cc thit b l khng ging nhau. Nhng hng hc c cho l nghim trng l nhng s c c th dn ti nhng hu qu: 1. 2. 3. 4. Dng sn xut Nhn cng nhn ri. Khng p ng yu cu v cht lng. Khng p ng yu cu v thi hn,

2. Mc ch 2.1. Lin quan n bo dng Nhm pht hin cc thit b v/hoc h thng gy ra hng hc thc hin qu trnh phn tch v nng cao tin cy. Nhm chn ra cc phng php bo dng thch hp nht cho tng loi thit b. Nhm thc hin bo dng theo ng vi nhu cu cn thit. Nhm ci thin v ti u ho vic qun l ph tng thay th,

Hng hc i vi mt s my mc khc c th dn n nhng hu qu nh. Tuy nhin ch ring vi cc s c nh ny ta cng c nhiu cch khc nhau x l: c v phng php bo dng ln cch thc lu h s. Chi ph bo dng lin quan n tng loi loi thit b cng l mt tiu ch quan trng lp h s. nh lut Pareto s gip cho vic chn lc. nh lut ny cho rng chi ph bo dng ca 20 - 30% s thit b c th chim 70 n 80% tng chi ph bo dng ca ton nh my. V vy, vic lp h s i hi cn phi c kin thc y v thit b. Phi lp mt bng phn loi theo mc quan trng phn cho mi h thng hoc tiu h thng mt ch s quan trng nhm xc nh mc quan tm cn thit. 4. Ngun d liu lp h s B phn bo dng v cc cng vic cn thc hin c qun l qua cc ti liu lu hnh trong ni b b phn bo dng cng nh trong cc dch v v tinh. Cc loi giy t c trnh by ti 2 chng khc trc cho ra mt bn kho st v vic cch thc thu thp thng tin.

2.2. Lin quan n sn xut Nhm ti u ho cc iu kin vn hnh hiu qu. Nhm kim sot cc hng dn khi ng. Nhm m bo cc bin php kim sot. Nhm quan trc cc thit b sn sut. Nhm ci thin mi quan h gia b phn bo dng v sn xut,

164

165

S QUY TRNH CAN THIP BO DNG HH

5. Lu ca thng tin bo dng

Quy trnh can thip/ bt k c cu no Qun l bo dng Yu cu cng vic (W.R.) Cng vic theo k hoch Yu cu cng vic

Tnh ton chi ph

Cng vic hnh chnh v bo dng

Lp k hoch/ thi gian biu

Cng vic hnh chnh v bo dng

B phn bo dng

X l W.R.
Phn b, phn loai, b tr, hiu lc, tm quan trng, mc

Lnh giao vic (Lnh bo dng)

Lnh giao vic

Chun b, lp thi gian biu, ti chnh

Phiu lnh, t mua cc ph tng, cc thit b chuyn dng, qun l ngun nhn lc, giao quyn, tip cn thit b bo dng,

Trin khai hot ng

Phiu lm vic
Th tc, chi tit, giy t v k hoch

Bo co can thip bo dng

Tin hnh can thip bo dng Hnh 2.32: Lu thng tin bo dng Kim sot v bo co Ngi chu trch nhim v b phn bo dng
Bo co v tin cy ca thit b k thut, t chc vic bo dng ci tin, kho v kim sot cc ngun lc tng th, bo co v vic qun l v cc khon u t

Bo co

Lm th no truyn ti thng tin? Mi thng tin c a ra t b phn bo dng phi l kt qu ca yu cu cng vic (W.R.) t pha nh sn xut hoc t pha cng ty khai thc thit b. Bn yu cu ny c th do b phn sn xut a ra nhm yu cu Bo dng sa cha hoc Bo dng ci tin, hoc do chnh B phn bo dng a ra v d nh bo dng phng nga, hoc ngoi ra cn c th do cc b phn v tinh a ra. Yu cu cng vic c chuyn ti b phn bo dng. B phn bo dng c th chp nhn hoc khng chp nhn yu cu cng vic . Trong c hai trng hp th ngi np yu cu cng vic phi c thng tin y v nhng hot ng lin quan n yu cu ca anh ta. Nu

Hnh 2.31: S quy trnh can thip bo dng

166

167

c chp thun, anh ta cng s phi c kh nng gim st qu trnh can thip. Mt khi yu cu cng vic c thng qua, n s c gi n phng K hoch v lp thi gian biu. Phng ny, kt hp vi phng Phng php v Kho ph tng thay th a ra lnh giao vic cn thit c th trin khai can thip bo dng hiu qu. Sau khi tin hnh can thip, nhn vin k thut vit bn bo co v cng vic bo dng ca mnh (I.R) v gi n b phn hnh chnh v bo dng. B phn ny s chuyn bn bo co cho b phn lin quan khc m thng tin ny c th c ch v c bit l chuyn ti ngi a ra yu cu cng vic. Th tc c th c thc hin bng my tnh hoc di dng vn bn ty theo iu kin ca cng ty. Vic thu thp d liu phi c tin hnh theo trnh t thi gian v ngun d liu nm trong cc lnh giao vic. Cc lnh ny phi c phn loi v lu cn c theo thi im tin hnh cng vic. Sau , nhng file h s phi c hon thin vi thng tin c la chn lu. Nhng d liu c thu thp t: 1. Bo co can thip ca k thut vin. Bo co ny c ghi chp trn mt mu xc nh nhng thng tin m chng ta mun thu thp chng hn nh thi gian cho mi ln can thip, cc chi tit hao mn, b phn thay th s dng, gii php, hng hc thc s l g, triu chng,. Mt phn ca bo co ny l nhng ch thch ring trong phn dnh cho k thut vin (nhng gi ci tin, phn tch tnh hung,); Nhng ti liu ph dng trong lc lp lnh giao vic: Phiu cng vic; Cc ph tng thay th, thit b chuyn dng v ngun nhn lc cn thit hon thnh cng vic theo lnh giao vic. V d: Thit b nng, Cn trc lu ng pha trn, H thng rng rc thu lc, H thng an ton (lnh cu ho, thit b dp la,), v...v... Nhng ti liu tnh ton chi ph can thip cho s c hng lp ra bi vic hch ton chi ph. Tt c nhng ti liu c th c ch gip cho vic hiu d liu thu thp c.

13. CP NHT TI LIU BO DNG

2.

3. 4.

Bin php thu thp d liu ny ch th hin nhng thng tin v hot ng can thip ca b phn bo dng. Nhng d liu v can thip ca b phn sn xut s c lu trong s vn hnh v c th tham kho bt c khi no cn. Vic b qua nhng ch dn lin quan n cng vic ca b phn vn hnh l mt sai lm khng c php mc phi. Cc d liu cng c th c cc nh thu ph cung cp. Nht thit phi ch n nhng thng tin ny v chng khng ch cn thit cho vic nh gi gi thu m cn bo v b quyt sn xut v bin php kim sot chung cho ton b kho my mc.

168

169

I.

KHI LC

II.

LM TH NO CP NHT H S THIT B?

Vic cp nht cc ti liu lin quan ti 2 kha cnh khc nhau ty vo vic chng ta ang xem xt phn trc s dng hay phn qu trnh s dng trong h s thit b. 1. Phn trc s dng trong h s thit b Vic cp nht phn ny trong h s thit b phi c thc hin nh k. minh ha mt vi kha cnh thc tin ca cng vic ny, tt c nhng g chng ta cn lm l xem xt cc ci bin khc nhau thc hin i vi thit b: tun th vi cc quy nh v an ton ang c tng cng. ci tin vic s dng thit b theo mong mun ca b phn sn xut. quan tm n ch vn hnh thit b v s iu chnh chnh sch bo dng.

Trc tin, chng ti mun nhn mnh s cn thit phi cp nht h s thit b theo nh k v bng mt cch thc thu o. Nhim v ny l ti quan trng v c th mt nhiu cng sc. 1. Cp nht phn qu trnh s dng trong h s thit b Nhim v u tin hng ngy v cp nht h s thit b l nhp vo ton b cc bo co can thip (I.R). y l trch nhim ca nhng k thut vin bo dng ngi thc hin nhng can thip cn thit. Nhng ngi ny c b nhim r rng v phi c thng bo v ni dung cng vic cn thc hin v v sao h cn phi lm. Tuy nhin, vic kim sot thng xuyn (v d mi tun mt ln) cng phi c thc hin c t chc. Cn trnh hin tng nhm hnh chnh eo bng tham gia kim sot hng l cng vic. K thut vin vit bo co can thip s chu trch nhim v nhng g c vit ra v ch cn 1 ngi kim tra v s nht qun l . Nhng ci bin c lin quan ti ti chnh s do cn b qun l b phn bo dng hoc ca b phn khc lin quan cp nht. Vic kim sot nghim ngt v s gn kt ca cc s liu phi do mt ngi chu trch nhim v bo dng m nhn. Ngi ny s c kh nng pht hin nhng im bt thng gia cc gi tr a ra v cc dng can thip m s liu dn chng ti. 2. Cp nht phn trc s dng trong h s thit b Phn h strc s dng cn c cp nht ngay khi c yu cu ci bin thit b. Thc t, iu ny l khng th nu khng lm nh hng n t chc cc hot ng bo dng trong k hoch ngn hn. y l l do ti sao chng ta t ra cho mnh mt nh k sot xt ph hp vi nhng g sn c. Ngoi l cho nguyn tc ny l khi cn thit phi c nhng khc phc nh trong ti liu trnh nhm ln lin quan ti la chn vt dng hoc cng c hoc lm r mt th tc cn m h. Ngun gc ca mt s ci bin c th l t bn ngoi: Yu cu ca nh cung cp, Mt tiu chun an ton mi.

Mi ci bin trong s s c gii thiu: Ph hp vi i hi ca lut php v an ton ngh nghip. Theo tha thun vi nh sn xut v nhng ci bin cn thc hin Ph hp vi mong mun ca b phn sn xut. Theo k hoch ci bin do nh sn xut cung cp hoc do phng k thut xy dng c s ng ca nh sn xut.

Cc ti liu khc nhau c nh s v lp thnh danh sch: Nhng ti liu hin hu c chnh sa v danh mc sot xt ca cc ti liu ny cng s c iu chnh c ngy tham chiu. K hoch mi c xy dng, nu cn thit. Danh sch k hoch c iu chnh, danh mc sot xt ca danh sch c iu chnh c ngy tham chiu.

Ngun gc ca mt s ci bin c th l t bn trong: Chnh sa nh k do hnh ng bo dng phng nga, Thc hin cc bin php kim sot b sung, Th tc i theo mt vn pht sinh trong sn xut.

2. Phn qu trnh s dng trong h s thit b Phn qu trnh s dng to nn h s thi gian ca vng i thit b. Phn ny c b sung thng tin hng ngy qua cc bo co can thip (I.R.) v phn tch thng k c lin quan. Cc tc nghip ci bin, ni chung, c thc hin trn c s yu cu cng vic (W.R.). W.R. ph thuc vo k hoch v th tc cng nh vo danh sch cc vt dng cn thit thc hin cc ci bin. W.R. s to lp trt t lm vic cn thit hon thnh cng vic. Sau mi can thip bo dng, k thut vin s vit v mt bo co th nghim.

Nhng hnh ng cp nht ni trn s dn ti vic iu chnh k hoch v th tc hoc c cc k hoch, phc ha, s , ghi ch k thut hoc th tc mi. gim thiu nguy c c s mu thun, ngi chu trch nhim cp nht cc phn ca h s thit b phi l nhn s c ch nh.

170

171

3. Nhn xt v vic nh s trang trong h s Vic thm hoc sp xp mt trang trong mt ti liu hot ng cn c s iu chnh v nh s trang. C th tham kho h thng di y: Mi chng c nh s bng mt s (v d: phn bit bng cc s La m: I, II, III, IV, ...). Cn mt on tm tt m t ni dung v cp ti s trang trong chng mc . Vic nh s trang ca mi chng s l lin tip. Mi trang u phi c s ca h s, chng, trang, ch s sot xt v ngy sot xt. Cn mt bng tm tt cc chnh sa thc hin. Bng ny s m t ngn gn v mi chnh sa (ti a 2 dng) v cp ti (nhng) trang c lin quan, ln sa i, s v ngy sa i. Khng c hy b nhng trang c lu h s m ch c php phn loi sau khi c nhn din bng du H S.

14. T KIM TON BO DNG

4. Hin th s chnh sa Khi mt phn no trong mt trang c chnh sa, c mt cch hu hiu l nh du bng mt ng thng ng phn l ca on . y l cch gip to s ch ti phn c chnh sa c. Nu chnh sa mt trang no yu cu phi c b sung thm trang, th trang b sung s c nh s ging trang ny v gn thm ch ci m ha, v d a. V d: Trang II-22, th trang b sung thm s l II-22a. Khi c qu nhiu chnh sa trong mt file hoc trong mt chng, th iu cn lm l phi to ra mt phin bn hon chnh mi. Phin bn mi ny s c nh ch s 0 (s hiu ca file ng nhin l vn gi nh c) v ngy c hiu lc mi.

172

173

1. H s din gii Gii thiu Kim ton bo dng c bn mc tiu: 1. 2. 3. 4. a ra mt bc tranh r rng v chc nng bo dng trong ngy chn on. xc nh nhng im yu km. Gp phn vo thit lp ln cc cng c x l d liu (C.M.M.S.), L mt c s cho kim ton kim sot tin trnh ca chc nng bo dng.

STT 101

NG V tr ca thit b c th c xc nh (theo cc b phn, theo phn xng,). C mt danh sch cc thit b. C mt ngi trong nhm sa cha bo dng ph trch vic cp nht danh sch cc thit b (t nht l mi nm mt ln). Tt c cc thit b chnh u c nh m s (Code). E c th quy cho m s theo logic topo (danh php) hoc cho mt s tham chiu (s s-ri ca mt ng c chng hn). i vi tt c cc thit b chnh, cc c trng cn bn dn ti tnh trng vn hnh tt phi c nhn bit, v d, p lc, tc vng quay, n, tc ra phoi, bc tin (dao tin), ... i vi tt c cc thit b, hng dn an ton cn p dng trong thi gian can thip phi c nhn bit. Hn na, chng phi lun c vit c th ra thnh vn bn. i vi tt c cc chi tit ca thit b, cc ph tng thay th chnh c kh nng cn s dng trong sut thi gian can thip phi c nhn bit. i vi tt c cc thit b, bn bit c mnh cn mang theo cng c g cho vic gian can thip bo dng.

SAI Khng c danh sch cc thit b. V tr ca thit b c th xc nh c khu vc nhng theo trong tr nh. Khng c ai cp nht danh sch ny c.

102

103

Cc chi tit ca thit b khng c nh m s. Chng thng c xc nh theo tn cng nghip ca chng (cu to, kiu cch,...). Cc c tnh thng thng dn ti tnh trng hot ng tt khng c nhn bit, ngay c i vi nhng chi tit chnh ca thit b. Cc quy tc thc hin (hay nhng s ch dn) cn tun th trong sut qu trnh can thip l khng c bit hoc khng c p dng (th sa cha lm nhng g m h thch lm). Cc ph tng cn thit sa cha thay th cc chi tit ca thit b khng c nhn bit (v d chng c cung cp sau khi thit b c tho ra). Bn khng bit cng c no cn phi mang theo trong qu trnh can thip, ngay c khi l mt chi tit quan trng ca thit b. Mi ln can thip, cc k thut vin bo dng phi thng xuyn i li nhiu ln ly dng c phn xng bo dng. Khng c mt ti liu ghi chp no lin quan ti bt k mt thit b no. Cc m s lin quan n thit b, nu tn ti, c th c vit trong s nhng chng li khng gn nhng thit b c lin quan. Mi ln can thip, k thut vin bo dng khng th xc nh mt cch nhanh chng cc thit b c lin quan. Khng c s m cng khng c c bn v hoc l c nhng khng c cp nht. Bn c th bit l chng c tn ti nhng ln cui cng m bn nhn thy n l khi m thit b c nhn v. K t chng c ct mt cch ngn np trong t! Cc bn chi chp cng vic c tn ti nhng bn khng bit phi tm n u hoc chng khng th s dng c.

2. Nguyn tc lm vic Vic kim ton ny d kin p dng cho cc cng ty quy m va (t 50 cho n 1.200 cn b cng nhn vin). Mt b phn ca nn cng nghip nh. N c bin son thnh 8 biu bng, mi bng cp mt lot cc cu hi v rt nhiu lnh vc khc nhau ca vic bo dng v mi lin h thc t ca chng trong ni b cng ty. Cc cu tr li cho mi cu hi c phn chia thnh theo bn nhm (ng, kh ng, kh sai, sai). Nhng biu bng ny s c in y bi mt nhm nh cc thnh vin (t nht l 2 ngi), nhng ngi c mt ci nhn tng th v hot ng bo dng. Cn c theo cc cu tr li, mt phn mm my tnh s phn tch v cn i ton b s liu v a ra chn on. phn ph lc, mt h s din gii s gip cho vic hiu thu o hn cc cu hi iu tra thm d. Chn on Hai kiu kt lun c th c suy ra t kt qu chn on. 1. 2. Nu n l mt tiu ch loi tr, n phi c lm li. Theo nhm mc trong biu mu, chng ta c th kt lun da trn nhng n lc cn lm: Mc. 1: Bn c hiu bit tt v m-un ny. Tip tc! Mc 2: Bn c hiu bit hot ng ca mnh. Tuy nhin n vn c th tt hn. Mc 3: Bn c kin thc trung bnh v m-un ny. Cc im gp s c nn c kim tra li. Mc 4: Bn khng c hiu bit v m-un ny. Phi kim tra li mt cch k lng. 107 104

105

106

108

i vi mi mt thit b, bn c th d dng tm thy h s ghi chp cc cng vic m trc y thc hin vi n. M s thit b c th s dng mt cch d dng v r rng. C ngha l chng phi c gn trn cc thit b hoc gn . Chng khng b ph mt lp bi dy v khng b che khut! Mi thit b u c cc s hoc bn v ca nh sn xut. Chng c cp nht v bn bit chng nm u.

S tr gip ca nh t vn trong giai on ci thin ny c th c ngha tch cc. 3. Qun l thit b Khi nim thit b y khng qu b hp. N c th l mt c my, mt t my, hy mt dy chuyn,...

109

110

111

Cn c cc h s ghi chp cng vic lin quan n thit b v bn bit mt cch chnh xc ni lu tr n. Bn c th d dng tm li n mt cch nhanh nht.

174

175

112

Vi tt c cc thit b chnh, bn bit r mc cp thit ca can thip bo dng. Cc ghi chp khng ch c lu mt cch y m chng cn phi c bin tp li v c phn tch t nht l mi nm mt ln. Nhng phn tch ny c s dng v rt ra nhng kt lun lin quan n cc vn phng nga chng hn. Mi thit b c mt v ch mt m s duy nht. Tn thit b, tn m hoc tn quy trnh cng ngh khng c ln vi nhau. i vi tt c cc thit b chnh, bn u c mt h s, cha ng tt c cc thng s k thut lin quan n thit b ny.

Khng th nh gi th t u tin theo mc cp bch ca cc can thip i vi thit b c lin quan. C th c cc bn ghi chp nhng chng li c lp h s v ct k trong t m khng dng n bao gi.

5. Qun l ph tng thay th v kho cha (ph tng) Phn ny ch cp v ph tng thay th v cc chi tit hao mn. STT 301 NG Cc yu cu v mua sm (P.R) lun lun c thc hin theo cng mtcch thc. C mt v ch mt m s cho mt loi chi tit c lu tr. i vi mi mt ph tng thay th c th, bn c th tm thy cc m t c tnh k thut c lin quan. Thng tin ny c th tm thy t cc nh cung cp. Ch lu tr nhng ph tng m bn chc chn cn dng. C s cp nht thng xuyn (v cht lng v s lng) v tnh trng kho. B phn bo dng lun nm c thng tin ny. Cc k thut vin bo dng c th d dng tm thy ph tng m h cn. Bn bit c ai l ngi cung cp tng ph tng c ct tr (c mt bn ghi chp y ). Bn c th xc nh thi gian cn thit c c thit b chuyn dng v kho... SAI Khng h c mu trin khai PR no. Mi ngi lm theo mt cch thc ring ca mnh. Khng c m s hoc c rt nhiu m s cho mi loi chi tit c ct tr trong kho. Cc chi tit lu kho v nhng c tnh k thut khng c lin quan g vi nhau. Tt c mi th u c lu tr, k c nhng th m bn s khng bao gi dng n na. B phn bo dng khng bit tnh trng cng nh gi tr ca kho ph tng d tr. Phi rt vt v lc li mi c th tm thy c ph tng cn dng. Thng tin v cc nh cung cp ph tng khng c ghi chp li. Bn khng bit thi gian giao hng.

113

114

C nhiu m s c dng cho cng mt thit b (v d mt m phn tch, mt m tp). Mi ngi u ni v cng mt thit b nhng s dng cc tn gi khc nhau. Khng c mt h s k thut lin quan ti tng thit b.

302 303 304 305 306 307 308 309

115

4. Cp bo dng 1 Cp thp nht ca bo dng nhm vo cc hot ng cn bn, th d nh lau chi, tra du m cho thit b. Chng c thc hin thng xuyn (thm ch, c th l hng ngy) bi cc nhn vin bo dng, cng nhn sn xut hay bt k mt ngi s dng no khc STT 201 NG SAI

Hot ng tra du, m v bi trn c thc Khng c ghi chp no v cc hot ng hin theo mt mu chung v theo cch thc bi trn. ging ht nhau. Hot ng tra du m c thc hin theo mt mu chung v theo cch thc ging ht nhau. Bn bit ai l ngi xc nh cng vic ai l ngi lm vic g v khi no. C s theo di thng xuyn cc ti liu lin lin quan n hot ng tra du m (thc hin bi nh my hoc nh sn xut). Cng vic tra m c thc hin khng theo nguyn tc, lm theo cm tnh ca ngi ph trch vng v ph trch cng vic tra du m. Cng vic tra du m khng c theo di gim st.

202

Bn bit c cc ph tng thay th c th Bn khng bit c chi tit no c th dng thay th cho nhau (tng ng) c s dng trn nhiu thit b khc nhau. cho nhiu thit b. Chng c lit k v bn c th nhanh chng tm thy chng. Kho cha c th s dng chung vi cc C th c kho cha nhng b phn qun l b phn khc hoc c nhng chc nng khng phi l b phn bo dng. khc nhng b phn bo dng phi l b phn qun l. Mt vi ph tng c th khng cn lu tr bi v bn bit c rng n c th c cung cp mt cch ht sc nhanh chng khi cn thit. iu ny ni ln rng bn bit c thi hn v ai l ngi cung cp chng. (Mc 307 v 308). Vic nhp xut ph tng ti kho khng c thc hin mt cch ty tin thiu ngn np. C th s p dng cc quy nh v kho (S.R.). i vi cc ph tng then cht th cn phi xc nh v cn nhc mt ngng an ton , ngha l di mt s lng no th cc ph tng phi c b sung mt cch c h thng. Tt c nhng th m bn cn u c ct tr trong kho. Khng c mt th g lu ti ni ca nh cung cp.

203

310

204

Nu k thut vin bo dng pht hin Khng c s sch ghi chp, khng c biu im bt thng no ca thit b trong , v.v... Nhn vin k thut bo dng c khi thc hin cng tc bi trn, anh ta c th th nh hoc qun thng tin ny. vit ra u sau bit c thng tin ny trong nhng ln can thip sau . Hot ng tra du m v lm sch thit b c vch ra theo mt lch trnh nh k v c k hoch. Hot ng bo dng khng c lp k hoch.

311

205

312

Vic nhp/xut ph tng ti kho din ra ty tin thiu ngn np. Mi ngi c th t mnh lm g th lm. B xung ph tng trong kho khi bn mong mun hoc l khi c mt s thiu ht trong kho v nhu cu tng ln.

206

C ngi ph trch vic cp nht vic gim Cc hot ng gim st cng vic ca cp st hot ng bo dng cp thp nht bo dng 1 khng c cp nht. ny. Nm r tnh hnh kho du bi trn, v bn bit chnh xc tnh trng ca cht bi trn dnh cho thit b l nh th no. Khng bit v lng du bi trn, thit b c bi trn khi bn rnh ch khng theo tnh trng ca chng. Khng bit v lng du bi trn, thit b c bi trn khi bn rnh ch khng theo tnh trng ca chng. Cc sn phm v ph tng s dungjcho Bo dng Cp 1 c hiu r, lu tr v theo di bi B phn Bo dng

313

207

208

314

t nht mt ln trong nm, s xut nhp Bn khng c n lc no tm hiu iu g kho phi c phn tch theo mt phng xy ra vi cng tc xut nhp kho. php phn loi hoc nhm li nh l th t alphabe, ...

176

177

6. Qun l cng vic Phn ny cp ton b mi cng vic bo dng, vic qun l v trin khai cc cng vic ny. STT 401 NG SAI

7. Phn tch r.m.a.s. Mc ny lin quan ti cng vic qun l cc d liu lin quan ti tin cy, bn, tnh sn sng v tnh an ton ca thit b (R.M.A.S - Reliability, Maintainability, Availability and Safety). STT 501 NG i vi cc thit b chnh, bn c th thu thp c nhng thng tin lin quan n tin cy (hoc tnh sn sng hay bn) v tnh an ton. Bn c th lu tr n v bn bit cc bc phi theo. SAI Bn khng quan tm ti tin cy (hoc tnh sn sng hoc bn hoc an ton), thm ch l cc thit b chnh.

Bn c th phn loi cc thit b theo cp Bn khng th xc nh c th t u tin quan trng ca chng (v d: sng cn/ cho thit b (v mt sn xut, an ton, ...) quan trng/th yu). Nhng s can thip bt u theo mt cch S can thip bt u mt cch ln xn thc mu nht nh, bi yu cu cng vic khng theo bt k mt quy trnh no c. (W.R.) hoc cc ti liu khc. K hiu: W.R. : Yu cu cng vic W.O.: Lnh lm vic W.S. : Bng cng vic I.R. : Bo co can thip Khi gp phi tnh hung c qu nhiu yu cu cng vic, bn c th la chn cng vic no lm trc, phn chia cc yu cu v lp k hoch thc hin chng. Sau mi ln can thip, c mt bn ghi chp y cch thc m bn tin hnh cng vic v l do ca vic can thip. Khng c s theo di cc yu cu cng vic. Mt khi cc yu cu cng vic c ban hnh, bn can thip m khng h bn khon ti vic la chn, ghi chp, phn chia hoc lp k hoch thc hin chng. Bn thc hin ht can thip ny n can thip khc m khng h c ghi chp g v cng vic lm.

402

502 503 504

Sau mi can thip bo dng, mt bo co Ht can thip ny n can thip khc, cc vn bn c lp, lm thnh h s ri lu d liu khng c ghi nh v cng khng v tr c bit. c ghi chp. Cc bo co can thip c s dng phn tch chi ph, thi gian, s ln hng hc xy ra ... Cc kt lun c rt ra nh s phn tch nhm ci thin cc can thip trong tng lai. V d tun th mt quy trnh rt ngn thi gian can thip, ... Mt ch s v tnh trng hot ng tt c th l thi gian trung bnh gia cc ln hng. (M.T.B.F.) a.o. Mt ch s v thi gian can thip c th l thi gian trung bnh sa cha (M.T.T.R.) a.o. Mt ch s v tnh sn sng ca my mc c th l s nh gi nng lc ton b. (G.E.R.) a.o. Trong thi gian can thip ln mt thit b chnh th bn bit cc hng dn an ton v quy tc can thip. Cng ty c sn thit b phn tch rung, xc nh nhit bng tia hng ngoi, ... Thit b ny c s dng mt cch thng xuyn v c t chc. Ngay c khi c lp v lu h s th chng li b xp di y ngn ko v khng mt ai s dng cc d liu . Cc kt qu phn tch khng c khai thc s dng. Cc ch s nh th ny khng c dng n. Cc ch s nh th ny khng c dng n. Cc ch s nh th ny khng c dng n Trong hu ht cc trng hp, hng dn an ton cn tun th khi can thip khng c bit n. Cho n nay cha tng c mt thit b no nh th c s dng. Ngay c trong trng hp nu nh bn c thit b i chng na th bn vn phi s dng n nhng dch v khc hoc phi k mt hp ng ph.

403

404

505 506 507 508

405 406 407

Trong trng hp phi thc hin mt cng Bn t mnh phn loi cng vic mt cch vic mi th bn cng bit c cc th thiu cn thn! tc tin hnh. Ly v d, bn bit cn phi gi n ai hi v phn n, ai hi v phn in, ... Cc cng vic khc nhau c qun l v thi gian v chi ph. Bn bit cch lm vic vi tin v cc nh thu ph s dng mt phng php chung. Cc cng vic khc nhau khng c qun l m chng ch n gin l c thc hin. Trong trng hp cng vic c s hp tc qun l, bn khng bit phi lm cch no lin h c vi cc nh thu ph khc nhau cng nh khng bit gim st cng vic l nh th no. Bn sng theo kiu qua ngy on thng. Bn khng h bn tm k hoch sn xut.

509

408

Cng vic c bt u v c thc hin c s xem xt k hoch sn xut (P.P.), s s dng thit b hoc lch sn xut v my mc s dng. Vi cng vic phc tp, d n lin quan n vic bo dng sa cha hay l bo dng phng nga th vn phi tun theo mt quy trnh c vch ra.

510 Bn c mc k, lm theo nhng suy ngh cm tnh, nhng yu cu, nhng kh nng mch bo ... 511 512

409

Bn c th theo di tn sut v tnh cht Bn khng theo di cc tc ng phn hi nghim trng ca cc li, tn tht v mt ca hot ng bo dng. thu nhp, mc hi lng ca khch hng vi vic bo dng, ... Mi thit b chnh u c mt h s c xem nh l h s bnh n, phn nh cc hot ng can thip, nhng hng hc v nhng thay i thc hin. t nht mi nm mt ln, cc bn ghi chp c dng phn tch tui th ca thit b v rt ra nhng kt lun cho nhng ln can thip tip theo. Kh c th kim c thng tin g v thit b ngoi nhng g c c da vo kinh nghim. Khng h c ghi chp g trong sut thi gian tn ti ca thit b. Cc ghi chp khng c khai thc.

410

Trong qu trnh can thip, bn c trong tay Bn khng bit hay bn khng c trc tip nhng hng dn an ton tun theo. trong tay quy nh an ton tun theo N c th c vit trong W.S hay mt ti trong qu trnh can thip. liu bt k. Trong trng hp c qu nhiu cc yu Khi ngi ph trch vng mt, khng ai bit cu cng vic (W.R.), bn bit lm cch no phi lp th t u tin cng vic th no. sp xp th t u tin cc cng vic. Bn t mnh phn loi n. Vi cc thit b chnh, c mt h s tp hp tt c cc ti liu lin quan n W.O. / W.S. / I.R. Khng c mt h s no i loi nh th c.

411 412

513

C mt ch s chung th hin cc thng s Khng c mt ch s no nh th. nh nng sut ca nhn vin bo dng, thi gian phn hi, s chia s cng vic sa cha tm thi trong hot ng bo dng...

178

179

8. Phn tch chi ph Trong phn ny ch cp n cng vic qun l cc chi ph Bo dng. STT 601 NG Ngn sch bo dng khng phi c qun l bi phng k ton m l c qun l mt cch rt cn thn bi phng sa cha bo dng. C th d dng bit c tnh trng ca ngn sch SAI Phng bo dng khng chu trch nhim i vi cc ngn sch bo dng m l b phn khc ph trch cng vic ny, v d phng k ton. Bn khng th nhanh chng tm hiu c ngn sch cho bo dng l bao nhiu. Bn phi chuyn cng vic ny sang cc b phn khc. Thm ch bn cn khng th xc nh c vn ny.

9. C s d liu C s d liu m ch cng tc qun l, lu tr v lp h s lin quan n b phn bo dng. Vic x l d liu c th khng nht thit l phi gn lin vi khi nim ny. Phn ny lin quan n vic lu v tham kho tt c cc s liu lin quan n thit b v cc can thip.

STT

NG Nu mt hot ng can thip din ra trong nhiu ngy, bn c th bit mt cch chnh xc tin trnh cng vic nh th no, thm ch l sau khi ngh mt thi gian di. Mt quy trnh khc c p dng i vi tin trnh ca cng vic mi.

SAI Trong trng hp hot ng can thip ko di v c s gin on th bn li khng khng h c ghi chp no cn c tm hiu nhng g c lm.

701

602

603

C mt ngn sch c th cho mi loi hnh Bn c mt ngn qu tng th nhng khng bo dng khc nhau (bo dng phng c phn chia theo cc chi ph. nga, bo dng sa cha, ...). C s theo di st sao chi ph cng nh s B phn bo dng khng h quan tm ti y cn i gia k hoch v thnh qu tnh hnh ngn sch nh k hoch c bao t c. nhiu, t c bao nhiu v phn vic cn phi lm cn li l bao nhiu. Cc chi ph c phn b mt cch c h thng theo cc hot ng can thip v theo mc ch, ... B phn bo dng (hoc c nhn c ch nh) t n a ra lnh lm vic m bo khng vt qu mc chi ph ti a xc nh. Bn c mt con s tng th c s dng m khng phn b n theo cc hot ng can thip hay theo mc tiu, ... Cc k thut vin bo dng cn phi c mt cp trung gian a ra lnh lm vic.

702

C mt danh sch cc nh cung cp v cc Khng c mt ti liu no lin quan n cc c tnh k thut lin quan n cc sn nh cung cp. Ch c mt vi ngi bit. phm ca h (v chi ph, thi hn, cht lng ...). Danh sch ny c cp nht mt cch thng xuyn. S qun l rt cht ch. Mt ngi (lun lun l ngi ) c giao ph trch cc bn ghi chp d liu. Vic ny cng c th c thc hin bng vic x l s liu. Khi bn phi ghi chp s liu (v R.M.A.S, d liu lin quan n qu kh, ...), bn khng bit phi x l iu nh th no.

604

703

605

704

606

Mt biu qun l th hin cc ch s Cc s liu khng c mt mi lin h no vi chi ph v thi gian c hin th mt nhau. Khng c tnh minh bch, r rng. cch thng xuyn. N cho php th hin cc tnh hung mt cch trc quan (bo dng, trnh trng ca hot ng sn xut, ...). C th s dng C.M.M.S hoc ch s dng bng tnh n gin i vi mi thit b chnh, cc bn ghi chp tng ng c th c tm thy mt cch nhanh chng. Mi thit b chnh u c mt h s cha ng y cc c tnh k thut ca n. Cc s v bn v c th c cung cp bi nh cung cp hoc l c t lm. Ti liu ca nh cung cp lin quan n nhng thit b chnh c th tm thy mt cch nhanh chng. C th bn c mt ci my tnh nhng li khng c ai bit dng n qun l cng vic bo dng. Tm kim cc bn ghi chp mt cch nhanh chng l mt iu khng th. Nhng h s nh th l khng tn ti hoc l chng khng c cp nht thng xuyn. Khng c nhng bn v nh vy hoc l chng khng c cp nht sau khi c nhng thay i thit b. Khng th bit c ti liu ca cc nh cung cp nm u hoc l bn khng th d dng tip cn c nhng ti liu ny.

607

B phn bo dng qun l cc cng vic B phn bo dng khng gii quyt vn c thu hp ng ph v gii quyt cc v ngn sch dnh cho cc hp ng bo vn v ngn sch c phn b cho cc dng ph. hot ng can thip trong khun kh ca hp ng hp tc. Bn c th ni mt cch nhanh chng gi tr ca ph tng v cc chi tit hao mn nm trong kho. Khng th ni mt cch nhanh chng tng gi tr ca kho ph tng l bao nhiu.

705

706

608

707

609

V d, cc chi ph bo dng phng nga, Bn khng th ni chi ph cho bo dng bo dng sa cha v cc chi ph ca hp thit b l bao nhiu, ngay c khi l mt ng hp tc, ... thit b quan trng. Mt hoc nhiu ch s c th hin ra bn ngoi b phn bo dng mi nhn vin u c th tham kho mt cch nhanh chng . Khng c ch s no nh th.

708

610

709

180

181

10. Lp k hoch - phng nga Phn ny cp n vic lp k hoch trn vn v cng vic cng nh l s qun l bo dng phng nga, khi n xy ra.

STT 801

NG Ti lng ca my mc c a vo tnh ton trong k hoch sn xut. iu ny m ch rng c mt phng tin nhn bit v lp k hoch i vi ngun nhn lc sn sng cho hot ng bo dng. iu ny i hi phi theo di vic s dng cc ph tng thay th v cc dng c bo dng. C bin php c th phn b cc ngun lc cn thit cho cng vic can thip. C k hoch cho cc can thip phng nga cn tun th, ng thi bn lun theo di tin trnh din ra cc can thip. Bn khng b ph thuc vo ti lng cng vic. Vic lp lch bo dng c kim sot hng ngy. Mi thng u c mt bo co v cng vic hon thnh, tin v cng vic theo k hoch c cng b. Vic lp k hoch cho bo dng phng nga c tun th v ph hp vi cc hon cnh thc t.

SAI K hoch sn xut khng tnh n ti lng ca my mc. Bn khng th ln k hoch v ngun nhn lc sn sng cho cc hot ng bo dng.

802

803

Bn khng quan tm n vic s dng cc ph tng thay th cng nh cc dng c bo dng. Cc ngun lc c phn b theo nhu cu m khng c s nh gi k lng. Bo dng phng nga khng c ln lch, cng vic ny c thc hin khi bn c thi gian rnh. Ti lng cng vic khng c qun l, bn phi ph thuc vo n. Khng c bo co no nh vy.

15. L THUYT PHN TCH CHC NNG

804

805

806

807

808

Vic lp k hoch ny khng c tun th.

809

Hng tun vic lp k hoch theo loi hnh Khng c vic lp k hoch nh vy. cng vic u c tin hnh (phng nga, cng vic mi,) v cng b. B phn bo dng x l vic gi i tc bn ngoi lm hp ng ph (trong khun kh ca cc hot ng bo dng), theo di v qun l cng vic c k hp ng ph. C mt bng chung cho mi ngi ghi chp thng tin v qua c th th hin c tin cng vic. Ngay c khi ngi ph trch b phn bo dng ngh th vn c th chn c cc nhn vin bo dng tham gia can thip. V d c mt danh sch bo co nng lc ca tng ngi. B phn bo dng khng gii quyt cng vic k hp ng ph (trong khun kh cng vic bo dng)

810

811

Khng c ci bng no nh vy.

812

Ch c ngi ph trch mi bit c nn chn ai cho cng vic can thip.

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183

1. Cc nh ngha 1.1. nh ngha phn tch chc nng Phn tch chc nng bao gm nghin cu mt h thng thng qua vic phn chia n thnh cc b phn chc nng c th thay th c. B phn ny s khng c ln hn b phn thay th tiu chun. Ngoi ra, cng cn lu n trnh t sp xp v kt cu, khng lin quan n cc mi lin h v chc nng. Trnh t y l trnh t v v tr khng gian, ch khng phi v thi gian. N khng th hin chu trnh thi gian ca qu trnh hot ng. Phn tch chc nng cho php a ra cc mc tiu cho cng tc bo dng. i vi mt k thut vin, ngi c trong tay cc cng c h tr hiu qu: c th kim tra bt k h thng phc tp no, anh ta c th lt qua cc b phn ca thit b v xc nh rt nhanh chng tnh trng lm vic ca cc b phn chc nng khc nhau, cng nh ton b h thng lm vic ca thit b. i vi nhn vin bo dng: c trang b cc cng c hiu qu cho vic t chc cng vic k thut ca mnh v c kh nng qun l chi ph r rng v cht ch cho cng vic.

Mt h thng cng c th bao gm mt vi my mc kt hp vi nhau trong mt dy chuyn sn xut v ph thuc ln nhau trong qu trnh vn hnh. Trong mt cng ty va v nh, mt h thng cng c th ch l mt thit b cm tay. Trong mt khch sn, mt t lm lnh, mt thit b phn phi ung cng c th xem nh l nhng h thng. thi i cng nghip, mt nh my nh l mt h thng, cng c th gi l cc b phn chc nng. H thng cng nh mi b phn chc nng c mt (hoc nhiu hn) chc nng (cc chc nng) ring bit. 2. Lm th no phn chia mt h thng? phn chia mt h thng, cn phi lu n vic c th phn tch n thnh tng b phn cu thnh ring r hon ton. V d, cc b phn thit b ln c th tho ra khi thit b chnh. Kch thc ca mi mnh s ph thuc vo mc chi tit c trnh by sau y. Chng ta s trnh phn tch thit b thnh cc khi c cc kch thc qu khc bit nhau (v d mt l xo v mt bng iu khin). Li khuyn y l chng ta nn u tin xc nh mc phn tch ng u. Chng ta s xem chi tit di y cc b phn thay th c xc nh bi nh sn xut (chng hn cc mch in). Trong trng hp m hnh nh my nh, mc phn chia u tin l 6 khu vc d kin ca nh sn xut. mi khu vc nh sn xut kt hp c thit b v bng iu khin lin h n qu trnh to ra sn phm. Mt tng khc l phn tch ring r bng iu khin v h thng c in ti mt khu vc.

Do vy, vic phn tch chc nng cho php: Thit lp cc iu kin lm vic ti u cho thit b. Tm ra nhng b phn hao mn ca cc thit b. a ra c cc ch bo gip cho vic theo di qu trnh tin trin cc h hng ca thit b Xc nh cc dng v phng php bo dng cn p dng cho mi b phn ca thit b. a ra c k hoch bo dng. Phn loi cc h s ti liu bo dng v cch tra cu khi cn thit, Pht trin mt k hoch bo dng tt hn thng qua cc h s lu tr, Xc nh trnh v k nng cn c cho vic bo dng cc thit b my mc, Xc nh v h thng ha ton b h thng my mc ca n v hin c, Phn tch v tnh ton cc chi ph cho cng tc bo dng, Quyt nh ngn qu cho nguyn vt liu phc v cng tc bo dng v theo di vic s dng chng.

BNG IU KHIN

THIT B C IN

1.2. nh ngha v mt h thng Mt h thng l tp hp ca cc thit b v cc b phn thit b, c nhim v chc nng c th phc v mt cng vic no . Khi nim h thng lin quan n bn cht ca thc th. V d, trong mt trm sa cha my mc, mt thit b c th c xem nh l mt h thng.

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3. V d p dng cho m hnh nh my nh

Nh vy phn tch chc nng nhm mc ch ch r: Cc chc nng cn phi c bo dng. Cc ch bo cho vic tip tc theo di hot ng ca thit b. Cc iu kin vn hnh ti u. Cc ph tng thay th.

3.2.2. M t thit b Nh my mini l mt dy chuyn ng b v t ng, c thit k ng gi cp phi. t c iu ny, cn phi c mt s giai on cng ngh, nh nghin nh , ra sch, sy s b, sy kh, cn, ng gi v cui cng l xut hng. Ci gi l khu vc tng ng vi tng cng on ny. C c thy 6 khu vc. Mi khu vc c mt thit b t ng c th c lp trnh (IPA) c th p ng cc yu cu s dng thc t, cc thit b an ton lin quan n s dng thit b, giao din cho ngi s dng my. Trnh t do nh sn xut khuyn co nhm mc ch tha mn cc yu cu: D hiu qui trnh vn hnh. Trnh t theo chc nng. iu khin c nhm theo khu vc. Qun l qui trnh n gin. Cc iu khin c nhm theo khu vc. Giao din cho ngi s dng ti mi khu vc. Hiu qu v c th can thip sa cha nhanh chng . Cc trc trc v chc nng s trc tip th hin cc khu vc. C th iu khin ch tm thi trong qu trnh sa cha k thut. C th kim sot c tng khu vc ch tm thi.

M hnh Nh My Nh

3.1. Gii thiu M hnh nh my Nh l mt h thng t ng phc tp. S phc tp ca h thng thit b ny trc ht do kch thc ca n v mt s lng ln cc thit b chc nng m n c trang b, do cn phi tch hp nhiu cng ngh vo vi nhau. Mt l do khc, l mc t ng ha cao trong hot ng. R rng l khng th tin hnh mt phn tch chc nng nu khng phn tch c cu trc kt cu v mi lin quan gia chng. Mt khi nim mi xut hin, l mc . 3.2. Phn tch chc nng ca mt h thng t ng 3.2.1. Nh my Nh Thng thng c tnh ca thit b phc tp hn do nhng cng ngh m n p dng v s lng cc chc nng a vo. thc hin phn tch thnh cng, chng ta cn phi thit lp mt qui trnh cng vic cht ch trong sut qu trnh tip cn. Phn tch chc nng ca mt nh my nh ch c mt mc tiu duy nht l a ra c phng thc tip cn. Cc nh ngha cho chc nng u vo v u ra cn phi gip ti a cho vic c th o lng c v/hoc c th theo di c, gip cho ngi bo dng c thng tin cn thit s dng trong qu trnh tin hnh cng vic bo dng ca mnh (sa cha tm thi, cc ch bo v tin trin ca h hng v.v..). -

3.2.2.1. Phn tch chc nng cho m hnh nh my mini 3.2.2.1.1. Mc 0 1. Trnh t Bc th nht: xc nh cc b phn chc nng. Bc th hai: Bc th ba: Bc th t: xc nh cc chc nng u ra. xc nh cc chc nng u vo. thit lp s khi.

2. Hon thnh t bc 1 n buc 3

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CC B PHN CHC NNG

CC CHC NNG U RA nghin theo kch thc yu cu Khng kh cha bi loi Cc thng tin cn qun l Khng kh m

CC CHC NNG U VO nguyn khi Kh nn 7 bar Nc p lc 4 bar in nng 380V TRI+N Qun l thng tin Cc bao b Yu cu v hng dn Bo dng Khng kh

3.2.2.1.1. MC 1 1. Trnh t Bc th nht: Xc nh cc b phn chc nng. Bc th hai: Bc th ba: Bc th t: Xc nh cc chc nng u ra. Xc nh cc chc nng u vo. Thit lp s khi.

Nh my mini

My ht bi

Khng kh sch Bi Kh nn ti p sut 7 bar Cn bm Thot nc Kh nn 7 bar Cn bm v thot Cc thng tin phi qun l

Khng kh y bi in nng 380V TRI+N in nng 380V TRI+N Khng kh Kh nn kh p lc 7 bar Cc thng tin phi qun l Cc ha n Cc lnh yu cu cng vic in nng 220V MONO + T

2. Hon thnh t bc 1 n buc 3

My nn kh Sy kh khng kh

CC B PHN CHC NNG

CC CHC NNG U RA c nghin theo kch c mong mun, sng v cn ong sau chuyn sang khu vc 2 bng bng ti loi Cc thng tin qun l Mch in an ton Khng kh cha bi Ra trc khi chuyn sang khu vc 3 bng bng chuyn Cc thng tin cn qun l cho khu vc 1 Mch in an ton Sy s b trc khi chuyn qua khu vc 4 Nc thi Thng tin v qun l ti khu vc 4 Cc mch in an ton Khng kh m

CC CHC NNG U VO nguyn khi Kh nn 7 bar 380V TRI+N+T Cc thng tin v qun l Cc yu cu v hng dn Thng tin v qun l khu vc 2 Bo dng Mch in an ton c nghin theo kch c yu cu, sng v xc nh khi lng 380V TRI+N+T Nc p lc 4 bar Thng tin v qun l Mch in an ton Bo dng Yu cu cng vic v hng dn Nc thi

Gim st

Khu vc 1

cp 0 cc thnh t chc nng phc hp khng lin quan n nh my mini c tm ra. Chng l: Thit b lc bi, Ngi gim st, My nn kh, My sy kh. Khu vc 2

Chng c hiu l khng lin quan bi v chng khng nm trong tng th nh my mini. Chng c th c cung cp t cc thit b khc. V d, my nn kh c cung cp t thit b trung tm (bung in, bung my ). Chng l thit b th cp. trong mt nh my, cc trm bin p, khoang cha ga, trm thy in v cc thit b khc c th c xem nh l cc thit b th cp.

Khu vc 3

c ra sch 380V TRI+N+T Thng tin qun l khu vc 4 Cc mch in an ton Bo dng Yu cu cng vic v hng dn Khng kh

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CC B PHN CHC NNG

CC CHC NNG U RA c sy kh v chuyn qua khu vc 5 Thng tin v qun l n vi thit b gim st Mch in an ton loi Khng kh bi

CC CHC NNG U VO c sy s b 380V TRI+N+T Thng tin v qun l cc khu vc 3, 5, 6 Mch in an ton Bo dng Cc yu cu cng vic v hng dn Kh nn 7 bar c sy kh Kh nn 7 bar 380V TRI+N+T Thng tin qun l khu vc 4 Mch in an ton Bo dng Yu cu cng vic v hng dn c cn ong v ng gi Kh nn 7 bar 380V TRI+N+T Thng tin qun l khu vc 4 Mch in an ton Bo dng Cc yu cu cng vic v hng dn

Khu vc 4

Khu vc 5

Cn v ng gi trc khi chuyn qua khu vc 6 Thng tin qun l ti khu vc 4 Mch in an ton

Khu vc 6

theo kch c qui nh Thng tin v qun l khu vc 4 Mch in an ton

Ghi ch Cc thit b th cp, nh l thit b ht bi, thit b gim st, my nn kh v my sy bng kh nng khng c th hin trong s khi di y. iu ny gip n gin ha vic c v hiu phn tch chc nng lm. M d vy, cc chc nng u ra ca chng s c cn nhc nh cc chc nng u vo bt c khi no cn chng m bo s hot ng tt ca cc b phn chc nng.

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CC THNG TIN QUN L

KHNG KH LN BI TNG 7 BAR 380V TRI + N + T YU CU & HNG DN MCH IN AN TON RA EAU 4 BAR ATR 380V TRI + N + T NC THI, KHNG KH, KH M EAUXUSEES

KHU VC 1

THEO KCH C, SNG & NH LNG LOI BO DNG

KHU VC 2

MCH IN AN TON BO DNG

KHU VC 3

BO DNG

YU CU & HNG DN

YU CU & HNG DN

MCH IN AN TON 380V TRI + N + T 7 BAR BO DNG YU CU & HNG DN KHNG KH BI LOI BO DNG YU CU & HNG DN GRAVIERS PESES & ENSACHES

KHU VC 4

7 BAR 380V TRI + N + T

KHU VC 5

7 BAR 380V TRI + N + T BO DNG YU CU & HNG DN

KHU VC 6

THEO CP PHI

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Ghi ch Mi lin h hai chiu mc 1: thng tin qun l v mch in an ton. 1. Thng tin qun l: nhng thng tin ny gip chng ta hiu c mng li thng tin gia cc thit b t ng khc nhau v cc thit b gim st. S trao i thng tin ny c lm gia hai thit b t ng hoc gia mt thit b t ng v thit b gim st thng qua cng mt ng cp. Trong m hnh nh my nh cc thit b c th c nhiu nhn mc v ngun gc xut x. Ging nh con ngi, mi loi my c ngn ng ring ca mnh. Trong thc t, chng ta c th gp cc thit b cng nghip t ng lp trnh ca cc hng Siemens, Allen Bradley v Telemechanics. Cng ngh ca mng li cho php nhng IPA ny c th trao i vi nhau. Cng ngh ny khng c a vo gii thiu trong s tay ny v do vy chng ta khng i phn tch chc nng ca chng y. Tuy vy, c th hiu tt c mt nh my mini vn hnh nh th no, chng ta cn phi bit rng IPA thuc v hai nhm: Ba thit b t ng Siemens khu vc 4-5-6 v mt thit b t ng Allen Bradley khu vc 3. Vi cng mt nhm th ch c mt u mi. y IPA Siemens khu vc 4 chu trch nhim thng tin gia ba thit b t ng v thit b kim sot. N l thit b tp trung. N nhn tt c cc thng tin gi ti ca ba thit b IPA khc v thit b kim sot. Sau n gi cc thng tin ti cc thit b cn nhn. IPA iu khin c hc ti khu vc 1 l mt thit b tp trung cho hai thit b t ng iu khin c hc khc. 2. Mch in an ton: chng s tng hp tt c cc tnh hung bo ng v tt in ton khu vc. Nh vy, vic kch hot nt ngng khn cp ti khu vc 3 s lm ngng ton b cc khu vc khc.

16. QUN L TI CHNH BO DNG DA TRN TNH TRNG

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I.

KHI LC

1. Gii thiu Gia cc mc tiu v mc ch chng trnh bo dng da trn tnh trng cho thit b, c bit l vi cc cng ngh c lin quan nht c p dng nhm t c nhng mc tiu ra. Bc tip theo l bc tng kt kha cnh ti chnh ca chng trnh bo dng da trn tnh trng. Bc ny gm c: Lm th no xc nh c chi ph v cc khon tit kim, Gii trnh cc chi ph, Lp mt chng trnh bo dng da trn tnh trng.

Khi cc li ch v chi ph c nh gi, thc hin cc tnh ton ca mnh da trn c s thng k lin quan n my mc tr nn d dng o lng v s dng c. Trong s nhng th c sn, bn c: chi ph bo dng hng thng, cc n v c sn, tng s thi gian ginh cho sa cha/ bo dng, cc chi ph bn ngoi khng c lin quan ti bo dng, nng sut sn xut, v.v... Yu cu ban qun l cung cp cho bn nhng trch on ca bo co m c xem nh c gi tr hng dn nht. Cc chi ph v d ton phi c thng nht bi tt c cc bn c lin quan. Mt im rt quan trng l ban lnh o, b phn bo dng v b phn lnh o cn phi thng nht v cch thc o c cc kt qu trc khi tin hnh trin khai chng trnh bo dng. Trong tho thun ca h cn xc nh phi t c cc mc tiu no, s dng s liu thng k no, v phn tch cc gi tr no. S tho thun ny phi cho ra mt cng thc xc nh chi ph trong thi gian my ngng hot ng. Cc bn lin quan s s dng cng mt cng thc chun b cc bo co ti chnh ca mnh. Hn na, mt im quan trng l ban qun l phi chp nhn rng cc chi ph bo dng s chc chn tng ln trong su thng u tin p dng chng trnh bo dng da trn tnh trng trc khi c s xut hin ca xu hng gim chi ph ng k. S gia tng ny cng c th l do mt thc t rng chng trnh ch ra nhng vn m trc khng mt ai n/pht hin ra. S c mt vi vn chnh cn phi ch ngay lp tc v c th s c nh gi trong khong thi gian ngng my thng thng phc v cho mc ch bo dng. Vn quan tm cui cng c th k n l tnh cht v cng quan trng ca cc chi ph v d ton chi ph. nh hng ti chnh ca chng trnh bo dng da trn tnh trng thng rt ln v rt nhiu ngi thy kh tin vo cc s liu thng k. Mt chng trnh tit kim c 10 nghn la M ngay trong thng u tin v hng trm nghn la M ngay trong nm u tin khng c g l ng ngc nhin c. Mt nghin cu M cung cp nhng ti liu cho thy khon tit kim hng nm ln ti trn 10 triu la M t khon u t di 1 triu la M cho thit b v chi ph lp t. Cc kt qu ti chnh phi c trnh ln ban qun l mt cch r rng d hiu. Cc bo co cn phi n gin v d dng nm bt c. Tt c cc bo co phi c tm lc v khng c di qu mt trang. Mu bo co s phi thng nht c th phn tch mt cch nhanh chng. b sung thm vo cc bo co v chi ph bo dng v chi ph sn xut hin ti, ta thng cn mt s phn tch nh: R.O.I. T L THU HI VN U T V THI GIAN HON VN R.O.I. T l thu hi vn u t R.O.I. l s tnh ton xc nh li ch kinh t mang li cho cng ty nh vic u t vo chng trnh. T l thu hi vn u t cao l rt quan trng. Ban qun l lun lun ng h cho cc chng trnh m n m bo mt t l thu hi vn u t hp dn nht trong sut thi gian di. Cng thc tnh ton t l thu hi vn u t c th hin nh sau: R.O.I. = ( TNG TIT KIM - TNG MC U T)/ TNG MC U T

Nhng bc ny c ngha rt quan trng i vi vic thc hin mt chng trnh bo dng da trn tnh trng v i vi vic duy tr h tr cho ban qun l v to ra nhng h tr cho cc nhn vin sn xut v bo dng. 2. Lm cch no xc nh c chi ph v cc khon tit kim Trc khi vit mt bn gii trnh chi ph v chng trnh bo dng da trn hin trng, bn phi am hiu nhng c tnh quan trng ph bin i vic phn tch ti chnh cho hot ng bo dng da trn tnh trng. C nhiu cch nh gi tc ng ti chnh khc nhau cho hot ng bo dng my mc da trn hin trng. Nhiu cng ty pht hin ra nhng vn v thit b c xc nh bng nhng thit b bo dng da trn tnh trng ngay trong thi gian dng my thng thng. H so snh chi ph sa cha nhng trc trc ny vi chi ph vn hnh ca chnh c my y trong thi gian trc . Nhng cng ty khc hng ti so snh thng tin v chi ph sa cha vi chi ph ca cc chng trnh bo dng da trn tnh trng c p dng cho cc my mc t mang tnh then cht hn. Vic phn tch ti chnh c th phn nh c lp nhng mc ch v tiu ch ca mi cng ty. Tuy nhin, khi khng tnh n phng php phn tch, vic phn tch ti chnh s th hin nhng c im chung sau y: Cc kt qu phi o lng v nh lng c. Cc chi ph v c tnh cn phi c cc bn lin quan thng nht. Cc kt qu ti chnh cn phi c trnh ln ban qun l bng nhng thut ng d hiu. Lp h s theo nh k v ngun thu ti chnh phi l mt b phn khng th tch ri ca chng trnh bo dng.

Nhng c im ny c cp mt cch chi tit nh sau: Cc kt qu phi o lng v nh lng c. Chc hn phi c mt cch thc no nh gi s thnh cng hay tht bi ca mt chng trnh. S l cha nu ch ni rng chng trnh c th mang li li ch kinh t v c th tnh ton v/hoc c tnh khi no v bao nhiu. Nhiu cng ty d nh ct gim 25% chi ph dng my hoc ct gim 5% phm vi bo dng v chi ph nhn cng. Hu ht cc cng ty yu cu cn phi ko di thi gian hot ng nh ct gim 20-25% thi gian my tt.

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Ly v d, nu mt chng trnh c chi ph l 25,000 la M v nu n mang li li ch tit kim l 35,000 la M trong nm u tin, R.O.I. s l: (35,000 USD - 25,000 USD)/25,000 USD = 40 hay 40%. Nu chi ph vn hnh chng trnh l 10 ngn la M trong nm th 2 v nu n lun m bo mt mc li tch tit kim l 35,000 la M, khi R.O.I. c th l 250% tnh cho nm th 2. Thi gian hon vn Cng thc thi gian hon vn tnh ton khong thi gian theo thng hay nm m mt chng trnh cn thit c th thu hi li c s vn u t ban u. iu ny c m t theo cng thc tnh thi gian hon vn n gin: THI GIAN HON VN (NM) = (TNG MC U T)/(TNG LI CH TIT KIM THU C HNG NM) Ly v d, nu chi ph ca mt chng trnh l 25 nghn la v nu n mang li mt li ch tit kim trong nm u tin l 30,000 USD th thi gian hon vn trong trng hp ny l 0,71 nm hoc tng ng vi 8,5 thng. Hu ht cc chng trnh bo dng da trn tnh trng l c thi gian hon vn di 18 thng v rt nhiu chng trnh c thi gian hon vn di mt nm. Lp h s nh k v khon thu ti chnh phi l mt phn khng th tch ri ca chng trnh. S thnh cng lu di ca mt chng trnh bo dng da trn tnh trng i hi nhng ghi chp chi tit v nhng u im v nhng ci thin ca n lu di. S liu kinh t s c thu thp ngay sau khi pht hin v gii quyt s c, khi bn vn c nhng bc tranh r rng v s vic, hnh dng v nhng c on. Cn phi chn ra mt mu bo co d s dng khi tin hnh sa cha v nhn mnh ti cc li ch ti chnh thu c t chng trnh. Cc bo co ny duy tr thng bo thng xuyn v lin tc cc thnh cng cho ban qun l v l ngun thng tin hu ch cho cc bo co nm v bo co qu. Nhng bo co ny trn thc t phc v cho rt nhiu mc ch. Chng nhn mnh nhng kt lun, chng hn cn phi nng cao trnh k thut cho cng nhn, nhng im sa cha c thc hin bi mt nh cung cp dch v c th hoc ca hng sa cha nhng thng xuyn c cht lng ti, hoc nhng mi quan tm lin quan n thit b vn hnh nhng c hiu sut khc xa so vi d kin. Chng c dng hun luyn cho nhn vin bo dng v nhn vin sn xut v nhng li ch thu c t chng trnh. Chng cung cp nhng ti liu gi tr cng c s pht trin ca chng trnh, nm bt cc lnh vc hot ng mi ca nh my, hoc tch hp thm cc cng ngh mi.

II.

LM TH NO C C MT BN DIN GII CHI PH THT THUYT PHC.

Din di chi ph quyt nh gi tr ca mt chng trnh bo dng da trn tnh trng trong iu kin ti chnh hin ti: Li ch tng th ca Bo dng/ Sa cha. T l thu hi vn - R.O.I. Thi gian hon vn. Tm quan trng ca vic tng sn lng.

lp mt bn din gii cc chi ph thuyt phc cn c nhng thng tin v chi ph ca mt chng trnh bo dng hin c, chi ph ca mt chng trnh bo dng da trn tnh trng v cc khon tit kim (li ch) c chng minh t c t chng trnh. III. XC NH CHI PH

Ch ph ca chng trnh bo dng hin thi, gm c chi ph cho nhn vin bo dng, ph tng sa cha, cc hp ng sa cha ngoi v chi ph qun l chung, c th c xc nh da vo cc bo co ti chnh hin c. Xc nh chi ph tn tht sn xut c th kh khn hn. Chi ph dng my l khc nhau gia cng ty ny vi cng ty khc, t nh my ny n nh my khc, t thit b ny n thit b khc. S hp tc cht ch gia cc b phn sn xut, k ton v bo dng l ht sc cn thit xc nh chi ph hoc d tnh hp l thi gian dng my. Nh cp t trc, s thng nht gia khu qun l, sn xut v bo dng v cc chi ph v d ton l rt quan trng. Chi ph ca mt chng trnh bo dng da trn tnh trng bao gm: Ch ph nhn cng / cng vic. Chi ph lp t thit b / phn mm. Chi ph dch v k thut. Chi ph o to. Chi ph qun l chung.

Ch ph nhn cng/cng vic c nh gi bng cch xc nh s lng cc v tr o c kim sot, bng cch c tnh thi gian cn thit tin hnh thu thp s liu (hoc ly mt mu du), phn tch, nhn nh v s liu v c nhng hnh ng thch hp i vi chng. Nhng loi my mc n gin (ng c, bm, hoc qut thng gi) c th c t 2 n 3 im o c rung i vi mi mt vng bi nhm xc nh chnh xc nhng vn pht hin. Cc thit b phc tp hn c th cn n hng trm im o c bao qut tt c cc vng bi, c cu then cht, v cc cng c h tr.

Ni mt cch ngn gn, bn c im ph bin i vi phn tch ti chnh lin quan ti bo dng da trn tnh trng phi c hiu r bi tt c cc bn c lin quan trc khi a ra bt c din gii no v chi ph hoc phn tch ti chnh lin quan ti Bo dng da trn tnh trng.

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Khi tin hnh bo dng nh k, bn c th c tnh rng mt loi rung ng k thut c th ghi c 40-50 im/1 gi v vic bo dng, k thut vin c th cho php bn ly 2-3 mu du/1 gi, 2-20 s liu nhit/gi v 60-90 s liu lin quan n hiu sut/gi. Thit b cng quan trng th cc cng tc bo dng cng phi thng xuyn hn, v th nhn cng cng tng ln. Nhn chung, cn c mt khong thi gian tng ng phn tch s liu, vit bo co, v qun l chng trnh. Nhiu cng ty bt u bng mt chng trnh quy m nh, vi s lng rt t cc my mc, t 15-20 my. Trong s ny, mt vi my mc c vai tr quan trng i vi sn xut, s cn li th gp phi nhng vn mn tnh, hoc vn hnh trn tru hn. Vic m s my mc thng xuyn gp s c l v cng quan trng bi v chng cho thy ngay lp tc nhng u im ca chng trnh. Bt u trn quy m nh gip xy dng kinh nghim cho nhn vin, o to h tr trc khi chng trnh c tin hnh v p dng vi nhiu my mc quan trng hn. Xc nh chi ph lp t thit b/phn mm. N ph thuc vo cch thc m bn xc nh nhu cu ca mnh. Mt chng trnh quan trc mc rung ng gm c mt thit b thu thp d liu xch tay (PC) v phn mm phn tch, c th c gi t 15 nghn n 20 nghn la M, tu vo c tnh k thut ca n. Cc u cm bin theo di khng phi lc no cng nguyn bn m cng phi c mua v lp t. Vic c c mt nh cung cp chuyn cung cp thit b bo dng da trn tnh trng cho mnh s gip bn bit c phn mm v vt t cn thit mua. Cc chi ph lp t cng c th c hoc khng c coi l mt nhn t khc cn quan tm, tu thuc vo vic liu c mt khng gian thch hp hay liu cc kt ni in c ng hay khng. Cc lp t bn trong tng, lp t u cm bin hoc v h thng ng in l nhng cng vic rt tn km. Hy hiu r v tng yu cu mt v quan tm n chng. Cc dch v k thut thu ngoi Vic phn tch du v qut ph nhit c chi ph lin quan n nhu cu ca bn. Chi ph cho phn tch mt mu du c th khng vt qu 8 USD n 10 USD. Cc chi ph qun l C th gm c chi ph dch v vn phng, cc cng vic hnh chnh, thi gian s dng my tnh hoc chng cng c th tnh bng phn trm ca mt khon chi tiu c nh. o to L mt trong nhng phn ngn sch quan trng nht. Pht ng v theo di mt chng trnh o to c chng minh l cng tc cn thit xy dng cc k thut mi v ci thin nhng k thut hin c. Khi mt chng trnh mi v Bo dng da trn tnh trng c tung ra, nh cung cp thng s gip bn tip cn lm quen vi cc thit b ban u v o to cho bn. Vic c c nhng gio vin gii l ht sc quan trng v h c th h tr c ln nhau. Mt khi chng trnh bo dng da trn tnh trng i vo hot ng th cc kho o to v pht trin k nng chnh l cha kho dn ti thnh cng ca chng trnh. Theo ui vic xy dng k thut v kinh nghim gp phn duy tr s hng th ca nhn vin lun mc cao v t l b vic s thp. Khi kin thc c chia s gia cc cng nhn vi nhau th hiu qu chung ca ton b chng trnh cng tng ln. Nhu cu o to phn nh s cn thit phi xy dng cho cng nhn bo dng nhng k thut m h ang thiu ht. iu ny hon ton ng nu nh mt nhn vin quan st s dng cc k thut phn tch khng ph hp l kt qu ca mt phn tch cht lng ti xc nh nguyn nhn dn n phi thay vng bi trong khi s c li lin quan n thng bng hoc tnh ng trc.

IV.

XC NH TIT KIM/LI CH

Yu t ti chnh trong mt minh ho tiu biu v chi ph l li ch d kin c mang li bi chng trnh. Chng ta hy ly v d ca mt cng ty gi nh rng c th ct gim 20% cc chi ph cho gim st (bng cch h thp mc nghim trng ca cc vn ), gim 35% thi gian v 20% hp ng thu ph (bng cch ci thin tay ngh cho cng nhn v ct gim 30% thi gian dng my. V d minh ho cho cc chi ph (n v US $) Trong nm u tin Cng vic bo dng - (1) k thut vin - (1) ngi gim st Lp t / phn mm / vt liu Hp ng dch v (phn tch du 200/nm) Hp ng dch v (cc gim nh nhit ) o to Giy bng knh Tng chi ph khi ng chng trnh Gim 20% chi ph dnh cho vt liu bo dng Gim 35% thi gian Gim 20% chi ph dnh cho cc hp ng sa cha thu ngoi Tng cc li ch ca chng trnh trong nm u tin Thu hi vn u t Thi gian hon vn Ct gim 30% ngng my dn n tng sn lng Tng ng doanh s Trong nm th 2 Cng vic bo dng - (1) nhn vin k thut - (1) ngi gim st Hp ng dch v (phn tch du) Hp ng dch v (Cc gim nh nhit ) o to Giy bng knh Tng cc chi ph trong nm th 2 Gim 30% chi ph dnh cho vt liu bo dng Gim 40% thi gian Gim 30% cc dch v sa cha thu ngoi Tng cc li ch thu c trong nm th 2 T l thu hi vn u t Ct gim 50% thi gian dng my dn n tng sn lng Tng ng doanh s 30,000 45,000 6,000 15,000 10,000 5,000 111,000 37,000 80,000 105,000 225,000 200% 5,270 chi tit 3,425 30,000 45,000 20,000 4,000 10,000 10,000 5,000 124,000 25,000 70,000 70,000 165,000 133% 9 thng 2,940 chi tit 1,911

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Ta c th ch thy rng t l thu hi vn u t (R.O.I) l ng k ngay c vi nhng c tnh khim tn ny v thi gian hon vn l di 1 nm. iu quan trng hn l chng trnh m bo rng cng ty s t mc gia tng nng lc sn xut l 2.940 chi tit v gi tr doanh s tng ng l 2 triu la. V cng nn mt im rng chng trnh nng cao kinh nghim v cc li ch ca n tip tc l nhng con s n tng trong nm th 2. V. LM TH NO THC HIN C MT CHNG TRNH BO DNG DA TRN TNH TRNG

3. Xy dng mt k hoch thc hin Mt k hoch thc hin l mt ti liu chi tit nhn mnh cc bc quan trng trong khu thit k, lp t v v vic thc hin chng trnh bo dng da trn tnh trng. Bn k hoch ny tp trung vo cc hnh ng c th phi c tin hnh, tm tt nhng nhim v v vch ra mt tin thi gian. K hoch thc hin cho php cc phng ban, cc nhm lm vic c lin quan c c s nh hng trc tip ln chng trnh v nm bt khi qut ton b vn . Nh k hoch hnh ng m ta c th lng trc c cc vn c th xy ra v c k hoch i ph.

1. Ngun nhn lc v s pht trin Khi bn thc hin chng trnh bo dng da trn tnh trng th bn cn c bit quan tm n ngun nhn lc v s pht trin. y l yu t v cng quan trng to ra s h tr cho nhng ngi ng u b phn, nhng ngi ngh s trong hot ng kinh doanh ca mnh, v cho cc cng nhn sa cha v sn xut. Huy ng mi ngi tham gia vo vic thc hin chng trnh ny ngay t cc bc i u tin. iu ny s cung cp cho bn cc thng tin ng tin cy v s gip bn pht trin chng trnh. Khng nn khin cc cng nhn lm vic theo kiu rp khun my mc. Cc cng nhn bc cao, ngi c kinh nghim v c kh vng vng thng hng hi i u trong cc chng trnh bo dng da trn tnh trng ca my mc. Ging nh trng hp ca mt nh phn tch, s am hiu rng ri v c kh ca h trao cho h quyn t ch khi bt tay vo lm vic vi cc h thng my mc khc. Nu mt c my khng c cn thng chun, h c th nh vo kin thc c kh ca mnh gii quyt vn m khng nht thit phi s dng phng tin quang ph pht hin ra vn . Mt khi chng trnh bo dng da trn tnh trng i vo hot ng, ta nn tip tc cng c s h tr trong khi bn tho mt cch rng ri v nhng thnh cng v tht bi. Ghi nhn nhng khim khuyt ca chng trnh s nng cao kh nng thnh cng. Ghi nhn nhng pht hin ca cc nhn vin sn xut v bo dng v nhng khim khuyt ca chng trnh khuyn khch h tp trung hn vo chng trnh. 2. La chn qun c/ gim st vin La chn mt qun c hay mt gim st vin l yu t quan trng quyt nh s thnh cng hay tht bi ca mt chng trnh. Mt chng trnh mi i hi ngi qun c phi c kim tra nng lc hng ngy trong vic giao tip vi nhng thnh vin khc. Nhng cng nhn trc tip sn xut v cng nhn bo dng phi c nhc nh rng h l mt phn khng th thiu ca chng trnh; h cng cn bit c l h c th ng gp vo s thnh cng ca chng trnh nh th no v bit c nhng li ch thu c s trc tip nh hng n h. S hng ng ca h s cho php cc k thut vin, cc nh phn tch thc hin cng vic ca h mt cch hiu qu. Qun c phi nm bt c v ch vn hnh ca cc thit b m anh ta qun l nh bm, tuc bin, van, ng ng, thit b trao i nhit, v.v... Anh ta cng cn hiu c cc dng mi mn, cc dng hng, s cn thit i vi vic bo dng phng nga v cc th tc quan trc khc nhau nh hng ti s nhn bit rung v/hoc vic phn tch thnh phn du bi trn. Cc k thut c nhn l ht sc cn thit. Mt qun c mi pht trin hn na cc k thut phn tch ca anh bng cch nghin cu cn thn thit b ca mnh trong mt khong thi gian di. Anh ta phi tch cc tm ti thng tin, chia s thng tin vi cc thnh vin khc v ng vin h hc hi tt c nhng g c th v thit b v ng dng ca cng tc bo dng da trn tnh trng.

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1. Gii thiu Khng c c cu l tng no cho mi b phn bo dng. c im cc cng ty rt khc nhau v th m khng th p dng mt m hnh cho mi cng ty. Mt s im khc nhau gia cc cng ty nh: 1. 2. 3. Quy m Trang thit b Phng thc sn xut S tham gia ca b phn Sn xut vo cng vic Bo dng. Cc iu kin sn c nh: Ngun nhn lc Hu cn

17. T CHC BO DNG

4. 5.

Trc khi tnh ton mt c cu bo dng ti u th nht thit phi xem xt din bin ca mi quan gia sn xut v bo dng. Theo kinh nghim tin hnh bo dng cho thy i tc chnh chnh l b phn sn xut. Trc y, b phn vn hnh buc phi chp nhn mt s hn ch sn xut ngn hoc trung hn. B phn Sn xut chp nhn mt s can thip x l li nh gy t im bt li (nh: bi trn, thay i u lc...). H t nhiu cng chp nhn cc ln dng my do s c hng hc xy ra. Nhng h nht quyt phn i bt c chng trnh bo dng theo k hoch no gy cn tr vic kim sot cng c sn xut ca h. 2. C cu bo dng truyn thng

BP. Sn Xut

BP. Mua sm

BP. Bo dng Hnh 2.33: C cu bo dng truyn thng M hnh trn ch ra rng bo dng ch l mt b phn ca qu trnh sn xut m thi. B phn bo dng khng c quyn kim sot thit b m h ph trch cng tc k thut.

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3. S pht trin ca b phn bo dng S pht trin ca cc chc nng lin quan n bo dng, sn xut v cc b phn khc nhm tch hp chung vi cc mc tiu c chng minh l ging nhau tc l sn xut vi gi thnh tt nht trong khi vn m bo cht lng cng nh nhng iu kin an ton khc. Bo dng l cn thit duy tr v thm ch cn nng cao nng sut ca cc cng c sn xut. N cng phi gn lin vi cht lng ca sn phm yu t ph thuc rt nhiu vo trng thi ca thit b. H thng gim st khng ch m bo kim sot c cc thit b sn xut - yu t quan trng ca b phn vn hnh, m cn c chng minh l cng c phc v cho vic phn tch v pht hin nhng li, nhng lnh vc trong kh nng ca b phn bo dng. Hnh thc qun l sn xut vi s tr gip ca my tnh c quan h khng kht vi hnh thc qun l bo dng bng my tnh. Bo dng Hiu nng Tng th (vit tt l T.P.M) c p dng rt nhiu cng ty cho thy mt im rt th v l vic giao mt s nhim v v trch nhim nht nh no cho cc cng nhn vn hnh l rt c li. Bn phn tch Hiu Sut Tng th (G.E.R) c nhiu ngi ph trch cng vic bo dng tin hnh khin cho b phn bo dng gn vi sn xut hn. Hiu Sut Tng th l mt ch s qun l tch hp song song gia b phn bo dng v sn xut. Tt c nhng d liu ny l nhm tm kim mt s ci tin trong vic kt hp cc b phn vi nhau cho php ti u ho k nng ca mi ngi nhm p ng mc tiu chung ca cng ty. 3.1. C cu bo dng mi

C rt nhiu kin cho rng vic b tr nh vy s c lp rt nhiu hot ng, gim v thm ch lm mt tnh linh ng ca h thng. Nhng lung thng tin cng phi c xc nh trn lu . Thc t cho thy rt nhiu cng ty vn c c cu hnh chp vi nhng bt li c hu ca n. Tuy nhin, xu hng hin nay l s dng s t chc hng ngang, gip gim ng k cc giai on trung gian v khch l mi ngi gnh vc nhiu trch nhim hn. Mt lu tt l lu c th trnh s trng lp chc nng, trch nhim, c nguy c gy xung t v c th m rng c. Lu cn phi cho php ti c cu cc b phn khi cc mc tiu ca cng ty c thay i. 4. Chc nng bo dng 4.1. Chc nng phng php (k hoch v phng n k thut) Chc nng Phng php gm vic nghin cu v phn tch cc hot ng ca b phn bo dng nhm gip cho cng tc chun b c hiu qu hn. Nhng hot ng lin kt vi chc nng phng php c lin quan n mt cng vic c th hoc lin quan n ton b mt n v sn xut no . Mc tiu ca chc nng phng php l: Ti u ho cc chng trnh bo dng phng nga. Kim sot vic lp k hoch di hn Ti u tnh tiu chun ha ca cc ph tng thay th. Khai thc trit cc cng c chuyn dng Ti u ho cc phng php bo dng khc nhau.

iu hnh

iu c ngha l chc nng ny bao gm nhiu lnh vc: Mua hng Sn xut Bo dng H s thit b. Bo dng phng nga. Kho ph tng thay th. Phn tch s c hng. Phn tch d liu lu tr t ci tin hot ng bo dng Nhng cng c chuyn dng. Cng vic mi. Vi tnh ho cc bin php qun l,..

Hnh 2.34: C cu bo dng thc y vic kt hp cc b phn vi nhau th tt c cc b phn chnh ca cng ty cn phi c t ngang hng nhau. B phn bo dng phi c mi lin h trc tip vi ban lnh o cng ty. iu ny khng trit tiu mu thun v xung t gia cc b phn. N ph thuc vo vic liu ban lnh o cng ty c to c mt mi trng ph hp cc b phn hp tc cht ch vi nhau hay khng. iu ny c th t c nh vic t chc cc cuc hp, thng bo cho mi ngi bit c nhng hn ch, mc tiu v phng php loi b nhng mu thun . Cc cuc hp ny phi l mt knh i thoi gn gi, thng xuyn gia cc b phn vi nhau. 3.2. Phn tch lu Lu l mt s minh ho cu trc ca mt h thng, mt cng ty hay mt b phn no . Mc ch ca loi s ny l xc nh, phn nh trch nhim cho mi thnh t. Do , n c th gip xc nh c cng vic i km vi trch nhim cho mi b phn. Lu c th tr li cho cu hi Ai lm vic g?. Tng t, ta c th xy dng c lu chc nng.

Nh vy r rng l chc nng ny rt quan trng trong hot ng bo dng v ngi gi chc nng ny phi c mi quan h trc tip vi ngi qun l b phn bo dng, ngi m phi c cung cp tt c nhng d liu cn thit xy dng cc s qun l.

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 thc hin c chc nng ny i hi cn c rt nhiu cc k nng nh: Kin thc v cng ngh. Kin thc v nhng gi phn mm vn phng t ng. S nng ng ca cc nhm ci tin. Kin thc t chc b phn bo dng,

BNG 2.10 NH GI THI GIAN LNG PH DO KHNG CHUN B NGUYN NHN Do di chuyn. Do phi ch tip cn vi thit b Do thng tin khng y Do ph tng ch lu kho TNG Nh vy vic khng chun b c th gy lng ph ti 40% thi gian Nhng k nng cn thit chun b cho cng vic l: Hiu bit v cng ngh Kin thc t chc bo dng Bit cch phn tch thi gian Nhng cng c x l d liu,.. THI GIAN % 15% 15% 10 - 20% 5% 45 - 50%

4.2. Chun b cng vic Hot ng quan trng ny gm c vic chun b cho mt can thip c th. Trong phm vi hot ng ca mi mt ln can thip nh vy, cn phi xc nh: Cc quy trnh Ngun lc k thut Ngun nhn lc. Hp ng vi nh thu ph. Sp xp cng vic theo cc hot ng c th c nhng ln can thip mt cch hp l v hiu qu.

Nhng thng tin trn rt c ch cho cc b phn khc nh: an ninh, k ton, cht lng. Mc ch ca chc nng ny l: Chia nh cng vic, Gim lng ph tng lu kho, S dng mt cch hp l cc k nng ca tng ngi, Gim M.T.T.R, Nng cao tnh an ton, D tr chi ph can thip.

Khng nht thit phi c cng tc chun b cho tt c nhng ln can thip. Trc tin, n i hi phi c kh nng lm cho R.O.I khng ng k, thm ch l khng c. Sau n tnh n bn cht ca mt s hot ng bo dng. Nht thit phi sn sng cho sa cha tm thi ti mc mt ngi phi lm trong nhng trng hp khn v thi gian can thip phi ngn. Tuy nhin, hon ton c th gim c thi gian cht do bo dng gy ra. Mt mt, chng ta c rt nhiu bin php thc hin iu ny, mt khc th c th chn cng vic yu cu cn c s chun b. Phng php Pareto ch ra rng 20% cng vic li chi phi ti 80% thi gian can thip. Cng vic c tnh cht lp i lp li. Cng vic i hi ngng sn xut. V mt bng sp xp theo mc quan trng.

Thng tin: Theo nhng tiu ch c th th cn phi c cng tc chun b cho nhng can thip c thi gian ln hn 50 gi. Theo c tnh th vi can thip 25 gi th cn 1 gi chun b. T l ny c th thay i tu thuc vo tm quan trng ca cng vic, lnh vc cng nghip, ...

Thng tin: bng nh gi v thi gian lng ph do khng c s chun b.

5. Chc nng Lp thi gian biu Chc nng chun b chun b cng vic bng cch xc nh ngun lc tng th cn thit m bo cng vic c kt qu. Vic phn tch ny c thc hin bng chc nng lp thi gian biu thy c tt c nhng thit b sn c ti thi im tin hnh can thip. Vic ny yu cu:

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Phi qun l vic lp k hoch trung v di hn Phi m bo th t u tin. Phi tun th theo lnh lm vic. Phi theo di cc gi cng vic thu khon. Phi tun theo tin trnh cng vic da trn k hoch. Phi m bo nhng nguyn tc m bo an ton c tun th.

6.3 Lp k hoch di hn (t 3 n 4 thng) Vic lp k hoch di hn bao gm nhng trng hp can thip sau y: Ngng sn xut hng nm tin hnh bo dng. Ngng hot ng. C nhng thay i trn quy m ln. Lp t thm nhng n v sn xut mi,...

Chc nng lp thi gian biu s nh hng trc tip nhiu lnh vc ng b nh: Vic lp k hoch ca b phn sn xut. Lp k hoch v ngun lc. Qun l cc s kin bt ng v tnh hung khn cp xy ra ti cc b phn. K hp ng ph. Khng th c mt k hoch nht nh no c quyn v tnh linh hot kt hp vi nhng can thip khc.

Vic lp k hoch di hn phi gip: Phn loi cng vic theo ng trt t ti u ho s ln phi can thip, Phn b cng vic ph hp v trong trng hp b thiu nhn lc th phi c k hoch phn chia cng vic, Qun l mt cch hiu qu cc ph tng thay th hoc cc chi tit hao mn, t hng, Mua hng trc tip. Qun l cng tc hu cn mt cch hp l, Xc nh chi ph d kin ca cng vic v tng trnh nhng chi ph cho tng lnh lm vic.

Tt c nhng yu t trn ch ra nhng kh khn gp phi trong qu trnh lp thi gian biu i hi c s h tr k thut cho qun l cng vic. 6. Cc phng php lp k hoch 6.1 Khng lp k hoch g ht p dng phng php ny trong nhng trng hp: Cc tnh hung khn cp c mc quan trng khc nhau (tm thi sa cha), Kho cha ph tng thay th qu ln nn khng th lp c k hoch, Thiu nhn lc, Thiu ngun lc cho vic k hp ng ph, Yu cu 100% trang thit b phi sn sng cho vic sn xut.

Nhng k nng cn thit cho vic lp thi gian biu l: Kin thc v cng ngh, Kin thc t chc bo dng, Kh nng x l d liu cho vic qun l ti nguyn, Hiu bit v k nng lp k hoch: P.E.R.T., GANTT.

6.2 Lp k hoch ngn hn (t 2 n 4 tun) Phng php lp k hoch c th gip: Xc nh vi b phn sn xut v quyn tip cn thit b ca b phn bo dng, Qun l vic lp k hoch nhn lc, Theo di tnh sn sng v ngun lc k thut: Ph tng thay th, Hu cn,...

i vi nhng k hoch ngn v di hn, khng nht thit phi lp k hoch cho tt c mi cng vic hay nhm t c 100% khi lng cng vic. Kinh nghim cho thy rng lun c nhng yu cu mi trong cng vic do m cn phi tin hnh k hp ng ph hoc hu b mt s can thip trong k hoch. Ti sao li phi lp k hoch trong nhng trng hp nh th ny? Mt t l chp nhn c l t 50 n 60%. 7. Chc nng to Cng vic mi Chc nng ny lin quan n cc nghin cu cng nh vic trin khai: Vic thit lp cc n v mi, Tng trang thit b hin c, Thay i ln cc trang thit b hin c.

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Vic can thip l nhm p ng nhng mc tiu sau: Tng cng sut ca trang thit b. Tng hiu sut ca cng c sn xut. Tng cht lng sn phm. Ti u ho bn ca trang thit b,...

8. Chc nng trin khai Cc chc nng lin quan n vic trin khai cng khng km phn quan trng so vi cc chc nng: phng php, chun b, lp thi gian biu. Qun c l ngi chu trch nhim chnh cho bc ny. Nhng cng vic trc c thc hin tin hnh trin khai can thip khi tnh n: -

Hin nhin l chc nng ny, do nhm vo nhiu mc tiu, quan tm n tt c cc cng ngh v k thut. N can thip n ton b d n trin khai. Chc nng ny phi qun l tt c cc lnh vc lin quan n: Nghin cu. Trin khai. Gim st. Khi ng cc h thng thit b. Pht trin trang thit b. Cng vic tip qun cui cng.

Tnh n nh ti u ca: Trang thit b. Hu cn. Ngun nhn lc.v...v... Tun th theo nhng quy nh m bo an ton. Tun th theo thi hn tho thun. m bo chi ph sn xut cng st vi chi ph d kin cng tt. Cht lng ng dng phi ph hp vi yu cu thc tin.

Chc nng ny cng phi qun l c tnh ng b ca mi ngi can thip, c ngi ni b hay thu ngoi. Thng tin Ni chung, nhng chc nng lin quan n phng php, chun b, lp thi gian biu, cng vic mi c phn loi trong ni b phng k thut bo dng.

Ngi qun c phi xc nh ci g l cn thit thc hin nhim v ng ngy, m bo nhng iu kin an ton tt nht c th. lm c iu ny th vic chc nng trin khai cn c: Ngun nhn lc, Nhng phng tin phn b v gim st nhim v, Lnh lm vic vi tt c cc ti liu cn thit trin khai cng vic. S h tr t chc nng phng php.

BAN GIM C

Phng t chc v qun l bo dng

Sn xut

K ton

Mua hng

Trong khi trin khai cng vic, cng dng ca cc chc nng lin quan n phng thc, chun b, lp thi gian biu cn c nh gi mt cch chnh xc nht nu khng chng ta c th: S dng khng ht nng sut lm vic ca i ng nhn vin bo dng. Khng thch nghi tt s dng trang thit b. i ng nhn vin c cht lng li phi qun l cng vic khng thuc lnh vc ca h, Ph tng thay th tn kho, Mt tnh ng b nu nhiu ngi lm vic trong nhng lnh vc ca ngi khc.

Phng k thut bo dng

Phng thc

Chun b

Lp thi gian biu

Lp k hoch

Trin khai

Hnh 2.35: S t chc

Chc chn nhng bt cp ny s y gi thnh bo dng ln cao. Bt c s trin khai cng vic no cng cn phi c s kim sot. Vic kim sot s m bo hiu qu ca qu trnh bo dng cng nh nhng chc nng khc ca n. Trc tin, vic kim sot l trch nhim ca qun c v k thut vin v tip n chc nng phng php. Trong mt s trng hp th bc kim sot c th l mt chc nng ca ring n. Trong bt c trng hp no th cng tc ny cng yu cu cn c s u t v trang thit b t pha kim sot cht lng.

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9. C cu ca b phn bo dng Khi thit lp mt cu trc bo dng no th lun t cu hi l: LIU C CN THIT PHI TP TRUNG HAY PHN QUYN RA KHNG? Cu tr li cho cu hi ny rt m v n ph thuc ch yu vo nhng c im k thut v cc yu t con ngi ca tng cng ty. Mt cu hi na l b phn bo dng nn xut hin u trong s t chc ca mt cng ty. Do sn xut v bo dng cng chung mc ch - m bo cht lng sn phm vi gi c hp l nht trong khi vn tun th nhng quy nh v an ton nh vy r rng l hai b phn ny cn t nhng v tr ngang nhau trong s t chc cng ty v c mi quan h trc tip n ban gim c. Chnh ban lnh o l ni gi chc nng thc y mi quan h khng kht gia b phn bo dng v b phn sn xut. 9.1. C cu bo dng tp trung Lu c cu

BAN GIM C

Phng t chc v qun l bo dng

Qun l kho

Sn xut

Phng KT BD

Trin khai

Xng SX

B phn in

B phn C kh

Dy chuyn sn xut 1

Dy chuyn sn xut 2

Dy chuyn sn xut 3

Hnh 2.36: Lu c cu tp trung

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u im L knh thng tin nhanh ch vi mt ngun duy nht. Lu h s tp trung cho php khai thc ti a d liu c c. Mt vn phng k thut bo dng tp trung gip c c cng tc chun b v phn b cng vic mt cch ng nht. Ti u ho li ch ca: Trang thit b cng knh. My cng c, trang thit b chuyn dng,.. Qun l i ng nhn vin bo dng. Ti u ho vic qun l ti chnh nh mt ngun ngn sch duy nht. T chc qun l ngun nhn lc hiu qu. Thng nht trong quy trnh, h thng quy tc,... Kh nng tp trung tt c cc ngun lc (vt lc v nhn lc) bo dng hng nm.

9.2. T chc bo dng phn quyn Lu c cu

BAN GIM C

Phng t chc v qun l bo dng

Sn xut

M.T.O.

Phn xng

Bo dng chung

Dy chuyn

Bo dng 1

Dy chuyn

Bo dng 2

B phn SX 1

B phn SX 2

Hnh 2.37: Lu c cu phn quyn

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u im 1. Cho thy s tham gia ca b phn sn xut vo cng tc bo dng. 2. 3. 4. 5. 6. D dng phn chia cng vic bo dng gia c hai b phn. Nhn vin phi gnh nhiu trch nhim hn trong cng vic Tng kh nng kim sot k thut ca trang thit b. i ng nhn vin sn xut v bo dng s phn ng mt cch hiu qu hn. Ci thin mi quan h gia sn xut v bo dng.

C th p dng nhng t l trn ch khi cng ty c mt c cu bo dng hiu qu cao da trn c s: Cc h s k thut. i ng nhn vin gii. C ngun thng tin r rng v h thng. C kh nng thc hin v c cng c kim sot phn tch, tch s liu,...

10. V lu c cu t chc bo dng 10.1. Gii thiu Mc ch ca lu l th hin cc chc nng ca b phn bo dng. Quy m ca cng ty d ln hay nh th cc chc nng ny u cn phi c nh gi cn thn. Mt chc nng c th do vi ngi ph trch v mt ngi c th ph trch nhiu chc nng (xem Module 1, chng II, phn tch chc nng) 10.2. nh lng cu trc bo dng Chc nng Phng php Kinh nghim cho chng ti thy l mt nhn vin k thut m nhim chc nng phng php cn phi c kh nng qun l ngn sch bo dng dao ng t 48 n 60 MBF/nm. Mt cch khc l nh gi thi gian cn cho chc nng phng php.

Nu chc nng phng php khng yu cu phi c mt nhn vin k thut lm vic ton thi gian c nh th h c th c giao thm cc vic khc. Trong trng hp ny th trch nhim s phi c nh gi v th hin trn s qun l ca nhn vin k thut nhm theo di nh k v lun p ng yu cu ph hp vi cc mc tiu ra. BNG 2.11 THEO DI NH K HOT NG Theo di h s k thut K hoch bo dng d phng Phn tch chi ph K hoch I.M. Chun b can thip H tr k thut Qun l k thut tng hp K hoch ci tin tnh an ton TNG S
S gi cng vic chun b S gi chun b

THI GIAN D KIN Thng 1 10 10 10 5 40 10 10 5 100% 15

THNG Thng 2 Thng 3 Thng 4 Thng 5 Thng 6

Xc nh thi gian thng c dng chun b cho vic can thip: 100 gi c chia nh sau: 100h 25 = 4h

15 gi cho cc cng vic lin quan n in. 20 n 25 gi cho cng vic c kh. 30 hoc 35 gi cho cng vic ni hi v ng ng. 40h k hp ng thu bn ngoi.

S ln gii quyt nhng li lp i lp li

c c thi gian cn thit cho phng php: 4 gi 2 = 8 gi phng php

2 vi nhng ngnh cng nghip x l t ng. 2,5 cho ngnh cng nghip ch bin.

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Vic nh gi hot ng, yu cu ca chc nng phng php v s qun l ca n ch c th p dng c vi mt chc nng phng php c t chc tt. Khng tnh nhng trng hp khn cp lin quan n vn chuyn mn khi lp k hoch bo dng d phng hay cho cc chc nng khc th r rng l khi trin khai chc nng phng php mt ngi khng nn lm ngay tt c mi vic. C th phi cn n s tr gip. C th khai thc t cc ngun: Nhng ngi ln tui lm cng tc bo dng chun b ngh hu. Cc k s tr ang hc vic trong khun kh ca kha o to. Phng k thut v thit k nu cng ty c.

Tm quan trng chin lc ca trang thit b: Liu c th dng tho thit b khng? Trong tnh hung k hp ng sn xut ph. Trong trng hp thit b tha hoc s dng khng ht cng sut. Liu c th yu cu dng thit b trong gi sn xut khng? nh gi nhng can thip khng phi l bo dng sa cha: Bo dng phng nga. Bo dng ci tin,.. Liu cc can thip ny c i hi cc phng tin sn xut ngng hot ng hay khng? Nu c th s dng bao nhiu phng tin? Tng thi gian sa cha Thi gian thit b ngng hot ng >5

Chc nng Lp thi gian biu Chc nng lp thi gian biu ch yu gm cc vn chnh sau: Bo dng d phng c th cn ngng hoc khng ngng sn xut. Cc can thip chun b cho khong thi gian trung hn (t 4 n 8 tun).

Nu

Chc nng lp thi gian biu thng quan tm n vn : LIU C CN THIT PHI C MT I NG NHN VIN BO DNG HAY KHNG? Nu cn: Theo ca 1. 3 8 gi 2. 4 8 gi Trong nhng ngy ngh cui tun Th 6 Th 7 Ch nht

C ngha l c qu nhiu ngi lm vic trong lnh vc bo dng sa cha. Kinh nghim cng ch ra rng nng sut lm vic ca i ng bo dng s khng hiu qu trong nhng trng hp sau: 1. 2. Lm vic vo bui ti (cng vic thng kt thc trc khi ht ca 1 n 2 gi) Lm vic cui tun (thiu s kim tra, gim st)

V d Trng hp bo dng sa cha nu khng c nhng can thip khc c giao Thi gian lm vic = Mt k thut vin/ca: 3 ca 8 gi 5 ngy/tun 8h (3 ca 8 gi) 5 ngy = 120 gi

F .S .S

Gi hnh chnh Ch c th c c cu tr li khi c c nhng thng tin sau: nh gi bo dng sa cha:

Tng thi gian cho cc KT vin bo dng sa cha: Thi gian dng thit b: 30 gi 120 h 30 h =4

( THI GIAN CHUN CHO NHN VIN BO DNG SA CHA)

S ln hng/ngy trong hay ngoi gi lm vic, S ln can thip/ngy trong hoc ngoi gi lm vic. Ghi li thi gian sn xut b nh tr: Trong gi lm vic. Ngoi gi lm vic. nh gi s ln can thip do b phn sn xut tin hnh trong hoc ngoi gi bo dng. Vic chuyn i cng vic ny i hi phi c o to v c bin php tin hnh. nh gi mt hay nhiu yu t nhiu ln can thip bng k thut.

Chc nng sn xut Vai tr ca b phn sn xut trong lu c cu ca b phn bo dng l g? S pht trin ca cng ty ca chng ta v ca b phn bo dng dn n kt qu phn cng nhim v gia b phn sn xut v b phn bo dng. C rt nhiu u im: Tng v th ca nhn vin b phn sn xut. Tng s quan tm ca nhn vin n tnh trng trang thit b. duy tr bn b ca thit b tt hn.

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Nhn vin vn hnh c th h tr cc k thut vin trong mt s can thip. Gim chi ph i vi mt s vn nht nh lin quan n bo dng d phng v/hoc bo dng sa cha.

11. Mt s v d v lu nh gi mt cch tng th v c cu bo dng, b phn bo dng phi bao gm 5 chc nng sau: Chc nng phn nh ni b phng k thut bo dng (phng php, chun b, v lp k hoch), Chc nng trin khai, Chc nng kim sot (thng khng t c), Chc nng hu cn, bao gm tt c cc b phn h tr b phn vic bo dng (cn trc di chuyn trn cao, xe y, kho cha,), Chc nng qun l, bao gm 2 phn: Qun l v mt k thut, Phn tch nguyn nhn gy hng, Ph tng thay th, Bo dng ci tin, K hoch bo dng d phng v.v... Qun l ti chnh, Phn tch chi ph, Ngn sch dnh cho vic bo dng, sa cha...

ti u ho nhng u im trn th nht thit phi xc nh v m t chnh xc cng vic trong qu trnh sn xut. Chng ta c th lm c vic ny bng cch xc nh cc cp bo dng Cp bo dng th nht Cp bo dng th 2 To ra cc cuc i thoi n gin mang li nhng trao i tiu chun. To k hoch linh hot cho phng n bo dng d phng. H tr mt cch tch cc trong sut qu trnh sa cha ca nhn vin k thut (hay cng s ca h).

Trong phm vi hot ng, cng vic phi c xc nh mt cch r rng v phi c chnh thc ha bng mt b h s nh km vo thit b. B h s ny phi bao gm: Mt bn phn tch hot ng ca cc thit b. Nhng iu kin vn hnh tt. Cc ch dn theo sn phm. Cc tiu chun cht lng. K hoch bo dng d phng. Tr gip cho vic tm nguyn nhn v bin php sa cha.

Nhng chc nng trn l nhng yu cu bt buc trong mt t chc bo dng cho d n c nh n my i chng na. Lun nh mt iu l mt chc nng khng tng ng vi mt ngi hay mt cng vic no . Trc khi a ra mt vi v d v lu , chng ti xin c mt vi gi sau: Trc tin, phi xc nh v phn loi cng vic theo tiu ch bo dng sa cha hay bo dng d phng. Sau thnh lp mt (hay mt s) nhm (hay ch nh mt s ngi) chu trch nhim cho cng tc bo dng d phng. Vic ny c th c tin hnh vo ban ngy. Cc nhm (hoc nhng ngi) khc s chu trch nhim cho cng tc bo dng sa cha v phi t sn xut ln u tin hng u. Nhng nhm (hay ngi) ny s lm vic theo h thng sn xut. Ti bc ny ta cn xc nh mc linh hot v chuyn mn ha tin hnh phn b cng vic mt cch hp l trong cc nhm. Cui cng l chc nng hu cn nn c t chc mt cch tp trung.

Nhng thng tin ny l ht sc cn thit nhng cha . Trc tin, chng ta nn thm vo cc kho o to m mc tiu l tp hun v nhng vn cn thc hin v ph hp vi k hoch bn giao nhim v v trch nhim. Sau cn phi xem xt lung thng tin trao i gip b phn bo dng c th theo di c cc chi ph v h s bo dng. Tt c nhng iu ny cn phi t c bng cch trnh khng t chc c cu bo dng ph thuc vo b phn sn xut. Sau chng ta c th gii quyt mt vn c hu l: bo dng ch c tin hnh do sc p ca qu trnh sn xut trong khi sc p li i lp vi vic ti u ho cc thit b. Mt dng cng vic khc c th tin hnh l: tch hp s chuyn giao cng vic t thit k ban u ca thit b c th to ra c cm thit b ln nht nh c th d dng tin hnh vic thay th.

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S T CHC B PHN BO DNG GM C 5 NGI S ny c cu trc ht sc n gin P.M./ M.T.O.

- p ng nhng yu cu: . Gi c, . Vic la chn nh cung cp, . t hng. y l trch nhim ca b phn mua hng. - Bt c b phn no cng c th m bo c vic qun l kho. Tuy nhin, v hiu qu cng vic, ngi ph trch b phn bo dng nht thit phi trc tip qun l kho vt t. Thm ch c th anh ta cn m nhim vic t mua ph tng. S C CU B PHN BO DNG GM 10 N 20 NHN VIN

TR L

HU CN

TRIN KHAI

PHN XNG P.M.

CA

NGY

M.T.O.

Hnh 2.38: S t chc b phn bo dng nh gi V d trn m t s mt ngi phi ph trch rt nhiu vic. Ngi ph trch cng vic bo dng (vit tt l P.M) gi chc nng phng k thut bo dng (vit tt l MTO). Anh ta phi s dng t 30% n 50% thi gian ca mnh cho vic t chc. Anh ta cng phi hon thnh cng vic ca chc nng qun l. Nhng d sao i na th anh ta cng kh lng c kh nng m bo thc hin cc chc nng mt cch y . Do , anh ta phi huy ng h tr t cc ngun nh nhng ngi tp s, hoc s phi to ra s h tr trong cng vic (R.A. 258) t chc v qun l mt s cng vic nht nh lin quan n qun l phng k thut bo dng bo dng bao gm: H s k thut. K hoch bo dng d phng. Ghi chp,...

Qun l kho

B phn trin khai

Phn xng

Sa cha Sa cha nh

Bo dng d phng Sa cha quan trng

Sa cha

Ni hi

D tr cng c

Nguyn liu th

Cng c my mc

Hin nhin l chc nng trin khai s tp trung vo tnh a nng. Lc phn xng phi h tr cho chc nng trin khai v mt c kh, in, hn.. Phn xng cng phi tin hnh mt s thay i hoc lp t nh. Trong nhng trng hp thc hin can thip quan trng, th chc nng trin khai phi tin hnh k hp ng thu bn ngoi. Vic qun l ph tng thay th phi c xc nh theo 4 u tin di y: Ngi ph trch b phn bo dng xc nh nhu cu Th hin nhu cu , ngha l: M ha, Cc c im k thut, Xc nh lng ph tng ti thiu v ti a

Hnh 2.39: S c cu b phn bo dng

y l trch nhim ca ngi ph trch b phn bo dng.

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 bc ny, ngi ph trch cng vic bo dng cn phi c mt ngi h tr cho anh ta trong cng vic qun l k thut v trin khai. Bt c khi no cn th h s c s tr gip t pha nhn vin mi. a nng trong cng vic l yu t ht sc cn thit, nht l vi nhng nhn vin lm vic theo ca. Lc lng chuyn mn cao c giao vic ch yu vo ban ngy. Phn xng c tng cng thm cc loi my cng c, cc cng c v nguyn liu th c chng cho nhng cng vic c th no . Chc nng ny th hin theo cch quan trng hn l s chuyn mn ho ca: My mc c kh. Th in. Th hn, th lm ni hi...

Kin thc v cc c ch hot ng ca i ng nhn vin bo dng, Thi ca b phn sn xut v ca nhng b phn khc trong nh my i vi dch v bo dng.

c c cu bo dng tt th phi ch n nhng bc sau: Dch v bo dng cn phi c kim ton trong mi quan h tng quan vi sn xut v nhng b phn khc trong cng ty. Cng vic kim ton ny phi nh gi c mi quan h i vi nhng ngi cung cp cc dch v v nhng ngi cung cp ph tng thay th. Cng vic kim ton s gip xc nh c l cn phi tc ng vo u v s quyt nh u tin lm g vi cc mc tiu c xc nh r rng.

Cu trc trn cho php c th chia nhm nhn vin cng ni v tr cng vic v c cng trch nhim nh nhau v: Kho bo dng. Kho thit b chuyn dng. D tr nguyn liu th.

i vi nh my bc ny rt quan trng v cn c s ng h t Ban Gim c. Ban gim c cn phi khng nh quyt tm thc hin thnh cng d n bng vic thnh lp mt nhm ngi cm li trong bao gm: Ngi ph trch b phn bo dng. Ngi ph trch b phn sn xut. Mt ngi i din cho ban gim c. Nhm ngi ny phi gi chc nng cm li trong vic thc hin nhiu khu ca d n. Vic duy tr thng tin lin lc gia B phn bo dng v sn xut l ht sc cn thit. H phi bit mc tiu ca cng vic l g. H phi bit r rng tin ca d n ra sao. H phi thc c tm quan trng ca vn l g. Mt cu hi thng c t ra l liu c cn thit phi thng bo vi cc nhn vin bo dng trc khi tin hnh kim ton hay khng. Cu tr li cn ph thuc vo nh my v hon cnh ca n. Tuy nhin, chng ta phi lun quan nim l rt t ngi nh gi cao nhng vic khng khng tn hay khng chc chn. iu ny c th dn n nhng cng thng kh kim sot. Chnh thc ho mt c cu t chc mi v mt knh thng tin mi. La chn loi cu trc. Tp trung hay phn quyn. Thnh lp b phn mi. Ti bc ny ni ln mt cu hi l liu b phn mi c c p dng cho ton b cc cng c sn xut ngay t u hay khng. Kinh nghim cho thy l nn bt u p dng vi nhng thit b th nghim trc kim tra b phn mi ny v nh gi nhng kh khn gp phi i vi nhng ngi thc hin. Tin hnh sa i nu cn thit sau dn m rng t chc ny ra cho ton b thit b. Thnh lp cc i bo dng. nh gi t th nghim, tin hnh iu chnh cn thit. Dn m rng p dng chc nng ca t chc ra nhng cc thit b khc. Thnh lp chc nng M.T.O.

Ngi ph trch b phn bo dng s gim bt c gnh nng ca vic yu cu mua nguyn liu k thut. T lu ta c th d dng lp k hoch cho nhng b phn quan trng hn. TI C CU B PHN BO DNG C cu ca b phn bo dng thng cn c vo hai trng hp sau: Mt cng ty mi t chc mt b phn bo dng t u. Kinh nghim thc t c th phi tr gi nhng ng thi n c th l mt ngun thng tin v mt c s c lin quan. Mt cng ty t nhiu c kinh nghim ch yu v c mt b phn bo dng cn t chc p ng tt hn mc tiu t ra. -

Module ny lin quan n trng hp th 2. Phng php tip cn chung Quy trnh c m t di y ht sc c trng, cho php thch nghi c vi nhng tnh hung hay xy ra. Nhng tnh hung hay xy ra cn phi c xc nh. Thc s kh c th gii quyt c cu hi l lm th no t chc v/hoc ti c cu mt b phn nu nh ngi thc hin li khng hon ton thc c nhng tnh hung c th xy ra. i vi b phn bo dng th nht thit phi nhn din nhng tnh hung hay xy theo cc kha cnh v: 1. 2. Vic t chc. Cc knh thng tin.

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Chc nng ny sau s c p dng cho nhng b phn khc. K hp ng ph thu bn ngoi. Chun b cho thi gian dng my hng nm. Cc ln ngng my. Gii quyt cc vn lin quan n vic o to i ng nhn vin (bo dng v ti sao li khng phi l sn xut?). Ton b phng php tip cn ny nm trong phm vi ca mt C.M.M.S (H thng qun l bo dng bng my tnh). Vic qun l bo dng bng my tnh khng c ngha l ta kt thc cng vic . y ch l mt bc trong s pht trin ca b phn bo dng m thi.

Mi bc ni trn khng nht thit phi din ra theo ng trt t trnh by. T chc/ ti c cu mt b phn bo dng cn c s h tr tch cc ca Ban gim c v nhm ch o. S thnh cng ca d n ch c m bo nh s thay i v thi ca tt c nhng ngi lin quan. chnh l l do ti sao m i ng nhn vin li phi tham gia vo tt c cc bc trong quy trnh. Kinh nghim cho thy l phi mt t hai n ba nm mi c th kim sot c qu trnh ti c cu. Cng phi mt ngn y nm trin khai v kim sot mt h thng qun l bo dng bng my tnh (C.M.M.S)

18. H THNG GIM ST V CHN ON TNH TRNG THIT B BNG K THUT DAO NG MY

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1. M t h thng gim st v chn on tnh trng thit b H thng gim st v chn on tnh trng thit b bao gm 2 cu thnh: H thng gim st v H thng phn tch v chn on. H thng gim st chu trch nhim gim st cc hin tng xut hin trong qu trnh lm vic ca thit b nh ting n, rung, nhit ... kim tra tnh trng thc t ca thit b, pht hin cc trng thi bt thng ca thit b, qua xc nh chnh xc xu hng h hng ca thit b. H thng phn tch v chn on chu trch nhim phn tch cc kt qu thu c t h thng gim st, thng bo chnh xc v tr, phm vi, mc hng gip ngi s dng kp thi iu chnh hoc thay th cc phn b hng trnh cc hin tng hng theo dy chuyn. Nh nhng kt qu ny, cc cn b qun l bo dng c th xc nh c cc li v hng ca thit b t rt sm v ch ng trong vic hoch nh k hoch sa cha v chun b ph tng thay th. Trong phng php ny thay v sa cha, bo dng theo chu k thi gian ngi s dng s gim st tnh trng ca cc thit b thng qua cc php o theo cc chu k thi gian. Tu theo tnh trng hot ng ca thit b, mc phc tp v quan trng ca n ngi ta xc nh cc khong thi gian o ph hp v nh vy ngi bo dng c th gim st cht ch tt c cc thit b cn thit. V chi ph cho cng vic thc hin cc php o v phn tch nh hn rt nhiu so vi cng vic sa cha; an ton v tin cy ca dy chuyn rt cao do c gim st cht ch, do phng php bo dng ny oc coi l gii php ti u cho vic qun l bo dng cho cc dy chuyn cng nghip. 2. K thut chn on tnh trng thit b da trn k thut gim st v phn tch dao ng 2.1. Cc khi nim c bn v dao ng my Khi my mc xut hin cc hin tng bt thng, trong phn ln cc trng hp, chng s lm thay i bin v tn s ca dao ng ca my. Do , nu dao ng c o v phn tch, ta c th xc nh c cc h hng ca my m khng cn dng hoc tho my. y chnh l l do ti sao m dao ng c coi l mt i lng ch th tnh trng ca my. Dao ng ca my c nh ngha l "s thay i theo cc khong thi gian,trong ln ca i lng ch th s chuyn ng hoc chuyn v ca mt h thng my mc tr nn ln hn gi tr trung bnh hoc gi tr quy c ti mt thi im no m tr nn nh hn ti thi im tip theo, sau lin tc lp li hai trng thi ny". (Theo tiu chun JIS B O 153-1975). Dao ng ca my (gi tt l dao ng) c th phn chia thnh 2 loi chnh: Dao ng c quy tc: L loi dao ng m dng sng c xc nh trc tip theo thi gian. Dao ng bt quy tc: L loi dao ng m dng sng ch c th xc nh bi cc ch s thng k nh gi tr trung bnh v h s phn b , ti mt thi im t no .

2.2. Tng quan v cc dng dao ng ca my Thng thng, dao ng ca mt h thng thit b trong thc t l rt phc tp. Tuy nhin, da trn c s l thuyt dao ng, ngi ta c th chia dao ng ca h thng my mc, thit b thnh cc dng dao ng c bn sau: a. Dao ng c quy tc : Dao ng c xc nh l hm s ton hc ca thi gian : d = D ( t ) i. Dao ng c chu k: Dao ng c dng sng lp li 1 khong thi gian bng nhau T: d (t) = d ( t + T ) Dao ng iu ha : Dng sng dao ng c biu th bi 1 dng sng hnh sin. Cn c gi l dao ng iu ha n . Dao ng theo chu k : dao ng m dng sng l tng ca cc sng hnh sin . ii. Dao ng khng c chu k: Dao ng khng theo chu k no. Dao ng gi chu k : l dao ng khng theo chu k t nhin, c th chuyn i thnh dng c chu k thng qua vic x l tn hiu . Dao ng tt dn : Bin dao ng tt dn , tng ng nng b gii hn . b. Dao ng bt quy tc : Dng sng ca dao ng l bt quy tc v c coi nh 1 bin ngu nhin. i. Dao ng bt quy tc lu di: Dng dao ng l lin tc trong thi gian kho st. Dao ng bt quy tc di tn hp : Dao ng bt quy tc b gii hn trong 1 di tn s. Dao ng bt quy tc di tn rng: Dao ng bt quy tc vi di tn bt k. ii. Dao ng bt quy tc tc thi : Dng dao ng thay i trong khong thi gian kho st. Dao ng bt quy tc c bit. 2.3. Dao ng iu ha v cc c tnh c bn: Nh m t trn, dao ng ca my c rt nhiu dng khc nhau, tuy nhin hin nay cng vi s pht trin ca cng ngh in t v tin hc ngi ta c cc thit b phn tch cc dng dao ng phc tp thnh dng dao ng n gin nht - dao ng iu ho n theo cc phng php s. Cc bc phn tch v chn on dao ng u c da trn cc php phn tch ny. V vy, trong ni dung bo co ny, chng ti ch tp trung vo vic phn tch, tm hiu cc i lng c bn ca dao ng iu ho, cc i lng ny cng chnh l cc i lng c bn s c s dng trong vic chn on tnh trng thit b. H thng bao gm l xo vi cng k ni vi vt nng c khi lng M. Nu vt nng c ko i vi 1 khong cch D so vi chiu di ban u sau th ra, vt nng s di chuyn theo chu k theo phng thng ng. Trong trng hp ny, v tr ca vt nng ti cc thi im no (v tr ny c gi l chuyn v) to nn dng sng hnh sin . Dao ng m chuyn v ca n l mt hnh sin theo thi gian c gi l dao ng iu ha hay dao ng iu ha n. Chuyn v d theo thi gian t c m t bi cng thc : d = D sin ( 2t/T+) (2) Vi D: na bin dao ng 2D l bin dao ng Bin dao ng c o bng mm hoc m (1m = 0,001 mm). Chu k T (giy) l khong thi gian ngn nht m cc trng thi tng t lp li v l dn xut ca tn s f : f = 1/T [Hz] (3) = 2/T [rad/s] (4) vi l tn s gc.

Bin dao ng c quy tc d l mt hm ca thi gian t : d =D ( t ) (1) Cng thc ny p dng cho dao ng c chu k v khng c chu k. Mt khc, vi cc dao ng bt quy tc, sng dao ng thay i khng theo quy lut thi gian v khng th m t chng nh l mt hm ca thi gian, ngc li vi biu thc (1). Qu trnh x l cc sng dao ng bt quy tc ny gi l qu trnh stochastic v trong trng hp ny, s phn tch s da trn l thuyt xc sut. m t bn cht ca dao ng, ngi ta dng cc ch s thng k nh hm xc sut P(d), gi tr trung bnh d v h s phn b . Ni dung bo co ny khng m t chi tit bn cht ca dao ng. Chng ti ch mun a ra mt s dng dao ng c bn c th gp trong qu trnh chn on tnh trng thit b. Dng dao ng thng gp trong chn on cc my quay l dao ng c chu k, dao ng gi chu k, dao ng bt quy tc c di hp, dao ng bt quy tc di rng...

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Mi lin h gia v f l : = 2f [rad/s] f =/2 [Hz] (5) Do cng thc (2) c th vit li nh sau : d =D sin ( t + ) (1') Nu t = t + (6) th : pha dao ng : pha ban u Vn tc v (cm/s) v gia tc a (cm/s2) ca dao ng iu ha l o hm bc 1 v bc 2 ca chuyn v theo cng thc (1'): v =dd/dt =D cos (t + )= V cos (t + ) (7) Nh vy vn tc v c dng sng hnh sin c lch pha l /2 so vi chuyn v. a = dv/ dt = D sin (t + ) = Asin (t + ) (8) Gia tc a cng c dng sng hnh sin v c lch pha l so vi chuyn v. T cc cng thc (1'), (7), (8) mi lin h vn tc v, gia tc a so vi chuyn v D v tn s f l: v = D = 2 fD. A = D = (2 f ) D. Trong s cc thng s ca dao ng iu ha, gi tr trung bnh dav v gi tr bnh phng trung bnh drms l 2 thng s quan trng. Gi tr dav l gi tr trung bnh ca 1na chu k. Gi tr bnh phng trung bnh l gi tr trung bnh ca nng lng dao ng :
T 2

2.4. ng dng k thut phn tch dao ng trong gim st v chn on tnh trng thit b Tt c cc my v cm cc chi tit my khi chuyn ng u gy ra cc dao ng c tnh cht lp li ti mt di tn s no .

Dao ng

Tn s Hnh 2.40: Ph tn s ca dao ng my Cc tn s dao ng ny c th xc nh t c tnh hnh hc ca cc chi tit my v c v thnh cc th m t ln ca dao ng ti tng gi tr tn s c th. Cc th ny c gi l cc ph tn s ca dao ng. Cch thc phn tch ph tn s ca dao ng s c trnh by phn tip theo. Ph tn s ca dao ng cho php ta phn bit c cc dao ng gy ra do khng chnh xc ca cc khp ni, n khp bnh rng, li ln v t nhiu hin tng khc Phng php ng dng dao ng chn on tnh trng my Ta c th xc nh chnh xc tnh trng my bng cc gi tr dao ng o c thng qua vic gim st s thay i ca cc ph tn s dao ng Hin nay ngi ta c th gim st qu trnh pht trin ca bt c h hng no ca thit b m gy ra dao ng thng qua cc qu trnh s l d liu c bit v cc phn tch thng k. Khi gim st c cc dao ng xut hin trn my ta c th xc nh chnh xc cc h hng trc khi sa cha thit b v da theo ln ca cc dao ng gy ra do cc h hng c th ta c th d bo chnh xc khong thi gian h hng s xy ra t hon ton ch ng trong vic xy dng lch sa cha bo dng cn thit.

2 2 dav = D sin td t = D = 0.637 D T0

(9)

D 2 2 2 d rms = 1 ( D sin t ) d t = = 0.5 D T0

(10)

drms =

D/ 2 = 0,707 D

(11)

Mc sa cha

drms tng ng vi lch tiu chun trong cc dao ng bt quy tc . H s hnh dng Ff dng th hin dng sng ca dao ng : Ff = drms/dav = 1. 11 H s Crest Fc ch ra thuc tnh nh hng ca dng sng : Fc = D/drms = 2

Php o d on
(12) (13)

Cc gi tr dav, drms, Ff v Fc thng c s dng trong chun on tnh trng my nh l cc ch s th hin c tnh khng ch ca dao ng iu ha m cn cho cc dng dao ng ni chung.

Thi gian bo dng

Hnh 2.41: Mi quan h gia bin dao ng vi tnh trng thit b (my)

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Xc nh ph tn s ca dao ng Quan st ph tn s l mt cch khc quan st dao ng my. V d ta o dao ng my bng u o dao ng nh trn hnh v. Nu ta a cc tn hiu do c qua b lc loi b cc thnh phn tn s qu cao hoc qu thp, ta c th quan st cc tn hiu dao ng trn oxylo MIN THI GIAN

Hnh 2.42: S o v chuyn i dao ng my thnh tn hiu trong min thi gian Cc tn hiu dao ng quan st trn oxylo ch cho ta thy bin dao ng v s thay i ca chng theo thi gian. Cc tn hiu nh vy gi l cc tn hiu theo thi gian, cc tn hiu ny s cho chng ta thy cc tn hiu dao ng thng thng ca thit b v chng rt phc tp. c th nhn c cc thng tin cn thit t tn hiu ny ta cn phi o gi tr cc i ca dao ng (Peak value), ta cng c th o c gi tr bnh phng trung bnh ca dao ng (root mean square) gi tr rms. Hai gi tr ny l hai gi tr c bn nht ca dao ng v c th c o c t cc thit b o cm tay n gin.
MIN THI GIAN

Hnh 2.44: S chuyn i t min thi gian sang min tn s Mc d dao ng c th c quan st theo hai cch khc nhau, nhng ta vn c th thy c cc im tng ng gia cc dng tn hiu theo thi gian v tn hiu theo tn s. Gi tr cc i ca dao ng ti mt gi tr tn s cng xp x gi tr cc i ca dao ng theo thi gian. Tng din tch phn pha di ca ng cong ph tn s chnh bng gi tr rms ca tn hiu dao ng theo thi gian. 3. S nguyn l ca h thng gim st v chn on tnh trng thit b trn c s gim st v phn tch dao ng. 3.1. S nguyn l ca mt h thng gim st tnh trng thit b Cu trc chung ca mt h thng gim st v chn on tnh trng thit b v cc thnh phn chnh ca chng c ch ra hnh di y:

Hnh 2.43: o cc gi tr bin trong min thi gian c th nhn c cc d liu v ph dao ng, ta phi chuyn tn hiu dao ng t dng tn hiu theo thi gian thnh tn hiu theo tn s. lm iu ny, u tin ta phi s ho cc tn hiu dao ng bng cch ly gi tr ca bin dao ng ti cc khong thi gian c nh. Cc gi tr ny s c lu tr theo cc dy trn my tnh Sau khi c cc dy d liu trong my tnh ta c th chuyn cc dy tn hiu ny thnh cc tn hiu theo tn s. Qu trnh x l ny gi l qu trnh bin i Fourier nhanh (Fast Fourier Transform - FFT). Php s l FFT cho php bin i cc bin theo thi gian thnh bin theo tn s. Lc ny ta c bin ca dao ng theo cc gi tr tn s khc nhau.

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Cc u o tn hiu

B phn thu nhn v x l

B phn phn tch tn hiu

Thit b trong dy chuyn sn xut

B phn chn on v gim st tnh trng thit b

B phn chn on v gim st tnh trng thit b Hnh 2. 45: S nguyn l ca h thng gim st v chn on tnh trng thit b y l m hnh nguyn l tng i tng qut i vi mt h thng gim st v chn on tnh trng thit b. Tu theo tng nh my c th, tu mc p dng m cc thit b trong h thng cng nh s kt ni gia cc b phn trong h thng c cc mc hon thin khc nhau. Tuy nhin, d mc no, cc thnh phn chnh ca h thng u phi m bo cc chc nng ch yu sau: a. Thit b trong dy chuyn sn xut: y chnh l cc thit b cn c gim st v chn on h hng. S lng, chng loi thit b s c la chn ph hp vi tng nhu cu c th ca cc nh my. b. Cc u o tn hiu: Cc u o tn hiu l cc thit b thu nhn cc yu t bt thng xut hin trn my. Khi cc yu t ny l dao ng my cc u o tn hiu thng l cc Gia tc k (Accelerometer) v cc u o tc v chuyn v (Tacho Photoelectric Probe). Cc u o ny c nhim v thu nhn ton b cc tn hiu dao ng xut hin trn my. Cc tn hiu thng l cc gi tr trung bnh (RMS), gi tr cc tr (Peak) ca bin dao ng hoc l dy gi tr bin i ca bin dao ng theo thi gian. Cc u o c th gn trc tip trn my (gia tc k) hoc gn c lp vi my (Tacho). Trong mt s trng hp, khi gim st s trt tn s cc ng c ba pha khng ng b (s khng ng u v khong cch gia cc thanh roto v stato) ngi ta cn hay dng cc u o dng in AC Current Probe. c. B phn thu nhn v x l tn hiu. y chnh l cc my o dao ng. Vi cc h gim st gin on (Off-line) cc my o c th l cc h thu nhn d liu (Data Collector) hoc cc thit b o dao ng (Vibrometer), vi cc h gim st lin tc (On-line) th chng l cc thit b gim st dao ng (Vibration Monitoring). Ngoi nhim v thu nhn y cc tn hiu t u o, cc my o ny cn c cc b lc (Filter) loi b cc thnh phn dao ng vi tn rt thp v rt cao, b khuch i (Amplifier) khuch i cc bin dao ng gip ngi s dng c th quan st d dng cc gi tr dao ng. d. B phn phn tch tn hiu Trong qu trnh gim st tnh trng thit b, sau khi c cc gi tr dao ng o c trn cc my o, ta hon ton c th nh gi s b c tnh trng ca thit b da trn s bin i ca gi tr dao ng qua tng thi im o. Nu nh cc gi tr bin dao ng tng dn theo thi gian ta c th kt lun rng trong my bt u xut hin cc h hng. Tuy nhin xc nh chnh xc loi h hng (mt

cn bng, lch tm...), mc h hng cng nh v tr ca cc h hng ny ch s dng cc gi tr o c cha , ngi ta cn phi s dng rt nhiu phng php x l tn hiu thch hp cho php d bo chnh xc v tnh trng ca thit b. Hin nay, cng vi s pht trin ca cng ngh in t v tin hc, ngi ta xy dng c rt nhiu cc php x l tn hiu tin tin. Cc php x l ny c th c tch hp trc tip ln cc my o, hoc c vit di dng cc phn mm my tnh cho php ngi s dng d bo rt d dng chn on cc h hng ca thit b vi chnh xc rt cao. Mt trong cc php bin i tn hiu rt ni ting c p dng trong hu ht cc h thng phn tch tn hiu l php bin i Fourier nhanh (Fast Fourier Transform - FFT) trnh by phn trc. Php bin i ny cng vi php bin i CPB (Constant Percentage Bandwidth) c p dng chn on cc li c bn ca thit b nh: mt cn bng, lch tm, lng c kh... ngoi ra ngi ta cn p dng cc php x l c bit chn on h hng ca ln (Selected Envelope Detection - SED) v bnh rng n khp (Cepstrum)... e. B phn gim st v chn on tnh trng thit b. Chc nng chnh ca b phn ny l tng hp cc kt qu o v phn tch dao ng cc b phn trc nhm xc nh tnh trng chung ca cc thit b, xc nh kp thi cc h hng xut hin trong cc thit b v a ra cc thng bo cn thit cho cc khi qun l bo dng ln k hoch bo dng, sa cha. Vi cc h gim st gin on (Off-line), cc chuyn gia v bo dng v phn tch tnh trng thit b s dng cc phn mm chuyn dng a ra cc quyt nh cn thit, vi cc h gim st lin tc (Online) tt c cc cng vic ny u c thc hin bi h thng my tnh v cc phn mm chuyn dng (v d h thng COMPASS v phn mm ADVISOR ca Hng Bruel & Kjaer - an Mch). 3.2. Phn loi cc h thng gim st v chn on tnh trng Hin nay, vic gim st tnh trng thit b c pht trin theo hai hng chnh. a. Hng th nht, ngi ta c gng gim khong thi gian gia hai ln o v 0 bng cch p dng h thng gim st trc tuyn (On line Monitoring System). Trong h thng gim st trc tuyn, cc b phn ca h thng c kt ni lin tc vi nhau 24/24h. B phn phn tch v x l d liu phi dng a knh cho php giao tip vi nhiu u o cng mt lc. Tuy nhin theo phng php ny, khi s lng my cn gim st tng ln s lng cc u o cng tng ln phc tp ca h thng cng tng ln nhiu ln. Do mc t ng ho ca h thng rt cao, s can thip ca con ngi l rt t, nn h thng cn phi trang b cc phn mm chn on cng nh qun l thit b t ng. Qua phn tch trn ta thy mc d c tin cy rt cao nhng do chi ph qu ln nn h thng ny ch thch hp vi nhng b phn my hoc nh my c phc tp v nguy him cao. N rt thch hp vi cc thit b trong cc khu vc c hi v phng x cc nh my ho cht v nh my in nguyn t, cc thit b nh tua bin, my nn c cng xut ln... i vi cc nh my, dy chuyn sn xut c phc tp va phi, tc h hng hc ca cc thit b trong dy chuyn khng qu nhanh (nh my giy, nh my xi mng...) ngi ta thng dng gii php kinh t hn. b. Hng th hai, gim ti a s lng u o tng khong thi gian gia hai ln o ph hp vi tng loi thit b bng cch p dng h thng gim st gin on (Off line Monitoring System). Trong h thng gin on, cc b phn hot ng tng i c lp vi nhau v ph thuc kh nhiu vo ngi s dng. Vi mt cu hnh phn cng va phi, h thng cho php gim st v chn on tnh trng ca kh nhiu cc thit b trong dy chuyn. Khi tng s lng thit b cn gim st, khng cn thit thay thay i cu hnh ca h thng. Hn na khi cn thit ta c th d dng nng cp h thng thnh h thng gim st trc tuyn. Mc d h thng hot ng tt hay xu ph thuc kh nhiu vo ngi s dng tuy nhin vi s tr gip ca my tnh v phn mm chuyn dng, ch cn c o to mt cch c h thng l cc k thut vin c th d dng vn hnh v pht huy ht nng lc ca h thng.

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H thng ny thng c p dng gin st v chn on tnh trng cc thit b nh qut, bm, l quay, ln, bnh rng... Cc h thng gim st gin on (offline) v trc tuyn (online) u c nhng u v nhc im ring. Tu theo nhng yu cu c th ca tng nh my, tng thit b ngi ta c th p dng mt trong hai h thng ny. i khi do c th ring ca cc nh my, ngi ta p dng cng lc c hai h thng trn. V d nh trong nh my giy, vi mt s cc thit b c bit nh my ho cht v tua bin nh my in, ngi ta phi p dng h thng gim st trc tuyn, vi cc l sy, l lnh dy chuyn xeo ngi ta c th p dng h thng gim st gin on. 4. Cc giai on thc hin - p dng k thut phn tch dao ng trong gim st tnh trng thit b Trong cc phn trc, ta cp n cc khi nim c bn v dao ng my cng nh vic ng dng dao ng my trong gim st tnh trng thit b v cc h thng gim st dao ng. Phn ny s trnh by c th cc giai on trin khai k thut gim st v phn tch dao ng trong gim st v chn on tnh trng cc my quay. Cc hin tng bt thng ca cc my quay Nh m t phn trc, dao ng ca my bao gm nhiu dng sng dao ng khc nhau t di tn s thp n di tn s cao. Do , dao ng sinh ra ti cc my quay cng tng t bao gm mt di rt rng cc thnh phn tn s. Tuy nhin, cho n nay, trong vic kim sot cc dao ng sinh ra t cc my quay, ngi ta ch quan tm n di tn s gp vi ln tn s quay. Hin tng bt thng ca my quay bao gm cc xung dao ng gy ra do cc phn t va p... nhng hin tng ny rt kh quan st di tn s thp. Do , trong chn on cc my quay, dao ng phi c gim st trong di tn s rng nhn c y cc thng tin cn thit. Bng di y ch ra cc hin tng bt thng c trng thng xut hin cc trc quay (bao gm c rotor) v cc c im ti di tn s tng ng. Nh c th thy trong bng, th hin vic chn on tnh trng my mc mt cch c hiu qu, cn thit phi thu nhn c cng nhiu thng tin cng tt trong mt s gii hn cc im o.

Di tn s

Hin tng bt thng chnh. - c im ca dao ng

c im ca dao ng Gy ra do s phn b khi lng khng u xung quanh trc quay. Thng thng, mt tn s quay c sinh ra. Gy ra do s phn b khi lng khng u xung quanh trc quay. Thng thng, mt tn s quay c sinh ra. Gy ra do bu lng mng b hng hc bnh rng mn. Thng thng tn s sinh ra cao hn so vi tn s quay. Gy ra trong b phn quay do lc tc ng ca du ti trt, dao ng sinh ra do cc c tnh ng hc ca . Thng gy ra dao ng c tn s trng vi tn s ring ca trc p sut cht lng phn b khc nhau trn cc c cu ca bm hoc qut gi, mi khi bnh cng tc i qua phn v xon c. Nu c bt c sai lch no ca lc tc ng ln cc c cu, p sut va p s b thay i Dao ng gy ra trong qu trnh vn hnh cc tua bin my nn kh, ly tm hoc hng trc do s va chm gia rotor v cnh ng yn, gia bnh cng tc v vng khuch tn, gia phn np v bnh. Trong cc my thy kh, p sut ti ch gim to thnh cc bong bng kh, ti ni c p sut cao chng b v v trong cc trng hp tng qut to ra cc ting n v dao ng ngu nhin vi tn s cao. Mt dng ca dng xoy gy ra trong cc c cu thy kh do cc p sut bt thng gy ra trong cc c cu... Trong trng hp tng qut gy ra ting n v cc tn s dao ng ngu nhin vi tn s cao.

- Lp lch Di tn s thp - Rung

- Kh du

- Va p p sut Di tn trung bnh - Dao ng ca cnh khi quay

- L hng

Di tn cao - Rung v n ca cht lng.

Hnh 2.46: V d v cc hin tng bt thng gy ra t trong cc my quay

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Cc hin tng bt thng gy ra dao ng trong thc t cc my quay c th c phn loi theo cc t l phn trm nh sau: Mt cn bng 30% H hng bnh rng: 10.3% H hng ln: 7% Lch: 6.3% Cc nguyn nhn khc: 47.4% T l ny c xy dng da trn vic kho st rt nhiu cng ty trong cc ngnh cng nghip khc nhau. Theo s ny, rt nhiu hin tng bt thng sinh ra trn cc my quay di tn s thp l do s mt cn bng, lp t lch.... mt s khc xut hin di tn s cao. Do , trn thc t cn phi kim sot trn mt di tn rt rng. Nh ni trn, chn on cc my quay cn thit phi xt n mt di tn s rt rng v ta s dng dao ng lm tham s biu th. Trong phn ny, cc phng php nh lng cc h hng sinh ra cc my quay bng cch s dng k thut dao ng (phng php kho st tnh trng my) s c m t cng vi nhng khi nim c bn ca chng. Cc bc c bn ca phng php ny c m t c th nh sau: 4.1. La chn cc my c gim st : Theo quan im v hiu qu, vic gim st ton b cc my mc trong nh my l khng cn thit. Trn quan im k thut, iu ny i khi cn thit, i khi khng. Do , cc my mc thit b cn gim st phi c la chn sau khi c nhng kho st nh gi c th. Cc my mc c gim st cn c tha mn cc iu kin sau : a. My mc thit b nm trong dy chuyn sn xut. b. My mc s gy cc h hi nghim trng nu b dng, thm ch chng c th l cc thit b ph. c. My mc gy ra cc h hng th yu khi b hng. d. My mc c chi ph bo dng cao. Sau khi my mc cn gim st c quyt nh ta cng phi la chn php o tng ng vi cc my ny. Ba php o ch yu bao gm: a. Thc hin o bng tay theo chu k. b. Thc hin o bng tay theo chu k, s dng cc hp trung gian t ti cc ni an ton nhn tn hiu, p dng cho cc my t ti cc mi trng nguy him. c. o t ng, s dng cc cng c qun l d liu theo chu k hoc lin tc bi cc u o. Phng php ny p dng cho cc my mc khng n nh c iu kin o hoc tc h hng nhanh. Cc phng php o s c quyt nh da theo cc my c th. 4.2. La chn cc tham s o: Dao ng sinh ra do cc my quay c o bi 3 tham s: chuyn v, vn tc, gia tc. Khi qun l mc h hng ca my mc bi vic o cc dao ng ta cn phi xc nh c th 3 i lng ny. Cc i lng chuyn v v vn tc thng c dng vi cc dao ng di tn s thp; di tn s trung bnh ngi ta s dng vn tc; cn di tn s cao thng s dng gia tc. V d, trong dao ng n gin vi sng hnh sin mi lin h gia chuyn v, vn tc v gia tc c dng: d = v/ = a Cng thc trn cho thy rng: cc di tn s thp kh nng o chuyn v d dng hn v ti cc di tn s cng cao kh nng o gia tc cng cao. Cc tham s o theo dng cc h hng c ch ra trong bng di y.

BNG 2.12 THAM S O THEO CC DNG TNH TRNG BT THNG Tham s o Chuyn v Dng tnh trng bt thng Cc hin tng bt thng gy ra cc di chuyn. Cc hin tng bt thng cn kho st v nng lng dao ng v cc h hng dng mi. Cc hin tng bt thng cn kho st v ln ca lc tc ng khi dao ng. V d Va p ca my cng c, trc quay bi gi... Dao ng ca h thng my quay.

Vn tc

Gia tc

Dao ng khi xut hin cc hin tng nt rn bnh rng v ln.

Nh ni trn, ph thuc vo dng cc h hng v di tn s o c ta phi la chn cc tham s o cho hp l. Mt cch tng qut, cc tham s o tng ng vi cc di tn s c ch ra trn hnh di. BNG 2.13 XC NH THAM S O THEO DI TN S

Di tn s Tham s o

10

100

1.000

10.000

Chuyn v

Vn tc

Gia tc Cc hin tng bt thng ch yu Mt cn bng, lch, kh du Xung p sut, Dao ng do chi tit chuyn ng To hc. Va chm. Tip xc....

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4.3. La chn cc im o: Trong cc my quay thng thng, ngi ta thng phn loi dao ng khi o thnh hai loi dao ng chnh sau: dao ng ca trc v dao ng ca . Ni chung, cc phng php o cc dao ng ca c s dng trong phn ln cc trng hp, phng php o dao ng ca trc ch c p dng trong cc trng hp h thng quay vi tc cao (trong trng hp ny ngi ta hay dng cc phng php o chuyn v ca trc). S khc bit ca phng php o dao ng ca trc v c so snh bng sau: BNG 2.14 SO SNH PHNG PHP O DAO NG CA TRC V CA Dao ng ca Thit b o 1. Tho lp cc u o n gin. 2. o dao ng n gin. 3. Dng c o dao ng c gi thnh thp. 1. nhy dao ng thp (trong khi trc l cao vi trng hp v cng, thay i ln trong dao ng hoc cc dao ng bt thng c th xc nh nhy vi dao ng thp. 2. Thu thp nhiu loi d liu, cc gi tr ti hn kh tng qut. 3. tin cy ca thit b o cao. Dao ng ca trc 1. t phng php lp u o. 2. o dao ng kh hn trong trng hp ln. 3. Dng c o c gi thnh cao. 1. nhy dao ng cao (trong bt c trng hp no, s thay i ln trong dao ng hoc cc dao ng bt thng c th xc ng ch vi nhy dao ng cao). 2. Cc i lng ti hn c bn (mt cn bng, ni lc ca ln...) c o trc tip. 3. Cc gi tr ti hn khng c tnh tng qut (ch p dng cho 1 s lng my). 4. tin cy ca thit b o (c bit l cc u o thp) .

Do , i vi chi tit quay tc cao, c th pht hin sm cc h hng bng cch o cc dao ng ca trc. Tuy nhin, i vi nhng h thng my lp t, chnh xc ca chuyn v trc rt kh pht hin, n ph thuc vo chnh xc ca b mt v trng thi lm vic ca trc. Mt vn khc cn ch l khi la chn cc im o, cc ln o phi lun c thc hin ti cc im ny. V d vi cc dao ng vi tn s cao, cc gi tr o ti cc im cch nhau vi mm c th lch ti 5-6 ln. Thng thng sau khi chn cc im o ngi ta nh du cc im ny li 4.4. Xc nh chu k o Khi s dng phng php o dao ng ca trc hoc ca xc nh tnh trng h hng ca my mc thit b cn thit phi nh ra chu k do tng ng vi tng loi thit b. Chu k o c xc nh ch yu da trn tc h hng. V d nh khi qu trnh h hng din ra chm (qu trnh mn) chu k o c th ln. Nhng i vi cc my c th gy h hng ngay sau khi c bt c thay i g (cc chi tit quay vi t cao) cn phi o thng xuyn. BNG 2.15 V D C TRNG V CC CHU K O 1. My quay tc cao 2. Cc my quay ni chung 1. My quay tc cao Bm, qut, qut gi tua bin hi nc o hng ngy o hng tun

c im lm vic

Do , mt cch tng qut, khi thc hin cc php o, cn thit phi xc nh cc chu k o tng ng vi mc h hng ca my nhm tng hiu qu php o v tit kim c chi ph. Trong qu trnh xc nh chu k o, thng ngi ta xc nh chu k o c bn, v d, khi quan st thy c s thay i qua cc gi tr o c trong mt s trng hp ngi ta cn phi gim chu k o. 4.5. Xc nh tiu chun nh g Sau khi xc nh c my v phng php o qu trnh o c bt u. Trong trng hp ny cc gi tr o s c nh gi l bnh thng hoc bt bnh thng. Cc phng php nh gi c m t tip sau y. Ngi ta thng s dng 3 tiu chun nh gi, cc khi nim c bn v cc tiu chun ny c m t bng 5. Nhng tiu chun ny c la chn tng ng vi tng loi my. Trong thc t, tiu chun nh gi tuyt i l d s dng nht, tuy nhin n ch c p dng vi cc my quay tiu chun c mt s my khng ph hp vi tiu chun ny. Vi cc dng my ny ngi ta thng dng cc tiu chun nh gi tng i v tiu chun so snh. Khng c mt tiu chun no tng qut p dng cho tt c cc my, ng vi mi trng thi, mc quan trng ca mi my ngi ta s chn cc tiu chun nh gi tng ng. a. Chun nh gi tuyt i :

Hiu qu ti cc im o ng dng

Cc im o dao ng d chn la, gi Gi tr o ph thuc nhiu vo im o. tr o t ph thuc vo im o. Gim st hu ht cc dng dao ng ca my. Gim st s t cc dao ng, thng dng cung cp cc d liu chnh xc cn bng ng.

Do nhiu lon Bin

Bin

Lc kch ng (do mt cn bng)

Lc kch ng (do mt cn bng)

Chun nh gi tuyt i l tiu chun ch t c hiu qu khi thc hin cc php o chnh xc. Do , chun ny c la chn sau khi phn loi cc di tn s c th p dng c, cc phng php o... Do , ta cn ch rng chun tuyt i bao gm dao ng ca trc v ca .

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Theo cc chun nh gi, chuyn v cho php t l nghch vi tc quay. Cn ch rng cc gi tr tiu chun cng nh cc gi tr chuyn v tiu chun khc c p dng cho cc my thng thng quay vi tc khng i. Do , theo cc nguyn nhn nu ra bng di y chun chuyn v thng c thay th bi chun tc . o dao ng ca trc ngi ta dng chun chuyn v, theo quan im iu khin l chuyn v tng i gia trc v . BNG 2.16 CHUN NH GI

Chun tuyt i

Mt gi tr o ti 1 vng ( thng l trn ln) c so snh vi chun, v c phn loi "tt" "cn ch " v "xu".

Cc tiu chun m t phn trn ch yu p dng cho cc dao ng tn s thp. Vi cc dao ng c tn s cao, cc tiu chun c p dng da trn gi tr gia tc. Tuy nhin, di tn s cao rt kh khn khi o cc i lng vt l tuyt i bng cc dng c o bng tay. Thng thng khi cn thit, ta c th c nh dng c o dao ng khi o di tn cao. Nguyn nhn do cng hng ti ch tip xc hoc cng hng tng phn sinh ra do u d . Ngoi ra, cc c tnh tn s ca u o cng nh hng n kt qu o, qu trnh o ch c thc hin khi c tnh tn s l bng phng. Tuy nhin, khi thc hin cc php o, khng cn thit phi o c gi tr tuyt i do php o s c thc hin khi m bo rng di tn s c tnh l bng phng. Theo cch ny, o dao ng vi tn s cao bng thit b o cm tay, trnh vic gy ra cc cng hng tip xc gy ra do vic cm dng c o. Khi chuyn ng tng i gia dao v phi to ra cc kch thc chnh xc ca sn phm trc tip trn my cng c, ta c th hiu rng chuyn v c coi nh mt tiu chun. b. Chun tng i: Trong chun nh gi tng i, php o c thc hin mt cch c chu k trn cng mt vng v so snh theo chui thi gian, coi cc gi tr bnh thng nh l gi tr ban u. S lng cc mc thi gian tng ng vi nhng gi tr ny c tnh ton lm c s nh gi. Vi cc dao ng c tn s thp. Khi thay i 4 ln gi tr dao ng ta c th cm thy c s khc bit so vi cc gi tr pha trc. Tiu chun ny coi cc gi tr gp 1.5 2 ln gi tr bnh thng l nm trong gii hn cnh bo cn gp 4 ln cc hin tng bt thng. Vi cc dao ng tn s cao cc ch s tng ng l 3 ln gi tr ban u: gii hn cnh bo; 6 ln gi tr ban u: c hin tng bt thng. Cc gi tr ny cn ph thuc vo gi tr lc th ph hng trn tng loi my.

Chun tng i

Qu trnh o c thc hin ti 1 vng theo chu k cc gi tr o c so snh theo chui thi gian. Khi cc gi tr bnh thng tng ng vi gi tr ban u, khong thi gian tng ng vi gi tr ny c tnh ton lm c s kt lun. Khi c nhiu my ging nhau, ngi ta o cc gi tr cng tnh trng, so snh tng i v nh gi.

Chun so snh

BNG 2.17 CC L DO DNG CHUN TC Mc Ni dung 1. Qu trnh h hng v mi ca my mc do dao ng t l thun vi tc quay. 2. Nng lng sinh ra do dao ng t l thun vi bnh phng vn tc dao ng v nng lng gy mn v khuyt tt.

My hng

Cm gic

1. Cm gic ca con ngi thng t l thun vi vn tc dao ng. 2. Cc gi tr tiu chun theo kinh nghim trong qu kh thng p dng vi vn tc bng hng s. Gi tr tiu chun c th t c khng ph thuc tc .

Khc

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BNG 2.18 V D V CHUN TNG I T s so vi gi tr thng thng ( gi tr ban u) Phn quan st 1 2 3 4 5 6 7 8 (s ln) 9

4.6. Thit lp bng iu khin xu hng hng hc. cc phn t phn 1 n phn 5 ta xc nh cc phng thc iu khin xu hng hng hc. phn ny nhm xc lp cc phng thc thc hin, kt qu o c tnh ton da trn cc tiu chun o c nh ngha cc phn trc. Vi mc ch ghi li cc gi tr o nhm thit lp cc lch bo dng da trn cc gi tr o c ghi li, ngi ta thit lp bng iu khin xu hng hng hc. Bng ny c to theo cch m ngi s dng d iu khin nht tuy nhin n vn cn c y nhng thng tin chnh xc sau : (1) Tn nh my. (2) Tn my. (3) c tnh k thut ch yu ca my (vn tc, cng sut, kiu vng bi). (4) S cu trc my. (5) Tham s o. (6) Chu k o. (7) Tiu chun nh gi. (8) Chun an ton. (9) Gi tr ban u (gi tr bnh thng). (10) iu kin o. (11) Gi tr o ( ngy o, gi tr o). (12) Ghi ch bo dng. (13) Biu iu khin h hng. 5. CC GIAI ON THC HIN - P DNG K THUT PHN TCH DAO NG TRONG PHN TCH TNH TRNG THIT B Phn ny m t phng php phn tch iu kin c s dng tm kim cc nguyn nhn ca cc bt thng c gim st bi cc phng php gim st tnh trng nu phn trc.

C cu quay

Bnh rng

ln v trt

5.1. c im chnh ca php o v phn tch tnh trng ca my quay. Phn tch tnh trng ca my quay l k thut tm kim cc nguyn nhn gy ra cc tnh trng bt thng c tm thy trong qu trnh gim st tnh trng my. Do dao ng c dng lm tham s trong vic gim st tnh trng, vic ng dng dao ng cng s c p dng cho phn tch tnh trng. Trong qu trnh phn tch tnh trng, cc hin tng bt thng phi c phn tch theo nhiu kha cnh khc nhau. V d, cn thit phi thc hin vic phn tch bng cch t ra cc cu hi nh cc hin tng bt thng xut hin bt ng hay theo trnh t; n c xut hin thng xuyn trong qu kh khng; cc hin tng bt thng ny c n nh hay khng... Ngoi ra xc nh cc hin tng bt thng c sinh ra ta cn phi xc nh c c im thit k ca my ang quan st. bc tip theo, ta phi thc hin vic o v phn tch chnh xc cc dao ng c to ra. Trong trng hp ny, vic phn tch dao ng tng t nh vic phn tch tn s trung bnh. Tuy nhin, nu ch dng mt phng php phn tch, cc hin tng bt thng ch c th quan st theo mt quan im nn i khi c th lm cho vic chun on thiu chnh xc. Cng trong vic phn tch dao ng, qu trnh phn tch phi bao gm c phn tch tn s, pha, bin , thi gian... c th xc nh c dao ng t nhin v dao ng bt thng vi chnh xc cao nht. Mt phng php thng p dng l thit lp mt t kim tra ch ra cc c tnh t nhin ca dao ng tng ng vi cc trng thi bt thng v vi vic tham kho t kim tra ny vi cc kt qu phn tch qu trnh chn on c thc hin trn cc cu tr li v kinh nghim ca ngi s dng.

Tt

Cnh bo

Ti hn

c. Tiu chun so snh Tiu chun so snh c p dng khi c nhiu my ging nhau hot ng trong cng mt iu kin. Ngi ta thc hin php o ti cc v tr ging nhau trn cc my sau thc hin php so snh a ra kt lun v mc ca cc tnh trng bt thng. s dng c ba tiu chun ny, u tin ta phi a ra cc chun tuyt i, cn tp trung vo trng thi ca my cn gim st... tt nhin l khng phi lc no c ba tiu chun u c th p dng c. Do , trong cc trng hp nh vy, bt c tiu chun no ph hp cng cn phi c p dng tng ng vi cc loi my, ta s la chn gia hai tiu chun cn li.

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Mt phng php thng c p dng l ngi ta xy dng cc gi tr ch s h hng tiu chun tng ng vi cc trng thi bt thng. Cc gi tr tiu chun tng ng ny c tnh t cc kt qu phn tch dao ng v c lng cc nguyn nhn ca cc tnh trng bt thng t nhng gi tr ny v cc gi tr tiu chun cp trc. Phng php ny c gi l phng php chn on t ng. V d, cc ch s h hng bao gm : a. S kt hp ca cc thnh phn c bn b. S kt hp ca cc thnh phn iu ha c. Ch s kch ng. BNG 2.19 TN HIU U O Thit b o dao ng B khuch i dao ng, Encoder ... X l tn hiu Khuch i. X l lc, Envelop, Gi tr trung bnh... Phn tch Hin th

Phn tch theo bin

Phn tch theo cc kch ng... ca dao ng sinh ra. Phn tch theo dng dao ng (dao ng cng bc, dao ng t kch...) xoay ca trc theo tc quay v ng cong bin Kt lun cui cng da trn biu mu gim st v cc kt qu phn tch.

Phn tch theo mt phn b v cc gi tr cc tr. Phn tch kiu dao ng v Lissajous.

Phn tch theo thi gian

Kt lun

Kt qu phn tch, biu mu gim st v cc TSKT ca my.

Chu trnh chn on Chu trnh phn tch tnh trng ca my quay V d, s kt hp cc thnh phn c bn l ch s xc nh t l ca chu k quay c bn (fr) c trong dao ng. Nu phng php ny c s dng, qu trnh chun on da trn cc kt qu phn tch s rt hiu qu. Do , n thng c dng lm cng c cho vic chun on t ng. BNG 2.21 CC C IM CA CC PHNG PHP PHN TCH CHNH Cc phng php phn tch chnh c im V d (1) Cc thnh phn gy mt cn bng. (2) Cc thnh phn gy lch. (3) Cc thnh phn to xung p xut. (1) Dao ng cng bc khng i (2) Dao ng t kch thay i hoc cc dng dao ng khc 1) Dao ng cng bc (2) Cng hng (3) Dao ng do lc in t (1) Dao ng trong lng cht lng (2) Dao ng xung

FFT, phn tch thi gian Bn ghi X-Y; Oslo; Vidithc, o pha ban u, graph... tr s Lissajous...

a. Chu trnh phn cng BNG 2.20 CHU TRNH PHN TCH TNH TRNG CA MY QUAY Mc Kim tra ban u Ni dung Kim tra ban u cc c tnh ca thit b; t cc cu hi v trng thi to ra cc hin tng bt thng trong my. Phng tin Cc bn v chi tit v cc biu mu gim st Gim st iu kin v thit b o dao ng cm tay. u o gia tc, vn tc, chuyn v... Thit b ghi d liu v phn tch tnh trng

(1) Phn tch tn s

Kim tra tn s ca cc dao ng to ra

Xc nhn kt qu qu Xc nh di tn sinh ra do hin tng bt trnh gim st tnh trng thng trong cc s liu gim st Xc nh phng php o o dao ng X l tn hiu Quan st sng dao ng Phn tch theo tn s Phn tch theo pha Da vo kt qu cc bc trn, chn cc u o thch hp. Xc nh im o, thc hin cc thao tc o v ghi d liu

(2) Phn tch pha

Kim tra s ng b gia dao ng v qu trnh quay

Chn cc phng php x l chnh xc da Lc v Envelop theo cc hin tng dao ng sinh ra. Quan st dao ng v qu trnh quay ng thi, quan st c tnh dao ng. Oslo; Vidigraph...

(3) Phn tch dng dao ng

Thay i tc kim tra s thay i ca bin theo thi gian Kim tra s phn b bin ca dao ng c to ra

Phn tch cc thnh phn tn s hoc mc Phn tch FFT v thi gian ca dao ng c to ra. thc Phn tch gi tr pha tng ng vi cc thnh phn tn s ca dao ng sinh ra v s thay i ca pha theo cc chu k thi gian. Thit b o pha v phn tch FFT.

(4) Phn b ngu nhin

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5.2. Cc trng hp c trng ca dao ng vi tn s thp. Dao ng vi tn s thp sinh ra trong my quay do nhiu nguyn nhn khc nhau, do cc phng n khc phc cng khc nhau. V vy cn thit phi loi cc nguyn nhn gy dao ng. Dao ng vi tn s thp c th chia lm hai loi dao ng: dao ng cng bc v dao ng t kch. Bng di y so snh cc c im ca hai loi dao ng ny. Cc c tnh ca cc hin tng bt thng c trng c m t phn di y. BNG 2.22 SO SNH DAO NG T KCH V DAO NG CNG BC

a. Mt cn bng: L hin tng xut hin nhiu nht trong cc nguyn nhn gy dao ng do hin tng bt thng trong cc my quay. V d, cc nguyn nhn gy mt cn bng trn puli c th do: nh hng ca v tr l L trc b lch nh hng vt liu Mn tng phn c im ni bt ca dao ng gy ra do mt cn bng l xut hin tn s quay c bn ng b vi qu trnh quay. Lch tm cng gy ra cc dao ng tng t nh mt cn bng BNG 2.23 C TNH CA DAO NG DO MT CN BNG Tham s Hng ca dao ng c tnh - Gy cc dao ng hng knh, nhng do c im ca ln, cc dao ng thng theo phng ngang. - Vi cc my dng cng xn, dao ng hng trc xp x dao ng hng knh

Ni dung

Dao ng cng bc

Dao ng t kch

Quan h gia tn s v tc

Tn s bng tn s quay hoc bng n ln tn s quay hoc bng 1/n ln tn s quay (n l s nguyn dng).

Tn s l hng s khng ph thuc vo tc quay.

Quan h gia tc v bin

Bin t cc tr ti mt vn tc no , gi tr cc tr thng ng vi vn tc ti hn hoc n ln vn tc ti hn.

Bin ln bt ng ti mt gi tr tc no sau n khng gim na mc d tc c gim. Tn s dao ng

Fr : trng vi tn s quay.

Dao ng c cn

Gi tr cc tr nh i nhng vn tc gy ra gi tr cc tr vn khng i.

Nu c cn, tc lm bin tng n ln sau khi bin ln n s khng i na.

S thay i pha

Lun lch pha 1 gc no .

Xoay Tnh trng bt thng Gi tr bin khng ph Bin t l thun vi mc bt thng. thuc vo mc bt thng.

Trng hng quay.

Lin h vi vn tc

Khi vn tc gim ti mt gi tr no chuyn v tr n im 0 (khng k min cng hng).

To tn s

Tn s quay, n hoc 1/n ln tn s quay, hoc tn s ring.

Tn s ring ca trc.

b. Lch tm Dao ng do lch tm ca cc trc quay l hin tng dao ng gy ra khi hai trc ni nhau qua khp ni b lch tm. Lch tm gy ra cc dao ng dc trc. Khi lch nh tn s dao ng trng vi tn s quay; vi lch ln, xut hin dao ng iu ha vi thnh phn chnh l tn s quay xut hin. Do , v mt tn s, lch tm c th rt kh phn bit vi hin tng mt cn bng. Nhng nu ta thit lp mi quan h gia bin v tc d dng phn bit c 2 hin tng ny. Trong hin tng mt cn bng bin tng t l thun vi bnh phng tc trong khi trong hin tng lch tm bin l hng s.

Phng php phng nga

- t tc lm vic khc tc ti hn. - Gim ti a ngo1 lc. - Khi buc phi s dng tc ti hn dng cn gim bin dao ng.

- t tc < tc gy hin tng t kch. - Gim nguyn nhn gy mt n nh. - Lp gim chn y tc gy t kch ln cao.

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BNG 2.24 C IM CA DAO NG DO LCH Thng s Hng dao ng c im Dao ng hng trc. Nu dao ng ln hn 50% ca dao ng hng knh hin tng lch xut hin

d. Dao ng t kch. Dao ng t kch gy ra do cc nguyn nhn, v d, trc trt, thay i m du... c im ca dao ng ny l dao ng xut hin theo cc tn s t nhin ca cc thnh phn cu to nn my. Do , phn bit dao ng t kch v dao ng cng bc, cn phi quan st s thay i ca pha dao ng. BNG 2.26 C TNH CA DAO NG T KCH Thng s Hng dao ng Khng c hng xc nh c im

Tn s dao ng

Trong cc biu khp ni thng thng Fr xut hin l chnh, tuy nhin nu lchqu ln cc dao ng iu ha (2fr & 3fr) c to ra.

S thay i pha

Lun lun tn ti gc lch pha.

Tn s chnh

Tn s dao ng khng lin quan ti tn s quay

Lin h vi tc

Khng ph thuc vo gim ca tc , chuyn v c th gim hoc bng hng s nhng khng tin ti 0.

lch pha

Thay i (khng ng b)

Lin h vi tc c. Rung Hin tng rung c th gy ra do lc kp bu lng mng my khng . Khi hin tng ny xut hin, n gy ra dao ng theo phng thng ng. Trong trng hp rung ta phi quan tm n nh hng ca lc trng trng, thm vo na l lc cng bc do mt cn bng v lch tm. Trong hin tng rung, c tnh dao ng l phi tuyn do kh phn tch. y ch gii thiu mt vi v d n gin. Khi trng lc ln hn lc ly tm, hin tng ging nh mt cn bng nhng vi tc cao hn, lm cho hin tng mt cn bng tng ln. Chuyn v ln ch gy ra trn mt phn no ca trc trong mt vng quay. Do , trong trng hp ny, cc hi dao ng cp cao hn s c sinh ra cng vi dao ng vi tn s quay. Bng di y ch ra c tnh ca dao ng ny. BNG 2.25 C TNH CA DAO NG DO RUNG Thng s Hng dao ng c tnh Thng theo phng thng ng. e. Dao ng do lc in t :

Ti mt tc no , bin t ngt tng, sau tc thay i, bin vn c xu hng tng.

Trong cc my quay, ngoi cc lc c kh cc lc in t cng c th gy ra dao ng. Khi dao ng do lc in t xut hin, tn s ca dng in l tn s c bn. Do khi ng c 60Hz quay vi tc 3600v/ph dao ng gy ra c tn s 60Hz hoc 120Hz. Mt khc, nu c bt c hin tng bt thng no v c kh, tn s dao ng sinh ra s nh hn mt cht so vi tn s quay, v d 60Hz hoc 120Hz. Nguyn nhn l do ng c lun gy trt. Do , trong trng hp ny, iu quan trng l quan st s thay i ca pha. Bng 2.27 ch ra cc c tnh ca dao ng in t.

Tn s chnh

Thng thng cng vi tn s c bn fr cc thnh phn iu ha (2fr; 3fr ...) c to ra. Cc tn s 1/2fr; 1/3fr cng c to ra.

lch pha

Khng i (ng b).

Lin h vi tc

Nu vn tc thay i chuyn v t ngt tng hoc gim.

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BNG 2.27 DAO NG DO LC IN T H thng tnh trng bt thng Hin tng bt thng c tnh dao ng

6. MT S TRNG HP NG DNG PHN TCH DAO NG CHN ON H HNG CA THIT B. 6.1. Mt cn bng Static Unbalance

in th cp khng n nh (bao gm mt cn bng cun dy

- Trng thi dao ng bnh phng 2P - Dao ng vi tn s 2f v fk tng - Khng ph thuc vo ti.

FFM H thng tnh Khng cn bng khe h - Trng thi dao ng bnh phng (2P 1) - 2f v fk ln - Khng ph thuc vo ti Dynamic Unbalance

Radiel

Please Note: Strong Unbalance Cause Harmonics

Overhung Rotor Unbalance

Lch tm t

- Ngoi cc tnh cht trn cn c + Dao ng hng trc ln vi tn s 2f + Tn s 2f fr ln

6.2. Lch tm A. Parallelmisalignment

Mt cn bng cun th cp

H thng quay

- Tn s 2f & fk ln - Thnh phn 2f trong khong 2sf v fr - Thnh phn fk trong khong 2sf & fr - Khi tng ti hoc lc khi ng mc dao ng ln

B. Angularmisalignment

Trc b un

Ngoi cc hin tng trn - Ph s ln ti 2f nfr - Tn s 2f nfr 2msf ln - Ph ln ti fr 6.3. Trc un

f : Tn s dng. fr: Tn s quay.

fn: Tn s rnh. s: Thanh trt.

P: S i cc.

5.3. Trng hp c trng ca dao ng vi tn s cao Dao ng thng xut hin do tip xc. Dao ng ny xut hin ch yu ln v cc cp bnh rng n khp. Cc dao ng ny l tng i phc tp v cng phi s dng cc phng php x l s liu c bit. Cc dng dao ng ny cn c nghin cu k lng trong nhng ti c phm vi ln hn.

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6.4. Dao ng ca ln

6.6. Dao ng do nht du khng m bo

W0 = 0

Oil Instability
10 3.1 1

W0 = Ws

0.031

W0 ~ 0.3 - 0.5

Ws

0.43X

1X

2X

6.7. H hng v mn bnh rng

No Fault

Bearning Fault

Envelope Spectrum

PFFI

6.5. Lng cc c cu ghp ni

Loose Foundation

Gear Box Spectrum 6.8. H hng ng c in

Gear Box Cepstrum

Stator Bars Loose Shaft

Rotors Bars 35 dB 45 dB

Zoom spectrum

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7. THIT B V PHN MM GIM ST CHN ON TNH TRNG THIT B GIN ON Vic p dng cc phn mm my tnh lm tng hiu qu ca vic gim st v chn on tnh trng thit b ln rt nhiu. Trong lnh vc ny, c rt nhiu phn mm ca nhiu hng trn th gii c Nghin cu v pht trin. Mc d c th do nhiu nh sn xut khc nhau, nhng mt cch tng qut cc chc nng ca cc phn mm gim st v chn on tnh trng u tng t nhau. Trong phm vi bo co ny chng ti s tp trung gii thiu phng php ng dng phn mm my tnh trong vic gim st v chn on tnh trng thit b. Phn mm c s dng y l phn mm SENTINEL ca Hng Bruel & Kjaer - an Mch. y l mt hng rt ni ting trn th gii trong lnh vc gim st v chn on tnh trng thit b. 7.1.Cc thit b o cn trang b: - Cc u o: + Gia tc k (Accelerometor): BK 4391 + u o tc v chuyn v (Tacho Photoelectric): ZC0028 - H thng thu nhn v phn tch d liu: + My o (Data Collector): BK2526 + Phn mm cn bng ng ti hin trng (Field Balancing Software): FAB 7112 - H thng phn tch v chn on tnh trng thit b: + My tnh c nhn Pentium III 500MHz + Phn mm gim st v chn on: Sentinel Modul K, L, M. Cc thit b ny u ca Hng Bruel & Kjaer (an Mch) sn xut 7.2. Gii thiu phn mm SENTINEL: Phn mm SENTINEL do Hng Bruel & Kjaer (an Mch) vit, kt hp vi h thng thu thp d liu (Data Collector) v cc u o to thnh H thng gim st v chn on tnh trng gin on (Machine Condition Monitoring and Diagnosis System). Phn mm Sentinel cho php: Kt ni v thu nhn cc tn hiu t cc my o (Data Collector) vo PC Qun l v lu tr cc tn hiu o, xy dng c s d liu qun l cc thit b trong nh my. Cung cp cc phng php x l tn hiu ( y l ph dao ng) cho php phn tch v pht hin cc dng h hng c trng ca cc chi tit quay nh mt cn bng, lch tm..., cc dng h hng c bit ca ln v bnh rng. Xut ra cc bo co cn thit v tnh trng ca thit b. 7.3. C s d liu qun l nh my ca phn mm SENTINEL: C s d liu ca phn mm SENTINEL cho php qun l cc thit b trong nh my vi s lng khng hn ch. SENTINEL qun l thit b theo cu trc hnh cy (Node Tree), cc thit b c cu trc di dng mt nt (node) ca cu trc cy. Hnh 2.47: Cu trc cy d liu Cu trc cy d liu bao gm 4 kiu nt sau: Plant: Nt cp cao nht cha cc thng tin v trng thi ca nh my cn gim st. Cc thng tin ny gm tn ca nh my v trng thi ca nh my. Area: Nt cp cao th hai cha cc thng tin v trng thi ca khu vc cn gim st. Cc thng tin ny gm tn ca khu vc v trng thi ca khu vc. Unit: Nt cp cao th ba cha cc thng tin v trng thi ca b phn cn gim st. Cc thng tin ny gm tn ca b phn v trng thi ca b phn. Machine: Nt cp thp nht cha cc thng tin v trng thi ca my, thit b cn gim st. Cc thng tin v my bao gm: + Cu trc ng hc ca my. + V tr cc im o. + Cc php o tng ng vi cc im o.

Hnh 2.48: Giao din o v qun l d liu dao ng Ngoi ra ti tt c cc nt, u c h thng n bo hiu thng bo tnh trng ca thit b. n (Red light): Thit b tnh trng nguy him, cn dng hot ng sa cha. n vng (Yellow light): Thit b tnh trng cnh bo, cn theo di cht ch tnh trng ca h thng. n xanh (Green light): Thit b hot ng bnh thng. n xanh nc bin (Blue light): H thng gim st c li, cn sa cha.

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7.4. Trnh t cc bc xy dng c s gim st thit b bng phn mm SENTINEL: a. nh ngha tn Nh my (Plant) Ngi s dng nh ngha tn ca nh my m thit b c t.

b. nh ngha tn khu vc (Area) Ngi s dng nh ngha tn khu vc t thit b trong nh my

im o v v tr o

c. nh ngha tn b phn (Units) Ngi s dng nh ngha tn b phn t thit b trong trong khu vc nh ngha.

u o v cc phng php o

d. t cu hnh cho my gim st (Machine) Phn mm SENTINEL cho php xy dng cu hnh gim st mt thit b bao gm cc thng s c bn sau: Tn v cu trc ng hc ca my

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- t cc gi tr chun cho cc php o

f. Thc hin cc php o Sau khi nh ngha y cc tham s o, ngi s dng tin hnh o bng cch mang cc my o xch tay ti cc im o nh ti hin trng v tin hnh cc php o. Sau khi cc php o c thc hin, ngi s dng c th nh gi s b v tnh trng thit b thng qua cc gi tr o. Trong cc trng hp tng qut, cc gi tr o s c truyn v my tnh c nhn c ci phn mm SENTINEL, ti y cc gi tr dao ng o c v cc gi tr ph tn s s c phn tch xc nh chnh xc tnh trng ca thit b v cc h hng xut hin trn my cng nh nguyn nhn gy cc h hng ny. 7.5. Gim st v phn tch tnh trng thit b: Phn mm SENTINEL cho php ngi s dng gim st v phn tch tnh trng theo hai dng sau: a. Biu xc nh xu hng h hng ca thit b (trend plot): Vi dng biu ny, cc gi tr cc tr (peak) hoc trung bnh (rms) ca bin dao ng theo thi gian c tch lu v v thnh th. th ny cho php ngi s dng c th gim st c s thay i ca dao ng my theo thi gian, d bo xu hng pht trin ca dao ng, so snh cc tn hiu dao ng vi cc chun nhm nh gi c tnh trng ca thit b.

e. t cc tuyn o (route) kt ni ng truyn cc tn hiu o t Data Collector v PC. Phn mm SENTINEL cho php xy dng cc tuyn o nhm kt ni ng truyn cc tn hiu o t Data Collector vo PC. Vic xy dng cc tuyn o ny cho php d dng chuyn cc tn hiu chnh xc n tng im o, tng php o trong trng hp ngi s dng phi thc hin o rt nhiu php o trong mt ca lm vic.

b. th ph tn s (Spectrum Display): Bin dao ng theo tn s trong mt ln o c hin th trn th hai chiu cho php phn tch xc nh cc dng li h hng c trng ca thit b.

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Ngoi ra, ta c th hin th th ph tn s di dng 3 chiu - trong c 1 chiu thi gian (Water fall plot) cho php gim st v phn tch qu trnh h hng ca tng dng li c th.

7.6. Xut cc thng bo. SENTINEL cho php xut cc thng bo y cho cho ngi s dng cc thng tin v tnh trng my, im o, thi gian o tip theo... Cc thng bo ny gip cho ngi s dng c th a ra c chnh xc thng tin v tnh trng my qua hon ton ch ng a ra cc phng n sa cha, bo dng ph hp.

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1. Tnh hnh v trnh pht trin ca bo dng Cng ty Giy Bi Bng Cng ty Giy Bi Bng l c s sn xut bt giy, giy ln v hin i nht nc ta hin nay. Cng ty c mt t hp cc dy chuyn thit b sn xut hon chnh v ng b t cc ngun cung cp ng lc v nguyn, nhin liu: x l v cp mnh g, in, hi nc, kh nn, nc cng ngh, ho cht cc loi.. n cc dy chuyn sn xut bt giy, dy chuyn xeo giy v h thng kho bi, cc loi phng tin vn chuyn ng thy, ng b v ng st... Do vy, cc loi my mc thit b s dng trong Cng ty rt a dng c v chng loi ln s lng cng nh iu kin lm vic. Vi c th , cng tc bo dng Cng ty Giy Bi Bng rt phc tp, khi lng cng vic rt nhiu t khu qun l, lp k hoch bo dng n sa cha, bo dng ngoi hin trng. Cho ti nay, phng php bo dng c p dng Cng ty vn l Bo dng Phng nga nh k (Time- based preventive maintenance). Hng nm, theo k hoch bo dng, Cng ty dng ton b dy chuyn sn xut tin hnh cng tc bo dng: tho ri cc cm my kim tra, thay th du m bi trn, lm v sinh my, thay th cc chi tit hng v cc chi tit n k hn thay th, phc hi cc chi tit xung cp, hiu chnh hot ng ca thit b sau khi sa cha, nng cp.. C cu t chc thc hin cng tc bo dng ca cng ty gm c: mt xng c kh lm cng tc ch to cc chi tit thay th hoc phc hi cc chi tit hng; cc t, i bo dng i theo cc khu vc sn xut lm cng tc x l s c, bo tr, duy tu.... Tt c cc n v bo dng ca Cng ty c bin ch vo Nh my Bo dng. Vic ln k hoch bo dng c da trn k hoch sn xut, tnh trng xung cp ca my mc thit b, nhn lc, vt lc v tin nhp hoc ch to cc chi tit, thit b, ph tng thay th. Ni chung, so vi cc c s sn xut trong nc, trnh pht trin ca bo dng Cng ty Giy Bi Bng l kh hin i v hiu qu, nht l vi s lng v chng loi cng vic a dng nh vy. Tuy nhin, trn th gii phng php bo dng phng nga nh k lc hu v cn nhiu nhc im: Hn ch chung ca cc phng php bo dng phng nga l "Bo dng qu mc". Do vy, tnh kinh t ca phng php bo dng ny cha cao. Mt s thit b, my mc b xung cp do tho lp hoc do dng my- khi ng li kim tra. Chng hn nh hao mn do khi ng li mt tua bin hi c tnh tng ng vi 30 gi lm vic lin tc. Ngoi ra, my mc cn c th b hng hc khi tho lp do li ca cng nhn bo dng. Quan im ca bo dng hin i l ch dng my khi c vn cn x l. Do quy lut phn b hng ngu nhin ca cc chi tit, c nhiu chi tit b hng trc khi n thi gian thay th gy hng my v phi dng sn xut ngoi k hoch, ngc li, c nhng chi tit vn cn tt nhng vn phi thay th theo nh k. iu ny gy ra nhiu thit hi cho sn xut v lm lng ph chi ph bo dng. Kh b tr k hoch s dng ngun nhn, vt lc mt cch hp l. Vo thi k dng my bo dng, cc cng nhn vn hnh phi ngh ch vic, trong cng thi im cng lao ng ca cng nhn bo dng li rt cao. Ngc li, khi dy chuyn sn xut n nh, cng nhn bo dng v cc thit b my mc phc v bo dng thng c t vic lm. Kh lp k hoch bo dng v ln danh sch cc ph tng, chi tit d tr thay th do khng bit c tnh trng xung cp ca cc thit b my mc trong dy chuyn v tui th d kin cn li ca tng b phn, chi tit.

19.V D NG DNG V TRIN KHAI TPM CNG TY GIY BI BNG

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2. Trin khai TPM Cng ty Giy Bi Bng Sau khi nghin cu v kho st k tnh hnh bo dng Cng ty Giy Bi Bng, chng ti a ra phng n trin khai TPM v thc hin c th ti cng ty theo cc bc sau: Gii thiu cc khi nim v phn tch s cn thit, cc li ch ca vic ng dng v trin khai TPM, cc khuyn ngh c th vi lnh o Cng ty Giy Bi Bng. T vn v cung cp ti liu cho lnh o Cng ty v cc cn b ph trch bo dng lp ra trnh t v phng n trin khai TPM ti Cng ty. T chc cc hi ngh, hi tho gii thiu v TPM v phi hp vi Cng ty Giy Bi Bng t chc cc kho o to v cc ni dung TPM cho cc qun c, cc cng nhn bo dng v vn hnh. Cung cp cc phng tin v gii php k thut: cc k thut chn on, gim st tnh trng thit b; h tr cng tc lp k hoch bo dng v qun l bo dng lm c s cho trin khai TPM. Bc u gii thiu v trin khai m hnh "thit k thit b khng cn bo dng" vi i tc cung cp thit b truyn thng l Vin Nghin cu C kh. H tr v t vn cho Cng ty Giy Bi Bng trong cc bc trin khai th im TPM: xc nh cc mc tiu TPM cho cc nhm cng nhn vn hnh v cng nhn bo dng, t chc cc y ban TPM cc cp, cc u ban thi ua, cung cp cc ti liu v cc kho hc nng cao k nng bo dng v cc k thut bo dng tin tin ca th gii..

20. KHI NIM V CC NI DUNG C BN CA TPM

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1. nh ngha TPM- Bo dng Hiu nng Tng th TPM- Bo dng Hiu nng Tng th l s pht trin tip theo ca Bo dng Sn xut (PM) vi cc ni dung sau: Hng ti hiu sut s dng thit b ti a. Thit lp mt h thng qun l thu tm ton b chu k s dng thit b. Bao gm tt c cc b phn: lp k hoch, vn hnh, bo dng.. C s tham gia ca tt c mi ngi t ngi lnh o cao nht cho ti cc cng nhn cc xng. Hot ng t qun ca cc nhm nh cng nhn. Thut ng PM trong nhm t TPM khng phi l Bo dng Phng nga m c ngha l Bo dng Sn xut cho c chu k s dng ca thit b. TPM ch thc s c hiu qu khi c 5 iu kin nu trn c thc hin. T "Tng th" trong thut ng bo dng sn xut tng th c 3 ngha: Tng th vi ngha "Hiu sut Tng th" Tng th vi ngha " Ton b h thng " Tng th vi ngha "s tham gia ca Tt c" Cng ngh bo dng TPM khng nhng khc phc c nhng nhc im, pht huy c tt c cc u im cc loi hnh bo dng trc y m cn c thm nhng u im khc (H.2.49): TPM trnh c nhng tn tht do bo dng qu mc ca Bo dng Phng nga v s th ng, s thiu hiu qu ca cng nhn vn hnh trong vic tham gia vo cng tc bo dng trong Bo dng Sn xut, hn na, TPM cn to ra mt mi trng lm vic thun li, d chu v tch cc. Do vy, trong loi hnh bo dng TPM, cc thit b c s dng vi hiu qu ti a, cc li vn hnh c gim thiu, trang thit b lun tnh trng tt v c sa cha, nng cp kp thi.

2. Cc ni dung ca TPM 2.1. T tng ch o ca TPM em li li nhun: Hiu qu kinh t, khng c tai nn, khng khuyt tt, khng hng my. Chnh sch Phng nga (Phng trnh tai nn xy ra): c thc hin v m bo nh cc k thut MP (Phng nga Bo dng), PM (Bo dng Phng nga), CM (Gim st tnh trng thit b) C s tham gia ca tt c: S phi hp hot ng ca cc nhm nh thc hin bo dng t qun. Gn cht vi thc t sn xut: Cc thit b lun trong tnh trng ti u, kim tra, nh xng gn, sch, p. Mc t ng ho cao: Hng ti sn xut hon ton t ng, khng c ngi iu khin.

2.2. Mc ch ca TPM TPM nhm ti cu trc cng ty thng qua nng cao cht lng ngun nhn lc v trang thit b.

Nng cao cht lng ngun nhn lc

o to nhn cng p ng cc yu cu: (1) Cng nhn vn hnh: kh nng thc hin cc k nng bo dng, chm sc my mc hng ngy. (2) Cng nhn bo dng: kh nng thc hin cng tc bo dng chuyn ngnh. (3) K s khi sn xut: kh nng iu hnh chung.

Cc nhm bo dng H thng hon chnh t qun ca cng nhn (Phng nga Bo vn hnh dng - Bo dng Phng nga - Bo dng Hiu chnh) X X X

Hiu qu kinh t (Bo dng em li li nhun) Nng cao cht lng trang thit b X X X Cc c im ca TPM Cc c im ca Bo dng Sn xut Cc c im ca Bo dng Phng nga (1) Nng cp, tn trang thit b ci thin hiu sut thit b. (2) Ch trng ti yu t chu k s dng thit b v thi gian chy khi ng khi thit k th h my mi.

2.3. Cc ni dung c bn ca TPM Cng tc trin khai TPM ti bt c c s no u tri qua 12 bc thc hin, tun th 8 nguyn tc c bn v da trn 8 tr ct TPM, vi mt c cu t chc hp l, hiu qu. Cc bc trin khai TPM mt cng ty tri qua cc giai on: chun b, bt u, trin khai v duy tr. Cng tc trin khai TPM bao gm 12 bc (Bng 2.28) Cc nguyn tc c bn ca TPM l nhng yu t gn b hu c, b sung v h tr ln nhau. 8 nguyn tc ny phi c tun th trong sut qu trnh trin khai TPM. Cc tr ct ca TPM thc cht l sc c th ho cc nguyn tc c bn ca TPM thnh cc mc ch, ni dung, i tng v cc bc thc hin (H.2.50). Mi quan h ca cc tr ct TPM th hin trong (H.2.51)

Hnh 2.49: Cc c im u vit ca TPM

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BNG 2.28 BC CA CHNG TRNH PHT TRIN TPM Giai on Bc thc hin 1. Cng b quyt nh trin khai TPM ca ban lnh o cng ty Cng tc chun b trin khai TPM 2. T chc cc cng tc tuyn truyn, gii thiu v o to v TPM 3. Thnh lp c cu t chc chuyn trch thc y s pht trin TPM 4. Xc nh cc mc tiu v nguyn tc c bn cho TPM 5. Xy dng mt k hoch tng th cho trin khai TPM Bt u trin khai 6. Pht ng TPM Trng tm Cng b quyt nh trin khai TPM trong hi ngh ni b ng ti cng b trn trong cc n phm ni b ca cng ty Cc nh qun l: o to ti ch v TPM cho tng cp Cng nhn vin: tham d hi ngh v TPM vi ni dung trnh by trc quan T chc cc u ban v cc tiu ban chuyn trch Bu ra cc th k u ban v tiu ban Xc nh cc tiu ch, im chun v mc tiu Xc nh hiu qu d kin Bao gm t khu chun b gii thiu n t chc kim tra, nh gi Mi tham d: - Cc nh cung cp - Cc cng ty i tc - Cc cng ty lin kt Theo ui hiu qu sn xut ti a t k hoch cho cc hot ng theo i v theo cc nhm nh trong mi phn xng Lp cc h thng trnh t, chn on v xc nhn kh nng chuyn mn Bo dng ci tin, bo dng nh k, bo dng d bo o to nhm cho lnh o cng ty v cc hng dn vin Pht trin cc sn phm theo tiu ch d ch to v thit b d vn hnh To ra cc iu kin sn xut khng sai hng, d kim tra v bo dng H tr sn xut, nng cao hiu qu cng tc ti b phn ca mnh v tng hiu qu s dng trang thit b Xy dng h thng Khng tai nn v Khng nhim T chc cc gii thng PM (Bo dng Sn xut) Xc nh cc mc tiu phn u cao hn

7. Xy dng h thng nng cao hiu qu sn xut 7.1 S pht trin c nhn 7.2 Bo dng t qun 7.3 Bo dng theo k hoch Trin khai TPM 7.4 o to nng cao cc k nng vn hnh v bo dng 8. Thit lp h thng kim sot ban u cho cc thit b v sn phm mi 9. Thit lp c cu t chc bo dng cht lng 10. Thit lp h thng nng cao hiu qu cng tc ca b phn hnh chnh v cc b phn gin tip khc 11. Thit lp h thng kim tra an ton, v sinh v mi trng lm vic Duy tr 12. p dng TPM mt cch ton din v khng ngng nng cao mc pht trin

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274 TI N B C NHN BO D NG THEO K HOC H H TH NG PH NG NGA BO D NG O TO BO D NG T QUN BO M C HT LNG Q UN L HNH C HNH AN TO N, V SINH V M I TR NG
Hnh 2.50: Nguyn tc c bn ca TPM

275

Ci thin r rt hiu qu sn xut

Lp ra mt h thng nhm t c hiu qu sn xut cao nht - Nng cao hiu qu sn xut. - Gim 16 tn tht chnh - Nng cao cht lng thit b; trnh v thc ngi vn hnh Thit lp h thng bo dng c k hoch - Thc hin cc chng trnh hun luyn nng cao k nng cho cng nhn bo dng v vn hnh - Nng cao trnh p dng v k nng ca cng nhn vn hnh v cng nhn bo dng Thit lp h thng qun l thit b v sn phm t trn xung Thit lp h thng duy tr cht lng thit b ti u Thc hin TPM trong vn phng, t chc h thng nhm t hiu qu cao Xy dng cng ty theo tiu chun: an ton, v sinh, bo v mi trng.

i ni mc

- Thc hin mc tiu khng tn tht i vi li sn phm v hng thit b. - Thc hin mc tiu t hiu qu sn xut ti a.

- Khuyn khch pht trin k nng ca cng nhn vn hnh. - Nng cao thc bo qun v s dng ng thit b

- Nng cao hiu qu cng tc ti b phn bo dng nhm gim thiu 8 tn tht chnh

- Rt ngn thi gian th nghim sn phm mi - Rt ngn thi gian nghin cu, thit k v ch to thit b mi - Rt ngn thi gian lp t v chy th thit b mi sn phm

- Thc hin khng li thit b - lun tun th ch bo dng yu cu ca thit b

- Thc hin phng chm khng tn tht chc nng - T chc vn phng lm vic hiu qu cao - Gip v h tr b phn sn xut

m bo nguyn tc Khng tai nn. Ci thin mi trng lm vic

- Ton b i ng cn b cng nhn - Lnh o

- Cng nhn vn hnh - Ton b cc cn b - Cn b ph trch cng nhn b phn dy chuyn bo dng

- Cng nhn vn hnh - i ng nghin cu - Cng nhn bo v pht trin dng - i ng k thut chuyn trch khu sn phm - i ng bo dng - Cc bc bo dng c bn - Sit cht cc mi ghp bu lng - Bo dng cc quay - Bo dng cc hp s truyn ng - Phng nga r r - Bo dng cc hit b kh nn v thu lc - Bo dng cc h thng iu khin in - t ra cc mc tiu cho nghin cu v thit k - t 5 tiu ch: d sn xut, d m bo cht lng, d s dng, d bo dng, tin cy cao. (H thng thit k khng Bo dng) - Nghin cu v LCC (chi ph chu k s dng thit b) - Thit k: nghin cu k vt mu, rt ra cc im cn khc phc, iu chnh.. - Xem xt li thit k

- B phn ph trch Lnh o v nhn vin m bo cht lng b phn bn hng v - i ng k thut hnh chnh chuyn trch khu sn phm - Cn b ph trch dy chuyn - Thng qua cc tiu chun nh gi cht lng v pht hin li. - m bo cht lng sn phm, kho st quy trnh, tiu hao vt liu, tnh trng thit b cho tng phng php sn xut c th - t ra cc nguyn tc cho vic kim tra v theo di tnh trng thit b - Thc hin cc hot ng bo qun v s dng ng thit b 1. V sinh tng th khu vc lm vic ca mi cng nhn 2. V sinh ton b khu vc sn xut 3. Nng cao hiu qu lm vic 4. Tiu chun ha 5. Qun l cng tc vn phng theo mc tiu hiu qu v tit kim

- B phn mi trng, y t v an ton ca cng ty. - Ton b nhn vin cng ty

- Hiu r v 16 tn tht chnh. - Tnh ton cc yu t hiu sut s dng my mc, vt liu, dng c, nng lng.. cho mi n v sn phm v t mc tiu nng cao cc hiu sut . -Phn tch k cc hin tng v nguyn nhn - Tin hnh cc phn tch bo dng sn xut - La chn thit b gia cng thch hp

Thc hin 7 bc 1. V sinh tng th 2. Khc phc cc nguyn nhn gy bn v cn tr cng tc v sinh 3. Th nghim cc tiu chun bo dng c th v thch hp vi thc tin. 4. Kim tra tng th 5. T gic kim tra hng ngy 6. Tiu chun ha 7. Qun l cht ch tt c cc mc tiu t ra

- Bo dng hng ngy - Bo dng nh k - Bo dng d bo - Nng cao thi gian s dng (tui th) thit b - Kim sot v thay th cc b phn my - Phn tch li v tin hnh cc bin php phng nga lp li h hng - Kim sot cng tc bi trn

- Thc hin cc quy tc an ton bo v ngi vn hnh. - Xy dng quy trnh thao tc an ton - Ci thin mi trng: gim bi, khi, n v rung ng - Thc hin nghim ngt cng tc bo v mi trng - Thc hin tt cng tc chm sc sc kho cn b, nhn vin - Khuyn khch nng cao thc bo v, cai thin mi trng lm vic

Cc bc thc hin

Hnh 2.51: Tr ct ca TPM

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277

V D V T CHC H THNG SN XUT HIU QU

H THNG PHT HUY HIU QU VN HNH NGI/MY TI U

(3)
Cc yu cu v vt liu v nng lng m bo sn phm khng khuyt tt

H THNG DUY TR CHT LNG THIT B TI U

Cc yu cu v thit b m bo sn phm khng khuyt tt Cc yu cu v phng php cng ngh m bo sn phm khng khuyt tt Cc yu cu v thao tc vn hnh m bo sn phm khng khuyt tt

(1-1)
Tn tht dng my

Nng cao hiu qu sn xut CCH TIP CN

Gim tnh khng ng u ca tui th lm vic thit b

Tng kt s b d n v a ra cc bin php x l cho tng giai on

Tn tht hng my Tn tht qun l Tn tht lp t v hiu chnh Tn tht di chuyn vn hnh Tn tht thay dng c gia cng Tn tht t chc dy chuyn Khi ng Tn tht chun b sn xut Tm dng my Tn tht o lng v hiu chnh Tn tht tc Tn tht sn lng Tn tht do li v sa li sn phm Tn tht nng lng

Phc hi

H thng duy tr cht lng thit b ti u

Tng tui th lm vic thit k ca thit b Khc phc cc nhc im trong khu thit k Loi tr tai nn

_ Thng xuyn tin hnh bo dng nng cao tui th lm vic thit b c lng tui th thit b v thng xuyn thc hin cng tc bo dng phc hi

D bo tui th lm vic ca thit b

Tiu chun thit k chc nng

(1-3)

Giai on 1

Giai on 2

Giai on 3

Giai on 4

Phn hi cc thng tin bo dng

H thng qun l d liu ban u

(2)

Thc hin cc chun t ra cho ngi v my Gim thiu cc khuyt tt sn phm nh

Phc hi chng xung cp do thiu s chm sc Loi tr s xung cp cng bc _To ra cc iu kin vn hnh c bn _ Gi vng cc iu kin

D bo tui th lm vic thit b bng cc cng ngh chun on

Duy tr chnh xc ca thit b

Kim sot qu trnh ban u

Phc hi duy tr cht lng thit b, chng xung cp do nguyn nhn bn ngoi

Phn tch cc triu chng xung cp bt thng

Tiu chun thit k v C v D

Nng cao tnh d bo dng

Phn tch li

Phn loi cc k nng

Pht trin song song cc ni dung

Bo dng cc thit b xung cp

(1-2)
H thng bo qun v s dng ng thit b

Bc 1
V sinh tng th

Bc 4
Kim tra tng th

Bc 5
Kim tra t qun

Bc 6
Tiu chun ha

Tiu chun thit k v MP

Hiu chnh iu khin

Giai on 2

Phn tch bo dng sn xut

Bc 2
_ Cc bin php chng nhim bn thit b v nng cao tnh d tip cn cc khu vc kh v sinh

Giai on 3

IE, VE, QC

Bc 7
Qun l t qun

Bc 3
H thng bo qun v s dng ng thit b tm thi

nh gi chi ph chu k s dng thit b

Giai on 4

Tn tht dng c gia cng

K nng nng cao K nng yu cu

(1-4) Gio dc/o to vn hnh v bo dng

(4) (5)

Cc k nng bo dng sn xut v bo qun v s dng ng thit b

Khi ng/cc thnh qu QCDSM

Cc k nng s dng cc thit b mi

H thng qun l hiu qu cc n v hnh chnh Cc h thng m bo an ton, v sinh v mi trng lm vic
Hnh 2.52: V d v t chc h thng sn xut hiu qu

278

H thng qun l ban u sn phm, trang thit b v dng c

Giai on 1

279

Hnh 2.53: C cu t chc ca TPM theo nguyn tc phn nhnh

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281

C cu t chc ca TPM da trn 2 nguyn tc: Nguyn tc phn nhnh v nguyn tc phn cp. Nguyn tc phn nhnh: (Hnh 2.53) cc u ban TPM t cp nh my tr xung c t chc thnh cc y ban, tiu ban ngang cp ti mi n v. Nguyn tc ny cho php cng tc trin khai v thc y TPM tng nh my, phn xng, t, nhm.. tr nn linh hot, bm st iu kin v yu cu thc t v nh c hiu qu cao. Nguyn tc phn cp: (Hnh 2.54) theo nguyn tc ny, cc y ban TPM trong ton b cng ty c t chc thnh cp c s v c iu phi thng nht bi cp cao nht (ch tch v y ban TPM ton cng ty). Nh , vic t mc tiu v qu trnh thc hin cc mc tiu lun bm st thc t sn xut, ng thi vn m bo s thng nht v li ch chung ca ton cng ty.

Cc im c bn 1. Gim s c hng my 2. Gim thi gian ch v lp t 3. S dng c hiu qu cc thit b hin c 4. Qun l cht ch trang thit b v dng c 5. Gi gn cc ngun lc v tit kim nng lng 6. Ch trng cng tc o to v gio dc ngun nhn lc

Mc ch:
Lnh o cao nht

S liu thc t 1. Gim s c hng my

Phng tng hp

Mc tiu Di 10/ thng Di 0,1%/ 100 gi Di 0,2% Di 1.200 gi/ thng Trn 95% Trn 169% Di 0,1% Di 70% 60/nm/ ngi Tiu ch t gii thng PM

938/ thng 1,03%/100 gi 1,59% 88,8% 113% 0,7%

Phng k hoch

Phng ti chnh

Phng nhn s

2. T l s c hng my 3. S c hng my 5. Hiu qu tng th thit b 6. Ci thin nng sut 7. Gim li sn phm v cng khc phc li 9. S lng sng kin ci tin lin quan ti PM 10. S v tai nn

4. Thi gian ngng my 5.800 gi/ thng

Khi sn xut
Nh Nh Nh Nh my my my my

Pht trin sn xut v thit b

Bn hng

TPM CP 1

TPM CP 2

8. Tit kim nng lng 100% 2,1/ nm/ ngi

Hnh 2.54: C cu t chc ca TPM theo nguyn tc phn cp V d v hoch nh chnh sch chin lc pht trin TPM v xc nh mc tiu TPM ca mt cng ty

11/ nm

0/ nm

CC I HI CA TH TRNG 1. a ra sn phm mi mt cch kp thi v hiu qu 2. Phn ng linh hot vi cc din bin ca th trng 3. Gim gi thnh sn phm 4. m bo cht lng tt 5. Gi gn cc ngun lc v tit kim nng lng

CC I HI CA TH TRNG 1. S gia tng cc li sn xut v sn phm 2. Hao mn thit b do qu ti 3. S lng thit b c khim khuyt trong thit k gia tng 4. Cng nhn vn hnh thiu thc v kin thc qun l thit b 5. Cng nhn vn hnh thiu tinh thn trch nhim v chn nn do s thiu tin cy ca thit b

2.3. Hiu qu ca TPM Hiu qu ca TPM vi cc yu t u ra PQCDSM: * P: Production Q: Quality C : Cost D : Distribution S : Safety M: Morale Sn lng Cht lng Chi ph Phn phi An ton Cc gi tr phi vt cht

Chnh sch v chin lc TPM: Trin khai Bo dng Sn xut vi s tham gia ca tt c cc thnh vin cng ty, huy ng s ng gp ca h trong nng cao hiu qu s dng thit b tng th v gim gi thnh sn xut, hng ti: "Khng hng my", "Khng li sn phm", "Khng tai nn".

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283

P Q-

Tng sn lng 1,5 n 2 ln Gim cc s c hng my ngu nhin 1/10 n 1/250 Thi gian vn hnh thit b 1,5 n 2 ln Gim khuyt tt trong sn phm 1/10 Gim s ph bnh v phn nn ca khch hng 1/4 CGim chi ph bo dng 30% DGim hng ha tn kho 0 SGim tai nn v nhim 0 MTng s lng sng kin xut ca cng nhn 5 - 10 ln TPM lm tng hiu qu tng th nh my nh gim thiu cc loi tn tht (H.2.55 v H.2.56) Cc li ch gin tip ca TPM Khi h thng bo dng t qun pht huy tc dng, cng nhn vn hnh t gic chm sc v bo dng my mc ch khng th ch c giao nhim v. Vi cc phong tro "Zero Breakdowns "- (Khng hng my) v "Zero Defect" - (Khng li sn phm), cng nhn vn hnh thy t tin hn vo kh nng ca mnh. Nh xng sch s v ngn np, to mi trng lm vic d chu, thoi mi, ci thin iu kin cng tc ca cn b, nhn vin. Nng cao uy tn ca cng ty.

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285

Nh my

8 tn tht chnh

Tnh ton hiu sut tng th nh my

Thi gian theo lch sn xut (A)

(1) Bo dng theo k hoch Hiu sut =

(A) - (1) . (2) . (3) . (4) A

x 100(%)

(2) Qun l sn xut Thi gian chy my (B) Tn tht my ngh (3) Hng my Hiu sut = (C) (A) x 100(%)

Thi gian vn hnh (C)

Tn tht dng my

(4) Hng dy chuyn

Hiu sut vn hnh (SLTB) - (1) . (2) . (3) . (4) (SLTC)

x 100(%)

(5) Sn xut bnh thng Thi gian vn hnh thc (D) Tn tht cng sut (6) Sn xut khng u Thi gian vn hnh hiu qu (E) Tn tht do k nng km

Hiu sut vn hnh =

(D) (C)

x 100(%)

T l sn phm t cht lng (7) Thiu st cng ngh (SL) - (7) . (8) . (SL) (SLTC) (8) X l l T l sn phm t cht lng = (E) (D)

x 100(%)

x 100(%)

Hnh 2.55: Hiu qu tng th ca nh my * (SL) : Sn lng (SLTB): Sn lng trung bnh (SLTC): Sn lng tiu chun Hiu qu tng th nh my = Hiu sut x Hiu sut vn hnh x T l sn phm t cht lng

286

287

Hnh 2.56: C cu tn tht trong qu trnh sn xut (16 tn tht chnh)

288

289

1. Cc giai on pht trin ca bo dng v cc tiu ch nh gi trnh pht trin ca bo dng. (1) Giai on 1 (2) Giai on 2 (3) Giai on 3 Bo dng Hng my Bo dng Phng nga Bo dng hiu nng (PM) Bo dng hiu nng Tng th (TPM)

21. L THUYT TPM V HNG DN TRIN KHAI TPM

(4) Giai on 4

BNG 2.29 PHNG PHP V TIU CH NH GI MC PHT TRIN CA BO DNG Mc kim tra 1.Cng thc ho sch lc v PM & t ra cc mc tiu hot ng cho cc b phn Giai on 1 (1) 1.1 + Khng c cc h thng qun l xc nh nhim v. Do vy khng c s xc nh r vai tr ca PM. + H thng tiu chun hoc cc quy nh quc t khng c h thng ho + Khng c cc hot ng JK v H thng khuyn ngh 2.1 + V mt t chc, khng c chc nng ch to v sa cha my mc. + Mt t sa cha nh c bin ch vo b phn sn xut. Vic sa cha ln c thc hin b phn c kh (hoc b phn sa cha) Giai on 2 (2) 1.2 + c H thng qun l xc nh nhim v + Chnh sch PM cho nh my r rng + Thng nht quy nh ni b trn giy t, nhng cha y . + c cc hot ng JK nhng cha tch cc 2.2. + B phn bo dng c tch ra c lp. Cc t sa cha vn thuc v cc b phn sn xut c tp trung li di s qun l ca b phn bo dng. + Cc chc nng bo dng c tp trung ho, tuy vy mt s nh my, b phn bo dng vn c phn cng theo cc khu vc sn xut. Giai on 3 (3) 1.3 + Mi b phn u c gng thc hin c nhim v xc nh + Cc hot ng ca cc nhm QC (qun l cht lng) c thc y c hiu qu. Vic tin hnh bo dng c hon thin 2.3 + B phn bo dng c t chc vi trch nhim c xc nh r rng. Trong ngnh cng nghip gia cng, mt ban k thut b phn bo dng. Trong ngnh cng nghip lp rp, ban k thut thuc vo b phn sn xut. Giai on 4 (4) 1.4 + Khi nim PM gn lin vi qun l doanh nghip.

2. T chc

2.4. + B phn sn xut nh gi li cng lm vic ca th vn hnh +o to th vn hnh c chuyn mn ho theo thit b. Chuyn giao cng vic bo dng c in hng ngy cho khi sn xut

290

291

+ Trong qu trnh lm vic, s trao i thng tin gia hai b phn bo dng v sn xut cha thc hin tt. Cng tc bo dng thc hin ti b phn sn xut c a ra tho lun v tch ring. 3.H thng 5S 3.1 + Cc hot ng 5S ch yu c thc hin bi ban lnh o. + i khi c s tham gia ca nhng cng nhn v sinh. + Thiu s ng gp ca ton b tp th. 3.2 + Cc hot ng 5S c pht trin theo mc tiu qun l nh my. + Phm vi ca cc hot ng 5S c chuyn mn ho. Xc lp quy tc ca cc hot ng 5S. + Cc tiu chun qun l bng mu sc. + S chuyn bin theo hng yu cu s ng gp ca ton b tp th 4.2 + Thit lp h thng kim tra hng ngy. Son tho cc cun S tay tiu chun kim tra hng ngy. p dng cc tiu chun bi trn p dng cc tiu chun v sinh my mc Danh sch kim tra +Khng c tiu chun cho i tu 3.3. + nh gi ln nhau v cc hot ng 5S ca mi nhm. + Ci thin hot ng JK. + Nn xng lun sch v kh, khng c vt du m, khng n trong nh my.

+B phn bo dng trin khai bo dng theo k hoch, ci tin thit k, pht trin cc k thut kim tra. +Thnh lp xng c kh ring.

+ Bo dng theo k hoch c ln lch. Nhng thi gian i tu v kim tra vn khng nh trc.

+ Cng vi khi nim bo dng d bo cc k thut kim tra c pht trin v ng dng trnh "bo dng qu mc". + Tng cng kh nng x l kt qu kim tra. 5.4 + Thi k sa cha v kim tra c quyt nh da trn cc s liu ghi chp bo dng. Chuyn i cc s liu KT thnh EDPS + nh gi cc k hoch mua ph tng. + Bo dng hiu chnh tch cc bng phn tch h hng + Phn hi cc s liu k thut bo dng ti nh sn xut thit b + Thc y vic thit k hng ti tng tin cy v tng tnh d bo dng. 6.4 + Thc y cc hot ng phn tch gi v gim chi ph mua ph tng. + Nghin cu phng php ghi chp thanh ton lm gim bin ch nhn vin kho v n gin ho th tc giao nhn hng + S dng EPP cho kim sot danh mc kim k hng

+ 5S gn lin vi qu trnh sn xut, bo dng v ci tin c thc hin 1 cch t gic. + Kt qu thc hin cc hot ng 5S c thng bo hng thng.

5. Qun l bo dng: h thng ghi chp bo dng, Phn tch h hng.

5.1 + Khng c l lch bo dng + Khng c cc s liu k thut cho vic phn tch hng hc + Ch da trn k nng th vn hnh, do vy khng ci tin c cng tc sa cha

5.2 + c h thng ghi chp l lch bo dng + Phn tch h hng thit b c cc c nhn thc hin nhng cha c h thng ho. Phn tch h hng v ghi chp bo dng khng c s dng hiu qu.

5.3 + Vic c lng tui th thit b bng cch phn tch cc s liu bo dng vn cha c ln k hoch lp k hoch bo dng kinh t + Vic phn tch h hng c thc hin bi cc nhn vin k thut bo dng v c lu li lm cc s liu bo dng

4. H thng kim tra: - Kim tra hng ngy - i tu

4.1 + Kim tra da theo kinh nghim th vn hnh. + Khng c cc tiu chun cho kim tra hng ngy. + Khng c tiu chun i tu.

4.3 + Phm vi cng vic v trch nhim c phn cng r rng cho cc b phn SX v bo dng. + Son tho cc tiu chun i tu v kim tra cc my chuyn ng quay. Vn cha c tiu chun kim tra cho cc chi tit cu thp, thng v cc h thng ng ng.

4.4 + C danh sch kim tra hng ngy cho cc my v h thng in. Tiu chun bo dng hng ngy ca th vn hnh bao gm c vic kim tra v bo dng bng dng c + C cc tiu chun kim tra my quay + Thit lp cc tiu chun kim tra hot ng ca thit b + Thit lp cc tiu chun kim tra cc h thng thp, thng v ng ng

6. Qun l ph tng bo dng

6.1 Mc kim tra khng r rng + Nhiu ph tng tn kho, nhiu loi ph tng li thiu. + T l lun chuyn hng tn kho thp. + Hiu sut s dng khng gian kho hng thp. + Nhn vin bo dng mt qu nhiu thi gian cho k hoch ngn sch v mua hng.

6.2 + Danh mc kim k r rng + C s phn loi v sp xp ph tng + Ph tng trng thi sn sng cung cp. + Xc nh r phng php v th tc mua hng. + Thun tin cho vic kim tra v quan st kho. + p dng phng php qun l bng n hng.

6.3 + Gim s ph tng trong kho v tng s khon mc mua ph tng theo k hoch. + Nghin cu tiu chun ho ph tng. + Phn ph tng ra 2 loi: loi kim sot tp trung v loi kim sot phi tp trung. + Kim tra pht hin v sa li trong cc bn v.

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293

+ Nu r n gi ph tng mi ngi thc c cc chi ph + Xem xt li cch sp xp ph tng trong kho 7. Kim sot 7.1 + Cng tc cng vic sa cha h hng khng y (khng c kh nng sa cha) 7.2 + C th kim sot c s nhn cng cn thit b phn bo dng trung tm + c lng c cng vic, kim sot khi lng cng vic, nm c s gi cng thc t (ch thc hin c xng bo dng trung tm) 7.3 + Sp xp cc th c kh, th vn hnh, nhn vin kim tra k thut theo dy chuyn sn xut qun l s gi cng hp l da trn k hoch sa cha hng nm

+ Nghin cu h thng qun l kho hng c tr gip ca my tnh

10. nh gi hot ng PM (h thng ghi chp)

10.1 + Khng c h thng ghi chp, lu tr, ch bo co bng ming.

7.4. + Xc nh k hoch bo dng hng nm tit kim nht, xc nh chi ph thi gian dng my v chi ph bo dng thng qua s dng EDP + p dng cc phng php qun l theo lch trnh nh: PERT, CPM... +S dng phng php IE nng cao nng sut v hon thin cc phng php sa cha 8.4 + Sp xp b tr b phn sa cha v k thut trn c s t chi tr. Cc nghin cu gim chi ph & tng hiu sut. + Hp ng cc cng vic sa cha, cc cng vic lp t v xy dng vi cc nh my khc hng 9.4 + Phn tch k thut v k nng + o to ton din chuyn su theo c hai hng k nng v k thut. + o to nng cao k thut vi IE, VA v QC

10.2. + Thit lp h thng ghi chp nh gi hot ng PM + Bo co hng thng v PM c chun b nhng cha c s dng.

10.3. + Nghin cu cc s liu qun l ph hp vi c im nh my v trnh iu khin + Mc d bo co hng thng v PM cn ngn gn nhng cc s liu c s dng c hiu qu

10.4. + Hon thin ch t qun ca PM + Chun b bo co qun l bng EDT. Tnh ton h s vn hnh hiu qu, t l dng my ngoi d kin, thi gian ngng my, tn s hng hc, t l hng

11. Kt qu bo dng (u ra)/ s nhn cng (u vo)

11.1.+ Hiu qu thp + S lng nhn cng nhiu BM (Bo dng hng my)

11.2 + Hiu qu cao 11.3.+ Hiu qu cao 11.4. + Hiu qu + S lng nhn + S lng nhn cao cng nhiu cng gim + S lng nhn vin t PM (Bo dng Phng nga) PM (bo dng Hiu nng) TPM (Bo dng Hiu nng tng th)

8. Lc lng 8.1 Ch c cc nhn bo dng vin sa cha sch v mua hng

8.2. B phn bo dng, cc nhn vin kim tra k thut

8.3 + Mt s nhn vin kim tra bo dng c th m nhim nhng cng vic kim tra chuyn su sau khi nng cao trnh . Cc nhn vin bo dng khc h tr cng tc thit k li v tiu chun ho + C th yu cu sa cha thm 9.3. + C k hoch o to theo h thng cc nhn vin bo dng + Nghin cu nng cao hiu qu cng tc o to + Thc hin y k hoch o to hng nm

9. o to nhn vin kim tra k thut bo dng

9.1. Khng c

9.2. Khng o to mt cch c k hoch

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* Ch thch: - H thng khuyn ngh: H thng a ra bin php gii quyt vn v hon thin vn hnh trn c s kin ngh ca cc c nhn hoc nhm nh. - 5S: vit tt ting Nht. C ngha l: Phn loi, Sp xp, Lau chi, V sinh v K lut (C nhiu cc dch khc nhau sang ting Vit) Theo s liu iu tra 1977, t l phn b trnh pht trin bo dng ca cc x nghip Nht Bn nh sau: - Giai on 1: (Bo dng Hng my) - Giai on 2: (Bo dng Phng nga) - Giai on 3: (Bo dng hiu nng) - Giai on 4: (Bo dng hiu nng Tng th) 13% 38% 38% 11%

* T Tng th trong thut ng bo dng hiu nng tng th c 3 ngha: Tng th vi ngha Hiu sut Tng th Tng th vi ngha Ton b h thng Tng th vi ngha s tham gia ca Tt c

Hiu qu ca TPM Ly trng hp ca nh my Chuo Spriry Hekinan ti Nht Bn lm v d: nh my ny c nhn gii thng PM 1978 Nht nh nhng thnh qu t c vi TPM. Nh my p dng TPM trong thi gian 3 nm v thu c nhng thnh qu to ln: thit lp mt h thng PM ton b hng ti hiu sut tng th ca c nh my c s tham gia ca tt c cc cp t lnh o ti cng nhn vo cng tc bo dng hiu nng. Chuo Spriry Hekinan l mt nh my sn xut cc loi l xo v nhp cho xe hi. Trc khi p dng h thng TPM, cc my mc thit b v nh xng trong nh my lun trong tnh trng thiu v sinh do du m v phoi, g... Du m dnh vo my l t sn phm hay r r t cc h thng thu lc. Hiu qu vn hnh thp do thng xuyn xy ra s c nn cng nhn thng phi lm thm gi v lm chm thi gian giao hng. Vi vic p dng 5S trong vng 3 nm trin khai TPM, nh my tr nn sch s; s c hng thit b gim hn, t 1500 gi xung cn 480 gi; h s vn hnh thit b tng t 63% ln 82%, giao hng ng thi hn, gim cc chi ph cho nhin liu 15%, nng lng 8%, sn 52%, du thu lc 78%..(TL1) 2.2. Trin khai TPM Cc thnh qu t c nh p dng TPM khng phi c c mt cch d dng m l kt qu n lc phn u ca c tp th trong nhiu nm nhm nng cao trnh k thut bo dng nh my, p dng 5S v bo dng t qun. Trong phn ny chng ti mun a ra mt mu c bn ca TPM, cc khi nim v cch tip cn ca n. Coi PM sinh li nhun l mc tiu Mt trong nhng mc tiu ca TPM l tng hiu qu tng th, ni mt cch n gin l sinh li. Hiu qu ca nh my l t s u ra / u vo v c coi l thc o nh gi li nhun nh my. Hiu qu ca nh my = Sn lng u ra Chi ph u vo

S khc bit ch yu ca giai on 3 vi giai on 4 l trong khi giai on 3 tp trung vo b phn bo dng thit b th giai on 4 li da trn s tham gia ca tt c cc b phn, tc l mt h thng bo dng t qun ca cc cng nhn vn hnh

Bo dng t qun: l phng php bo dng trong th vn hnh kim tra v bo dng thit b nh l nhng hot ng JK, thc hin nhng nhim v bo dng n gin v tn t thi gian chng hng hc v xung cp thit b.

2. Trin khai TPM v vai tr ca qun c 2. 1. TPM v hiu qu ca n Nhng nm gn y, thut ng kim tra cht lng vi s tham gia ca tt c, nh my an ton vi s tham gia ca tt c... thng c nhc ti cc nc pht trin. Thut ng PM vi s tham gia ca tt c, tc l TPM c a ra vo nm 1976. nh ngha TPM - Bo dng hiu nng Tng th TPM l thc y s pht trin PM thng qua cc bc sau: Hng ti hiu sut s dng thit b ti a. Thit lp mt h thng qun l thu tm ton b chu k s dng thit b. Bao gm tt c cc b phn: lp k hoch, vn hnh, bo dng... C s tham gia ca tt c mi ngi t ngi lnh o cao nht cho ti cng nhn cc xng. Hot ng t qun ca cc nhm nh

i vi Terotechnology hiu qu ca chi ph thng c dng nh gi tnh kinh t ca chi ph chu k s dng thit b (LCC) Hiu qu ca chi ph = Hiu sut ca h thng Chi ph chu k s dng thit b

Trong cng thc trn, LCC l chi ph u vo cho trang thit b tc l s tin cn cho trang thit b v hiu sut ca h thng l sn lng u ra do thit b sn sinh ra hay l s tin do sn xut lm ra . Ni cch khc cc cng thc trn l ging nhau nhng pht biu khc nhau. S khc bit duy nht l Hiu qu ca chi ph c phm vi ng dng rng hn bao gm c sn phm, h thng v cc chng trnh nm ngoi thit b Ni v gim chi ph chng ta thng nhc n, chng hn nh gim 20% ngn sch bo dng .... nu nh gim s tin cn thit cho bo dng l nh nhng n lc ci tin cng tc bo dng th l

Thut ng PM trong nhm t TPM khng phi l Bo dng Phng nga m c ngha l Bo dng hiu nng cho c chu k s dng ca thit b. TPM ch thc s c hiu qu khi c 5 iu kin nu trn c thc hin.

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hiu qu thc s. Cn nu nh gim chi ph lm nh hng n cng tc bo dng cn thit th s dn ti nhng vn ging nh git g ly trng. Nh vy vic cn lm l nng cao hiu qu chung lin quan ti sn lng ca thit b, tc l s tin lm ra, ch khng phi l tit kim bng cch ct gim cc chi ph bo dng - tc l gim s tin cn thit. Khi so snh cc thit b cng c tnh k thut vi nhau v mt hiu sut hay v hiu qu chi ph, gi s rng sn lng u ra l nh nhau th thit b no c LCC thp s l thit b tt hn B quc phng M p dng chnh sch k kt hp ng vi cc nh cung cp a ra c LCC thp nht. Chng hn nh xem trong bng 2.30, cc thit b c cng c tnh k thut th cng ty C s thng phn nh LCC thp nht. (TL1) BNG 2.30 SO SNH DA TRN LCC KHON MC Gi mua trang thit b - 1 , USD Chi ph bo dng vn hnh trong 5 nm theo gi hin hnh - 2 ,USD LCC 3 = 1 + 2 ,USD A 500.000.000 700.000.000 1.200.000.000 B 1.000.000.000 400.000.000 1.400.000.000 C 700.000.000 200.000.000 900.000.000

2.3. Xy dng h thng thit k thit b khng cn bo dng t c mc tiu ca TPM l PM sinh li nhun cn xy dng mt h thng PM tng th xuyn sut chu k lm vic ca thit b. Trong iu kin l tng, thit b hon ton khng cn phi bo dng. D nhin l khng th t c iu kin l tng . Tuy nhin, c th xy dng c mt h thng cho php tip cn iu kin l tng ngy cng gn. H thng chnh l h thng tng th ca PM trong nh ngha ca TPM. Cc thit b gia dng nh my git hay t lnh chnh l cc my mc c thit k theo nguyn tc khng bo dng phc v cho i tng ngi s dng ch yu l cc b ni tr khng hiu bit v k thut. Nu em so vi chng th cc thit b cng nghip cn thua xa v tiu chun thit k khng cn bo dng. Hot ng thc t ca cc thit b cng nghip lm au u ngi s dng vi nhng cng vic bo dng tn km cng sc v tin bc nh kim tra, thay du m, bo qun, thay th ph tng.... Hn na, hng hc bt thng v s gim chnh xc ca my mc lm gim sn lng cng nh cht lng sn phm. M hnh h thng chc nng Thit k - Vn hnh - Bo dng do cng ty Ty c Hesch Steel Work a ra c coi l 1 v d ni bt v thit k thit b khng cn bo dng da trn tng Terotechnology. M hnh ny c pht trin thnh m hnh c trnh by trn hnh 2.58. Vng trn bn phi l h thng cho cc thit b ang trong giai on vn hnh v bo dng, cn vng trn bn tri l h thng cho giai on thit k v lp t. Chu k s dng ca thit b bt u t thit k thit b khng cn bo dng qua cc phn ch to, lp t v hiu chnh ti giai on vn hnh bnh thng. Cc vn cn c pht hin v khc phc ngay trong thi gian vn hnh ban u, tc l trc khi xy ra hng. Cc thng tin thu nhn c trong thi gian ny c phn hi v khu thit k hon thin thit k cho cc th h thit b sau. Ngay khi thit b bt u lm vic phi thng xuyn kim tra v gim st cc thng s lm vic v tnh trng thit b, cn khc phc cc vn ngay khi mi c pht hin. Cn lp k hoch kim tra s vn hnh ca thit b. Nu pht hin cc khuyt tt cn lp k hoch v tin hnh sa cha. Sau khi kim tra xong tip tc vn hnh thit b. ngy cng tin gn ti iu kin l tng ca thit k thit b khng cn bo dng cn nghin cu gim khi lng cng vic bo dng i vi cc thit b ang trong giai on vn hnh v bo dng. Sau , cc kt qu nghin cu c phn hi theo cc ni dung sau: Cc thng tin ci tin, nng cp thit b ang vn hnh (CM) Ci tin cc hot ng bo dng v h thng iu khin p dng vo thit k thit b khng cn bo dng ngay t khu thit k

Phng php so snh da trn LCC bao gm c chi ph bo dng vn hnh tc l tng chi ph, ch khng phi l so snh thit b ch theo gi mua thit b. Phng php c s dng khng nhng vo thi im mua mi m cn vo lc mua ph tng hay bo dng nng cp. Chng hn nh khi mua cc ph tng c cng c tnh k thut, cng ty X a ra gi 200.000 USD v cng ty Y a ra 150.000 USD, vy nn chn ph tng ca cng ty no? (Xem Bng 2.31 so snh X v Y). T kt qu so snh c th d dng la chn nh cung cp. Nu so snh hai cng ty X v Y trn phng din tng chi ph bo dng hng nm v thit ha do ngng my th: X : 350.000 x 2 ln / nm = 700.000 USD Y : 300.000 x 4 ln / nm = 1.200.000 USD BNG 2.31 SO SNH X V Y KHON MC 1. Gi ph tng, USD 2. Chi ph nhn cng cho vic thay th, USD 3. Thit hi do dng my thay th, USD 4. = 1 + 2 + 3 : chi ph bo dng + thit hi do dng my /ln, USD 5. Tui th ph tng, USD 6. S ln thay th trong 1 nm (tng ng 8.000 gi lm vic 7. = 4 x 6 : Tng chi ph hng nm X 200.000/chic 50.000/ln 100.000/ln 350.000/ln 4.000h 2 ln/nm 700.000/nm Y 150.000/chic 50.000/ln 100.000/ln 300.000/ln 2.000h 4 ln/nm 1.200.000/nm

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Giai on thit k v lp t

Giai on vn hnh v bo dng

Lp t

Vn hnh th

- K hoch kim tra - Kim tra

S phi hp ca cc nhn vin bo dng v ngi vn hnh trong PM cng tng t nh mi quan h gia ngi li xe vi trm dch v bo dng hay gia bnh nhn vi bc s (xem bng 2.32). Ngi li xe kim tra hng ngy cn cc cng vic bo dng vn hnh, kim tra ng k an ton, sa cha v hiu chnh do trm bo dng xe thc hin. Trong chm sc sc kho, c nhn t chm sc v theo di din bin sc kho ca mnh, cn vic khm, pht hin v cha bnh do cc chuyn gia y t thc hin. xy dng H thng bo dng t qun, cn o to c mt i ng cng nhn vn hnh hiu bit v my mc v cc k thut bo dng, v quan trng l h phi tham gia vo cng tc bo dng cc thit b do chnh h vn hnh. Tt nhin nhng nhn vin bo dng vn phi l nhng chuyn gia gii trong lnh vc ca mnh v m nhim nhng lnh vc chuyn trch, h tr v ch dn hot ng bo dng t qun ca cng nhn vn hnh.

Ch to

Vn hnh

Quyt nh thay th BNG 2.32 PHN CNG NHIM V BO DNG PHNG NGA

Thit k khng bo

Qun l ban u

Kim tra & phn b cng vic

K hoch cng tc

Bo dng nh my

Cng nhn vn hnh: -Kim tra bo dng hng ngy -Vn hnh bnh thng -Thng bo v cc hng hc Li xe: -Ch ti sc kho hng ngy -Li xe an ton -Thng bo v cc hng hc C nhn: -Ch ti sc kho hng ngy -Trnh cng thng mt mi -Thng bo vi bc s v nhng bt thng

Nhn vin bo dng: -Kim tra nh k -Sa cha -Bo dng thit k li Trm bo dng xe: -Kim tra hng ngy, hiu chnh, KT ti ng k -Sa cha -Trung i tu xe Bc s: -Kim tra sc kho nh k, pht hin bnh -iu tr -Phc hi chc nng v sc kho

Cng vic

Bo dng t

Nghin cu gim cng tc bo dng

Chm sc sc khe

Hnh 2.57: M hnh h thng thit k khng cn bo dng 2.4. Thc y PM vi s tham gia ca tt c v bo dng t qun ca cc nhm nh cng nhn Phn ny trnh by h thng khuyn khch bo dng t qun v t chc thc y TPM. 1. H thng khuyn khch bo dng t qun Cc phi cng lun phi kim tra tnh trng ca ng c phn lc trong khi bay. Mt s t ch khch hin i c trang b mt h thng trn bng iu khin xe thng bo li v tnh trng cc h thng bng cc n nhy v hot ng ca n chiu sng, mc du ng c, dy phanh ... nhm bo cho li xe bit n lc phi thc hin t bo dng. Vai tr ca cng nhn vn hnh trong H thng khuyn khch bo dng t qun cng ging nh ca phi cng hay li xe trong cc v d trn.

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2. Thc y TPM S tham gia ca tt c cc b phn t lp k hoch n vn hnh, bo dng v ca tt c mi ngi, t cp lnh o n cng nhn l iu khng th thiu c i vi TPM. Mc d vy, cng vi cch t chc t trn xung, TPM cn c pht trin nh t chc cc b phn ngang cp t c s lin lc tt hn mi cp . u tin: thnh lp hi ng TPM bao gm cp qun l cao nht v nhng ngi ng u cc b phn. Hi ng ny thng qua chnh sch PM ca cng ty, xc nh mc tiu v phng hng cho tt c cc thnh vin cng ty. ng lc ca ban lnh o l yu t quyt nh kt qu ca TPM v n khuyn khch v thc y s tham gia ng gp ca mi thnh vin khc. Th hai: thnh lp u ban TPM b phn, thnh phn bao gm cc nhn vin trung cp, c nhim v thng qua chnh sch PM ca b phn v xc nh mc tiu PM ca b phn mnh theo nh hng chung ca chnh sch v mc tiu PM ca ton b nh my hoc cng ty. Cp trung gian phi ng vai tr l cu ni gia cp lnh o vi cp phn xng. Cc hot ng JK nh cc nhm ZD v QC c thc hin cp phn xng. Da trn cc hot ng JK ny, cc nhm xc nh cho mnh cc mc tiu ph hp vi chnh sch PM chung ca cng ty v b phn mnh. Cp cao (xc nh mc tiu/ chin lc PM ca cng ty) Hi ng PM cng ty Cp trung (xc nh mc tiu/ chin lc PM ca b phn) Hi ng PM b phn Cp phn xng (xc nh mc tiu ca nhm) Cc hot ng PM ca nhm B phn quy hoch nh my B phn bo dng nh my B phn vn hnh nh my

2.3. Vai tr ca qun c trong vic trin khai v thc hin TPM Vai tr ca qun c trong thc y TPM th hin trong hai lnh vc: Lnh o nhm t c mc ch t ra Cng c on kt trong nhm v ng vin mi thnh vin ca nhm tch cc ng gp cho vic pht trin nhm

Vai tr ny c th hin c th trong cc cng tc sau: (1) Xc nh cc mc tiu hot ng ca nhm: Cc nhim v ca mt nhm c t ra mt cch t nguyn bi cc thnh vin ca nhm di s hng dn v ng gp ca cc cp lnh o. Cc mc tiu ca nhm phi ph hp vi mc tiu chung ca nh my v xng. Cc mc tiu c th ca bo dng hiu nng l: h s vn hnh my mc, thi gian dng my do s c (2) Thc y hot ng bo dng hng ngy: Bao gm thc y cc hot ng 5S, kim tra hng ngy, tra du m, sit li cc mi ghp bu lng (3) Bo co cc cng tc vn hnh v bo dng (4) T chc hi ngh nh k nh gi tin thc hin cc mc tiu t ra (5) Nu mc tiu t c, cn bo co ln cp trn v xc nh mc tiu mi cho nhm (6) Tuyn dng v khen thng kp thi nhng thnh tch t c ca cc nhm 3. Hot ng bo dng t qun ca cc nhm nh. 3.1. Cc khi nim c bn: QC - Kim sot cht lng: l cc hot ng kim sot cht lng ca cc nhm cng nhn nh. Cc hot ng ny xut hin u tin Nht Bn. ZD - Khng sai st: Xut hin u tin M, y l phong tro ca cng nhn mt nh my sn xut tn la theo n t hngca B Quc phng M. kp thi gian giao hng, cc cng nhn cam kt sn xut ra cc sn phm hon ho, khng c sai st. ZD sau nhanh chng c ph bin cc nc cng nghip pht trin. ZD ging vi QC mc ch, nhng ZD ch yu da vo hot ng ca cc c nhn trong khi QC da trn n lc ca c nhm. JK: L vit tt ca thut ng bng ting Nht, c ngha l hot ng t qun ca cc nhm nh. y l s thng nht ca QC vi ZD, kt hp n lc c nhn vi tp th.

Hnh 2.58: C cu thc y TPM thng qua s tham gia ton b C cu t chc thc hin TPM cn c s kt ni v gn b cht ch theo chiu dc t u ban TPM cng ty xung cc trung tm. Nu s nhn vin ca mt nhm qu ng, c th chia nhm ra nhiu nhm nh 5 n 10 ngi. Qun c va l ngi ng u ca cc nhm PM phn xng mnh, va l thnh vin ca u ban PM cp nh my. Ngi lnh o ca u ban PM cp nh my l gim c, ng thi cng l thnh vin ca u ban PM cng ty. ng u u ban PM cng ty l gim c chuyn trch v bo dng ca cng ty. Cch t chc ny lm cho cc qun c v gim c nh my tr thnh khu kt ni gia cc cp t cng ty xung nh my v cui cng l phn xng. -

3.2. Khi nim c bn ca cc hot ng JK (1) - Mc ch ca cc hot ng JK l nhm t c cc mc tiu ra ca cng ty. Theo nh ngha ca cc hot ng nhm QC: Qun l phn xng v cc ci tin c thc hin thng qua s tham gia ca tt c cc b phn v nhn vin c coi l mt phn ca qun l cht lng trn phm vi ton nh my. nh ngha ny mang li 3 t tng c bn: ci thin cht lng qun l, nng cao cht lng cuc sng v th hin kh nng ca mi ngi.

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BNG 2.33 MC CH CA DOANH NGHIP Mc tiu Bin s Mc ch ngn hn (nh hng hot ng) Li nhun Doanh s bn hng nm Kim k l li Tham s Mc ch di hn (nh hng con ngi) Cc mi quan h cng ng hiu qu Tp th on kt Kh nng ra quyt nh tp th S t nguyn K nng Mi trng cng tc

BNG 2.34 BA IU KIN THNH CNG Gio dc con ngi o to k thut Nhim v ca nhm Pht trin thc Cc k nng iu khin Cc k nng c bit Mi trng tm l Phng tin vt cht: dng c, trang, thit b, tiu chun...

Bng 2.33 cho thy mc ch ca t chc l khng ngng ci thin cc bin s kinh doanh (li nhun v doanh s...) cng nh cc tham s (yu t con ngi - phng tin t c kt qu kinh doanh), hay ni cch khc l c cng vic ln con ngi. (2) - Ly cng nhn lm trung tm Khi nim c bn ca ZD l ngi cng nhn l trung tm. Khi nim ny cng c p dng cho cc hot ng JK. N c ngha l ngi th t gic qun l cng vic ca mnh t c kt qu tt, t xc nh rngy l cng vic ca mnh, ch khng phi l mnh lm vic theo ng lng c tr. iu ny c th so snh vi cng tc m bo an ton giao thng. R rng l khi ch c cnh st giao thng thc hin nhim v th kt qu thp hn nhiu so vi khi tt c nhng ngi tham gia giao thng u t thy c trch nhim chp hnh ng lut. (3) - Thc y cc hot ng JK Bn yu t thc y cc hot ng JK: Nhn thc r rng tm quan trng ca cng tc bo dng t qun. La chn v thc hin mc tiu. xut cc sng kin v gii php. Khen thng.

3.3. Bn giai on pht trin ca cc hot ng JK C 4 giai on nh gi mc pht trin ca cc hot ng JK. Vic nh gi ny da trn tiu ch v mc ng gp ca cc hot ng JK vo thnh qu ca cng ty: - Giai on 1 : - Giai on 2 : - Giai on 3 : - Giai on 4 : T gic Ci tin hot ng Gii quyt vn T qun BNG 2.35 BN GIAI ON PHT TRIN CA CC HOT NG JK Giai on Tm tt T gic Bc pht trin ban u ca cc hot ng JK. Cng nhn bt u thc c vai tr ca mnh v c thc t nguyn Cc mc tiu trc mt khng gn vi cc mc tiu ca cng ty. c nh gi tch ri khi cng vic Kh pht trin cc hot ng JK Ci tin hot ng Cng nhn a ra cc ngh ci tin thng qua cc hot ng JK, ng thi cc hot ng ny em li tm l hi lng vi kt qu cng vic Cc mc tiu ca cc hot ng JK khng nht thit phi ng nht vi mc tiu chung ca cng ty. Vai tr ca cc cp lnh o tng i th ng Thiu s ch o chung v phi hp hot ng Gii quyt vn Cng nhn la chn cc mc tiu JK theo mc tiu chung ca cng ty gii quyt vn T qun Cng nhn la chn cc mc tiu JK theo mc tiu chung ca cng ty v t gic kim sot cng vic ca mnh Mc tiu ca cc nhm nh hon ton ph hp vi mc tiu chung ca cng ty Cc hot ng JK tr thnh cng vic v c cc cp lnh o ch ng dn dt S lnh o su st v phi hp hot ng tt

(4) - Cha kha thnh cng cho cc hot ng JK: C 3 iu kin quyt nh s thnh cng ca cc hot ng JK: S t nguyn, K nng v Mi trng cng tc (bng 2.34 bng 3 iu kin thnh cng)

c im chnh

Mc tiu ca cc nhm nh ph hp vi mc tiu ca ton cng ty Cc hot ng JK c xem nh mt phn ca cng vic, tuy nhin mt b phn lnh o vn cn th ng C s ch o v phi hp chung

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4. Vai tr ca PM trong cc hot ng qun l nh my 4.1. T chc qun l nh my 4.1.1. V tr ca b phn bo dng Qun l nh my l cc hot ng qun l nhm s dng thit b mt cch c hiu qa trong sut chu k s dng thit b. Qun l nh my bao gm hai lnh vc: qun l ti chnh v qun l k thut. Bo dng nm trong qun l k thut nh my. T chc qun l nh my v v tr ca b phn bo dng thay i theo mc trch nhim m b phn ny c giao v c th ca tng nh my. Cc chc nng ca qun l nh my c th chia ra thnh qun l d n (tc l quy hoch v xy dng) v bo dng nh my. a- Chc nng ca qun l d n: Qun l d n l cc hot ng qun l u t kinh t, t nghin cu nng cp nh my cho ti quy hoch, xy dng nh my, nh gi ti sn c nh v xc nh hiu qu u t. Nhim v ca qun l d n l gim ti thiu chi ph u t cho cc chi ph xy dng, vn hnh v bo dng nh my b- Chc nng ca PM: PM l nhng k thut qun l bo dng kinh t ca mt nh my xy dng, bao gm t pht trin v ci tin cc k thut bo dng n lp k hoch v thc hin bo dng, ghi chp, lu tr v bo co cc s liu bo dng v nh gi hiu qu ca hot ng bo dng. Chc nng ca PM l cn bng chi ph v hiu qa tng tnh kinh t ca hot ng sn xut. 4.1.2. Cc m hnh c bn ca c quan bo dng: C th phn loi thnh 4 m hnh c bn: bo dng tp trung, bo dng khu vc, bo dng b phn v bo dng hn hp. S phn loi ny l da trn c im t chc nhn s bo dng l tp trung hay phn tn. * Bo dng tp trung: * Bo dng khu vc: * Bo dng b phn: * Bo dng hn hp: Tp trung c t chc ln trin khai Tp trung v t chc nhng phn tn v trin khai Phn tn c v t chc ln trin khai Kt hp cc m hnh trn Nhc im M hnh

BNG 2.36 CC M HNH T CHC C BN CA B PHN BO DNG: U V NHC IM Bo dng tp trung Bo dng khu vc Ton b nhn s v cng vic bo dng c t chc trong mt n v hnh chnh duy nht vi tt c cc v tr bo dng tp trung vo mt a im. Cng tc thit k, gim st bo dng v bo dng phng nga tp trung vo mt ch - C ng - Trin khai nhn cng linh hot - S dng hiu qu nhn lc v trang thit b bo dng - D o to nng cao tay ngh cho th bo dng, d thu tuyn cc cn b bo dng gii - Qun l nhn s tt - Chc nng nhim v r rng - Thiu s kt ni vi sn xut - Kh gim st cc hot ng ti hin trng - Mt thi gian i li - Kh lp k hoch v thi gian biu bo dng - Kh t c cc k nng bo dng chuyn su vi tng thit b c th V mt hnh chnh, bo dng c t chc tp trung. Nhng vic trin khai hot ng bo dng li phn tn theo cc c im a l, sn phm, cc b phn sn xut v vn hnh Bo dng b phn Cc nhn vin bo dng c t di s gim st ca ngi ph trch b phn sn xut Cng tc bo dng c t chc theo ch tiu sn xut Bo dng hn hp Bo dng khu vc hoc bo dng b phn c phi hp vi bo dng tp trung pht huy u im v hn ch nhc im ca mi loi

c im

u im

Khc phc c nhng nhc im ca m hnh bo dng tp trung. - D gim st ti hin trng - Gim thi gian i li - D lp k hoch bo dng - Chuyn mn ho bo dng mt s thit b c th cho mi nhm - S dng nhn cng km hiu qu hn - Trin khai nhn s thiu linh hot - S dng trang thit b bo dng chng cho

- Phi hp hi ha Ph thuc vo gia bo dng tnh cht kt hp vi sn xut - Cc u im tng t ca bo dng khu vc

- Coi nh bo Ph thuc vo dng do dnh tnh cht kt hp u tin cho sn xut - Kh pht trin cc k nng v k thut bo dng - Chia nh trch nhim bo dng

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Trn thc t, s kt hp gia m hnh bo dng tp trung vi bo dng khu vc l ph bin hn c. 4.2. Phn loi cng tc bo dng v s phn cng cng vic 4.2.1- Mc ch ca hot ng bo dng v phn loi phng thc thc hin: (1) Bo dng c hiu qa Mc ch ca bo dng, ni mt cch nhn gn, l: m bo sao cho my mc, thit b c th thc hin y cc chc nng yu cu. Vn l cn phi t c mc ch ny mt cch c hiu qu, tc l vi chi ph nh nht c th. Nh vy chng ta cn theo ui hai mc ch tri ngc: hiu qu cao nht vi chi ph thp nht. Cc phng thc t c mc ch phi r rng v cn phi thng xuyn nh gi hiu qu ca cc phng thc . Cn xc nh phng thc no l thch hp v thc hin n mt cch c h thng v nht qun. (2) Phn loi cc phng thc bo dng C hai loi bo dng c bn: Cc hot ng bo dng: phng nga v sa cha hng hc Cc hot ng ci tin, nng cp: ko di tui th thit b, gim thi gian bo dng v gim bt khi lng cng vic bo dng

4.2.2. Mi quan h gia vn hnh v bo dng B phn bo dng khng nn c thi th ng, ch thc hin nhng g b phn vn hnh yu cu. D nhin, m bo nhim v sn xut, b phn vn hnh lun yu cu cng vic bo dng hon thnh cng nhanh cng tt trong khi pha bo dng khng phi lc no cng c th m ng khi lng cng vic qu ln. V pha b phn vn hnh, thng c tm l l: chng ta lm ra sn phm v h sa cha. Tm l ny cn tr vic t c cc mc tiu ca bo dng. Cc mc tiu ny ch t c khi c hai b phn thc hin tt vai tr ca mnh trong bo dng. Do vy, b phn vn hnh cn ch ti cc hat ng phng trnh mn hng. Ch khi cc hot ng bo dng chuyn mn mi th hin c gi tr ca chng v to tin cho bo dng c hiu qu. 4.2.3. Thc thi v phn chia cng vic gia b phn bo dng v b phn vn hnh (1) Cc hot ng ca b phn vn hnh (bo dng t qun) Cc hot ng bo dng ca b phn vn hnh cn tp trung vo cc hat ng phng trnh mn hng: Cc hot ng phng trnh mn hng: hiu chnh, v sinh my, bi trn, sit cht cc mi ghp, iu chnh. Pht hin, ghi chp v bo co chnh xc cc h hng. Cng tc vi b phn bo dng tin hnh cc bin php sa cha nng cp. + + + +

Cn p dng ng thi hai loi bo dng ny. * Cc phng thc ca hot ng bo dng c phn loi nh sau: - Vn hnh bnh thng - Bo dng phng nga: bo dng hng ngy, bo dng nh k - Bo dng d bo - Bo dng hng my * Cc phng thc ca hot ng ci tin, nng cp c phn loi nh sau: - Bo dng hiu chnh: nng cao tin cy v tnh d bo tr - Phng nga bo dng: thit k khng bo dng Trn thc t, cc phng thc ny c kt hp vi nhau trong 1 hoc 3 lnh vc: Cc hot ng phng trnh mn hng Cc hot ng nh gi s mn hng Cc hot ng phc hi

Cc hot ng nh gi s mn hng (Ch yu thc hin bng cc gic quan) Kim tra hng ngy Mt phn ca vic kim tra nh k Cc hot ng phc hi mn hng Sa cha nh (thay th cc chi tit nh, n gin, v cc bin php khn cp) H tr sa cha khn cp

Trong cc hot ng nu trn, v sinh, thay du, sit cht li cc chi tit v kim tra hng ngy l quan trng nht v ngi vn hnh l ngi nm vng nht tnh trng thit b. Cc hot ng ny chnh l bo dng t qun vi s tham gia ca tt c trong TPM. (2) Cc hot ng ca b phn bo dng Cc hot ng ca b phn bo dng bao gm tt c cc hot ng bo dng m b phn vn hnh khng m nhim. Cc hot ng bo dng Nhim v c bn ca chuyn gia bo dng l ng dng cc k nng v k thut tin tin vo cng tc kim tra nh k, bo dng phng nga v bo dng hon thin, trong tp trung vo cc hot ng nh gi mn hng v phc hi mn hng. Hng dn v h tr cc hot ng bo dng t qun ca b phn vn hnh Cc hot ng bo dng t qun ch kh thi vi s hng dn v h tr ca b phn bo dng. Pht trin cc k thut bo dng v thit lp cc tiu chun bo dng Ghi chp v nh gi cc hot ng bo dng Cng tc vi cc nh thit k thit b

Thc t sn xut cho thy, phng trnh mn hng l quan trng nht trong cc hot ng bo dng, trong khi cc hot ng ny li thng b coi nh nht.

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5. Phn tch v x l hng 5.1. Khi nim v hng v tin cy 5.1.1. tin cy tin cy c ngha l s lm vic n nh ca nh my khng b s c v hng hc. C 3 nguyn nhn gy ra s c: S lng chi tit my nhiu Tn sut hng ca mi chi tit cao Thi gian vn hnh di

Trong trng hp hng dn dn, mc d chi tit vn lm vic nhng n c th gy ra nh hng xu hoc lm vic di cht lng yu cu. iu quan trng l phi xc nh khi no th hng xy ra, lm th no chn on s xung cp ca chi tit v cn p dng loi bo dng no. Hng t ngt cn c gi l hng chc nng, cn hng dn dn c gi l xung cp v chia ra hai loi: xung cp chc nng v xung cp cht lng. 5.1.3. Phn b t l hng Hnh 2.4 phn b t l hng khi khng bo dng phng nga. th phn b t l hng l mt ng cong lm v c th chia ra lm 3 giai on. Xc sut hng gim dn trong giai on Hng Ban u (A). Cc hng hc trong giai on ny l do li thit k v ch to sn phm, hoc do s hng ca cc chi tit c tui th s dng thp. gim cc hng hc xy ra trong giai on ny, cn gim st v phn hi cho b phn thit k cc li trn khng lp li. Giai on th hai l chy n nh (B). Xc xut hng phn b u. Trong giai on ny, cn duy tr bo dng hng ngy v trnh cc li do vn hnh sai. Giai on th ba l Hng do mn G (C). Nguyn nhn hng l do thi gian lm vic ca mt s chi tit trong h thng ht. C th ko di tui th lm vic ca my bng bo dng phc hi v bo dng phng nga. Cng c th gim xc sut xy ra hng bng cch thay th sm cc chi tit c. 5.1.4. C ch hng Hng xy ra theo trnh t sau: do nh hng ca thi gian lm vic, mi trng v ng sut, kiu hng xut hin thng qua c ch hng (nguyn nhn hng) dn n ph hng chi tit. (ng sut, thi gian...). V d: Bi Tc b lc Lng bu lng mng Khng c du Chy kim loi (c ch hng) (Kiu hng)

Ba nguyn nhn ny tng tc vi nhau lm tng kh nng xy ra s c BNG 2.37 S LNG CHI TIT CA CC LOI MY Sn phm TV en trng TV mu t My bay phn lc Tu v tr My tnh S lng chi tit 100 1.000 10.000 100.000 1.000.000 100.000 - 1.000.000

Bng 2.37 th hin s lng chi tit ca cc loi my khc nhau. Nh nu trn, nu mt my hay thit b c 10 chi tit v tin cy ca mt chi tit l 99% th tin cy ca ton b thit b hay my l 90%. Cng ngy cc my mc cng tr nn phc tp nn s lng chi tit ca cc thit b cng tng ln, lm tng nguy c xy ra hng. Xc sut hng ca mt chi tit t l vi thi gian, cng v mi trng lm vic ca n. Chng hn 0 nh xc sut hng ca mt linh kin in t tng ln 1,5 n 2 ln khi nhit tng 100 C (quy lut 0 100C). Do vy, tin cy ca nh my tng ln khi s lng chi tit nh v cng lm vic ca chi tit thp. 5.1.2. Hng xy ra nh th no? JIS nh ngha hng l s mt chc nng ca chi tit. C hai loi mt chc nng: S hng t ngt chng hn nh mt ni kt, gy rng, gy l xo... S hng dn dn xy ra do mn, xung cp, lo ho.. V d nh st p hay cch in km do cht cch in lo ho.

Va p

B my ri khi v tr lp t Mi Gy l xo

S chu k lm vic qu nhiu

ng sut c th chia ra hai loi: ng sut chuyn ng v ng sut mi trng. ng sut chuyn ng gy ra do cc nguyn nhn c v in. ng sut mi trng gy ra do nhit , m, rung ng... (xem bng 2.38) Khi phn tch hng, cn ch : * * * V d: * Nhiu yu t an xen ln nhau gy ra hng Trong nhiu trng hp, rt kh phn bit c ch hng vi kiu hng Trong x l hng, iu quan trng l xc nh v x l nguyn nhn v gim ng sut Khi hng cng tc hn v: + Thay th + Chuyn ti v tr t va p hn Cn ghi chp li nhng trng hp hng hc c gi tr v mt k thut rt kinh nghim v lm ti liu k thut.

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BNG 2.38 CC C CH V KIU HNG ng sut lm vic ng sut do cng dng in, in p, ti trng do cm ng Nng lng bc x in ha Ti trng c kh Xung cp trong qu trnh lu kho Ph hy b mt Yu t mi trng Bin thin nhit v nhit (c chu k v t ngt) p sut v bin thin p sut m v bin thin m Bc x Bc x mt tri Sng in t Bi, ct... Ma, nc mui nhim ho hc (mi trng kh) Nm, vi khun Rung ng Cng hng Gia tc Trng lc Kt hp cc yu t trn Yu t thi gian Cc n v thi gian (thi gian, tn s) ng sut lin tc Thay i thi tit Ti trng lp li Chu k ti trng Phn b ti trng Xung cp theo thi gian Kiu hng H quang Ting n H mch Ngn mch Xung cp (gim chc nng) R r Bin dng Thiu n nh Ngng chuyn ng Nhm b mt Ni lng mi ghp nhim Cc -bon ho Lch Dch chuyn Chy ... C ch hng H quang, in ha Cc -bon ho b mt tip xc Tng r r Ngn mch Qu p Hng in mi in phn nhim ho hc Qu ti Mt cn bng Co gin do nhit Thot cac -bon Lch v chuyn v Mn Thng hoa, bay hi Mi Khuych tn Phn ng ho hc ....

5.2. X l s c v ci thin tin cy 5.2.1. Hai kha cnh ca tin cy v x l s c: tin cy bao gm: tin cy vn c v tin cy s dng tin cy vn c l tin cy ca bn thn thit b tri qua cc giai on thit k, ch to v lp t. tin cy s dng l tin cy t c trong qu trnh s dng nh ch vn hnh v bo dng hp l. Do , tnh t h hng ca thit b c th c biu din nh sau: tin cy = tin cy vn c x tin cy s dng

* Cc bin php tng tin cy vn c v tin cy s dng:

Cc bin php nng cao tin cy vn c - Thay i hnh dng v kch thc - Thay i vt liu - La chn chi tit - Thay i dng c ct, o lng - Gim tc - Thay i c cu - Kim tra li ton b h thng - Xc nh tui th lm vic hiu qu - Tng cng vng, chnh xc lp rp v lp t 5.2.2. Cc li thng gp khi x l s c: tin cy vn s dng

Cc bin php nng cao tin cy s dng - Vn hnh ng - p dng bo dng hp l - Ci thin mi trng lm vic - Bi trn ng ch - Pht hin sm nhng khuyt tt v h hng nh. - Pht hin sm v phc hi chng xung cp - i tu ...

5.1.5 - nh gi tin cy Thi gian trung bnh gia 2 ln hng (Ttb) l mt tiu chun quan trng nh gi tin cy. Ttb c tnh nh sau: Ttb = Tng thi gian lm vic / tng s hng hc

Khng xem xt h hng nh l kt qu ca cc khuyt tt nh Khng to c cc iu kin cn thit cho thit b vn hnh Chng hn nh mt h thng thu lc khng th hot ng tt nu khng dng ng loi du thy lc hay du qu t hoc qu nhiu. Khng x l hng mt cch ng b v ton din. Thit b ch m nhim c chc nng ca n khi bn v chnh xc ca cc chi tit hi ha vi nhau. Phc hi mt vi chi tit m khng ch n khc phc s xung cp ton b thit b ch em li hiu qa tm thi. Khng phn tch k h hng tm ra nguyn nhn hng, cn tm hiu tnh trng my trc v sau hin tng hng, tm hiu c ch ca hin tng hng. Khng tm hiu nguyn nhn hng do ngi vn hnh: My mc thng t khi t hng. Cc li sau thng dn n h hng ca thit b v my: vn hnh sai, thiu du, bu lng b ni lng, khng kim tra, thay ph tng sai, iu chnh my sai, sa cha sai...

Hin nhin l tin cy tng khi Ttb tng. i lng nghch o 1/Ttb l t l hng c biu din bi ng cong tui th lm vic Mt tiu chun nh gi quan trng khc l tn sut hng: Tn sut hng = (Tng s hng / tng thi gian lm vic) x 100

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tin cy vn c

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5.2.3. Khi nim v cc bin php x l hng Cc bin php x l hng c phn loi nh sau: Chun b cc iu kin c bn: v sinh my, thay du v sit li cc bu lng Bo dng v phc hi chng xung cp Cc bin php chuyn bit: Nghin cu tm li thit k, phn tch vt l cc hin tng hng Hon thin cc k nng bo dng v vn hnh

5.2.7. Phn tch v hun luyn cc k nng Sau khi loi tr cc nguyn nhn gy hng khc, cn phn tch cc k nng ca ngi vn hnh hoc bo dng. Thiu cc k nng cn thit l mt nguyn nhn gy ra hng, ng thi lm tng chi ph vn hnh thit b v mt thi gian. Vic hun luyn k nng khng ch dng li vic bit lm nh th no m cn phi bit v sao li phi lm nh vy. 5.2.8. Khi nim "Dragging" "Dragging" - tm hiu l ko di tui th s dng - l cc bc tin hnh ngn nga hng ti din. Ngay sau khi phc hi, thit b li c xu hng bt u xung cp. Do vy, cn tin hnh cc bin php tng hp bao gm cc khu vn hnh, kim tra, bo dng v tiu chun thit k - bin php tng hp gi l "dragging". 5.3. Tnh d bo dng 5.3.1. Tnh d bo dng l g? Tnh d bo dng c ngha l mc d dng khi tin hnh bo dng mt thit b hay my mc. Nng cao tnh hiu qu ca nh my = Nng cao tin cy x Nng cao tnh d bo dng 5.3.2. nh gi tnh d bo dng: Thi gian trung bnh sa cha (TStb) l mt tiu chun nh gi quan trng. Ngoi ra cn c th dng i lng thi gian bo dng phng nga trung bnh hay thi gian bo dng hon thin trung bnh nh gi tnh d bo dng TStb = Tng thi gian sa cha / Tng thi gian vn hnh

5.2.4. Ci thin cc iu kin c bn trong pht hin v x l cc khuyt tt nh Ci thin cc iu kin c bn bao gm: Lm sch v pht hin cc khuyt tt nh mn, bin dng, xc Thay du m bi trn Sit cht li cc bu lng

Cng tc ny nhm chng xung cp v l nhim v ca b phn vn hnh (bo dng t qun) 5.2.5. Phc hi chng xung cp S xung cp c th xy ra theo hai cch: dn dn v t bin. Vi mi loi cn tm hiu chnh xc nguyn nhn v a ra cc bin php thch hp ko di tui th lm vic ca thit b. C hai loi xung cp: Xung cp t nhin: Hin nay khng th khc phc c Xung cp cng bc: Do cc iu kin s dng khng thch hp

Mt i lng khc nh gi tnh d bo dng ca mt nh my l T l cng hng T l cng hng 6. Bo dng t qun 6.1 - S cn thit ca bo dng t qun Khi sn xut cn thi k s khai, ngi vn hnh ng thi m nhim cng vic bo dng. Khi sn xut bt u pht trin, my mc tr nn phc tp hn v sn xut c quy m ln hn t ra yu cu v chuyn mn ho chc nng bo dng. Sn xut cng pht trin th s phn cc ca hai chc nng sn xut v bo dng cng r nt. Song ngy nay, khi cnh tranh tr nn khc lit th hiu qu ti a trong s dng cc trang thit b hin c l mt trong nhng yu t quyt nh s thnh cng ca doanh nghip. Di sc p cnh tranh, cc chc nng bo dng v vn hnh ang tr nn gn b hu c v tc ng qua li ln nhau. Hin nay, bo dng t qun c thc hin bi ngi vn hnh tp trung vo cc hot ng phng nga chng xung cp v lo ho hin l mt chc nng ch yu ca bo dng. 6.2 - Phm vi ca bo dng t qun 6.2.1- Vn hnh ng Vi s pht trin ca cc ngnh thu lc, kh nn, iu khin in, in t v o lng, cc my mc hin i ngy cng tr nn phc tp hn. Vic vn hnh cc my mc ny cng ang phn cc theo hai khuynh hng: phc tp ho v n gin ha. Nhng cho d vic vn hnh my tr nn phc tp hn hay n gin hn th hu qu ca vn hnh sai cng nghim trng hn so vi trc. Trn thc t, nhiu trng hp hng my v tai nn xy ra l do vn hnh khng ng. = (Tng thi gian bo dng / tng thi gian hot ng) x 100

Phn ln cc trng hp gp phi l xung cp cng bc. (bng 2.38) 5.2.6. Cc bin php chuyn bit: Ni chung, khong mt na s h hng c th khc phc bng cch ci thin cc iu kin c bn v phc hi chng xung cp. Tuy vy, cc bin php ny khng th khc phc c cc li do thit k. Li thit k ca mi chi tit chuyn bit cn theo di cn c vo cc hin tng hng. Do vy n c gi l bin php chuyn bit. Khi tin hnh cc bin php chuyn bit (cn gi l cc phn tch ln ngc du vt) cn lu : Cc bin php chuyn bit mc d rt hiu qu nhng khng th gii quyt c tt c Cc bin php chuyn bit cn c tin hnh sau hoc ng thi vi cc bin php ci thin cc iu kin c bn v phc hi chng xung cp. Cc phn tch cn tin hnh k lng v i su vo bn cht ch khng phi ch tp trung vo hin tng bn ngoi.

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Do vy, th vn hnh ngy nay phi p ng c cc yu cu sau: - Nm vng c cc c ch, nguyn tc lm vic, kt cu v chc nng ca my mc thit b hiu r ti sao phi vn hnh nh c hng dn - C kh nng d kin v x l thnh tho tt c cc tnh hung 6.2.2. V sinh, lm sch my V sinh my l cng vic loi b tt c bi, mnh vn, phoi, tp cht... khi thit b, qua pht hin v loi tr cc khuyt tt nh. (1) Tc hi ca bi bn v tp cht * * * * Tp cht v bi bn xm nhp vo cc mi ghp chuyn ng, cc b phn truyn ng, h thng thu lc, kh nn, in... gy ra kt, tc, mn, r r, chp, chy... Vi cc my t ng, bi bn trn vt liu lm nh hng n cp liu t ng, lm nh hng n hot ng bnh thng ca my Bi bn nh hng n cht lng ca sn phm Bi bn bm trn my gy cn tr cho vic kim tra pht hin cc du hiu hng: mn, ni lng bu lng, xc, bin dng... Hn na, n to ra tm l ngi kim tra my.

6.2.4. Sit li bu lng S ni lng hoc ri ra ca cc mi ghp (bu lng, ai c) trc tip hoc gin tip gy ra hng: Ph phm do ni lng khun hoc g H hng hoc vn hnh sai do ni lng bu lng ca cng tc hn v R r do ni lng bu lng sit bch lm kn

Thng thng, mt bu lng b lng gy ra rung ng v t n b ni lng thm, c ngha l rung ng gy ra rung ng ln hn, s ni lng gy ra ni lng thm, cc yu t ny gy ra xung cp, lm gim chnh xc v gy hng chi tit v b phn. loi tr hin tng ni lng, cn tin hnh cc bin php gim hoc kh rung, nh du cc bu lng quan trng d theo di, s dng ba kim tra... 6.2.5 - Cc hot ng 5S (Ch ci u ca 5 t ting Nht - phn loi, sp xp, lm sch, v sinh c nhn, k lut lao ng) 1. Phn loi: Phn loi c tin hnh theo cc tiu ch sau: Cc th cn vt b Cc th t dng n, cn xp vo cc gc xng Cc th thng dng n cn b tr gia xng Cc th lun dng n cn t v tr ca my hoc cng nhn

(2) V sinh my cng l kim tra my Khi tin hnh v sinh my, ngi th phi lau chi, thao tc trn tt c cc b mt v gc cnh ca my. Trong qu trnh cc khuyt tt nh trn my d dng c pht hin. Do vy, y l phng php hiu qu nht chng xung cp thit b do s t hp ca cc khuyt tt nh gy ra. 6.2.3. Bi trn, tra du m Bi trn l ht sc quan trng trong vic chng xung cp v duy tr chnh xc ca thit b. Tuy nhin, cng tc ny thng b xem nh do hu qu ca vic thiu du m bi trn khng xy ra ngay v thng khng nhn bit c bng trc quan. Bi trn km gy ra nhng thit hi gin tip hn l thit hi trc tip. Cc s c xy ra do thiu bi trn l: kt my, qu ti, mt chnh xc...Thng k cn cho thy bi trn tt gim chi ph nng lng khong 5%. (TL2) Bi trn km xy ra do cc nguyn nhn sau: Ngi th khng nm c nguyn tc ca bi trn, do vy, khng hiu c tm quan trng ca bi trn v nhng thit hi gy ra do thiu bi trn. Cc thng s bi trn (cc im bi trn, loi du bi trn, lng du bi trn, thit b...) khng ng. C qu nhiu loi du v v tr bi trn Thi im bi trn khng ng. V tr bi trn khng thun tin nn mt nhiu thi gian tra du m, do thiu thi gian nn vic tra du m khng c m bo

2. Sp xp: Xc nh v tr sp xp ca cc vt dng trong xng theo chng loi, kch c, yu cu v an ton. Cng tc sp xp nn t chc theo tng khu vc nh, c cc li i li v cc gc cha . Ranh gii cc li i v khu vc xp c v r rng bng sn mu. c c b tr theo phng vung gc hoc song song vi nhau. 3. Lm sch: cng tc lm sch c thc hin tt, cn c s tham gia ca tt c mi ngi trong nhm v phn cng trch nhim r rng ti tng c nhn. 4. V sinh c nhn V sinh c nhn rt quan trng trong nhng ngnh cng nghip thc phm v dc phm. Cn b v cng nhn bo dng phi mc gn gng, sch s khng lm nh hng n cht lng cng vic v sn phm cng nh m bo an ton cho chnh mnh. V d nh mt s ngi b tai nn do tc b qun vo cc b phn quay ca my. 5. K lut Tt c cc nhn vin khi lm vic phi tun th nghim ngt cc quy tc, quy nh an ton, lun c thc cnh gic, phng cc tinh hung tai nn, mang y cc phng tin bo v an ton: ng, m... Cng tc kim sot nhn s, kim sot thi gian c vai tr quan trng vi hiu qu cng vic.

316

317

BNG 2.39 CC VN CN KIM TRA VI HOT NG 5S Hot ng Phn loi Cc vn kim tra - Cc th vt b v t dng c xp vo cc v tr nh cha? - Cc vt dng, dng c c sp xp theo th t hp l cha? - Cc vt dng khng cn thit v t trang c ba bi trn my hay bn lm vic khng? - Cc li i, ch cha ... c phn nh r rng cha? - Cc vt dng nng v cng knh c xp xung di cha? - Cc vt qu di, cng knh c xp nm ngang hoc chng ri, cha? - Nn xng c b trn, trt, g gh hay h hi khng? - Cc bin ghi ch, cc thit b chng chy c b tr v tr thch hp cha? - Nn xng sch cha? - Cc bin ghi ch, hng dn c b m, bn hay mt khng? - Cc b phn my mc thit b c lm sch k cha? - Trang phc ca cc nhn vin c sch s v an ton khng? - n ung v ht thuc c ng v tr quy nh khng? - Cc hng dn v bo co cng vic ng v cha? - Cc nhn vin c mc v s dng ng, y cc trang thit b an ton: giy, ng, m bo him, qun o bo h.. cha? - Gh ngi c t ng v tr khng?

Mt s im cn lu khi tin hnh cc hot ng bo dng t qun v cc quy tc ca n: 1- Nhng im cn lu trong bo dng t qun (1) S pht trin bo dng t qun cn da trn cc ni dung c cp: 2.4 - Cc hot ng bo dng t qun theo nhm QC nh 2.5.2 - Phn loi cc hot ng bo dng v phn cng cng vic 2.6.2 - X l s c v ci thin tin cy 2.7.1 - S cn thit ca bo dng t qun 2.7.2 - Phm vi ca bo dng t qun (2) Mt khi lng cng vic rt ln cn c tin hnh thng qua cc hot ng bo dng t qun theo nhm QC nh (3) Qu trnh pht trin cn c chia ra nhiu giai on theo nhng mc tiu sau: Bt u t d n kh, chm nhng chc. Xc nh r rng cc bc thc hin, ch ra cc im quan trng cng nhn d thy cc kt qu t c (4) Cng nhn cn c hc qua thc hnh ch khng phi trn l thuyt (5) Cng tc gio dc v o to cn c ht sc ch trng gip cng nhn t c nhng kt qu c th (6) Cc tiu chun v v sinh v kim tra phi do t cc nhm ra pht huy thc t gic trong bo dng t qun.

Sp xp

Lm sch

V sinh c nhn K lut

6.3 - Quy tc ca bo dng t qun Bo dng t qun khng th pht huy tt nu mi ngi th vn hnh khng qun trit v vn dng vo thc t. Do , cc hot ng bo dng t qun bn r v pht trin su rng, cn pht trin chng thng qua cc hot ng nhm QC (Kim sot cht lng) vi s tham gia ton b.

2- Cc bc p dng bo dng t qun

318

319

BNG 2.40 CC BC PHT TRIN BO DNG T QUN Bc Tn bc Phm vi hot Mc tiu - theo Mc tiu - theo ng quan im quan im yu t thit b con ngi - Chng xng cp cng bc bng cch loi tr cc tc hi mi trng do bi bn - Loi tr bi bn nng cao cht lng cng tc kim tra v sa cha, tit kim thi gian - Loi tr s pht trin v bm bn, ci thin tin cy vn c ca thit b - Ci thin tnh d bo dng - To cm gic mun xem xt, kim tra my - Cc cp lnh o th hin c vai tr ca mnh bng vic tham gia vo cc hot ng nhm. S hng dn v h tr ca cp qun l v cn b bo dng - Phn tch mi quan h gia bi bn vi s xung cp v tnh d bo dng. - Ch ra cc v tr quan trng cn v sinh: ng bc, cc b phn bo v, cc b phn nh v, cc b phn tip xc khi lm vic. - Phn tch v tm quan trng ca v sinh, bi

Lm Lm sch v sinh ton b bi ban u bn khi my I

IV

Kim o to cc tra tng k nng qut kim tra bng cc s tay v o to k thut kim tra v phc hi cc khuyt tt nh thng qua kim tra tng qut

- Kim tra bng mt cc b phn chnh ca thit b nhm chng xung cp v ci thin tin cy - t s ph tng, tn my, k hiu v ch s phc v cng tc kim tra

II

Cc bin php x l cc ngun gy bi bn

Lai tr cc ngun gy bn cc khu vc kh lm sch v tra du m, gim thi gian cho cc cng tc ny

- cng nhn hc c cch tip cn v phng php ci thin iu kin lm vic thit b - Trin khai bin php ci thin thng qua cc hot ng nhm - To nim hng th cho cng nhn trong ci thin iu kin lm vic thit b - Bng vic lp ra cc tiu chun ca chnh mnh, cng nhn nhn thc c tm quan trng ca vic tun th cc tiu chun - mi ngi thc c vai tr ca mnh

- Gi p dng cc tng ci thin iu kin lm vic thit b. - Gip kim nhim cng vic ca nhm khc - Hng dn quan st kim tra

- Tm hiu c ch v chc nng ca thit b v cc tiu chun nh gi qua o to v k nng kim tra - Hc cc phng php sa cha thc hnh n gin - C ngi lnh o v nhn vin u thc c vai tr ca mnh - Bin son cc s liu kim tra tng qut nhm nghin cu tnh hiu qu ca s liu - Trin khai cng tc kim tra t qun bng cch son tho cc t danh mc kim tra hng ngy v nh k da trn cc s liu v ti liu hng dn - thc c s cn thit ca cc s liu tch lu theo thi gian

- Son tho cc s tay kim tra v o to nhng ngi ph trch cc k nng kim tra - Ln lch trnh kim tra - Gii quyt cc bt thng c pht hin qua thc t - Hun luyn cc phng php sa cha thc hnh n gin - To ra cc phng tin phc v kim tra quan trc d dng - Hng dn thu thp v x l d liu - Ngi lnh o tham gia vo lp k hoch bo dng

Kim tra Son tho v t qun pht hnh t danh mc kim tra cho cng tc kim tra t qun

- Duy tr mt cch chnh xc cc iu kin c phc hi chng xung cp sau kim tra tng qut

- Hng dn kim tra cc im quan trng v thi im kim tra - Hng dn son tho mu ca cc t danh mc kim tra - Trin khai bo dng phng nga chuyn bit theo lch v cc tiu chun i tu v iu khin chnh xc

III

Lp cc tiu chun lm sch

Lp cc tiu chun lm vic cc cng tc lm sch, bi trn v sit li cc bu lng c th c tin hnh chnh xc trong thi gian ngn

m bo 3 yu t l iu kin c bn ca bo dng nh my: lm sch, bi trn, sit li bu lng (cc hot ng chng xung cp)

- Gi lp ra cc mu cho cc cc tiu chun lm sch - Lm r quan im "lm sch l kim tra" VI

Phn loi v sp xp

Xy dng mt h thng kim sot bo dng hon chnh thng qua tiu chun ho cc danh mc kim sot khc nhau - Tiu chun lm sch v bi trn

- m bo hiu qu tt hn cho cng tc lm sch, bi trn v kim tra bng cch a ra cc bin php kim tra quan st

- M rng phm vi - Tr gip k thut cho cng t qun nh tiu tc tiu chun ho phc v chun ho cc cho cc nhm v b phn danh mc kim tra khc nhau - Nhn thc c s cn thit ca vic ci thin iu kin lm vic ca thit b bng ci tin cc tiu chun - Nhn thc c trch nhim ca qun c v khi qun l

320

321

- Cc tiu chun cho quy trnh sn xut cp phn xng - Tiu chun ha cc d liu ghi chp - Cc tiu chun v qun l khun mu Qun l cht ch theo cc mc tiu - Nhm pht trin chin lc v cc mc tiu ca cng ty v trin khai hot ng ci thin iu kin lm vic ca thit b nh cng tc thng xuyn - Trin khai ci thin thit b trong ton b nh my bng ghi chp chnh xc v h thng phn tch MTBF

- Pht hin cc im chnh nhm ci thin iu kin lm vic ca thit b bng cch xc nh chc chn li v cc d liu sai

7.1.1 - K nng l g: a. nh ngha C th nh ngha k nng nh sau K nng l kh nng hnh ng mt cch chun xc v c suy ngh trn c s nhng kin thc c c.

5 gic quan

No

Ton thn

Nhn bit - Ci thin tin cy, tnh d bo dng v kh nng lm vic ca thit b thng qua phn tch cc d liu v trc tip ci thin iu kin lm vic ca thit b - Thc hin cng tc ci thin iu kin lm vic ca thit b c u tin nh xc nh cc im yu ca thit b da trn cc s liu, nh ko di thi gian lm vic ca thit b. - Nhn thc r mc ch v chi ph, bao gm c cc chi ph bo dng - Lm ch cc k nng sa cha n gin - Nm c cc k thut ghi chp, phn tch v x l d liu - Tr gip k thut cho cng tc ci thin iu kin lm vic ca thit b trong ton cng ty - o to cc k nng sa cha - Tiu chun ho ca ni dung ci thin iu kin lm vic ca thit b

Suy xt

Hnh ng

- S ch - Kh nng pht hin

- Tr tu - Kh nng nh gi - Kh nng ng dng

- S phn x - Kh nng hnh ng - Kh nng hi tng - Kh nng phng v

Hnh 2.59: Cu trc ca k nng Mt v d n gin l khi mt ngi li xe phanh gp. Anh ta s dng tt c nhng nng lc vn c ca mnh: cc gic quan, no v ton thn mt cch hi ho v nhun nhuyn trong mt khong thi gian rt ngn. t c k nng cn mt qu trnh luyn tp nht nh. b. Nguyn nhn ca s khc nhau trong nm vng mt k nng Khng bit: Khng hiu nguyn l, nguyn tc hot ng Khng th: Mc d hiu nguyn l, nguyn tc hot ng, nhng khng th thc hin ng Khng lm: Mc d hiu nguyn l v c th thc hin ng nhng khng mun lm.

VII

c. Cc k nng lc hu: 7. nh gi cc k nng bo dng v o to 7.1. S cn thit ca o to cc k nng bo dng Vi s pht trin nhanh chng ca k thut hin i, bt c ai nu khng hc hi v hon thin cc k nng, kin thc ca mnh th s lp tc b tt hu. Do vy, qun c ca b phn bo dng khng nhng phi lun nh gi khch quan cc kin thc, k nng ca mnh m cn phi thy r nhng im yu ca cp di v khng ngng tin hnh cng tc hc tp, o to. cc nh my u c nhng cng nhn "lo lng". H l nhng ngi c kinh nghim v hiu bit v cc thit b trong xng. Tuy nhin, nhng ngi ny thng c xu hng theo kinh nghim ch ngha v khng tha nhn nhng sai st ca mnh. iu ny hn ch phm vi ng dng k nng ca h, d gy ra li, thao tc tha v kh tip thu k thut mi. Hn na, khi o to cng nhn mi, h s dy li nhng k nng lc hu ca mnh. Ngi lm cng tc bo dng khng nhng phi bit "Phi p dng cc bin php no " m cn phi hiu r "V sao phi p dng cc bin php ". d. Phn tch cc k nng ng: C th t c cc k nng sa cha n nh khi phn tch chi tit cc nguyn nhn gy hng cng nh phn tch chnh cng tc sa cha.

322

323

7.1.2 . Cc yu cu ca k nng bo dng: C 2 yu cu i vi cc k nng bo dng C l do, t ra mc ch v hiu qa r rng khi tin hnh cng tc bo dng Bo m cht lng cng tc bo dng a. Tng hiu qu cng vic: c th ca cng tc bo dng l khi lng cng vic lm bng tay nhiu (khong 50%), t hiu qu cao hn trong cng vic, cn o to nng cao k nng bo dng trong cc lnh vc sau: c bn v nh mc Cc thao tc sa cha v hiu chnh S dng g v dng c Hiu kt cu v nguyn l ca thit b Bit p dng cc phng php ci tin c lng cng tc sa cha v hiu chnh b. Nng cao v duy tr cht lng bo dng c. a dng ho cc k nng Ngi lm cng tc bo dng khng nhng cn c o to cc k thut kim tra, hiu chnh v sa cha m cn cn c nhng hiu bit v qu trnh sn xut, quy trnh cng ngh ca nh my mnh. Gn y, do yu cu nng cao hiu qu cng tc bo dng, a dng ho cc k nng bo dng cng c nhn mnh. Do t ng ho ngy cng c ng dng nhiu vo sn xut, cng tc sa cha, bo dng cng i hi nhiu kin thc v k nng hn, cc k nng cng ngy cng b "phn on" v chuyn bit hn. V vy, nhng h hng cng phc tp hn v lin quan n nhiu lnh vc hn dn n thi gian ch i ko di v yu cu nhiu chuyn gia trong nhng lnh vc khc nhau. a dng ho cc k nng khng ch gii quyt c tnh trng ny m cn gip nng cao tinh thn lm vic ca b phn bo dng. 7.2. Nhng im cn thit nng cao hiu qu hun luyn k nng Vi s pht trin nhanh chng ca khoa hc k thut, cc k thut v k nng bo dng hin nay lun trong xu hng tr nn lc hu. V vy, nhn vin bo dng phi lun c thc hc hi, nng cao trnh v k nng ca mnh. Nhn vin bo dng cn thc c rng cc k nng ca h khng ch c ch cho hin ti v cho nh my m cn c th c ch khi h chuyn sang cng tc ni khc. Cng tc hun luyn k nng cn bm st thc t v c th ca tng nh my, c s, p ng cc yu cu thc t. Cng tc hun luyn k nng cn t chc theo h thng song song. Do khng ch kin thc m cc k nng trn c s c rt kinh nghim cng rt quan trng i vi bo dng hiu nng nn mc nm bt cc k nng ph thuc nhiu vo s iu hnh ca ngi lnh o. M hnh lun phin thay i nhn vin di s qun l ca mt lnh o c k nng t ra c hiu qu. Trong cng tc hun luyn k nng, vic kim tra, nh gi (c thc hnh ln l thuyt) cn c ch .

7.3. nh gi cc k nng bo dng 7.3.1 - Mc ch nh gi k nng: Xc nh hiu qu ca cng tc hun luyn k nng Xc nh nguyn nhn ca s chnh lch gia trnh k nng yu cu v thc t Da trn cc kt qu trn, xc nh chng trnh hun luyn cn c chun ho v phng php ging dy thch hp t c cc k nng hnh thnh t cng vic hng ngy, cn a ra nhng ch dn no? Cng nhn c th t nh gi nhng im yu ca mnh mt cch khch quan t phn u nh gi cng bng cc n lc ca cng nhn khuyn khch h

7.3.2 - Cc tiu ch nh gi k nng Cn ch cc im sau khi nh gi k nng: Phm vi k nng nh gi phi r rng c th nh gi c kin thc ln thc hnh Cc mc nh gi cn c chia nh n mc thc hnh c th. V d khi mt cng nhn c th hiu chnh c cc loi bm xy lanh - pistng nhng khng th hiu chnh cc bm ly tm hay cnh gt th k nng ca anh ta khng th nh gi theo tiu ch: "Anh ta c th hiu chnh c cc h thng thy lc v kh nn khng? ". Nu nh gi khng ng, n khng th nu ra cc im yu ca ngi th v nhng g anh ta cn trau di thm. nh gi ton din, cn kim tra kin thc ca ngi th bng kim tra vit v kim tra k nng bng kim tra thc hnh c s dng ti liu. Mt khc, cng cn nh gi cng nhn hng ngy theo thc t cng vic. Vic nh gi cn tin hnh theo 3 gc : ngi hng dn, ngi qun l trc tip v t nh gi ca cng nhn. c bit, vic t nh gi l c hi ngi th t nhn nhn bn thn, xc nh mc tiu v ng c phn u.

324

325

Khi nim thit b y khng qu b hp. N c th l mt c my, mt t my, hay mt dy chuyn,...

Stt 101

ng V tr ca thit b c th c xc nh (theo cc b phn, theo phn xng,). C mt danh sch cc thit b. C mt ngi trong nhm sa cha bo dng ph trch vic cp nht danh sch cc thit b (t nht l mi nm mt ln). Tt c cc thit b chnh u c nh m s (Code). "E" c th quy cho m s theo logic topo (danh php) hoc cho mt s tham chiu (s s-ri ca mt ng c chng hn). i vi tt c cc thit b chnh, cc c trng cn bn dn ti tnh trng vn hnh tt phi c nhn bit, v d, p lc, tc vng quay, n, tc ra phoi, bc tin (dao tin), ... i vi tt c cc thit b, hng dn an ton cn p dng trong thi gian can thip phi c nhn bit. Hn na, chng phi lun c vit c th ra thnh vn bn. Cc quy tc thc hin (hay nhng s ch dn) cn tun th trong sut qu trnh can thip khng c bit n hoc khng c p dng (th sa cha lm nhng g m h thch lm). i vi tt c cc thit b, bn bit c mnh cn mang theo cng c g cho vic can thip bo dng.

Sai Khng c danh sch cc thit b. V tr ca thit b c th xc nh c khu vc nhng theo trong tr nh. Khng c ai cp nht danh sch ny c.

102

22. QUN L THIT B

103

Cc chi tit ca thit b khng c nh m s. Chng thng c xc nh theo tn cng nghip ca chng (cu to, kiu cch,...).

104

Cc c tnh "thng thng" dn ti tnh trng hot ng tt khng c nhn bit, ngay c i vi nhng chi tit chnh ca thit b.

105

Cc quy tc thc hin (hay nhng s ch dn) cn tun th trong sut qu trnh can thip khng c bit n hoc khng c p dng (th sa cha lm nhng g m h thch lm). Cc ph tng cn thit sa cha thay th cc chi tit ca thit b khng c nhn bit (v d chng c cung cp sau khi thit b c tho ra). Bn khng bit cng c no cn phi mang theo trong qu trnh can thip, ngay c khi l mt chi tit quan trng ca thit b. Mi ln can thip, cc k thut vin bo dng phi thng xuyn i li nhiu ln ly dng c phn xng bo dng.

106

107

108

i vi mi mt thit b, bn c th d Khng c mt ti liu ghi chp no lin quan dng tm thy h s ghi chp cc cng vic ti bt k mt thit b no. m trc y thc hin vi n.

326

327

109

M s thit b c th s dng mt cc d dng v r rng. C ngha l chng phi c gn trn cc thit b hoc gn . Chng b ph mt lp bi dy v khng b che khut! Mi thit b u c cc s hoc bn v ca nh sn xut. Chng c cp nht v bn bit chng nm u.

Cc m s lin quan n thit b, nu tn ti, c th c vit trong s nhng chng li khng gn nhng thit b c lin quan. Mi ln can thip, k thut vin bo dng khng th xc nh mt cch nhanh chng cc thit b c lin quan. Khng c s m cng khng c c bn v hoc l c nhng khng c cp nht. Bn c th bit l chng c tn ti nhng ln cui cng m bn nhn thy n l khi m thit b c nhn v. K t chng c ct mt cch ngn np trong t! Cc bn ghi chp cng vic c tn ti nhng bn khng bit phi tm n u hoc chng khng th s dng c.

QUN L PH TNG THAY TH V KHO PH TNG Stt 301 302 303 ng Cc yu cu v mua sm (P.R) lun lun c thc hin theo cng mt cch thc. C mt v ch mt m s cho mt loi chi tit c lu tr. i vi mi mt ph tng thay th c th, bn c th tm thy cc m t c tnh k thut c lin quan. Thng tin ny c th tm thy t cc nh cung cp. Ch lu tr nhng ph tng m bn chc chn cn dng. C s cp nht thng xuyn (v cht lng v s lng) v tnh trng kho. B phn bo dng lun nm c thng tin ny. Cc k thut vin bo dng c th d dng tm thy ph tng m h cn. Bn bit c ai l ngi cung cp tng ph tng c ct tr (c mt bn ghi chp y ). Bn c th xc nh thi gian cn thit c c thit b chuyn dng v kho... Sai Khng h c mu trin khai PR no. Mi ngi lm theo mt cch thc ring ca mnh. Khng c m s hoc c rt nhiu m s cho mi loi chi tit c ct tr trong kho. Cc chi tit lu kho v nhng c tnh k thut khng c lin quan g vi nhau. Tt c mi th u c lu tr, k c nhng th m bn s khng bao gi dng n na. B phn bo dng khng bit tnh trng cng nh gi tr ca kho ph tng d tr. Phi rt vt v lc li mi c th tm thy c ph tng cn dng. Thng tin v cc nh cung cp ph tng khng c ghi chp li. Bn khng bit thi gian giao hng.

110

304 305

111

Cn c cc h s ghi chp cng vic lin quan n thit b v bn bit mt cch chnh xc ni lu tr n. Bn c th d dng tm li n mt cch nhanh nht.

112

Vi tt c cc thit b chnh, bn bit r Khng th nh gi th t u tin theo mc mc cp thit ca can thip bo dng. cp bch ca cc can thip i vi thit b c lin quan. Cc ghi chp khng ch c lu mt cch y m chng cn phi c bin tp li v c phn tch t nht l mi nm mt ln. Nhng phn tch ny c s dng v rt ra nhng kt lun lin quan n cc vn phng nga chng hn. Mi thit b c mt v ch mt m s duy nht. Tn thit b, tn m hoc tn quy trnh cng ngh khng c ln vi nhau. C th c cc bn ghi chp nhng chng li c lp h s v ct k trong t m khng dng n bao gi.

306 307 308 309

113

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C nhiu m s c dng cho cng mt thit b (v d mt m phn tch, mt m t-p). Mi ngi u ni v cng mt thit b nhng s dng cc tn gi khc nhau.

Bn bit c cc ph tng thay th c th Bn khng bit c chi tit no c th c dng thay th cho nhau (tng ng) s dng trn nhiu thit b khc nhau. cho nhiu thit b. Chng c lit k v bn c th nhanh chng tm thy chng. Kho cha c th s dng chung vi cc b C th c kho cha nhng b phn qun l phn khc hoc c nhng chc nng khc khng phi l b phn bo dng. nhng b phn bo dng phi l b phn qun l. Mt vi ph tng c th khng cn lu tr bi v bn bit c rng n c th c cung cp mt cch ht sc nhanh chng khi cn thit. iu ny ni ln rng bn bit c thi hn v ai l ngi cung cp chng. (Mc 307 v 308). Vic nhp xut ph tng ti kho khng c thc hin mt cch ty tin, thiu ngn np. C th s p dng cc quy nh v kho (S.R.). Tt c nhng th m bn cn u c ct tr trong kho. Khng c mt th g lu ti ni ca nh cung cp.

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i vi tt c cc thit b chnh, bn u c Khng c mt h s k thut lin quan ti mt h s, cha ng tt c cc thng tng thit b. s k thut lin quan n thit b ny.

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Vic nhp/xut ph tng ti kho din ra ty tin, thiu ngn np. Mi ngi c th t mnh lm g th lm.

313

i vi cc ph tng then cht th cn phi Bn c th b xung ph tng trong kho khi xc nh v cn nhc mt ngng an ton , bn mong mun hoc l khi c mt s thiu ngha l di mt s lng no th cc ht trong kho v nhu cu tng ln. ph tng phi c b xung mt cch c h thng. t nht mt ln trong nm, x xut nhp Bn khng bao gi c gng tm hiu iu g kho phi c phn tch theo mt phng xy ra vi cng tc xut nhp kho. php phn loi hoc nhm li nh l th t alphabe, ...

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1.

Tai nn

1.1- Ti sao tai nn xy ra? (1) Cc trang b m bo an ton 70% tai nn xy ra cc nh my lin quan n cc thit b. Ngy nay, vi s pht trin ca t ng ho, con ngi t trc tip vn hnh my mc hn nn c im ca tai nn cng thay i. Tai nn xy ra nhiu hn cc nh my thiu mi lin h cht ch gia cc b phn, thng xuyn phi dng- khi ng li my, mt tp trung cao v hay xy ra s c... Cc nh my ny lun vn hnh vi cc iu kin trong bn khng th s sut vi thit b, thm ch ch trong 1 giy. Do vy, cc hot ng bo dng sn xut phi da trn quan im "m bo an ton cho ngi v thit b". (2) nh lut Heinrich nh lut Heinrich c xy dng trn c s nhng s liu v tai nn t thc t cc nc pht trin, trong t l Tai nn Nghim trng: Tai nn Nh : Tng s cc Trng hp kho st l 1 : 29 : 300 Cn c vo cc s liu, ta thy c 1 trng hp gy cht ngi, 29 trng hp tai nn nh v 300 trng hp cn li khng gy tai nn trong tng s 330 thao tc nguy him ging nhau. i khi ngi ta cho rng tai nn ch l s khng may v nhng nh my ni c quy tc an ton nghim ngt vn c tai nn xy ra trong khi nhng ni khc khng xy ra tai nn cho d khng c mt gii php an ton no c thc hin. Quan im ny l sai lm. nh lut Heinrich cho thy nu thng xuyn thc hin nhng thao tc nguy him, ti mt lc no tai nn s xy ra. Do vy, trnh tai nn, cn tin hnh cc bin php an ton theo c hai quan im "thit b" v "ngi", tc l loi tr cc thit b nguy him v cc thao tc nguy him. 1.2 - Cng tc bo dng v an ton Nhiu tai nn xy ra khi my mc c trc trc. V b phn bo dng thc hin cng tc sa cha nn h c nhiu nguy c b tai nn. C hai loi tai nn xy ra: * Tai nn trong khi bo dng * Tai nn do bo dng khng ng (1) Tai nn trong khi bo dng C hai loi tai nn xy ra trong khi bo dng: Tai nn do yu t con ngi, nh thiu cng tc chun b hay s sut S khi ng t ngt ca my mc thit b Tai nn d xy ra do thiu kinh nghim. V vy, cng tc bo dng nn do t nht 2 ngi thc hin. Nhng ngi ny cn hiu bit nhau rt r v lm vic n . Trong s rt nhiu nguyn nhn xy ra tai nn, nguyn nhn thng gp nht l s khi ng t ngt ca thit b, do: Ngi th ba bt cng tc ON/ OFF S hp tc thiu ng b Chm vo cng tc ON khng r nguyn nhn p sut d trong xy lanh kh nn, thu lc Hng cng tc dng Hiu khng ng v vn hnh t ng thit b Li vn hnh my Mt s tai nn thng gp khc l: hng, gin gio, li s dng thit b hoc dng c, in git... Nhng tai nn ny c th gim ng k khi tun th nghim ngt cc quy tc an ton v thng xuyn c thc cnh gic phng. trnh cc tai nn ny, cn tin hnh cc bin php phng nga t c hai pha thit b v con ngi. Yu t an ton cn c tnh ti ngay t giai on thit k, bao gm cc khi nim "d tr an ton" v "d s dng".

23. BO DNG SN XUT V AN TON

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(2) Tai nn do bo dng khng ng Cc tai nn ny cng c th c chia lm 2 loi Bo dng khng ng gy tai nn cho ngi vn hnh Bo dng khng ng trc tip gy tai nn Trong trng hp th nht, bo dng khng ng c th gy ra nhng li chng hn nh kt, tc, gy cc chi tit hoc b phn my. Khi my vn hnh c th xy ra s c gy tai nn cho ngi vn hnh. Cc tai nn thuc loi th hai c th xy ra trong bt c iu kin no khi tin hnh cng tc bo dng. Chng cng rt a dng: in git, i dy sai, cc mi ghp bng hn hay bu lng b li, hng cc thit b, dng c an ton... 2. Phng trnh tai nn 2.1- Coi an ton l mt nguyn tc hot ng ca nh my Cc bin php an ton ch c th thnh cng mt nh my khi ton th cc thnh vin t ban lnh o n cng nhn coi "an ton trn ht" l mt trong nhng nguyn tc hot ng ca c s mnh. 2.2 - Cc bin php an ton Tai nn xy ra trong qu trnh tip xc gia con ngi vi my. Do vy, gim tai nn, cn ch ti cc im sau: Cc tnh trng khng an ton ca my mc thit b S nguy him (cc thao tc khng an ton) (1) * Loi tr cc iu kin khng n nh: An ton ca bn thn my ( an ton thit k): Nhm trnh tai nn t giai on thit k v ch to bng cch to cho my cc chc nng an ton ngay c khi cc thao tc v tnh hung nguy him xy ra. D tr an ton: My mc thit b c thit k m bo an ton ngay c khi c s c. C 2 phng php d tr an ton: S dng 2 chi tit hoc b phn cng chc nng nu mt chi tit hay b phn b hng th my vn duy tr hot ng bnh thng. My c kh nng t tm ra nhng bt thng v t dng trc khi s c xy ra. D s dng: My c thit k sao cho ngi vn hnh khng thao tc nhm. Nu thao tc nhm th cng khng gy ra hng v tai nn.

Do vy, iu ht sc quan trng m bo an ton l cc im sau c kim tra v tun th nghim ngt: Trnh chuyn mn v lnh vc lm vic ca nhn vin sa cha dy chuyn. Cc thng tin phn hi trnh tai nn lp li. o to v cc phng php sa cha Gi lin lc vi nhn vin sa cha dy chuyn. Ch cc nhn vin sa cha dy chuyn mi c php thc hin cng tc sa cha (khng cho php cc cng nhn khc trong dy chuyn ). (2) Yu cu i vi nhn vin bo dng c im ca cc bin php sa cha hon thin thc hin khi ang vn hnh dy chuyn l tm thi v khng trnh khi ln xn. Tuy nhin, nhn vin bo dng vn cn phi ghi chp nhng yu cu ca cng tc sa cha hon thin thun li cho vic bo dng theo k hoch. Cc d liu phn hi cng cn thit cho bo dng phng nga. Cn lu rng khi c nhng bt thng xy ra, cc b phn, thit b an ton thng b tho ra d gy mt an ton. 2.4 - Cc bin php ngn nga tai nn lp li Phn tch nguyn nhn v nh gi cc tai nn khng gy thng vong Thc hin cng tc kim tra an ton Nghin cu cc thng tin, cc bo co v s liu thng k v tai nn Quan st kim tra

* *

(2) Loi tr cc thao tc mt an ton: V cng tc bo dng khng c mt hnh thc c nh v xy ra bt thng nn c nhiu nguy c mt an ton. Hn na, con ngi cng c th phm sai lm hoc thiu tp trung gy ra tai nn. Do vy, phn xng sa cha cn c cc bin php trnh cc li do thiu quan st. Chng hn nh s dng mu sc v k hiu biu th an ton v nguy him, cc du hiu r rng ca in cao p, mi tn ch hng, ch th mu ca cc ng ng... 2.3- Cc bin php sa cha hon thin trong khi vn hnh (1) Nhn vin bo dng v nhn vin sa cha dy chuyn Cc li nh gy dng dy chuyn sn xut hoc lp rp xy ra kh thng xuyn. V b phn bo dng khng th x l ht nhng li nh nh vy nn ngi ta bt u s dng cc nhn vin sa cha dy chuyn (kim nhim) gii quyt vn nhanh chng hn. Mc d theo quan im TPM, bo dng t qun do nhn vin sa cha dy chuyn thc hin l ng khuyn khch, nhng thi d di v vai tr ca h c th gy ra tai nn.

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Gii thiu: Vng i ca thit b tin cy ca my mc Trc khi h hng thc s din ra, cc thit b my mc lun c nhng biu hin bt thng. Cng tng t nh vi con ngi hay xe c, tuy khng phi lun lun c th nhng i lc ch bng cc gic quan thng thng, ta c th nhn bit c cc biu hin ny. Cng vic kim tra nn c tin hnh trc khi c cc du hiu xung cp. Mc d mc ch cui cng ca kim tra thit b l kim tra v nu khng c h hng th khng cn can thip, nhng trong thc t cng nghip, s vic thng khng n gin nh vy. Cc nh bo dng cn nhn thc r mc ch ca h l lm tng li nhun bng vic gi cho nh my hot ng khi c yu cu ch khng n thun l lun gi cho my mc iu kin tt. Hai mc tiu y khng phi lc no cng tng thch vi nhau. tin cy ca my c xc nh thng qua vic n c hot ng tt bt k khi no c yu cu hay khng. Trong thut ng thng k, tin cy c nh ngha l xc sut mt thit b lm vic lin tc theo yu cu trong mt khong thi gian mong mun no . tin cy l hm s ca quy trnh thit k my (vt liu s dng ra sao, thit k c hon ho khng, cc b phn c d tr an ton khng); cht lng (nh tnh cht vt liu, cht lng sn xut v thit k); v phng php bo dng c p dng. Nhn chung, tin cy ca my mc cng cao th gi thnh sn xut v s dng my cng t. tin cy ti u l s cn bng gia chi ph v mc tit kim c khi khai thc thit b, th hin nh sau: Trong ngn hn: gim chi ph sn xut. V d nh trong lnh vc pht in l gim chi ph pht in nhng ni c gi thnh sn xut ln, hay thm ch l gim chi ph khi khng pht in. Trong di hn: sn xut c tng ln s tit kim cc chi ph cho thit b my mi bng cch tr hon vic phi mua hay thm ch b i vic mua .

24. GIM ST TNH TRNG THIT B

Do , mc ch ca bo dng l gi tin cy ca nh my mc ti u, ph hp vi mc an ton cho con ngi v cho nh my, ng gp cho sn xut v cc mc tiu li nhun ca nh my hay doanh nghip. Nh ni trn, qu trnh ny KHNG ging nh vic gi nh my iu kin lm vic tt m ch ng vai tr l hng dn nhm tng hiu qu ca cng vic bo dng ni chung. ng cong dng bn tm v hm Weibull D my mc mi c sn xut hay l c sa cha li, chng u c c ba thi k h hng xy ra ring l hay ng thi. nh ngha v T l h hng: l kh nng mt thit b s c h hng trong mt khong thi gian nht nh vi iu kin l thit b hot ng n thi im u ca khong thi gian ny. T l ri ro v li ri ro l cc thut ng dng cc ni khc nhau nhng cng ch v kh nng ny. THI K U: cc h hng xy ra do cc li trong mt hay nhiu quy trnh nh thit k, sn xut, lp t, hay vn hnh. Cc h hng ny cn c gi l burn in, wear in, cht non. My mc s tr nn n nh hn sau khi a vo hot ng mt thi gian. THI K H HNG: trong qu trnh s dng, tnh nng ca my mc b suy gim do hin tng n mn hoc mi mn, c tnh thit b thay i xu i, cc b phn lng ra hay xut hin hin tng qu ti. My mc tr nn km tin cy hn v h hng cui cng xy ra. Thi gian hot ng ca my mc cho n khi b hng hc thng rt a dng, ngay c trong cng mt loi thit b.

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Trong qu trnh gim st tnh trng CM, chng ti xem xt hin tng dng hot ng gc kinh t rng nht, bao gm khng ch cc h hng vt l m c cc li vn hnh khng nh mong mun. V vy, cc tiu ch nh gi hng hc ca mt loi thit b khng ging ht nhau cho tt c cc i tng s dng. i vi mt s ngi, cc nh gi c th hon ton mang tnh ch quan nhng i vi nhng ngi khc li cn c s tnh ton cn nhc v ti chnh. Do , vng i my c tnh bng khong thi gian t khi bt u s dng my cho ti khi my b h hng theo nh gi ca tng trng hp. THI GIAN LM VIC HU CH: L khong thi gian gia hai giai on nu trn. giai on ny, t l h hng khng i theo thi gian. Thi im xy ra h hng l ngu nhin v t l h hng l nghch o khong thi gian gia cc ln h hng. Phng php tip cn bo dng ti u thay i tu theo tnh trng h hng xy ra giai on no. V vy, i vi mt d kin v h hng cho trc c a ra, cng vic ca chng ta l phi tm ra khi no tnh trng h hng bt u din ra. Mi giai on c th c din t bng ton hc, v chu k vng i ca thit b c th c minh ho bng mt ng cong c dng bn tm: Hnh 2.60. i vi mt s thit b, ng cong bao gm mt khong: ng Vng i hu ch cng ngn, tnh trng ca my cng ti t. Nu t l hng hc ca mt s b phn tng ng xy ra trong mt khong thi gian c biu th theo thi gian, chng ta c mt ng cong mi i vi mi giai on v c gi l cc hm mt xc sut. S chu k vn hnh dng lm thng s ph hp hn l khong thi gian.

Ch rng cc my mc hay cc b phn phi ging nhau v c vn hnh trong cng mt iu kin H hng y l ni n cc hng hc vt l. C rt nhiu cc thng tin hu ch c sn hin nay ni v vn ny, tuy nhin y chng ti ch n thun a ra cch s dng cc k thut xc nh cc phng php tip cn thng thng ca bo dng trong khong thi gian c nh sao cho ph hp nht. Ni chnh xc, phng thc tip cn ny ch c p dng vi mt b phn ch khng phi cho ton b h thng. Lu rng cc thit b in hay in t thng c t l h hng sn v khng c cc biu hin h hng trc . Phn tch Weibull ch yu c ng dng cho cc thit b c kh. (tham kho mc 1.13) V d v Phn tch Weibull Mt mu gm 10 trc b h hng sau khong thi gian s dng ln lt l 300, 410, 500, 600, 660, 750, 825, 900, 1200 gi. Quy trnh tm ra thng s hnh dng l: 1. Lit k cc d liu theo th t tng dn v thi gian s dng, da theo mc trung bnh ca kch c mu trong bng 2.41 di y. BNG 2.41 CC GI TR CA PHN TRM TCH LU CA MC TRUNG BNH CHO CC C MU KHC NHAU

Thi k u H hng T l hng hc

Vng i hu ch

Hnh 2.60: ng cong dng bn tm m t vng i thit b Dng ton hc ca cc ng cong trong tng giai on: Thi K u: hm siu m Thi Gian Hu ch: hm m m H hng: hm suy rng bnh thng Cc hm Weibull l cc m hnh ton hc da trn kinh nghim m t cc c im ca hu ht cc h hng. Trong mi trng thi thit b c mt thng s hnh dng m t d liu dng hnh hc. Phng php n gin nht tm kim cc thng s hnh dng hin nay c th s dng kim tra cho cc tnh hung thng thng trong cc ngnh cng nghip m cc d kin a ra rt t (c th ch vi 2 mu d kin). Cc phng php phc tp hn cho bit nhiu thng tin hn hin cng c trn th trng

Bng ny ly ra t nh l nh thc. i vi cc mu ln hn, mc trung bnh c th c xc nh theo cng thc: (S th t mc 0,3) X 100% (S mu +0,4) V d mc trung bnh cho v tr th 7 trn 10 v tr l = Thi k H hng: Phn trm Tch ly 6,8 (7-0,3) X 100 (10 + 0,4) 750 65 = 64,5%

300 16,2

410 26

500 36

600 45

660 55

825 74

900 84

1050 93

1200

(cc s liu c lm trn tin cho vic v th trn thc t)

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2. V cc cp gi tr trn th Weibull (theo t l lgart vi lga ca lga) nh trong s di y:

V mt ng thng qua cc im v v mt ng vung gc ti ng ny t im c tnh pha trn bn tri ca bng. 3. Xc nh v tr giao im ca ung vung gc vi ng . y t l =2,5 VNG I BO M, t0, l khong thi gian vn hnh cn li ti khi h hng u tin xy ra. Thi gian ny cn c gi l thi gian ngng ti hng hc hay thng s v tr Quy trnh ny gi thit rng t0=0. Trong hu ht cc trng hp, thng s tnh trng c a ra kh chnh xc. Tuy nhin, nu cc d liu c v KHNG nm trn mt ng thng m: (a) Ri vo hai ng thng ring bit: hai dng h hng s xy ra, v d nh cc h hng s din ra thi k u, v tip theo c th l cc trc trc trong giai on h hng. (b) To thnh mt ng cong. iu ny c ngha l t0 khc 0. Qu trnh v cn phi lp li vi 3 cp gi tr (t- t0 ), trong t l cc gi tr thi gian cho n t0. La chn s c dng gn nh mt ng thng, v s dng th ny cho phn tch th nh trc. Mt phng php khc nhanh hn l chn hai im bt k hai u ng cong. Chia i khong cch theo phng thng ng gia chng tm ra mt im theo mc thi gian, B. Xc inh cc gi tr thi gian tng ng t trc y theo ln tng dn l A, B, C. Tnh c: t0 = B (C-B) X (B-A) (C-B)(B-A)

Cng t0 vo gi tr thi gian trc v v li. Xc nh bng phng php u tin. Nu cc hng hc khng xy ra trc mt khong thi gian nht nh, ng cong s dng dng. y p dng phng php tng t nh m t nhng tr i gi tr o t0 ca d liu trc khi v th. Hnh 1-3 cui chng ny c th c in ra s dng. Thng s tnh trng c ngha g? i vi gi tr : <1: Thi k u: t l li gim theo thi gian. Sa cha h hng; ci thin thit k, nng cao cht lng sn xut v sa cha h hng. Nu ch n thun l thay th theo chu k th s h hng s s tng ln. ~ 1: thi gian lm vic hu ch: cc h hng xy ra vi xc sut khng i. Nu cc h hng xy ra thng xuyn, cn phi ci thin thit k. Vic thay th thng xuyn s tng kh nng xy ra cc h hng tc thi nh thi k u vn hnh. Qu trnh kim tra d on khi no h hng bt u xy ra cn thit so snh chi ph ny vi chi ph cho h hng. =1 n 3: cc h hng ging nh trong thi k h hng vi mt s c im ca h hng ngu nhin. Khng nn tin hnh vic thay th thit b theo chu k nh sn. Nn s dng quy trnh kim tra l kt hp vi bo dng h hng, s mang li hiu qu kinh t cao hn. >3: h hng. Vic thay th thit b theo chu k nh sn s c hiu qu vi iu kin chi ph nh hn nhiu so vi chi ph vn hnh n khi xy ra h hng. Gi tr cng cao th s phn b cng hp, c ngha l khong thi gian n khi h hng cng nh, khi nn s dng phng php bo dng nh k. Tuy nhin, i vi hu ht cc h hng ph thuc thi gian th khong thi gian t h hng ban u cho ti h hng cui cng thng rt a dng : gia 4:1 v 40:1.. Do phng php CM rt ph hp tin hnh. iu ny c minh ho chng 2.

S 1-2: v th Weibull ca d liu v d, mu s 10

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S dng thng s vng i bo m t0 xc nh cc thng tin khc. Nu t0 ln hn 0 th b phn vn ng tin cy n khong thi gian t0 v nu: <1: h hng dng mi =1: h hng dng mi, c th v gii hn bn ca vt liu khng chun xc >2: h hng dng mi i km vi gim tnh nng. Nu t0 nh hn 0, v: <1: c im h hng thi k u xy ra t trc khi a chi tit my vo vn hnh >1: h hng do s gim tnh nng thit b lin tc xy ra t trc khi a chi tit my vo vn hnh Bo dng da trn tnh trng l k thut xc nh tnh trng my : C tt khng? Nu tt th my hot ng bnh thng. Hay khng tt? Nu khng tt th ch can thip vo nhng b phn cn can thip. Mc ch ca phn ny l a ra cc cch gim st tnh trng kh thi, thng l vi chi ph thp nht v gip mi ngi suy ngh v cch qun l ngun ti nguyn v con ngi tt hn.

Trong qu trnh bo m hot ng, khi khng xc nh c nguyn nhn ca h hng KHNG C NGHA L khng c h hng v c th cc triu chng cng vi cc kt qu ca n cha biu l m thi. Cc Chin lc bo dng Hu ht cc ti liu xut bn v CM u m t v k thut phn tch dao ng cng vi rt nhiu thit b tin hnh k thut ny. im nhn mnh l vic bo dng da trn tnh trng my l chin lc duy nht c thc hin. Phng php phn tch dao ng dng nh rt d p dng, v c th xc nh c hu nh tt c cc h hng chnh. Tuy nhin nhiu k s li cho rng iu khng hon ton chnh xc. Nh c cp t trc l c 2 hnh thc bo dng: bo dng khi my b hng v bo dng ngn chn h hng.Tuy nhin, trong bo dng my cng nghip, nhng kiu bo dng khc c th thc hin c bao gm: Bo dng theo thi gian nh sn (cn c gi l bo dng nh k, thng thng, dch v, hay bo dng theo k hoch). Cng vic bo dng c thc hin thng xuyn nh k v khng nh hng ti sn xut. Quy trnh ny bao gm c vic kim tra h thng bo v t ng. Khong thi gian ny thng thng ph thuc vo ch hot ng ca thit b. V d nh i vi cc my pht in tuc bin hi hoc tuc bin kh, c th nh gi c s nh hng ca ng sut nhit khi khi ng ln tui th thit b: vic khi ng lnh c th lm gim tui th thit b vi khong thi gian tng ng l 30 gi lm vic vi u ra n nh. Vn hnh cho ti khi h hng xy ra: (cn c gi l bo dng hng hc, bo dng hiu chnh) Bo dng da trn tnh trng my (cn gi l bo dng d on, bo dng tnh trng) Cc Yu cu ca lut: gim st tnh trng ng dn chu p sut, kim tra cc thit b theo thi gian quy nh, gim pht thi ra mi trng Quyt nh qun l- lin quan n con ngi nh sc kho, an ton v cc mi quan h cng nghip; hay s tin li ca doanh nghip v d nh sn xut c th khng cn thit mt thi gian nht nh no : nh my phi ngng vn hnh cng nhn ngh ngi (c gi l tnh trngca s bo dng) Bo dng c hi-cng tc bo dng c thc hin ng thi vi mt hay nhiu cc phng php bo dng ni trn.

CHNG 2
Vai tr ca vic gim st tnh trng (CM) v k hoch bo dng nh ngha v CM Gim st tnh trng (CM) c th c nh ngha l: qu trnh thu thp d liu mt cch c h thng nh gi hot ng, tin cy, v/hoc cc nhu cu bo dng ca h thng nhm mc ch ln k hoch cho cc hot ng bo dng. CM c th c coi l s nng cao cc kh nng ca gic quan ca con ngi. Thut ng khc hay c s dng l kim tra chun on c lin quan ti mt phn trong quy trnh CM: cc kim tra ny c tin hnh khi cc h hng c xc nh bng cc phng php khc. Thut ng Pht hin cc li sm cng l mt thut ng c lin quan, tuy nhin thi gian cnh bo ca k thut ny li tng i ngn. Trong quyn sch ny, cc hot ng CM kt hp ton b vng i ca my t khu my vn hnh n kim tra v bo dng, vi mc tiu a ra cc d bo sm v thi gian din ra h hng ch khng ch tin hnh trong khong thi gian ngay trc khi xy ra h hng. V lu di, CM s bao gm c cc k thut nh gi thi gian s dng cn li ca cc thit b, thm nh s ph hp ca my so vi thit k. Mc d, vic u t thay th mt s b phn vn ht sc cn thit, tuy nhin vic nng cao tui th nh my ang chng t c tnh kh thi v mt kinh t vi ngnh cng nghip nng lng v vi c cc ngnh khc na. Quy trnh nh gi v mt kim loi l mt phn quan trng trong cc hot ng nng cao tui th nh my , nhng trong phm vi ca cun sch ny chng ti khng cp n quy trnh . Mc ch c bn ca CM l cho php ngi s dng quyt nh thi gian thch hp nht tin hnh bo dng ngha l khi thc s cn thit v trc khi cc h hng xy ra, hay chi tit hn l: a) Duy tr vn hnh thit b thng qua vic thng bo tnh trng my cho ch my (ngi vn hnh, k s nh my) v thc hin cc quy trnh duy tr vn hnh v ngn chn cc h hng nghim trng b) Tng ti a thi gian hot ng ca my trc khi sa cha v ch ra v tr h hng, t a ra nhng sa cha cn thit bao gm cc chng minh v tnh kinh t ca cc sa cha nu c th. iu ny cng bao gm c vic tranh lun phn i vic tho my ra. c) a ra cc cnh bo v tnh trng h hng, v nu c th cho php my chy ti thi im dng hot ng theo k hoch v chnh sa cc h hng . Thi gian ngng vn hnh ny c th din ra mt thi im kinh t hn hoc thun tin hn.

K hoch bo dng Cc chin lc trn y u c lin quan ti nhau mc no , v c th p dng nhiu chin lc cho mt thit b. Vic la chn cc chin lc tu thuc vo ngnh sn xut, tnh cht sn phm cng nh kh nng sn xut ca nh my tng ng vi doanh s bn v cng ph thuc vo vic ng dng cc k thut bo dng nh: ci tin nh my nng cao tui th thit b, gim thiu thi gian ngng hot ng thng qua vic thit k li cc thit b thun tin cho vic thay th, hoc s dng cc k hoch thch hp. Tt c cc chin lc u c nhng thun li v kh khn ring. Nguyn tc hoc k hoch bo dng nn c lp ra cho mi nh my vi phng thc tip cn tun theo cc yu cu sau: Cc c im v tin cy ca mi chi tit my (xem chng 1). Nu cc s liu khng c sn th s dng kinh nghim ca nh sn xut hoc ca bn thn k s.

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Cc h hng c th c pht hin ra t trc hay khng, v so snh chi ph thc hin quy trnh ny vi chi ph trong cc chin lc khc. Xem xt cc chi ph trong chin lc c p dng nh chi ph cho vt liu, cho nhn cng v cho thi gian my dng hot ng. Vn hnh cho n khi h hng xy ra vn l mt la chn c th p dng c. Mc sn sng thay th ca mt chi tit h hng (v d nh yu t nhanh chng, r), bao gm c chi ph cho cc ph tng. Xem xt cc xut ca nh sn xut v kinh nghim bn thn ca k s v loi thit b hay cc thit b tng t. Cn nhc vn an ton Kelley (tham kho mc 1.5) khuyn dng phng php tip cn sau y thit lp k hoch bo dng: Hiu c quy trnh sn xut, s dng biu pht trin. Xc nh cc chi tit my quan trng, v lu li mi ca s bo dng. Lit k cc m-un c th thay th trong nh my nh ng c, bm, hp s. Xc nh chin lc bo dng thch hp nht cho mi m-un t nhng chin lc nu trn. Xc nh k hoch bo dng cho mi n v hay mi phn ca nh my: cc chi tit ny s c duy tr nh th no trong qu trnh lm vic. Ln lch trnh bo dng cho ton b nh my. a ra cc hng dn v bo dng hiu chnh: hng dn, cc phng thc, cc ngun lc

D liu tin hnh CM. Cc d liu cn thit cho vic gim st tnh trng CM c th ly t: Khong thi gian nh sn ty thuc vo kinh nghim v kt qu mun thu c. Cc cuc kim tra ny c th tin hnh khi c xc nh t cc thit b, t nhn vin vn hnh nh my hay t kinh nghim cho thy chng c hiu qu.

Phn tch d liu lu tr: cc thit b o ca nh my v h thng lu tr thng c th cung cp cc d liu ph hp thng qua nhng thng tin c lu tr lin tc. Bn ghi d liu v h thng my tnh c th gip cho cng vic thu thp thng tin c d dng hn. Nu c s m bo v tnh n nh lu di ca cc thit b o chnh, hay chng c th c kim tra vi chi ph nh th vic tin hnh gim st tnh trng my lin tc rt kh thi v mt kinh t. Ch rng cc s liu lp li cn c cung gn nhau xc nh nhng thay i mt cch chnh xc. Cc s liu lp li ny khng nht thit phi l cc d liu chnh xc tuyt i. Mt s k thut i khi yu cu nh my phi gin on trong hot ng, tuy nhin cc phng php ang c pht trin c th tin hnh khi nh my ang vn hnh. Ch rng phng php gim st tnh trng my CM CH C P DNG KHI CHN C MT THNG S KIM TRA PH HP. S cn thit ca vic xc nh cc thng s Nu c kinh nghim xc nh cc gi tr gii hn hoc mc hot ng ca mt thng s tnh trng th cc mc tin hnh s c so snh da trn mt phng thc n gin l VN HNH TIP hoc NGNG VN HNH. Mc cnh bo thp hn c th c s dng tng mc kim tra hay cn c cc kim tra chi tit hn. Nu mc hot ng khng b qu gii hn, d liu s loi b : c bn l bo co cho cc trng hp c bit Trong hu ht cc trng hp, ngi tin hnh cn lu li tt c cc thng s t nht l lc ban u v gi li cc BIU XU HNG. ng cong ny c th trn v cc hnh chiu c s dng d on khi no n c cc mc cnh bo hay mc hot ng tng ng. ng cong biu din thi k h hng ca thit b c th c v ra bng cch s dng thng s tnh trng thch hp. Mc d ng ny khng ging chnh xc nh phn sau ca ng cong c dng bn tm c cp trc y nhng cng gn tng t. ng cong tng qut c m t hnh 2.62 ng vi mt mc hot ng ca thng s. Mt ng cong vi hnh dng tng t ch ra rng cn c cc bo dng nhm khi phc li qu trnh vn hnh theo ng nh yu cu. Lu rng cc h hng c th lm gim i cc thng s tnh trng my. Kinh nghim cho thy rng trong qu trnh phn tch nn nng cao cc thng s ln khi xc nh cc h hng. V trong mt s trng hp, cn phn tch nhiu thng s khc nhau nghin cu h hng v c th cc thng s ny l s ha trn ca cc xu hng tng ln hay gim i. Da trn cc d liu thu c cho ti thi im A c th d on vic tin hnh bo dng s xy ra thi im B. Sau my c cho tip tc hot ng v theo di. n thi im C, mt d on mi s c thit lp, kt hp cc d liu mi v thi im tin hnh bo dng mi s c d on l ti thi im D. Nu mun, ngi s dng c th dng cc chng trnh nh gn m t cc ng cong c sn cho my tnh b ti v my tnh c nhn trong h s tng quan s xc nh c ng cong no l ph hp nht vi d liu a ra. Tuy nhin, cc phng php ho th cng cng kh chnh xc khi da trn cc im c v to ra mt hnh nh ng cong n gin nhng tin s dng v s dng kh tt. Mt s h thng kim tra dao ng s dng cc phng php ton hc c lng nhng khong thi gian n cc mc tc ng khc nhau n thit b ca ngi s dng v m t tt c cc im d liu .

Rt nhiu gi phn mm qun l bo dng hin nay c sn v c th h tr hu ht cc hot ng ni trn. Nhng im lu khi tin hnh CM Nhng h hng c th c xc nh bng phng php gim st tnh trng ngay trc khi qu trnh ngng hot ng nh k din ra v c th trnh c cc thit hi do li ban u gy ra. Tuy nhin, mt s h hng s vn xy ra do khng th xc nh c tt c ngay t sm. Trong hu ht cc trng hp, nu hng hc c th d on c, cc thng s v tnh trng thit b my mc c th c tm thy v kim sot, CM, mt chng mc no , l rt tit kim. Phng php ny c th s khng ngn chn c ton b cc h hng xy ra, nhng n cho php la chn khi no th nn tin hnh sa cha. Phng php gim st tnh trng thit b CM s khng kh thi v kinh t nu nh cc chi ph cho vic dng hot ng sa cha hay thay th nh. Mt s phng php gim st tnh trng CM s dng cc thit b gi thnh cao hoc chi ph thu kim tra cao hn so vi cc chin lc bo dng khc. V d, tht khng hp l khi ch kim tra mt my bm nh m s dng c mt ngy lm vic ca mt k s hay ca c quan, trong khi vic tin hnh kim tra v thay th ch cn vi gi ng h. Phng php gim st tnh trng thit b khng cn thit phi qu t , v n li l mt lnh vc ang pht trin m nhng ngi tham gia c rt nhiu iu hc tp ln nhau.

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Action Line Parameter of Condition

Routine Piots A Time in service C B D

Phng php truyn thng-bo dng nh k Trong bo dng nh k, khong thi gian yu cu bo dng cc thit b ca nh my c quyt nh tu theo qu trnh hot ng trc y, theo li khuyn ca nh sn xut hay thi gian lm vic ca thit b. Khong thi gian ny i khi c la chn theo phng php thng k khi khong 2% cc thit b c nguy c b hng. Khng c xem xt no ph thuc vo tnh trng hin thi ca thit b. Hn ch ln nht ca phng php ny nh c cp l khng xc nh c thi gian lm vic ca tng thit b. V d, thi gian phc v ca mt trc cn theo thng k c xc nh l L10. y l s gi mt nhm trc s vn hnh v 10% s trc s c th b hng. C ngha l nu cc vng bi c thay i theo chu k L10, t l h hng ca chng s lun l 10%. Tui th trung bnh ca mt trc thng gp khong t 3 n 4 ln thi gian L10. T l gia cc h hng v cc khong thi gian hot ng to nn s phn b bnh thng- y mt ng cong c dng nh hnh 2.62 v c m t chng 1. Khi c d liu v cc trng hp h hng ta c th xc nh c mt ng cong i vi bt k my mc no hay b phn no. Khong cch cc ln h hng gn nhau s cho mt dng cong c dng hp, v phng php thay th nh k nn c s dng. (nh i vi trng hp thng s hnh dng Weibull >3 v chi ph cho mi chi tit thay th khi hng hc ln hn rt nhiu so vi chi ph ca vic bo dng nh k-xem chng 1 v tham kho mc 1.10). Hu ht my mc u hot ng nh cc trc v d trn, khong thi gian gia cc h hng ca chng thng din ra kh lu.

Hnh 2.61: th ng cong h hng da trn thng s CM trong s xung cp c th hin l gi tr dng. (gin ) Qu trnh gim st tnh trng thit b trong chu k hot ng-bo dng Gim st tnh trng thit b c th c coi l mt khu trong chu k hot ng my v bao gm cc cng on sau: My vn hnh, cc kim tra khng th hin c du hiu thay i ng k no Kim tra pht hin mt thay i ng k Nguyn nhn gy ra thay i c xc nh D on thi gian cn c bo dng (hay cc bo dng) Bo dng hiu chnh c thc hin (kt qu thu c lin quan ti chn on) My vn hnh tr li Nh cp, cc cng on trn s c an xen vo mt s hot ng bo dng nh k v c th l mt s bo dng hng hc. Gim st tnh trng thit b ang ngy cng c p dng nhiu trong ngnh cng nghip trn th gii v l khu quan trng trong chu k hot ng-bo dng. Bn phng php gim st tnh trng thit b (xem chng 4) c th c s dng mt cch ring r hay kt hp tu theo tm quan trng ca thit b trong qu trnh sn xut. Vic xc nh mc c th tin hnh phi tnh n yu t thc t. V d, vi loi bm ngang nhiu tng th ton b bm c th l b phn nh nht c th tho ri sa cha. Tuy nhin nu mt cnh bm no c xc nh trc l b phn duy nht cn c thay th th ch tin hnh trn b phn thi. Cc b phn ny c th c th coi nh ph kin thay th v sn c. Do v tr tin hnh ch n gin l thit b bm. Vi loi my phc tp hn, v d nh mt tuc-bin hi ln, cc ph kin thay th rt t trang b trc nhng phi mt hng thng t mua. Thng thng trng hp ny c dung ha v xc nh r cc b phn no d b h hng, cc b phn no khng th khng c mt trong qu trnh vn hnh v vic thay mi khng th tin hnh. Trong tnh hung ny vic xc nh r tnh trng h hng s rt ng gi.
Number of Breakdowns

Averae running time between breakdowns

Longgest recorded running time before breakdown

Totally safe period for fixed- time naintenance

L10

Running Time Until Breakdown Occurs

Hnh 2.62: S phn b theo thi gian cho n khi h hng (gin ) Ngi s dng c th chn thi gian thay th thit b ngn hn vng i ti thiu ca thit b, nhng cch thc ny cn mt khong thi gian my ngng lm vic khng thc t v cha k n chi ph ln cho vic thay th v chi ph cho cc thit b bi v hu ht cc thit b c thay th vn c th lm vic thm mt khong thi gian na. Thay th thng xuyn khng lm gim kh nng xy ra hng hc xy ra do cc nguyn nhn khc gy ra hay i khi thm ch c th h tr thm cho cc nguyn nhn ny. Thit b i khi gim tui th ch v thao tc lp t thiu chnh xc. Cc d vt lu li trong my mt cch v tnh hoc cc li thao tc lp t l nhng iu rt hay xy ra. i vi bo dung nh k, ng cong din t t l hng hc khi qu trnh thay th din ra nhiu ln c m t nh hnh 2.63.

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Quay tr li v d v trc, phng php CM cn m bo rng mi thit b c s dng ti a v tui th trong khi vn m bo pht hin nu c h hng bt k trc no. Cn xc nh r v d nh trc c b mi hay khng, c b tc ng bi cc tc nhn bn ngoi nh lp rp khng hp l, b bn hay thiu bi trn hay khng.

BO DNG
Hai s la chn: Qun l nh my: BO DNG PHNG NGA

Chance of Failure

nh k Cc yu cu v php lut Quyt nh qun l (v d, OH&S) C hi Thit k (phn tch nguyn nhn) Ngn nga/da trn trng thi (khi c cc du hiu hao mn

Maintenance Outage

Hoc my mc qun l chng ta: Time

VN HNH N KHI HNG HC

i khi kh tit kim chi ph do hng hc gy ra l bao nhiu? Hng hc c th tr thnh hng hc v kinh t sn xut vn duy tr, nhng mc thp hn hoc chi ph nng lng cao hn, hoc c hai.

Hnh 2.63: Cc ng cong m t t l h hng i vi phng php bo dng nh k Rt nhiu minh chng cho thy rng phng php bo dng da trn tnh trng thit b c kh nng rt ln trong vic m bo thit b my mc hot ng lin tc v ch ngng vn hnh hay tho d khi cn thit, u vit hn so vi cc phng php bo dng nh k hay bo dng h hng. QUYT NH nhng s kt hp tt nht cho K HOCH BO DNG VNG I CA BN.

THI GIAN CN HOT NG C D KHIN THNG S VN HNH NGNG HNG MY

GI TR O C

DI GI TR O LP LI

GI TR TH HIN S THAY I LN TRONG TNH TRNG THIT B

THI GIAN VN HNH (HOC CHU K)

Hnh 2.64: Nguyn l c bn ca CM Lp th cc thng s nhiu ln i vi my mi xc nh tin cy, sau lp th nh k xc nh cc thay i, v d bo thi gian h hng.

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CHNG 3
Minh chng cho li ch ca k thut gim st tnh trng CM Cc chi ph cho nhn cng v thit b tin hnh CM thng kh tn km, nhng li bin h nh chi ph sx s c b li nu s dng cc k thut CM bo v khng xy ra y ngy dng sn xut v h hng thng khng sc thuyt phc cc nh u t. Cc thng tin chng minh v li ch ca CM hin c bao gm: Cc li ch thc cht Kinh nghim trc tip thu c ca cc ni khc Cc minh chng ng tin cy c chp nhn cc ni khc Chun b cho chi ph v cc minh chng cho li ch ti a im c tin hnh CM Cc li ch ca CM Cc li ch ca CM hu ht c nu cc phn trc, nhng chng c th c tng kt nh sau: CM gim thiu vic dng v ti vn hnh khng cn thit, t : Gim tht thot sn xut Gim chi ph bo dng Tng s ho hng trong cng vic ca cc nh bo dng do cng vic mang tnh cht chnh sa v i mi thit b nhiu hn ch khng n thun ch l tho d v lp t thit b theo nh k. Tng hiu sut bo dng bng cch ng dng kinh nghim chuyn gia v nng lng vo cc v tr hiu sut km. Tng tui th thit b do t phi tho d v nu c th cng t sai st hn (My mc c thit k lm ra sn phm ch khng phi tho d). Tui th thit b tng cng ng ngha vi vic gim chi ph u t cho thit b mi. CM m bo tin cy ca nh my: v d nh nng cao kh nng vn hnh theo yu cu ca thit b. Nu my chy tt v khng c h hng th tt nht l c n hot ng CM m bo vn hnh an ton. Phng chm bo m tnh nguyn vn ca thit b lun c u tin hn l c gng tm ra cc h hng ca thit b. Thm ch nu nguyn nhn ca cc trc trc khng c xc nh ngay t u, cc nguyn nhn khc nu khng c cc biu hin c th c th c b qua bng cc k thut x l nh k thut phn loi cc triu chng vi phng thc tip cn C hoc Khng (IS-IS NOT). i khi cc h hng khc li c tnh an ton cao hn so vi cc nguyn nhn cn li. Gim chi ph bo dng c ngha l hiu sut v tnh cnh tranh c tng ln. t nht th vic gim chi ph c th gi vng nhng v tr cng vic hin ti v thm ch to ra nhiu vic lm hn. S dng kinh nghim ca cc ni khc K thut CM v ang c ng dng rng ri trong rt nhiu lnh vc cng nghip. Cc v d minh ha v ng dng ca k thut CM v li ch ca k thut ny c m t trong rt nhiu ti liu k thut, nht l cc ti liu gii thiu ca cc nh sn xut thit b CM. Di y l mt s kinh nghim v ng dng CM: Trong nh my giy Canada. Khong thi gian dng hot ng ca hai my ch to giy l 1160 pht/ thng t thng 6 nm 1981 n thng 7 nm 1982. Cng tc bo dng lin tc c tin hnh t thng 4 n thng 7 nm 82, v kt qu thu c l t thng 8/1982 n thng 9 nm 1983, thi gian dng hot ng gim xung trung bnh 226 pht/ thng, tng ng vi mc gim 81%. Chi ph tit kim c khong 231.000 USD /nm (tnh theo USD nm 1982).

Nh my giy Vng Quc Anh. Vo nm 1981, y c 210 trc trc k thut xy ra, lm thi gian dng hot ng trung bnh l 21 gi mi thng, tn tht n 260.000 bng. Mt chng trnh tng th v CM c tin hnh t thng 4 nm 1981 v kt qu thu c l mc h hng cng nh thi gian dng hot ng dn ci thin ng k, theo c tnh trung bnh ch cn 40 trc trc v 6,7 gi dng hot ng cho nm 1984, tit kim khong 180.000 bng. Nh my lc du M: kim tra hng thng s dao ng ca 4000 my quay. Trong vng 6 nm cc chi ph bo dng cho 100 my chnh (cng sut 1000 n 32000 m lc) gim 22%, t 7 USD n 5.45 USD trn 1m lc. Chi ph cho cc thit b khc gim 30%, t 6.36 USD n 4.47 USD trn 1m lc. (Chi ph tnh theo dollar nm 1975). Nhn chung, chu k bodng tng t 3 nm ln khong 7 hoc 8 nm. K hoch nghin cu tin hnh bi mt tp on vi s tham gia ca cc k s trong nghnh in ca Australia trong vng 3 tun (1984). i vi tuabin pht in 500MW chy than, mc u t cho CM l 550.000 USD vi 170.000 / nm. Hu ht khon u t ny dng mua cc thit b o c c bn. Mc tit kim t c c tnh ln ti 350.000 USD trn mt nm. H thng cp nc cho thnh ph vi hn 3 triu dn ( s dng trn 600 bm v 270 b thit b khc). Cc phn tch hng tun, hng thng v nh k cc dao ng t 500 n 1000 gi c tin hnh trong vng 10 nm. Thi gian vn hnh gia cc ln bo dng tng ln 400% v cc h hng gim hn do thit b c bo dng khi cn thit nhiu hn l bo dng khi ang hot ng tt. M khai thc ng vi cc thit b ch yu ( thit b nghin, thit b lc, thit b mi, thit b i). 3000 mu du c phn tch mi thng. Quy trnh phn tch dao ng c tin hnh trong vng 6 nm: 3 nm trin khai v 3 nm i vo thc hin. Chi ph cho CM l li nhun trong mt thng ca nm 1985. Kt qu t c l trong vng 3 nm sau khng h c s xut hin cc trc trc trn cc thit b c tin hnh kim tra. S dng kinh nghim ca cc ngnh cng nghip lin quan. Cc hip hi thng mi nu c c th t chc cc hi tho trao i kinh nghim v ng dng CM. Cc tp ch v k thut cng l mt ngun cung cp thng tin b sung.

Cc minh chng ng tin cy c chp nhn cc ni khc Kho st trn din rng ngnh cng nghip nc Anh. Trong nm 1975, mt nghin cu trn din rng c tin hnh cho vn phng cng nghip ca Vng Anh ch ra hai li ch chnh ca CM, l tng tnh an ton v em li li ch kinh t. Khong 2/3 mc tit kim c l do gim tht thot v dng sn xut, trong 1/3 l t cc chi ph bo dng. CM cng c th tng mc tit kim cc quy trnh sn xut c kh. Mc ny c th t c khi: Ngun vn u t hng nm trn mi nhn cng Sn lng u ra gia tng hng nm ca doanh nghip (v d nh tng doanh thu bn hng tr i chi ph nguyn vt liu u vo v nng lng) vt qu 300 triu bng, s dng bng Anh nm 1979 Sn phm c th c tnh theo cc ng tin khc nhng sau phi c quy v t gi trao i so vi ng bng so snh vi s liu 300 triu bng. Cng thc ny s dng cho c trng hp chu nh hng ca lm pht.

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Vi cc c tnh ban u, mc tit kim tng th hng nm trung bnh l 1.2% ca gi tr sn lng gia tng hng nm. Cc gi tr chnh xc hn i vi tng ngnh cng nghip c th l: Len Cung cp kh, in, nc Cc sn phm g , ni tht, da Giy v bng, cao su Cc lnh vc sn xut khc St v thp, ph tng xe my, khai thc m, gch, s, thy tinh My in, k thut c kh Dt, trang thit b v in t Than, sn phm xng du, ha cht, thc phm, ung, dt kim ng tu, k thut hng hi In n v xut bn 2.3% 2.2% 2.0% 1.8% 1.6% 1.5% 1.4% 1.2% 1.0% 0.7% 0.6%

Chi ph thit lp c tnh, bng 1% gi tr ca nh my, cng vi 5% ca cc thit b cn cc bo tr c bit = 0.01 X 4.5M + 0.05 X 0.5M = $70.000. Gi thit rng 40% l vn = $28.000, (khon d khng phi l chi ph trc tip: o to nhn cng, nng cao kinh nghim) Chi ph bo tr l 86% vn u t hng nm (v d 60.000/70.000) v c th gim c. i vi ngnh ny, tim nng tit kim tng th thng l 1.5% ca $3.9M = $58.000. Chi tit hn, mc tit kim l : [11.746 X 8 X 0.75] + [60.000 X 0.05] =$73480/ nm Chi ph vn hnh c tnh l 1/3 mc tit kim tng th = 73.480/3 =$24.500 / nm. (ch rng thi gian s dng ca cc thit b kim tra lun khc bit, nhng t khi di hn 5 nm nu l thit b kim tra dao ng s dng thng xuyn). Nu cng ty t thit lp hot ng CM ca ring mnh, mc tit kim trong nm u tin c th c gi thit l bng khng. Dng tin lu chuyn trong 5 nm s c nghin cu trn mc t l chit khu. S dng t l chit khu khong 8% vi cc yu t chit khu c nu trong bng di y:

Nm 0

Chi ph thit lp -28.000 -

Chi ph vn hnh -24.500 -24.500 -24.500 -24.500 -24.500

Tit kim

Dng tin mt -28.000

Gi tr thc hin ti -28.000 -22.685 +41.991 +38.880 +36.000 +32.281

Chi ph bo dng hng nm s c coi l cao nu ln hn chi ph trung bnh ca 80% chi ph hng nm cho cc nh my Anh. Chi ph dnh cho bo dng hng hc nu chim t 40% n 50% tng chi ph bo dng c ngha l vic bo dng khng tt. Khi cn s dng cc k thut chuyn su hn: c th do cng tc bo dng nh k tin hnh qu thng xuyn giai on u vn hnh, hoc cn thit k li thit b. Hoc nu cc h hng l do mi mn th nguyn nhn l do thiu bo dng. Cc kinh nghim hin ti trong vic p dng CM ch ra rng c th loi tr n 75% cc h hng bt ng v trung bnh c th gim 50% chi ph bo dng dnh cho cc hng hc bt ng nu xy ra, tng ng 5% ton b chi ph bo dng hng nm. Chi ph xp x cao nht cho vic tin hnh CM t nht l 1% tng gi tr vn ca nh my. Khon chi ny c th chim n 5% i vi cc thit b cn cc yu cu an ton c bit, v ln n 10% i vi cc quy trnh hoc dch v c th gy nguy him cho con ngi. Khong 40% s chi cho cc trang thit b v cng tc o to hun luyn. Cc chi ph cho cng on thay i cc dch v CM ti cng ty hay thu a im ngoi cn c tnh ton da trn k thut NPV (Gi tr hin ti rng). V d v qu trnh nh gi Mt cng ty m quy m nh vi 190 nhn cng, doanh s bn hng nm l $5M , chi ph nguyn vt liu l $1M, chi ph cho cc dch v bn ngoi l $100.000. My tr gi $5M, chi ph cho bo dng hng nm $60.000 v c nng ln l $70.000. Khong 10% ca quy trnh l c nguy him. Qu trnh sn xut c tin hnh 340 ngy trong nm v trung bnh 8 ngy dng sn xut v hng hc (t gi trao i l $2 n 1 bng). Sn lng gi tr gia tng hng nm=[ 5M-1M-100.000]=3.9M ($11746 trn mt ngy) Mc u t vn trn mt nhn cng (nhn vi) sn lng gi tr gia tng = [70.000 / 190] X 3.9M=1437 M. Khi chia bng t gi bnh phng , v d 2X2,=360M. Do n vt qu 300M, phng php CM c th tin hnh c da trn cc tiu chun mc trc.

1 2 3 4 5

Khng +73.480 +73.480 +73.480 +73.480

-24.500 +48.980 +48.980 +48.980 +48.980

Tng Gi tr Hin ti Rng vi 8% chit khu = +99.467 Nu Gi tr Hin ti Rng l 0 hoc dng, d n c tnh kh thi (nn s dng t l chit khu hoc cc mc t l chit khu a ra bi chnh cng ty ca bn) Chi ph so snh khi khng s dng CM = Gi tr Hin ti Rng ca cc tit kim tim nng khng c nhn nhn (v d nh tht thot) = -73.480 X 3.9927 = - $Q 293.384 (l yu t chit khu xc nh gi tr hin thi ca khon chi dnh cho mi nm trong vng 5 nm, mc 8%). Gi tr NPV m c ngha l s thay i ny cn c loi b. Cc gi tr thc t ca vic p dng CM c th thy r trong trng hp ny. Phng php NPV chit khu gi tr tin trong tng lai thnh cc gi tr hin ti so snh: c m t trong cc vn bn v qun l ti chnh v t l lm pht khng nh hng n kt qu. Mt phng thc khc l tnh ton t l thu hi trong (IRR), hu ht tin hnh bng my tnh. Trong v d ca chng ti, IRR l 37% v do phng php CM rt thu ht u t.

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S dng t l li ch/chi ph Xem xt hai v d sau y: i vi 1400 tu ha, s dng phng php kim tra dao ng bng tay. Chi ph cho cc thit b o v cc yu t khc l $ 70.000. Chi ph h hng nu khng s dng quy trnh kim tra ny c tnh l $ 2.029 M trn mt nm v nu s dng quy trnh l $ 1.353M. Gi thit chi ph nhn cng l $ 100.000, mc tit kim hng nm c tnh l $576.300, t l hon vn l 6. 160 tu ha, s dng phng php kim tra bng my tnh vi chi ph $20.000 v 400 b chuyn i. Chi ph h hng nu khng s dng quy trnh kim tra ny c tnh l $ 294.500 trn mt nm v nu s dng quy trnh l $ 74.600. Gi thit chi ph nhn cng $ 100.000, mc tit kim hng nm c tnh l $184.700, t l hon vn l 3,5. Chun b cho nhng minh chng v t l li ch/chi ph cho chnh cng ty ca bn Phng php tip cn trn c th dng chng minh v t l li ch/chi ph cho chnh cng ty ca bn. Mt phng php khc thch hp hn i cho cc qu trnh sn xut lin tc s c trnh by phn ny. N c th a ra cc mc xc sut thnh cng khc nhau xem xt, hay c coi l phng php phn tch nhy . Cc tc v tnh ton trong phng php ny c th tin hnh nhanh chng thng qua mt chng trnh c thit k trn my tnh c nhn. Chi ph c tnh hng nm dnh cho CM Chi ph cho mi phn c c tnh v tng hp li thnh chi ph hng nm ca c chng trnh CM. T l gia cc chu trnh khc nhau trong CM s thay i i vi cc phng php khc nhau. Chi ph thit b hng nm v thm ht v li tc c th c c tnh l 30% ca chi ph vn. Chi ph bo tr thit b hng nm c tnh da trn kinh nghim ca ring k s hoc da trn s liu sn bng chy t 10 n 15% ca chi ph vn thng c s dng cho cc thit b dng my tnh. Chi ph nhn cng vn hnh chng trnh kim tra dao ng: 2 k s c th kim tra 14000 tu ha trong mt thng Nu v tr kim tra l 50 : 1 k s kim sot lin tc T 50 n 1500 v tr kim tra: 1 k thut vin lm vic ti hin trng, 1 k s phn tch T 1500 n 3000 v tr kim tra: 1 k thut vin lm vic ti hin trng, 1 k s phn tch, 1 k s nh gi, ty thuc vo kh nng phn tch ca thit b c s dng quyt nh. Trn 3000 v tr kim tra: cn nhiu hn cc k thut vin o c ti hin trng, s lng k thut vin ph thuc vo thit b o, nhng s k s vn l 2 S dng my tnh xch tay lu tr d liu ti hin trng, sau ti v mt my ch x l, s dng cch thc ny c th kim tra c nhiu hn gp i cc v tr cn kim tra. Uc tnh li ch hng nm Nu h hng uc xc nh sm th nht nh khong thi gian dng hot ng ca thit b s c gim xung. Nhn mt cch tng th, s c th coi nh mt s khong thi gian dng hot ng bt ng l nhng khong thi gian c ln k hoch t trc. Do cc li ch hng nm c th c c tnh nh sau: (xc sut xc nh thnh cng cc h hng t sm) X [A+B]

Trong : A = =

Li ch do thi gian dng my gim i Chi ph trn n v thi gian cho vic dng hot ng bt buc (v d CF) X thi gian bt buc dng my hin ti ( v d TF) (s gi mt n v thit b mt nm) X khong thi giand dng my c loi b (v d FE) B = li ch do khong thi gian dng my bt buc nm trong k hoch = Chi ph trn n v gi ca cc ln dng my theo k hoch ( v d CS) X thi gian dng my theo k hoch hin ti (v d ST) (s gi trn mt n v thit b trn mt nm) CF x TF ( 1-FE ) {CS [ST +FS x FT ( 1- FE )] CF [FT ( 1-FE )( 1- FS)]} Li ch ca vic thay i thi im bo dng vo nhng khong thi gian dng my thch hp ch khng phi tin hnh trong nhng khong thi gian dng my bt buc l rt ln do c th trnh c vic dng my. c tnh ring cho trng hp ny , s dng B l (CF-CS)FT.FS trong FS l phn thi gian bt buc dng my cn li s c chuyn i thnh thi gian dng my trong k hoch. V d, trong ngnh cng nghip in, mt n v my pht tuc bin c th c CS =$4500, CF= $18000. C FE v FS c th c gi nh l 0.5. Cc gi tr trung bnh v tht thot sn lng do nguyn nhn h hng trc v cnh tuc bin c xc nh bng CM nh sau: Kh nng thnh cng ca vic xc nh cc h hng t sm 0.4 0.6 0.8 Tng li ch phng php kim tra mang li ($/nm) $ 181.000 $ 266.000 $ 375.000

Phng php phn tch nhy hon ton c th c tin hnh vi xc sut v d liu khc c tnh c cc mc li ch. nh gi kinh nghim ca chnh bn Cc phng php s dng CM hiu qu nn c lu li cng vi cc khon tit kim thu c. Cc thng tin ny v sau c th c s dng minh chng thm cho cc thit b hay ngi thc hin CM. Gim st tnh trng thit b: Trc tuyn hay ngoi tuyn, l mt bin php kim tra bo dng trong cc thit b vn hnh c kim sot v d liu thu thp c s c phn tch nhm: Pht hin du hiu hao mn Pht hin nguyn nhn h hng D bo khong thi gian vn hnh an ton (hoc kinh t) ca thit b

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CHNG 4 Tng quan v cc k thut kim sot tnh trng thit b CM Cc k thut kim sot thi im hin ti tuy c kh nhiu nhng c th c chia thnh 4 nhm chnh. Trn thc t nhng k thut ny c ng dng t kh lu mc d chng khng c bit n vi ci tn l k thut CM, tuy nhin vi nhng kt qu t c trong d bo, ta vn xt cp n chng trong mc nh ngha v k thut kim sot ny. Khi gii thiu v cc k thut kim sot hin i nn nhn mnh rng chng c tha hng v m rng t cc k thut trc . Kim tra hnh nh / phng php kim tra khng ph hu. Nhm cc phng php ny bao gm vic kim tra trc tip nh m cc b phn c php v xem xt cc b phn b mi mn hoc b tc nghn trong mt chu k lm vic ngn. a ra cc d bo v tui th cn li ca my trc khi chnh thc c cc bo dng, ng theo cch thc tip cn ca phng php gim st tnh trng CM. Nu cc d bo c th c tng hp a ra cc bin php chnh c th th c th tin hnh th nghim cc bin php . Cc phng php kim tra gin tip bao gm phng php s dng gng (mirrors), knh ngm (borescopes), si quang (fibrescopes), s dng mn hnh TV (closed circuit TV), my hot nghim (stroboscopes), v cc phng php kim tra khng ph hu khc. Phng php s dng nh hng ngoi cng c s dng vi iu kin cc hnh nh phi c phn tch v ch gii. Phng php ny cho bit cc sai lch nhit b mt hoc chnh lch so vi nn n 0.1 C thng qua quan st khng cn tip xc. Cc phng php khc bao gm: kim tra kch c- s dng o dn nhit ca cc chi tit chu nhit cao, hay phng php t xc nh nh gim st tnh trng mi mn ca cc ng dn cht lng c tnh mi mn da trn lng cht lng r r t y ng dn. (Phng php ny ch c s dng trong iu kin p sut thp cc ng dn khng b v ra v p sut). Phn tch sn phm mi mn v cc cht thi ra sau quy trnh i vi cc loi my s dng du bi trn trc hoc bnh rng, c rt nhiu k thut kim tra s mi mn. Cc thit b ht c t tnh c dng ht cc mt nh sinh ra trong qu trnh vn hnh. Mt lng mt nht nh s c loi b khi i chiu vi qu trnh vn hnh my. Lng mt cn li s cho bit trc s xut hin ca cc mi mn bt thng ngay t khi bt u din ra. Mt s k thut s phn bit cc mt mi mn nh v ln a ra cc thng tin v tnh trng mi mn c th hn. Hu ht cc k thut khc u cn c mt mu du bi trn tiu biu c trn cn thn, khng ln tp cht phn tch. Quy trnh phn tch ph k du (SOAP) hin c s dng rng ri v c coi nh l mt dch v thng mi. Vi phng php ny, mc cc cht c ch nh trc nu mc cao s cho bit c nhng mi mn nhng b phn my tng ng. Khng ch cc chi tit kim loi c kim tra, thng qua du my c th xc nh s c mt cc cht bn hoc r r cht lm mt trong ng c diesel. Phng php nghin cu mt st s dng mt trng nam chm thu gom cc mt st. Sau da trn cc kim tra trc tip v lin tc xc nh cc mi mn bt thng nu c trong my mc. Phng php ny s dng quy trnh phn tch mt st xc nh cc nguyn nhn gy ra mi mn, tuy nhin vic tin hnh rt mt thi gian v yu cu c chuyn mn nht nh do trong nhiu trng hp doanh nghip nn thc hin thng qua cc dch v thng mi hn l t tin hnh. i vi cc thit b in c t trong b du, nhng h hng nu c s to ra mt lng kh nht nh v chng ho tan vo trong du. Do qu trnh phn tch cc mu du v kh ln trong n s gip xc nh c cc hng hc nhng b phn tng ng nu c.

i vi cc quy trnh sn xut khc, vic phn tch cc cht thi to ra sau qu trnh vn hnh c th cho bit tnh trng xung cp ca thit b. Mt s cht tt nhin s mang tnh c trng cho quy trnh vn hnh , s cn li l cc do cc vt liu c a vo mt cch c ch ch to ra cc kh hoc cc cht d nhn bit khi chng t n mt nhit no . Phn tch biu hin Cc phn tch biu hin c th c tin hnh nu cc c tnh vn hnh ca my c bit n t trc. Phng php kim tra biu hin c th c tin hnh bng cch kim tra sn lng u ra hoc cht lng sn phm, kim tra so snh u vo v u ra, hoc kim tra khc bitgia hai m u ra. Phn tch biu hin thng da trn mt hoc mt v thng s v nhit , p sut hoc lu lng cht lng trong chu trnh. Cc thng s khc gm cc thng s v s dch chuyn (v d nh bin dng, mc chuyn ng) hoc thi gian- v d nh thi gian dng my. Ngoi ra, sn lng v mc tiu th nng lng cng c th l cc thng s tin hnh kim tra. Thng s thu c t qu trnh kim tra nhiu ln thng quan trng hn l thng s chnh xc truyt i, tuy c i lc cc s liu ny l nh nhau. C rt t thng tin trn th trng cp v phng php phn tch biu hin, nht l khi so snh vi cc ti liu v phng php phn tch dao ng. Phng php phn tch biu hin thng i hi cc thng s chi tit v mt nh my t chn la ra cc thng s ph hp nht hoc d tin hnh o c nht. c th l mt thng s ch ra c iu kin tng th ca c nh my hoc ca mt phn ring bit ca nh my. Thm ch nu cn, cc thng s phi c phn chia theo cc cp vn hnh c th xc nh c v tr h hng. Trong mt s nh my, s xung cp ca mt khu c th c b p bng s gia tng mt khu khc, do tnh trng tng th khng thay i v trong mt khong thi gian ngn, tnh trng ny c th khng gy ra bt k h hng no. Do vy, vic xc nh cc thng s phi c tin hnh c trn tng th v c i vi tng khu c th , t nht l giai on vn hnh ban u. Hoc phi c phng n s dng m hnh nh my vn hnh da trn my tnh loi b cc tnh trng . Cc nh my cng nghip rt a dng nn ch c nhng hiu bit tht s su sc v s vn hnh ca cc c s mi c th chn la ra cc thng s ph hp tin hnh kim tra bng phng php ny. Phn ny s cung cp cho ngi c mt s hng dn v cc loi my thng c s dng ring l hoc l mt b phn trong cc nh my ln. Cc k thut c th c nu ra c th c p dng cho tt c cc nh my, hay c th c s dng nh mt gi ban u cho ngi phn tch gii quyt vn . Phn tch dao ng Mi my mc u to ra dao ng, i khi dao ng c th gy ra nhiu vn hoc khng nhng i vi c hai trng hp, thng qua qu trnh phn tch dao ng, ta c th bit rt nhiu v tnh trng ca thit b . K thut phn tch dao ng my kh pht trin v thng xut hin trong cc bn hng dn ca nh sn xut thit b. Phng php kim tra dao ng tng quan c th thc hin bng rt nhiu k thut khc nhau. Cc thit b phn tch hin c c th xc nh cc tn s dao ng thng qua iu chnh bng tay. Thng thng, mt xung pht ra c th kch hot my hot nghim nn c th c o bng cc pha dao ng tng ng. K thut ny khng ch hu dng trong kim tra m cn to ra cn bng - mt gii php thng thng nhng c th gii quyt cho rt nhiu vn c lin quan n dao ng, v do vy ngi tin hnh cng cn c trang b thm cc kin thc v cn bng. Cc b lc s d tm ra cc thit b to ra dao ng dng chuyn ng quay trong qu trnh thay i tc ca my.

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Cc thit b phn tch dao ng tch hp vi x l lm vic trn thi gian thc s cho bit cc ch s v bin v tn s dao ng trung bnh tc thi sau kt hp vi my tnh x l cc ch s v a ra cc thay i trong quy trnh. Qu trnh x l cc thng s bng tay s tn thi gian v c th c nhiu sai st v hin nay th trng c nhiu cng c rt kinh t x l cc thng s ny. Cc thit b c trng dng kim tra cc trc cn bao gm: my o xung chn ng (Shock Pulse Meters), thit b o nng lng nh (Spike Energy), Kurtosis, v vic s dng cc thit b ny u c nhng ngi ng h v phn i khc nhau. Hin khng c mt k thut u vit no c c s chp nhn trn ton th gii. Cc k thut c lin quan vi nhau nh th no i vi hu ht cc thit b ca nh my, s dng t hai k thut tr ln s c th lm tng hiu qu ca kim tra v cng kim tra c nhiu yu t gy ra mi mn trn mt thit b. u tin, phi xc nh c dng hoc cc dng ca h hng chn la phng php kim tra ph hp nht. Phng php tt nht l Da trn kinh nghim i vi tng loi thit b xc nh cn bng ti u. Cc thng tin chnh xc lin quan n mc chnh xc trong ng dng ca cc k thut hin khng c sn, tuy nhin bng 2.41 (Cc k thut phn tch CM) m t mt s gn nh ph hp i vi mi nh my. i vi cc my mc s dng du bi trn, phong php phn tch cht thi sau quy trnh sn xut s xc nh c cc n mn ngay t lc ban u, tuy nhin phng php ny khng c chnh xc khi tui i ca my giai on u. BNG 2.41 CC K THUT PHN TCH CM Vng i Mi Phng php xc nh mt st * Phn tch ph du * Phn tch thng s dao dng Dao ng tng th S dng u t tnh * Kim tra m thanh v hnh nh Phn tch nhit / biu hin H hng (100% vng i) ( * ch dng cho my c s dng du bi trn) V d v mt nh my in s dng k thut gim st tnh trng CM Bng 2.43 trong chng ny m t mt s v d v ng dng ca k thut CM trong ngnh cng nghip in trn ton th gii. Tuy nhin khng phi tt c cc k thut u c p dng cho mi nh my v chng lun c s khc bit v cu trc, nhin liu s dng v c tnh kinh t. Mt trm pht in s dng nguyn liu ho thch theo tiu chun c rt nhiu loi thit b, tt t cc thit b ny u c mt trong cc ngnh cng nghip khc do ngi s dng thit b cc lnh vc khc c th tham kho bng m t ny nu thy ph hp. Chi tit v cc phng php s dng c m t trong cc mc tng ng ca sch ny cng vi cc thng tin tham kho cn thit khc. Cc v d khc v ng dng ca k thut CM Cc v d ny c c thng qua vic tm hiu v phng vn cc chuyn vin tham d vo cc kho hc trc nhm cho thy s a dng trong ng dng ca k thut CM. 100% 30 % 45% 62% 70% 82% 90%

BNG 2.42 V D V CC NG DNG K THUT CM Cc loi my, cc hnh thc kim tra v cc thng s kim tra Cc h hng c xc nh Phng php khc phc Ch thch

nh gi l hi v qu Cc cn tro hnh thnh trnh i lu trong l: trn b mt trong ng Cc h s trao i dn. nhit, Nhit ca l, Mc tng nhit hi, Mc gim nhit kh (theo ti liu Ops), Mc gim ca gi l. R r ti cc ch lm kn hoc ng ng ca b phn sy kh nng: % oxy trong cc kh thi ti qut ID tng ln khi i qua thit b cp nhit. R r qu nhiu ti mi hn hoc ng dn

Kim tra thit b thi cn trong lng ng. D on trc thi gian sn lng u ra st gim v tin hnh v sinh thm nu c bt c khong thi gian dng my no do bt c l do g.

Sa li thit b

Nu qut vn hot ng cng sut, lng hi ra s suy gim nu xut hin thm cc r r khc.

Lng bi gy ra tc Hiu sut b gp thp nghn ng kh ti v tr H thng t trc trc ng thng, ti ca np hay ca x ca b gp. Cht t c trong bi ng dn kh (hoc ti phu b gp) Hiu sut t cng gim nu c cng nhiu cht t trong bi

Dng hot ng mt phn hoc ton b thit b khc phc. Kim tra khu chun b trc khi t nh: phn loi vt liu, chun b kh

Cc cn bn c nhiu loi ty thuc vo iu kin t v ngun than. i vi ni hi t bng du, quy trnh o lng CO c th xc nh c vi phun b bn hoc cht lng phun khng tt

Kim tra hiu sut Cc nguyn nhn ca gin tip ca ni hi gim hiu sut (thng qua cc s liu phn tch c lu li)

Sa cha v iu chnh li Rt tin dng cho tnh chu trnh hot ng ton lng nhin liu tiu th ti nhng v tr khng th tin hnh o trc tip c. M np thit b thi kh ni hi n khi sa cha

Lng Chloride hay Silica trong nc ca ni hi

Lng cc cht ny M np thit b thi kh cng cao th cc r r ni hi n khi sa cha bnh ngng hoc do li trong khu x l nc cng nhiu

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C ha cht x l nc Nu suy gim th c trong nc ni hi ngha l c r r thnh b cha nc

Kim tra cho n khi sa cha

Cc r r xut hin khi lng nc tiu th cao hn bnh thng. Khi lng r r mc cao c th xc nh thng qua ting ng pht ra.

Phn tch tn hiu dao ng ca cc trc tuc bin trong trng thi np n nh v trong cc trng thi khc.

Phn tch tn hiu dao ng ca cc trc tuc bin trong trng thi np n nh v trong cc trng thi khc.

Nh my vn hnh di s kim tra k lng hn

Tnh trng ng c khi khng ti: Cc mc tc , n nh, Cc vng lp ma st van, chc Kim tra ng c c ti: Tc np, chuyn ng van/p sut du iu chnh, chc tng Van iu khin hi: Vn tc ti a khi ng Kim tra dao ng ca ng c mc tng quan. Xc nh s dao ng /vng v pha ca dao ng - i vi tt c cc trc Kim tra dao ng 1/ vng pha chu k th nghim. V th cc ng trn phn ng theo ch Kim tra dao ng ng c 1/vng, 2/ vng v pha trong khi chy theo qun tnh

Di cht/ tr/ chc qu ln; trng dy ni/mn trc cam qu ln

Nu khng th dng C th dng tip c c na th cn phi sa vi iu kin lng ti cha v p sut thch hp v my c th hot ng n nh Cc kim tra loi b ti thng rt t khi c tin hnh sau ln lp t ban u Mu nhin liu khng chy trong vi phunphn tch sng lc Kim tra ton b h thng tuabin cng sut VWO, p sut vn hnh, t l p sut, hiu sut gim hm nhit, chnh lch nhit ti b phn lm nng, tip xc my lm mt Kim tra t l nhit tuc bin: t l nhit c iu chnh, Kh nng hp th hi, Cc h s theo quy lut elip Qu trnh nghin khng tt hoc do iu chnh sai Cnh c th b hng, b mn. R r cc mu lin kt, thay i trong h thng cp nhit, tc b lc hi, R r van cn trong b phn ngng t ti thit b cp nhit Phn tch chi tit hn v tnh trng ng c nh gi tnh trng cnh tua bin hi iu chnh li hoc sa cha

Vn tc 0-1000 Hz Tng tc 0-15000 Hz C th xc nh c cc nt gy trn cnh tuc bin. M phng c im bng my tnh cn phi c lp thch hp bi cc iu kin vn hnh khc nhau, d liu a ra l khc nhau Cch thc tin hnh da trn khu nghin v / hoc da trn loi h thng t Dng hi np khng c o. Cc kt qu kim tra thng

Nh trn

Cn bm trn thn van

G b cn

Thi gian ng van lp li t hn Kim tra cc trc v trc

Cc thit b h hng vnh vin, Mt cn bng, Mt lin kt, Dn n, kht trc km Tnh trng mt cn bng cc ch khc nhau

Nu dao ng qu ln cn s dng cc thit b chuyn su chun on. Dng hot ng thit lp li cn bng v kim tra. iu chnh cn bng

Hi phi c lm ngui trc khi dng thit b, sau kim tra li. Nu tnh trng khng chuyn bin th phi cn nhc tnh kinh t gia dng hot ng hoc chi ph cho thiu ht sn lng. Nh trn, v s dng cho qu trnh np nu c th

C th kim tra 8 bnh rng bng tay trong vng hn 30 pht vi vn tc t 500 n 3000 vng/pht. Cn c thng tin lu tr trn bng t nhiu knh. Ch chy theo qun tnh lp li nhiu hn ch tng tc.

Him khi c thc hin tr khi c cho php. Tin hnh khi chi ph dnh cho nhin liu hoc cho qu trnh np mc cao Gi trng thi chn khng khng i

Nt rotor, mt cc cnh Kim tra k lng v tuabin khi ch th nh gi nghim

Kim tra thi gian Khong thi gian tuabin chy theo qun ny nu gia tng th tnh nguyn nhn do hin tng c xt Nhit trc kim loi khi ng c chy theo qun tnh p sut b phn nm trc khi trng thi chy tng tc ng nhit nu dng dc ng th hin c h hng trc Ch ra s cn chnh tng i p sut thng bng 3 x din tch chu ti Kim tra trc

tng GE

iu chnh lin kt nu hin tng rung xut hin

Thng s dng phng php ly mu p sut kch du ( khi bm kch khng hot ng).

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Lng tiu th hydrogen ca my pht Tnh trng hot ng ca my ngng: p sut so vi ch tiu

Tnh trng mi hn, r r cc cht lm mt Cc sai lch so vi ch tiu s ch ra cc h hng hoc hiu sut dng CW km

Dng hot ng kim Mc tiu th qu cao tra l ch yu Kim tra thm cc thng s khc xc nh l tc nghn hay r r kh Tin hnh Clo ha hoc chnh sa, kim tra cc thng s khc iu chnh v nhit CW nn, np n v, dng CW nu c th Tin hnh Clo ha hoc chnh sa, kim tra cc thng s khc

Tnh trng thit b Tc nghn ng ng ngng: HOC/ V S chnh lch nhit R r kh u cui (nhit bo ha ca thot ca CW) Dng kh ngng ca Nu mc cao c ra ca bm kh; st ngha l c tnh trng gim ht kh (nhit r r kh cao bo ha-nhit ht kh) Thi gian st ht p sut bnh ngng khi bm kh tt dn v lng natri trong phn ngng Kim tra u bm v dng bm np vo tuabin: Mc % lch ca u bm vi dng chy c nh trc Lu lng van cn bng ca bm cp cho ni hi Phn tch tn hiu dao ng ca bm cp vo ni hi Cc bm khc: Bm tch phn ngng, Bm nc lm mt, Bm thi tro Kim tra mi lin quan u bm/dng chy khi bm hot ng. Kim tra mc dao ng ca bm Nu thi gian din ra nhanh ngha l c r r cao ng dn trong bnh ngng r r

ng c, qut, hp s Bi trn km c cc trc quay: H hng trc Kim tra xung chn ng, Nng lng nh, kurtosis.. Vn tc hoc gia tc dao ng

Thay th v i tu trc

S dng que d cm tay, i khi trong cc trc kn c th c cc que d c lp sn c nh. T l thnh cng 75%. Vn tc cho bit mc ti tn s thp, gia tc cho bit tn s cao. o thi gian nng p sut Kh ch quan

Kim tra my nn kh v qu trnh bm Nu thay i p sut thit b ngng t, tm ra nguyn nhn r r thng tin hnh khi khng ti Nh trn Tin hnh n gin; r r kh cng to ra lng xy ha tan cao trong phn ngng hoc trong nguyn liu cp vo Van: R r van bm np Van np.. Kim tra bng thit b nghe siu m khi ng van B phn trao i nhit: S chnh lch nhit u cui Qut v my nghin than dng qut, ng x ti my nghin, mc rung. Tuc bin, hp s..: Phn tch mu du xc nh sn phm mi mn

Mi mn van, pit tng hoc mi ni R r van

i tu my nn i tu van

Tc ng dn

Lm sch khi my dng hot ng

C th s dng cc cp nhit tip xc trn cc ng dn Thit lp cn bng mt ln tng th bng cch s dng mt phng n hoc mt phng i S dng phng php ph hp th nguyn t (Atomic absorption Spectroscopy) hoc phng php nghin cu st t (Ferrography) Kim sot hu qu do tr ln.

Dng hot ng sa cha

Kim tra lin tc Chy gn mc xc nh nhit v tc S dng phng php o mc tng nhit nc rt c tnh kh thi

Mi mn qu cao cc Thay i bm trong qu mi hn lin kt, trnh i tu nu thch hp Trn van cn bng, n mn thn, Mi mn m.

Mt lin kt, n mn cnh, Cnh qut lng, Vt lng H hng trc kim loi trng, H hng trc chng ma st, H hng bnh rng

Thit lp li lin kt, V sinh thit b, Thit lp cn bng, Sit cht thit b Quan st thm cc ch s khc. Kim tra khi dng my v tin hnh cc sa cha

Mi mn bn trong

Khc phc, i khi tin hnh khi bm hot ng Nu dao ng qu ln cn tin hnh kim tra k hn v khi thun tin s i tu Thay i bm nu dng chy khng tt, hoc chnh sa h thng S dng thit b cn bng to trng thi cn bng khi lp t r to Cc thit b ch bo dng chy siu m rt hu ch s dng. Ngt u bm nu u cnh b n mn. Kim tra lu lng hoc cng sut tch ri nhau.

Mt cn bng, mt s lin kt

Mi mn vng m qu mc, thay i bn trong h thng ng (v d nh tc nghn, khng phun) Thiu lin kt, mi mn, h hng

Qut, lu lng trc Hao mn ti cc khp bn ni bc l cnh qut Hin tng tr iu khin My pht: Ni t, m/bn, in p nhiu radio, Cch in, hng cch Gc mt in mi in

i tu

Sa cha nu tnh trng qu trm trng

Nhiu phng php kim tra c th c s dng ty thuc mc in p v ty ngi bo dng chn la Kim tra cc mu ti thit b trung tm

Bin p du v cu dao: Kh ha tan trong du

Cc im nng, h quang, qu nhit, phng in hoa

Sa cha

Thit b ht bi tnh Cc khe h in cc in: hp, ni t, tia la nh gi in p v in, in cc bn dng in

iu chnh

Kim tra hng ngy.

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BNG 2.43 V D V CC NG DNG CA K THUT CM Thit b Cc loi tu hnh trnh ven bin Cc l xi mng ng c diesel K thut hoc thng s CM Mc tiu th nhin liu trn mi chuyn Dng in cp cho m t tng cao p sut Ccte c o 1000 gi mt ln Chnh lch p sut du gia trng thi nng v ngui p sut nn trong xylanh Cc h hng v ch thch Mc ny nu tng s ch ra c cc tc nghn trn v tu L qu nng, sn phm bn trong lm bt l p sut s cao khi cc l thng hi b chn hay b t chy qua piston Cng tng t nh cc ng c khc, p sut thp ng ngha vi vic trc b mn Cng tng t nh cc ng c khc, p sut thp ngha l vng pitton hoc van b mn i tu trong khong 8000 -20000 gi V vic i tu din ra trong khong 8000 -20000 gi nn t l dng my bt buc gim 0.3 cho 1000 gi vn hnh v gi nguyn sau khi vic i tu nh k kt thc Dy dn b r hoc khng c c bit v tr xung quanh cc mi ni cng thay i th hin vic thay i trong cu trc Xc nh nt gy Chn la di thng s kim tra, mc tng ca cc thng s th hin tnh trng mi mn. Khi h hng sp din ra, nhanh chng tng cao hnh trnh ct Q A B C D E F G H I J K L

BNG 2.44 NH GI TNH KH THI CA K THUT CM Hng mc S vn ca nh my T l ri ro ca nh my Sn lng hng nm (doanh thu bn hng) K hoch vn hnh: s ngy trong nm Chi phi nguyn vt liu v nng lng trong nm Vn u t hng nm cho mua mi v thay th thit b (trung bnh trong 5 nm) Chi ph bo dng hng nm (nhn cng, vt liu, hp ng) S ngy dng vn hnh do hng hc Chi ph cho ngi bo dng hng hc Gi tr sn xut theo ngy Sn lng gi tr gia tng hng nm (AVO) Tng lng tit kim tim nng-mc % AVO ca nh my (c d) (c - e) Chn mc ph hp nht trong danh sch trang 21 (k x l) 100 (g f ) 100 H x j x 0.75 I x 0.75 hoc g x 0.05 (o-p) (a x 0.01) +(a x b x 0.05 *) 100 0.4 x r 0.33 x o Thng tin lu tr ca nh my hoc theo c tnh S liu ngun S liu $ % $ $ $ $ $ $ $ $ $ %

ng c diesel

ng c diesel

Cc b truyn ng cui ca xe ti chuyn ch trong cc m Tuabin kh

Kim tra du, khe h bnh rng, v rng nhn thy c Kim tra bng knh ngm (21 v tr), kim tra hiu sut ng dn kh, dng que t tnh (4 v tr), dng SOAP, phn tch dao ng (2 v tr) Kim tra vi que d dng in xoy Kim tra chuyn ng hng nm bng my rung Kim tra xung t trn nh Kim tra dao ng ca my ct s dng gia tc k t trn mm tin

M N O P

C TNH S B v mc tit kim tim nng do p dng CM em li T l bo dng hng nm trn ngun vn u t hng nm Mc tit kim tim nng i vi cc thit hi bt ng Mc tit kim tim nng v chi ph cho ngi bo dng h hng D ON CHI TIT :tng mc tit kim t vic ng dng CM D tnh chi ph thit lp CM * (chn chi ph ph t 0.03 n 0.1 nng cao an ton) D tnh mc chi ph cho cc thit b CM D tnh chi ph vn hnh CM hng nm ( mc ti a)

$ $ $ $ $ $

Gia c bng chuyn, dy thp Cc cu trc Ct chng Cc my cng c

R S T

$ $

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CHNG 5
Kim tra bng hnh nh / Kim tra khng ph hy nh ngha v CM ca chng ti bao gm vic s dng tt c cc phng tin c th gim st tnh trng thit b. Phng php kim tra trc tip bng hnh nh kt hp vi cc nh gi v tnh trng v a ra d bo v thi gian s dng cn li ca thit b c th c coi l phng php CM k thut cao. i vi mt vi thit b, tnh trng mi mn c th nh gi nhanh chng thng qua vic kim tra cc ca hoc l thng trong khi my tm dng hot ng. Qu trnh kim tra ny din ra hon ton da trn hnh nh hoc s dng cc cng c n gin nh thc o hay thc t l. Kim tra bng hnh nh khi nh my ang vn hnh Thc hin cc nh gi CM khi khng cn dng hot ng ca nh my r rng mang li rt nhiu li ch. Cc k thut s dng trong trng hp ny bao gm cc k thut sau: Kim tra hnh nh nhit hng ngoi- phng php nhit k- phng php ny s dng cc my quay quan st b mt ca thit b ghi li mt profile nhit c dng cc ng ng mc. Cc hnh nh ny c th hin trn cc thit b nh th knh hoc trn cc mn hnh ln nh ty thuc vo model 0 thit b. Phng php nhit k c th phn bit cc mc nhit chnh lch n 0.1 C v vi di nhit 0 ln n 1600 C. Cc thit b c th hin th dng n sc hoc c mu, mt s cn c tch hp c b vi x l phn tch. Cc ng dng: Xc nh cc im nng trn cc ng dn trong, trn ng khi, l nung, v trn cc thit b khc xc nh v tr lp bc chu la b mn. Kim tra cc thit b sinh ra nhit cao do hot ng khng chnh xc. Mt v d v phng php kim tra nhanh t xa c th c ng dng l kim tra cc thit b cch in t trn trc thng. Cc v tr khc bao gm cc kim tra v im nng do cc mi ni kh trong cc tm in cc hoc trong cc b c quy, kim tra nhit cao qu mc cc trc hay cc bng chuyn di, kim tra cc b phn li trong bng mch in khi m cc phng php o nhit tip xc khng lm c hay chnh xc khng cao.

Cc k thut kim tra khng ph hy NDT c a vo y v kt qu ca chng ch yu dng hnh nh v c th c xem nh phng php m rng hn v cn c cc k nng phn tch hnh nh. C th thu cc chuyn gia k thut tin hnh kim tra mt s phn hoc ton b h thng ca nh my. Di y l danh sch lit k cc k thut NDT v cc ng dng ca chng: Phng php chp nh pht x, mt phng php ph bin xc nh mc gin on trong cu trc cc b phn hay mi hn, c bit hay s dng cho cc loi ng dn. Phng php ny s dng tia X ti 50mm, tia gamma ti 200mm. Cc hnh nh tia X theo thi gian thc (phng php nghim hunh quang) s hin th hnh nh trn mn hnh TV. Nhc im ca phng php chp nh bng phng x gm c: thi gian di, nguy him n sc khe, i khi khng th hin c cc vt nt gy vung gc vi tia X. Cc ng dng ca phng php ny gm: Xc nh cc h hng bn trong ca ng dy cao p do nt gy tr . Phng php ny c th tin hnh khi ng dy vn ang hot ng Xc nh mc n mn trong cc b thp ca bng ti hoc trong lng b tng Xc nh cc mnh vn trong cc ng ng Xc nh li ch to trong lp xe Kim tra lin tc trong cc hp c Phng php xc nh dy bng siu m cng c ng dng vi chi ph r v dy o c t 1mm n 700mm. Phng php ny c th c s dng o mn bn ngoi b phn vi iu kin b phn phi c v thun nht. Tn hiu siu m s phn hi tr li t bt c b mt no nu c trong qu trnh tin hnh, v d nh b mt ca mt nt gy bn trong. Cc thit b siu m chnh xc hn c s dng mt s di tn d xc nh v tr nt gy. Qu trnh phn tch kh kh khn v cn c chuyn gia xc nh. Cc phng php hin i cho php xc nh chnh xc kch c ca bt k h hng no. Phng php tin hnh nhanh v khng c hi. Cc ng dng: Kim tra mc lin tc ca lin kt trong cc vt liu c bc kn. Kim tra mi hn, v d nh kim tra ngu mi hn. Kim tra dy ton b b mt cc thit b ca nh my. H thng Crawler c bit s dng kim tra t xa cc b cha, bnh cha, ng dn m khng cn tn thi gian di chuyn cc gi hay gh thy Qun. Thit b treo ln mt dy dn v c sp xp v tr c c lin tc cht bi trn ngu lc c bit nhm thu c cc chuyn i v phn hi cn thit cho phng php s dng siu m. Cng vic kho st c th c tin hnh qua cc l ca ng dn, tuy nhin phng php ny s dng cc que thm d c bit v tin hnh mt thi gian nn thng c thay th bng cc phng php khc. Phng php s dng cc que d dng in xoy: cc que d c a vo cc l trong ng dn ca b trao i nhit xc nh cc h hng nh nt gy, cc vt lm, cc hc, cc n mn v mi mn trc khi phng php ng sut c th xc nh ra chng. ng dn phi c v sinh sch ht cn v que d phi va kht tng ti a nhy khi o. Yu cu v thao tc cao. Phng php tin hnh nhanh chng v c th s dng xc nh cc vt nt trn b mt thit b m khng cn v sinh sch b mt nh i vi cc phng php khc. Vi cc b mt ln nh cc bnh rng c bi trn th phng php ny thc s tit kim thi gian. Phng php nhum mu: i hi thit b phi c lau sch trc khi tin hnh. B mt thit b c ph mu, gi n nh mt thi gian v sau lau kh mu hin ln ti v tr cc nt gy nu c. Cc nt gy thng th hin bng mu hoc pht sng hunh quang di nh sng cc tm. Phng php ny s dng vi cc vt liu c t tnh v khng c t tnh, tuy nhin n ch xc nh s c mt ca cc nt gy ch khng xc nh c su ca chng. Phng php n gin hn so vi phng php kim tra dng ht t tnh v c bit hu dng vi cc b phn c hnh dng phc tp.

C kh nhiu ngnh cng nghip khng th s dng cc thit b o nhit hin i v cao cp do tc thc thi chm v chi ph thu chuyn gia kh tn km. Phng php hot nghim s dng mt xung nh sng pht ra t ngun bn ngoi nh t cc thit b phn tch hoc o dao ng, hoc t b phn pht xung kch hot bn trong thit b. Phng php ny rt hu ch o tc ca cc my quay v cc thit b chuyn ng dng tnh hoc chm, v d nh cc b truyn ng ai. Cc thit b o s dng nh sng trng thch hp hn cc thit b s dng nh sng hng ngoi nu my t ngoi tri hay ti v tr c nhiu nh sng. Cc k thut tch hp b kim tra vo thit b to ra kh nng t kim tra cho thit b, v d nh b ch bo mn ta-lng bnh xe. Phng php ny c th tng t nh phng php khoan cc l chn trn b mt ngoi ca ng dn cht lng mi mn vi mt p lc nh thit b c th duy tr vi mt lng r r nht nh. Lng r r nu c s cho bit mc n mn su n mc tng ng no. Phng php ny ni mt cch chnh xc hn chnh l phng php xc nh cc h hng ngay t khi bt u xy ra Phng php kim tra bng hnh nh khi nh my dng vn hnh-cc phng php kim tra khng ph hy Mt s phng php c th c s dng trong khi nh my vn hot ng ty thuc vo thit k nh my, quy trnh v phng php tin hnh.

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Phng php kim tra dng ht t tnh c s dng cho vt liu st t. Khi tin hnh s ph mt dung dch c bit c cha cc ht t nh. Sau p mt t trng to ra bi thit b chuyn dng vo ni cn xc nh v s dng phng php kim tra hnh nh xc nh cc nt gy theo cc ng hoc cc ht t. Cc nt gy s hin ln do tng phn mu sc, thng thng l mu en trn nn sn trng, hoc cc ht phn quang c s dng di nh sng cc tm. Cc vt nt trn b mt cng c xc nh. Tuy vy phng php ny cng khng xc nh c su ca cc nt gy. Phng php s dng xung m thanh (cng c bit n vi ci tn l o khong cch da trn m thanh thng qua loi thit b m n s dng) l mt phng php xc nh cc v tr b tc nghn, cc l hoc cc mnh vn trong ng dn kh nhanh chng. Khi tin hnh, t mt u ng, mt sng m tn s thp s c truyn vo v tn hiu phn hi s cho bit khong cch, kch c v hnh dng ca cc h hng. Da trn kh nng ni bt ca mnh, phng php ny c th kim tra n 800 ng dn trong vng 1h. Cc v tr yu cu cc kim tra k cng hn v chm hn th vic s dng cc phng php khc (nh phng php siu m) c th xc nh nhanh chng hn phng php ny. Phng php xc nh pht x m thanh l phng php xc nh cc sng ng sut to ra do s bin dng ca vt liu chu tc dng ca ng sut, v d nh cc nt gy xut hin hay qu trnh lan rng ca nt gy. Cc sng m vi tn s cao khong 100khz v 1000khz c th c xc nh bi cc thit b thu ph hp. T l pht x ny tng theo lc cng v t ti a ti im bin dng ca vt liu. Trong rt nhiu trng hp rt kh c th phn bit cc tn hiu cao tn vi cc ting ng khc nn phng php xc nh pht x m thanh t c s dng hn so vi cc phng php m t trc. Tuy nhin phng php ny cng ng c coi l phng php c trin vng trong tng lai, c bit trong vic xc nh trc tip lin tc cc nt gy trong b phn trc quay tc cao. Thut ng pht x m thanh cng i khi c s dng m t mt s phng php khc s dng sng m cao tn kim tra. Cc ng dng ca phng php ny cho cc my tnh s c m t ngay sau y. Kim tra hnh nh khi nh my ngng vn hnh- qu trnh quan st k hn Trong giai on thit k, cc my nn thit k c cc ca cho thit b kim tra c a vo, nu khng s rt kh tin hnh kim tra v sau. V d nh ng c phn lc trn my bay thng c ti 17 v tr quan st kim tra. Cc v tr ny cng c lm trn cc tuc bin kh. Phng php kim tra c th tin hnh trn cc my tnh hoc my quay xc nh cc h hng ca cnh tuc bin do vt liu l gy ra, cc n mn b mt cnh, s mi mn cnh hoc lp bc, hay tc thit b nn. Kim tra bung t xc nh lng cn ccbon hay cc nt gy nu c. Mc 5-1 m t mt s hnh nh minh ha ca Hi qun Hong gia. Mt s k thut c tin hnh trn tuc bin hi thng qua cc ca quan st trn tuc bin. Gng thng c th c s dng trong cc trng hp n gin, ngoi ra c rt nhiu cc thit b c th cho vo thng qua cc ca v kim tra ti v tr cc gc. Gii hn nhit l 40-60 C. Knh ngm hay knh ni soi l thit b quan st vi chiu di kh linh hot, cc thit b ny s dng mt chui cc knh chuyn tip lin tc truyn nh ca vt th n mt ngi quan st. Vt th c chiu sng bng bng n hoc cc model mi l bng nh sng truyn qua si quang. C th c rt nhiu gc quan st nhng gc nhn phi c c nh trc khi a thit b vo kim tra. ng knh cng nh v ln ca knh ngm cng ln th hnh nh vt th cng chnh xc. ng knh ca knh ngm thng t 1mm n 25mm v di thng thng ca thit b l 10m. phn gii c th ti 8 micromet.

Thit b si quang cng l mt dng thit b linh hot, n gm c hai b si quang: mt b s truyn nh sng vo v b si cn li s truyn hnh nh ca vt th ra bn ngoi. Thit b c th iu chnh thay i gc quan st t bn ngoi. Thit b si quang t gp 3 ln so vi thit b knh ngm, hn na phn gii ca hnh nh vt th ca phng php knh ngm cng tt hn 3 ln. Tuy nhin xt v kh nng quan st bn trong cc vt th dng cong th phng php si quang rt c li th. ng knh ln ti 1.8mm v di 6m. Cc thit b si quang dng thng thng rt ph hp kim tra cc gc v vng thit b c hnh th a dng. Cc my quay camera vi ng knh nh n 10mm c s dng a vo quan st cc ng hoc ca nh. Cc bng ghi li hnh nh c th c lu li tham kho v sau. Thit b quay camera ph thng thng c knh ngm linh hot theo 4 chiu quan st v cho hnh nh vi phn gii cao. Nhiu quan st vin c th theo di cng lc nn rt hiu qu cho vic o to hoc cng hp tc phn tch hnh nh. Cng nh cc thit b quan st khc, thit b camera c th c gn thm vo mt li o xc nh kch c ca cc h hng. Thng tin c th c lu lai di dng bng t i vi c phng php s dng knh ngm hay cp quang s dng kt hp vi cc kim tra khc v sau. Mt ng dng n gin khc l kim tra cc ng ni n cc thit b chnh nh tuc bin hi xem c cc vt liu l no lt vo trong qu trnh tho d my hay khng, v d nh cc dng c thao tc. Ty vo thit k my, cc vt liu c th cn tr lu thng v gy ra hin tng qu nhit hoc h hng cc b phn chuyn ng. (trong mt ln kim tra, xc nh c mt b phn ca my camera b ri vo my trc !). Mt s phng php cp trn c th tin hnh c trong cc ni m t. Nhng k thut khc hin c s dng cho cc ng dng cng nghip truyn thng c th c chp nhn trong CM gm c:phng php khuch i hnh nh, phng php ton nh, phng php xc nh hnh nh phn cc, v mt s k thut khc. Phng php s dng m thanh v mt s phng php khc K thut truyn thng gim st tnh trng trc l gi n nh mt tua vt gia tai ngi kim tra v hc trc nhm cho php ngi kim tra nghe c tn hiu lin quan n ting ng nn v t xc nh c cc h hng. Hin nay, cc k thut kim tra trc tin cy hn v hin i hn c pht trin kh phong ph. Mt phng php tin dng nng cao m thanh l s dng thit b nghe cng nghip. Cc u d ca thit b s nh v ngun m thanh v loi b cc ting n khc. Cc phng php tng t cng c s dng kh nhiu ty, thuc vo kinh nghim ca ngi kim tra trong cc k thut c th tin hnh lp li c a dng hn. Cc my nghe siu m cng c s dng tng kh nng nghe m thanh v nghe c cc di tn cao hn. Tai ngi thng ch nghe c ti 17khz trong khi thit b ny c th o t 20khz n 100khz. N thng dng cm tay chy pin v c mt micro phone xc nh ngun pht m cn kim tra, v d ti cc a im c r r kh, v sau xc nh chnh xc v tr r r. Tn hiu ra c pht qua h thng tai nghe v c th hin th dng cc mc m thanh qua thit b chuyn i tn hiu tng t. Mt s loi c th kt ni vi thit b lu tr v lu tn hiu m thanh dng biu . Cc r r van c th c xc nh thng qua vic kim tra k lng nh i vi cc r r ng ng, ni, vng m, hay ng ng trong thit b trao i nhit. Thit b b tr cho kim tra b mt cng c cung cp. Cc thit b nghe siu m rt hu ch xc nh tnh trng cc van khi chng trng thi ng bng cch xc nh cc ri lon ca dng chy r. Phng php ny rt c li cho cc h thng c nhiu ng dn phc tp v cc r r khng th xc

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nh bng cc phng php n l no khc. Kinh nghim c c ca cc chuyn gia l: cc tn hiu m thanh mnh thng v tr cc tay vn k nhau. Cc my nghe siu m c th c s dng kim tra cc by hi thng c s dng khi qu trnh x c khp kn. Dng hi khi di chuyn s to ra cc tn hiu cao hn rt nhiu so vi dng ngng. i vi cc by loi iu bin, cc d liu v thit b cn c xc nh trc cc by hi c th hot ng chun xc. Lng x cc b trong cc bin th c th c xc nh thng qua thit b ny. Thit b chuyn i c t mt vi v tr trn b bin th xc nh cc ngun thi cc b. Cc r r ti mi ni, vng m hay mi hn c th c xc nh trong cc nh my khi khng ti bng cch t mt thit b pht m bn trong. Nhng ting ng tn s cao pht ra khong 40khz s xuyn qua cc khe h nh n 1micromet v s c thu bng my d m bn ngoi. Trong mt s thit b d c thm b phn lc tch hp cho php chn la c tn s o nn c th xc nh c cc h hng chnh xc hn. Phin bn model hai knh c nhy cao v cho php kh tp m bn ngoi. Tn hiu u ra di dng th XY biu din bin v tn s t 10khz n 100khz. Xc nh c cc r r trong ng dn ca thit b trao i nhit l mt ng dng rt hu ch ca phng php s dng m thanh, hin ti c cc thit b kim tra cng nghip ln ti 25 knh. Cc r r nu khng c pht hin sm s c th n mn sang cc ng ln cn v gy ra cc h hng nng hn. Mt s h thng s dng mirophone cn mt s h thng li s dng b chuyn i p in hay cc gia tc k. Nhng h thng kim tra hin c di tn rt a dng ty theo yu cu cn kim tra, v d khong 2000Hz, 10.000 Hz n 15.000Hz v c th ln ti 600khz nu cn thit. Trong cc l hi, cc b chuyn i cn c lp t cch v tr nghi c r r trong phm vi 9m v ngoi ra chng c th xc nh c s hot ng khng chnh xc ca thit b thi mui. Kim tra kch c Cc b phn chu nhit cao c nguy c b ro v nhit c th c kim tra bng phng php o kch c mt cch thng xuyn. Nhng thng s c trng dng i chiu. Cc b phn v ng dn chu nhit cao hay thm ch cc phn quay- cc i tng thng xuyn c tho d -cng cn c kim tra. DA TRN NHNG C IM CA HNG HC LA CHN NHNG PHNG PHP BO DNG TT NHT I VI CC THIT B C TH THAY TH C (i vi giai on u vn hnh, cch thc tip cn c sp xp thnh hng theo tiu ch v mc hiu qu) HNG SM (< 1.0) Thit k bo dng: xc nh nguyn nhn gy hng hc: Kim tra qua trnh lp t Thit k li ngn chn hng hc Thit k li tng kh nng bo dng Vn hnh cho ti khi hng (nu chi ph trong thi gian hng v chi ph sa cha, cng vi ri ro thp) Tng cng kh nng bo dng

Vn hnh cho ti khi hng (nu chi ph trong thi gian hng v chi ph sa cha, cng vi ri ro thp hoc khi khng th pht hin ra li) Tng cng kh nng bo dng Thit k bo dng Thit k li ngn chn hng hc Gim s cn thit phi c cng nhn vn hnh tng cng kin thc cho cng nhn vn hnh v bo v t ng Thit k li tng cng kh nng bo dng

HNG DO HAO MN ( > > 1.0) Bo dng phng nga Nu pht hin li: Ty thuc vo tnh trng ca my mc Nu > 3.0 v chi ph thay th nh hn nhiu chi ph sa cha: Bo dng nh k Vn hnh cho ti khi hng (nu chi ph trong thi gian hng v chi ph sa cha, cng vi ri ro thp) Tng cng kh nng bo dng gim nhng yu cu v sa cha v thay th. Thit k bo dng Thit k li ngn chn hng hc hoc ko di thi gian s dng.

HNG TRONG VNG I HU CH ( ~ 1.0) Bo dng phng nga Nu pht hin li: Ty thuc vo tnh trng ca my mc

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Biu Ra a

Ti thiu Thc t Qun l thit b 15 Lp k hoch - phng nga 10 5 C s d liu 0 Ph tng d tr v mua sm Bo dng cp th nht Ti a

25. CH GII GIAO DIN PHN MM K TON BO DNG

Phn tch chi ph

Qun l cng vic

Phn tch R.M.A.S

Hnh 2.65: Biu Ra a

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1.

QUN L THIT B

NG Cc nh sn xut u c k hoch v s sn xut c cp nht lin tc.

SAI Mi ngi khng bit n k hoch hay s , hoc chng khng c cp nht. C th cc ti liu y c nhng chng li c xp ngay ngn trong mt ngn ko no .

Khi nim thit b c cp trong chng ny rt rng, c th l my mc, ph kin, cng c th l c 1 dy chuyn... 110 N 101 NG Cc thit b c nh v r rng (theo khu vc, theo phn xng) trong mt vn bn c th. Nhn vin lm nhim v bo dng cp 102 nht thng xuyn danh sch trn (t nht l 1 nm 1 ln). Tt c cc thit b quan trng u c 103 nh m. C th nh bng cc m topo (danh mc) hoc bng s (s hiu cng vic ca mt ng c chng hn). Vi tt c cc thit b chnh, mi ngi u 104 bit c cc c tnh vn hnh c bn. V d nh p sut, s vng quay, mc nhiu, tc sn xut, t sut... Vi tt c cc thit b, mi ngi u bit cc hng dn an ton khi xy ra cc s c 105 v bit cch can thip ng lc. Hn th na, cc ch dn ny c th c vit di dng vn bn. Vi tt c cc thit b, mi ngi u bit 106 cch thay th hoc ph kin c th s dng khi c s c. i vi tt c cc thit b, mi ngi u 107 bit cn phi s dng cng c no x l s c. Vi mi thit b, mi ngi c th d dng 108 nhn ra nhng cng vic g c hon tt vi n. Cc loi m lin quan ti thit b u d dng tip cn v c th nhn thy c. 109 Cc m ny thng c dn trn pha s v khng c t khut tm mt Cc m thit b, nu c, u khng d quan st. Khi tin hnh thao tc, nhn vin bo dng mt nhiu thi gian mi tm ra Mi ngi khng bit n cc ph kin cn thit c th s dng khi c s c xy ra (c th p dng sau khi tho g thit b). i vi tt c cc thit b, mi ngi u bit cn phi s dng cng c no x l s c. Khng h c lch s v cc cng vic c thc hin ti thit b y. Mi ngi khng bit hoc khng p dng cch x l (hoc hng dn) x l vo lc xy ra s c (mi ngi c 1 cch x l ring). 115 Mi ngi khng bit n cc c tnh vn hnh thng thng ca cc thit b, thm ch c cc thit b chnh. 114 Cc thit b khng c nh m. Chng c th c phn bit bng cc nhn hiu cng nghip (nhn hiu, tiu chun) 113 SAI Khng c vn bn c th, cc thit b ch c nh v trong u ca ngi vn hnh. Khng ai m nhn cng vic cp nht danh sch ny. 112 111

Mi ngi u bit n lch s vn hnh ca thit b v c th d dng tm ra trng thi ca thit b y. i vi cc thit b quan trng, mi ngi u bit c tnh nghim trng ca vic can thip vo my mc. Cc d liu v lch s vn hnh thit b phn tch thng nin. Mi ngi s s dng kt qu phn tch ny v a ra cch thc phng nga khi cn thit. Mi thit b ch c cp 1 m. Khng c s nhm ln tn thit b, m s hay quy trnh cng ngh. Vi tt c cc thit b chnh, mi ngi u c mt b h s c cha cc d liu cng ngh.

Lch s vn hnh ca thit b c, tuy nhin mi ngi khng bit trng thi ca thit b nh th no. Mi ngi khng bit c cn thit phi can thip vo my mc n u. C th lch s vn hnh ca cc thit b

khng ch c lu gi li, chng cn c tn ti nhng khng c s dng.

Mi thit b c nhiu m (m phn tch v m topo chng hn). Mi ngi c th cng ni v mt thit b nhng bng cc tn khc nhau Khng c h s k thut cho tng thit b ring.

phi ca cc thit b. Ch dn m phi sch cc thng tin c bn v thit b.

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2.

BO DNG CP 1

3.

KIM SOT LU KHO V CC PH KIN

Bo dng cp 1 c th c hiu l nhng vn hnh c bn v d nh: bi trn, tra m v v sinh thit b. Trong thc t cc cng vic thng xuyn (c th l hng ngy) ny c th do nhn vin bo dng, nh sn xut hay nhng ngi s dng khc tin hnh.

Phn ny ch bn v cc linh ph kin trong qu trnh bo dng.

N N 201 NG Vic tra m, bi trn c thc hin theo 1 s c sn v theo mt cch thc c xc nh r rng. Vic tra m, bi trn c thc hin theo 1 s c sn v theo mt cch thc c 202 xc nh r rng. Mi ngi u bit c ai thc hin, thc hin nhng g v khi no. Sau khi tra m, cc hot ng tip sau s 203 c tin hnh theo tn s nht nh (do doanh nghip hay nh sn xut quyt nh). Khi thao tc bo dng, nhn vin pht 204 hin ra nhng iu bt thng trong thit b, c th ghi li ngi sau tham kho. Cc hot ng tra m, bi trn, v sinh 205 nm). C ngi chu trch nhim cho vic cp 206 nht thng xuyn cc hot ng tip sau bo dng cp t. Mi ngi bit cch ly c du tra 207 v bit c tnh trng my mc khi tin hnh tra du. Cc sn phm v linh ph kin cn thit 208 cho vic bo dng cp t u c ph bin rng ri v c lu sn trong kho. Mi ngi khng bit tnh trng trn kho ca cht bi trn. My mc c tra du khi nhn vin c thi gian v khng ph thuc vo tnh trng my mc. Khng c sn cc sn phm phc v cho vic bo dng cp t. 310 Cc hot ng tip sau bo dng khng c cp nht thng xuyn. 309 Cc hot ng bo dng cp t 308 thit b tin hnh theo k hoch (hng khng c ln k hoch trc. Nhn vin bo dng khng ghi li hoc c th qun cc hin tng bt thng. 306 307 Cc hot ng tra m khng c tip tc. 305 Cc thao tc tra m khng tun th nghim ngt theo cc quy nh. 303 304 tra m, bi trn. SAI Khng c vn bn no v vic thc hin 301 302

NG Yu cu v mua sm (D.A.) lun c thc hin theo mt quy cch. C 1 m v ch 1 m duy nht cho 1 mc lu kho. Vi mi chi tit hay thay i c bit, mi ngi c th tm ra c c im thit k ca n (c th do cc nh cung cp a ra). Cc thit b c gi li khi chc chn s c dng li. Lu kho c cp nht thng xuyn (c dng s c tin hnh da trn d liu y.

SAI Khng c mt s c sn cho quy trnh D.A. Mi ngi lm theo 1 cch ring. C 1 m v ch 1 m duy nht cho 1 mc lu kho. Khng c bt k c im thit k no c cung cp. Tt c cc thit b c gi li cho d khng cn dng c na. Nhn vin bo dng khng h bit c v

v s lng v cht lng). Cc dch v bo cht lng cng nh s lng lu kho.

Nhn vin bo dng d dng tm thy cc Cn phi lc tm vt v mi c th ly ph kin cn thit. ph kin (dnh sch bn cng). Vi cc linh kin c bit, mi ngi c th bit c cn bao nhiu thi gian ly c hng. Mi ngi bit cc thit b no c th dng Mi ngi khng bit cc thit b no c thay th nhau. Chng c lit k v mi ngi c th tm thy mt cch d dng. Kho lu c th c dng cng vi cc dch v khc, hoc m nhim cc chc nng khc, tuy nhin bo dng vn l u tin hng u. C kho lu nhng mc ch phc v chnh khng phi l bo dng. th s dng thay th nhau. c cc ph kin cn thit. cung cp linh ph kin. Mi ngi khng bit thi gian mua hng l bao lu. Mi ngi bit c cc nh cung cp linh, Khng c danh dch bn cng cc nh

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C nhng thit b khng c lu kho bi 311 chng c th c phn phi kh nhanh. N ph thuc vo hn cui v cc nh cung cp (cf 307 v 308) u vo v u ra ca cc thit b lu kho 312 cn c ghi chp li cn thn, c th p dng cc phn mm chuyn dng. i vi cc thit b ph kin chnh, cn 313 phi a ra nh mc lu kho, c ngha l nu s lng di mc y, cn phi nhp kho ngay. Phn tch u vo/u ra cc thit b lu 314 kho cn c tin hnh thng xuyn, t nht l 1 nm 1 ln theo phng php phn loi hoc lp nhm nh ABC...

Tt c cc thit b u c lu kho.

4.

KIM SOT CNG VIC

Phn ny bn v ton b cc cng vic lin quan ti bo dng, cch thc qun l v vic thc hin. Vic kim sot u vo/u ra c thc hin theo cm hng. Thit b c nhp kho khi cn hay khi kho ht. N 401 NG C th phn chia cc thit b da trn tm kh quan trng). Cc thao tc c tin hnh theo mt s c sn, c quy nh trong Yu cu Khng ai bit tnh trng u vo/u ra ca cc thit b. 402 Kim sot (D.I.) hoc vn bn khc Ghi ch: D.I.: Yu cu Kim sot O.T.: Yu cu vn hnh B.T.: Phiu lm vic R.I.: Bo co theo yu cu Khi c D.I., nhn vin da trn , la chn 403 cc thit b khi u, chia nh cc yu cu v ln k hoch thc hin. Sau mi ln thao tc, c 1 vn bn dng 404 cng bo co li v nguyn nhn v cch khc phc. Nu nhn vin c giao mt cng vic 405 no , h phi bit cch thc hin chng. V d nh bit danh sch cc nh cung cp Cc cng vic c qun l theo gi v chi 406 ph. C cc phng php c s dng c 407 th d dng lin h c vi cc nh cung cp nh l. Cc cng vic c tin hnh, nhng khng c kim sot v gi gic v chi ph. Cch thc lin lc vi nh cung cp khng c ph bin rng ri Sau khi c D.I, bo dng c tin hnh ngay, b qua khu la chn, tch nh hay ln k hoch thc hin. Sau khi thao tc, cng vic c chuyn giao cho nhn vin mi m khng c vn bn bn giao v nhng thao tc thc hin. Lm n u bit n ! SAI Nhn vin khng nhn thc c thit b qu trnh sn xut, vi an ton). Cc thao tc c tin hnh khng theo mt chu trnh no.

quan trng ca chng (v d nh thit yu/ no quan trng hn thit b no (i vi

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Nhn vin khi ng v nhn vin hon 408 409 thnh bo dng da trn cc k hoch sn xut (P.D.P.) v vic s dng thit b Vi cc thao tc phc tp, theo ng cc quy trnh c a ra. Khi thao tc, tun theo cc hng dn v 410 an ton. Cc hng dn c th c quy nh trong vn bn B.T. hoc cc vn bn khc. 411 Khi D.I qu ti, nhn vin bit vic g c u tin lm trc. Vi cc thit b quan trng, c cc h s 412 tp hp nhng O.T. / B.T. / R.I lin quan ti chng.

P.D.P khng c s dng.

5.

PHN TCH F.M.D.S.

Phn ny cp n cc vn qun l d liu v tin cy, kh nng bo dng, sn sng v an ton thit b. Cc thao tc c thc hin da trn phng on hay li khuyn... Cc nhn vin khng c cung cp cc hng dn v an ton tun theo. N NG Vi cc thit b chnh, cc nhn vin c trch nhim thu thp thng tin v tin Khng ai bit cng vic g c u tin. Khng c nhng h s nh vy. 502 503 504 501 cy (vi sn sng, kh nng bo dng) v an ton. Nhn vin ghi li v bit cch tin hnh chng. Sau mi ln thao tc, cc file thu thp d liu c lu tr v in thnh cc bn cng. C cc nhn vin ph trch vic phn tch chi ph, thi gian, s lng hng hc... ra. Cc thit b o vn hnh chnh xc c th 505 506 o c thi gian trung bnh gia 2 ln hng hc (M.T.B.F.) hoc cc ch s khc. Thit b o thi gian sa cha (M.T.T.R.) c s dng. Thit v o tnh sn sng c th da trn 507 nng sut tng hp (T.R.S.) c th c s dng. Khi tin hnh thao tc, nhn vin bit p 508 dng cc hng dn an ton v ch dn c th. Cc vt liu ( phn tch rung, phn 509 tch tia cc tm) lun c sn v c sp xp c t chc. Cc nguyn vt liu y cha bao gi c s dng. Nhn vin bo hnh khng bit n cc hng dn an ton. Cc thit b o c nh vy khng c s dng Cc thit b o c nh vy khng c s dng Cc thit b o c nh vy khng c s dng Sau khi thao tc, cng vic c bn giao m khng c vn bn bn giao hay d liu thu thp no. Cc d liu c tng vo ngn ko v khng ai s dng. SAI Khng c cc thng tin v sn sng, kh nng bo dng, an ton thm ch l c vi cc thit b chnh.

T cc phn tch, cc gii php s c a Khng a ra 1 phn tch no ht.

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Cc thng tin v tn s, trng lc ca hng Cc thng tin trn khng c theo di. 510 hc, s sn sng cho vic ci t, tht thot Vi mi thit b quan trng u c h s 511 v tnh trng my mc, lu li cc ln s cha, thay th. t nht mi nm 1 ln, lch s my mc 512 s c dng phn tch vng i vn hnh ca thit b v a ra k hoch tip theo. C mt thit b o tng quan v nng sut 513 lao ng ca nhn vin bo dng, hot ng thay th, bo dng... Cc thit b o c nh vy khng c s dng Mi ngi khng h bit v lch s ca cc my mc. Khng c mt vn bn no v cc vn ny. Lch s my mc khng c s dng.

6.

PHN TCH CHI PH

Phn ny bn v cc vn lin quan ti vic qun l chi ph bo dng.

N 601

NG B phn bo dng, ch khng phi b phn k ton qun l ngn sch dnh cho bo dng. Tnh trng ngn sch bo dng c

SAI B phn bo dng khng c qun l ngn sch. Vic ny thuc trch nhim ca b phn k ton hoc 1 b phn no khc. Mi ngi khng bit thng tin g v ngn sch bo dng. C mt khon ngn sch chung v khng chia nh ra. B phn bo dng khng tnh ton c chi ph d tnh, chi ph thc chi v chi ph sp chi. Ngn sch khng c chia nh theo lt bo dng hay v tr Vic t hng phi thng qua b phn khc.

602

cng b rng ri (ngn sch bao nhiu, chi tiu nh th no) Vi mi loi bo dng khc nhau (sa

603

cha, phng nga), c 1 loi ngn sch khc nhau. Nhn vin bo dng nn nm r xu th

604 605

chi ph v trung ha c gia chi ph tm tnh v chi ph thc. Chi ph ngn sch c phn chia theo lt bo dng, theo v tr Nhn vin bo dng (hoc nhn vin

606

thit k) c quyn t hng cc thit b min l cc thit b y khng vt qu chi ph ti a. B phn bo dng c quyn t thc hin

B phn bo dng khng c quyn qun

607 608 609

cc hp ng nh vi mc ngn sch c l cc hp ng nh. quy nh sn. Mi ngi u d dng bit gi tr ca cc ph kin lu kho. Chi ph ca cc phng php bo dng phng nga, bo dng sa cha C cc thit b o c chi ph nm ngoi Nhn vin khng d dng bit c s lng lu kho l bao nhiu . Nhn vin khng bit chi ph bo dng, thm ch l vi cc thit b ch cht. Cc thit b o c nh vy khng c s dng

610

khu vc vn hnh v mi ngi c th t vn c.

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7.

D LIU NN

8.

LP K HOCH

Ni n d liu nn, c ngha l cch qun l, lu tr v in cc thng tin v d liu lin quan n bo dng. Khi nim ny cng bao hm c vic x l nhng d liu trn. Phn ny bn v cc vn thu thp v x l ton b d liu lin quan ti thit b v cc thao tc bo dng.

Phn ny bn v vic lp k hoch bo dng cng nh vic qun l.

N N 701 NG Nu vic bo dng ko di n vi ngy, nhn vin c th bit c thit b ang c x l nh th no v cn can thip nh th no. C vn bn v danh sch cc nh cung cp 702 v c tnh sn phm ca h (gi c, thi gian cp hng, cht lng) Danh sch ny c cp nht thng xuyn. Vic qun l phi c tin hnh cht ch. 703 Vic lu tr li cc d liu thu thp c phi giao cho 1 ngi duy nht v cng c th m nhn lun phn x l d liu. C bng in t hin th chi ph, thi 704 gian bo dng mi nhn vin c th tin theo di (tnh trng bo dng, sn xut). Vic qun l c th c thc hin thng 705 qua GMAO hoc 1 bng tnh n gin. Vi cc thit b quan trng, nhn vin c 706 707 708 th tm thy lich s vn hnh mt cch d dng. Mi thit b ch cht u c cc h s v cc c im thit k. Cc k hoch hay s v nhp thit b thng xuyn c cp nht. Mi ngi c th d dng tm c cc d 709 liu v cc nh cung cp cc thit b ch cht. Cc h s nh vy khng c hoc khng c cp nht thng xuyn. Nhng d liu nh vy khng c hoc khng c cp nht. Nhn vin khng bit cc d liu v nh cung cp c lu tr ti u v cng khng tip cn c chng. 812 C th c my tnh nhng khng ai bit cch s dng phc v hot ng bo dng. Lch s vn hnh ca my mc rt kh c tm thy. 811 810 809 D liu khng c ph cp cho mi ngi, khng c s minh bch. 807 808 Khng c ngi no ph trch v vn ny. 806 Khng phi ai cng bit n danh sch cc nh cung cp. 804 805 SAI Nu vic tin hnh qu di, khng c vn bn no cho bit tin hnh nhng g vi thit b. 803 802 801

NG sn xut C cch bit v d on tnh sn sng v nhn lc thc hin bo dng. Phi tnh n mc s dng cc thit b ph tr v cc cng c. C cc phng tin xc nh ngun lc cn thao tc bo dng. Nhn vin theo st k hoch bo dng. Nhn vin thc hin theo ti lng vic v c ngi gim st thng nht. Bo co tin trnh thc hin c pht hnh t nht mi thng 1 ln. thay i vi nhng trng hp tht c bit. Mi tun, mi k hoc theo s hnh cy li c xut bn. hoch sn xut

SAI

Thit b c tnh ton n trong k hoch Thit b c tnh ton n trong k sn sng v nhn lc trong cc hot ng bo dng khng c bit n. Mc s dng thit b ph tr v cc cng c khng c tnh n. Cc ngun lc cn thit khng c xc nh. Bo dng khng c ln k hoch r rng. N c thc hin khi c thi gian. Khng c ai qun l ti lng cng vic. Khng c bo co tin trnh thng xuyn. st sao. Khng xut bn cc s nh vy.

Mi ngi u tun theo k hoc ra, ch K hoch khng c tun th mt cch

B phn bo dng l b phn lin h trc B phn bo dng khng phi l b tip vi cc bn lin quan (trong khun kh quy nh ca bo dng). C bng hin th v tnh trng bo dng thit b cho tt c mi ngi. Nu nhn vin chu trch nhim vng mt, ngi khc c th bit phn cng cng vic. V d nh, c th c sn mt danh sch cc nhn vin v nng lc ca h. Ch c duy nht ngi qun l bit cch chn la ai ph hp cho vic bo dng. phn lin h trc tip vi cc bn lin quan (trong khun kh quy nh ca bo dng). Khng c nhng bng nh vy.

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383

DCH V KIM TON BO DNG 1. Nhn xt Mt trong nhng iu cn bit l cc phn tch u tin v kim ton s cho thy nhng g bo dng lm c v nhng g cha lm c. L mt b phn ring bit ti mi cng ty, cc bin php bo dng thit b cn phi c xy dng li cho ph hp vi tnh hnh thc t ca cng ty, tuy nhin vn cn phi c nhng khi nim chung nht p dng trong mi trng hp. K hoch c th s c thnh lp mt cch r rng cng tc bo dng c th c duy tr mt cch lu di. K hoch ny l s thng nht cht ch gia CEMI (trung tm bo dng cng nghip) v cng ty ph hp vi tnh hnh c th ti thi im ca cng ty. 2. Phn tch tng quan Trong s 8 mc kim ton th: 2 mc thuc loi 4 2 mc thuc loi 3 4 mc thuc loi 2 : Cn phi c kim tra li mt cch cn thn. : Cn phi kim tra li cc im c vn . : Kim sot y v lun theo xu hng nng cao.

Mc 5 Phn tch F.M.D.S. nh gi chung 6/13 Loi 3 Vic theo di cc thao tc bo dng hay cc cng vic c thc hin kh tt. Nhng im yu nht ca khu ny s c kim tra li. Mc 6 Phn tch chi ph nh gi chung 3.4/10 Loi 3 Mc d kt qu tng th l kh km, n vn c xp loi 3. Kim sot v chi ph cn phi c tng cng hn na, bi hin ti b phn bo dng vn khng phi l nhng ngi gim st vic ny. Mc 7 D liu nn nh gi chung: 2.9/9 Loi 4 D liu nn cn thiu rt nhiu v khng h c s x l d liu no c. Cn phi kim tra li mt cch chi tit. Mc 8 Lp k hoch nh gi chung 7.4/12 Loi 2 Nu k hoch a ra gp vn , trng b phn bo dng s a ra mt k hoch mi m c th p dng v nng cp trong thi gian gn.. C mt nhn vin chuyn gi trch nhim gim st ti lng cng vic v vic thc hin theo k hoch. 4. xut Nhng nguyn tc hng dn di y l iu cn thit c c mt c cu t chc hon ho, tuy nhin, iu ny vn cha c p dng. Cn phi c cu li t chc theo trc sau: a) b) c) Kim sot thit b Kim sot chi ph Qun l bo dng

3. Phn tch chi tit Cn phi sp xp cc mc kim ton theo ng th t lm sao cho cng vic c nhanh v thun tin nht. Trong 1 vi trng hp, nu trong 1 mc xc nh c u l im u tin, c th tin hnh kim tra im y trc cc im khc, ch khng cn phi tun th theo ng trnh t ra. Mc 1 Kim sot thit b nh gi chung: 3.6/15 Loi 4 Mc ny cn bc l nhiu im yu. Mc ny l nn tng ca c cng vic kim ton, v cn phi c tin hnh trc nht. Mc 2 Bo dng cp 1 nh gi chung: 4.4/8 Loi 2 Nhn chung, vic tra m c tin hnh ng quy cch. Khong cch tn ti cc khu lp k hoch, tin hnh v ghi chp li d liu. Mc 3 Kim sot lu kho nh gi chung: 8.8/14 Loi 2 Mc ny cng c tin hnh kh tt. Cc vn pht sinh c bn l vic tm kim cc linh kin lu kho (cu trc kho, thiu catalog) v thiu phn tch u ra ca cc linh kin lu kho. Mc 4 Qun l thao tc nh gi chung 7.8/12 Loi 2 Cng tng t nh cc mc trn, cc im yu nht vn l v cu trc, phn loi v ghi chp li.

4a. Kim sot thit b Tnh trng lu kho ca cc thit b cn c cp nht Mi thit b phi c mt m ring Chc nng ca tng thit b cng cn c nu r D liu v thit b cn c ci t Tnh trng bo dng Linh ph kin Cng c Bin php can thip Lch s thit b

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385

K hoch v s Thit lp c bin php tip cn d liu ...

4b. Kim sot chi ph a ra cch tip cn vi cc linh ph kin trong kho Phn tch s chia nh cc cng vic sao cho h thng Thit lp phng n vn hnh tt B phn bo dng thit lp ngn sch v tnh ton chi ph cho cc hot ng tip theo Phn tch cc d liu nn h thng ha (sp xp c s d liu) ...

26. KAIZEN

4c. Qun l bo dng Lp k hoch c th cho cc cng vic Qun l ti lng cng vic Khng ngng ci tin: Gim st v sa cha cc sai lch Lp t cc bng iu khin ...

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387

Kaizen l g? Kaizen c ngha l ci tin lin tc, c ngun gc t ting Nht, trong (kai) c ngha l thay i v (zen) mang ngha l tt. y l mt h thng cc phng php tp trung vo vic ci tin lin tc cc quy trnh sn xut, k thut, kinh doanh, v qun l. Kaizen ln u tin c p dng ti Hoa K, bi cc gio vin v qun l. Sau n bt u ph bin trong nn kinh t Nht Bn t sau th chin th II. Ngay sau , Kaizen c ph bin rng ri trn th gii. H thng ny c p dng trong cc ngnh y t, chnh ph, ngn hng v nhiu ngnh cng nghip khc. Khi c s dng trong sn xut, Kaizen bao gm tt c cc hot ng ci tin lin tc nhng chc nng v cn c s ng gp t tt c cc thnh vin, t lnh o cp cao CEO cho ti cc cng nhn vn hnh my mc. Mi nhn vin hay lnh o u c khuyn khch a ra cc tng nh theo mt vi nguyn tc c bn. Kaizen cn c p dng trong cc cng on nh mua sm v hu cn, kt ni sn phm vi chui cung trn th trng. Vi cc hot ng v quy trnh ci tin chun, Kaizen hng ti mc tiu gim cht thi. Kaizen khng phi l hot ng nh k mt thng hay mt nm mt ln, m n l mt hot ng lin tc. Ti cc cng ty ni ting ca Nht Bn, nh Toyota v Canon, trung bnh mi nhn vin a ra 60 n 70 tng mi nm, nhng tng ny c trnh by di dng vn bn mi ngi cng nhau chia s v nu kh thi, s c thc hin. Hu ht cc tng khng phi l nhng thay i ln lao. Kaizen da trn nhng thay i nh vi nguyn tc c bn: lun lun ci thin nng sut, an ton v hiu qu, ng thi gim thiu rc thi. Cc tng khng h b gii hn trong mt lnh vc no ht, nh sn xut hay marketing. Kaizen da trn vic ci tin bt c ni no c th. Quan im ca phng Ty trong sn xut c th gi gn trong cc t khng hng hc, khng thay i cn quan im ca Kaizen li l lm tt hn na, ci tin ngay c khi mi vic u n bi nu khng lm vy, chng ta s d dng b h gc bi cc i th khc. Kaizen l mt h thng ci tin ca Nht Bn bao gm c cuc sng gia nh v kinh doanh. N cn bao gm c cc hot ng x hi. y l mt quan im c th c p dng trong mi lnh vc ca i sng con ngi. Trong cc hot ng ca mnh, Kaizen bao gm rt nhiu cc quy trnh xut pht t Nht Bn v c p dng trong nhiu ngnh khc nhau. Cc chu trnh cht lng, t ng ha, h thng tng, phn phi ng thi gian, Kanban v 5S u c p dng trong h thng vn hnh kinh doanh Kaizen. Kaizen bao gm vic thit lp cc tiu chun v ci tit dn dn cc tiu chun y. t c cc tiu chun cao hn, kaizen cn bao gm cc kha o to, ti liu hng dn v cc bin php kim tra, gim st nhn vin trong vic t v duy tr kh nng p ng c cc tiu chun ny mt cch lin tc. Kaizen mang li nhng li ch g? Kaizen khuyn khch mi nhn vin a ra cc tng, a s l cc tng thay i tng dn. H thng tp trung vo vic xc nh vn tn gc, gii quyt tn gc v thay i cc tiu chun m bo cc vn lun c gii quyt thu o. Khng l qu kh cc h thng Kaizen c th t c con s 25 n 30 tng trong 1 nm t mi nhn vin trong doanh nghip v hn 90% trong s l c trin khai. V d nh trng hp ca Toyota, cng ty dn u trong vic p dng Kaizen. Nm 1999, ti mt nh my ti Hoa K, 7.000 nhn vin Toyota a ra 75.000 xut v 99% trong s c trin khai.

Tch tiu thnh i, nhng thay i nho nh ny gp phn tng sn lng, cht lng, an ton cao hn, phn phi nhanh hn, gi thnh thp hn v khch hng hi lng hn. Li ch hn ht l li ch i vi cc nhn vin lm vic ti cng ty khi m h cm thy mi vic d dng hn, th v hn to hng khi v l ng lc gip cc nhn vin hon thnh cng vic ca mnh. i vi mi nhn vin ang gp sc mnh vo cng cuc tm kim ci tin lin tc, nhng ci li m h c th nhn c l: Kaizen gim thi cc khu vc nh nh kho, thi gian ch, vn chuyn, di chuyn ca cng nhn, k nng nhn vin, sn xut qu , cht lng d tha v trong cc quy trnh sn xut. Kaizen tng cng vic ti u ha khng gian, cht lng sn phm, vic s dng ngun vn, giao tip, sn lng v vic gi chn cc nhn vin. Kaizen a ra nhng kt qu ngay lp tc. Thay cho vic tp trung vo tng ngun vn sao cho ln ln m tp trung vo cc u t hu ch, gip gii quyt mt c s cc vn nh pht sinh. Cc d n ngun vn hay d n ln v cc thay i ln vn rt cn thit v Kaizen gp phn thc hin cc nhim v y, tuy nhin sc mnh ca Kaizen vn tp trung vo cc chu trnh lin tc to nn nhng ci tin nh c th va tng nng sut, va gim cht thi. Ti sao phi p dng Kaizen? C rt nhiu l do Kaizen c a chung vi cc doanh nghip trn ton th gii: t c cc yu cu tng trng v sn xut v kinh doanh p ng cc yu cu ca khch hng v cht lng ca sn phm c th ng u trong cc cuc cnh tranh. Thc t hin nay cho thy, vic cc cng ty ln kt hp li vi nhau tr thnh mt cng ty ln mnh hn l iu kh ph bin, v l mi nguy him vi cc cng ty cn li. chin u trong cuc chin tng gi nhn cng. Cng vi cc chi ph trong x hi, chi ph nhn cng ngy cng tng, do cch duy nht c th b li khon tng y l mt nn sn xut hiu qu vi nng sut cao hn. Sn sng vi Kaizen Bn cnh cc phng php trin khai Kaizen s c cp di y, trn thc t cn rt nhiu cc phng php khc. Di y s l tng quan chung nht v vic gii thiu Kaizen ti Hoa K. i vi hu ht cc doanh nghip ti Hoa K, thc hin Kaizen cn c mt thay i ng k, ph hp vi vn ha cng s ti quc gia ny. Quan im ca nhn vin t cp lnh o cho ti nhng nhn vin cp thp mi c tuyn dng u cn phi thay i. Kaizen cn phi c cc nhn vin thc hin bi h thy h thc s mun hay bi h thc s hiu iu y l cn thit cho cng ty. Kaizen s tht bi nu nhn vin thc hin iu y ch n gin v y l ngha v v h phi lm nh vy v lnh o ra lnh phi lm. iu y cng ng ngha vi vic nu cp lnh o khng nhit tnh vi cng tc ch o, Kaizen cng chng th tin xa. o to v giao tip vi nhn vin l mt iu quan trng. i cng vi n, vic trc tip lnh o ca ban gim c l mt iu khng th thiu. V d nh, nu mt nh qun l chu b ra mt tun xung phn xng v cng lm vic vi cng nhn trong vic a ra cc tng, hiu qu cng vic s tng ln rt nhiu. Nh qun l cng phi m bo rng cc tng ca cng nhn s c trin khai ngay lp tc. iu ny c th mang li hng khi, gip cng nhn lm vic hng say hn. Do , khng nn tr hon vic trin khai sang tun sau hay thng sau. Trong mt vi trng hp, xut a ra bui sng, bui chiu c trin khai, thm ch l sm hn. Cc nhn vin cng nn c bit xut ca h ang c x l nh th no v tuyt i khng c nhng xut y ri vo h en ca cc nh qun l.

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Trong qu trnh khi ng Kaizen, nn thu mt vi chuyn gia bn ngoi. H s lm vic cng vi cng nhn trong nh my v c th pht hin ra cc vn m nhng cng nhn lm vic lu nm khng th nhn thy c. Vic ny gip doanh nghip vt qua nhng b ng ban u, hiu cch trin khai Kaizen v chng kin bc u nhng li ch m Kaizen mang li cho doanh nghip. Mt trong nhng tr ngi ln nht i vi Kaizen l tm l: vn ng ngha vi tiu cc. Bt c ai c lin quan n vic ny sinh vn s phi chu nh hng tiu cc (mc tng lng thp, khng c thng chc, thm ch l sa thi). Nhng i vi Kaizen th khc, c vn ngha l c c hi ci tin. Tiu ch vn hnh ca Kaizen l tm, pht hin v gii quyt cc vn . Kaizen khuyn khch v khen thng cc nhn vin pht hin ra cc vn tn ti. khuyn khch cc tng c a ra, nn nh gi cc nh gim st da trn s tng m nhng nhn vin do h gim st a ra ch khng phi nh gi cc nhn vin da trn s lng tng ca h. Nn nh gi cc gim st vin, cc nh lnh o da trn kh nng h thu ht nhng nhn vin ca mnh tham gia nhit tnh vo cc hot ng ca Kaizen. Cc nh qun l nn tm v pht trin cc phng php khuyn khch vic sng to ra cc tng v tng s lng cc tng. V d nh, h c th t thnh lp nn cc nhm lm vic t 5 n 12 thnh vin cng nhau nh gi v cc khu vc lm vic, quy trnh lm vic, cht lng, sn lng v kh nng sn c/ kh nng lp li ca thit b. Sau , ton i s a ra cc tng ci tin v h thm ch c th trin khai cc ci tin . Cc chng trnh o to cho nhn vin c th tp trung vo ni dung cc cng c Kaizen nh 5S, Kanban v Cn bng dy truyn. Cn phi lun nhn thc c rng kaizen ngha l hnh ng. Hnh ng a ra tng v hnh ng thc hin cc tng ngay lp tc.

DANH MC TI LIU THAM KHO

1. 2. 3. 4. 5. 6. 7. 8. Plant maintenance practice I, Japan International Cooperation Agency John H.WWilliams, Alan Davies, Paul R.Drake, Condition-based Mainenance and Machine Diag nostic, Chapman & Hall Victor Wowk, Machinery Vibration (1991), McGraw-Hill, Inc. Robert C.Eisenmann (1998), Machinery Malfunction Diagnosis and Correction, Prentice Hall PTR Upper Saddlle River, New Jeysey 07458 R.B.Ranfall, Frequency Analysis, Revision September 1987 Report on Capacity Building and Demonstration Projects in Industrial Maintenance project, Wallonie-Bruxelles 2007 Principles of maintenance and structure of Maintenance Manual GS.C. Kajdas, Du m bi trn (1993), Vin ha hc Cng nghip, Nh xut bn Khoa hc k thut

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LIN H: TRUNG TM SN XUT SCH VIT NAM Tng 4, C10, i hc Bch Khoa H Ni in thoi 04 38684849 Fax: 04 38681618 Email: long.nh@vncpc.org

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