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Thng 08-2010
MC LC
Trang CHNG 1: GII THIU 1.1 1.2 1.3 1.4 2.1 2.2 3.1 3.2 3.3 3.4 3.5 Gii thiu chung Cc nh ngha Bi cnh kinh doanh Ti sao phi ngng my CHNG 2: CC YU CU CHO S THNH CNG thc hin mt Turnaround thnh cng Cc iu chnh cho ngng my CHNG 3: CC GIAI ON CA MT TURNAROUND Gii thiu Giai on 1 Chun b Giai on 2 Lp k hoch Giai on 3 Thc thi Giai on 4 Kt thc 4 4 6 7 8 8 11 11 11 14 16
1. MC CH
Ti liu ny s gip cc k s v cn b qun l bo dng nm c tng quan v qu trnh xy dng, lp k hoch v trin khai mt t sa cha ngng my c hiu qu nh my cng nghip. 2. PHM VI P DNG Gio trnh ny tham kho cho cc k s c kh, in, iu khin t ng ha v cn b qun l bo dng trong nh my. 3. TI LIU THAM KHO Lenahan, Tom. Turnaround Management. Butterworth Heinemann, 1999. Kelly, Anthony. Maintenance Strategy:Business-Centred Maintenance. Butterworth Heinemann, 1997. Levitt, Joel. Managing Maintenance Shutdowns and Outages. Industry Press, 2004. 4. CH VIT TT
1.2 Cc nh ngha Khng c t ng duy nht no m bao qut ht cc thut ng c s dng trong bo tr, u vi kt qu l ngng my, cho nn thut ng i tu (Overhaul) v bo tr ton nh my (Turnaround) c th dng ln cho nhau. Chnh v th c th dn n mt s nhm ln, Tom Lenahan trong "Turnaround Management" s dng cc nh ngha sau y. tin cy (Reliability) l mc tiu c bn sinh li nhun, mt cng ty cn c mt phng tin sn xut ph hp c cung cp bi nh my m bo s tin cy. Mt nh my m bo tin cy c nh ngha nh l "mt nh my m c s sn sng khi c yu cu v kh nng thc hin cc yu cu mt cch kinh t v an ton". Bo tr (Maintenance) l "tng cc hot ng c thc hin bo v tin cy ca nh my". Ngng my (Shutdown) l khong thi gian t thi im nh my dng ton b dy chuyn cho n khi n c a tr li hot ng. Ngng my c th c lp k hoch hoc ngoi k hoch. iu ny cng ng hn xc nh thit hi do ngng my, nh l thi gian m dng nng sut v cht lng mong mun, t c y sn lng v cht lng tt nht. i tu (overhaul) l cc hot ng bo tr khi phc li cc hng mc thit b hoc cc h thng nh my tr li mt tnh trng mong mun bng cch v sinh, ci to, sa cha hoc thay th cc chi tit. Mt t i tu c th c thc hin online hoc offline v c th c thc hin ti ch, trong mt nh xng hoc nh my. Bo dng sa cha ton nh my (Turnaround) l mt s kin k thut, c nh hng bi nhu cu ca doanh nghip v cc yu cu quy nh ca php mail ca emlut m xy ra trong thi gian din ra mt t ngng my c k hoch lp t cc thit b mi, kim tra, i tu, thay th hoc nng cp cc thit b hin c hoc loi b cc thit b khng cn thit.
Hnh 2: Ngng my sa cha ton nh my 1.3 Bi cnh kinh doanh Bo tr l mt chc nng quan trng ca bt k doanh nghip v ngng my l mt thnh phn quan trng v bo tr ca doanh nghip. Cc phng php tip cn c s dng trong bi ny l cc nguyn tc ca Bo tr tp trung vo kinh doanh ca doanh nghip (Business Centred Maintenance-BCM) c p dng bi TS. Tony Kelly trong cun "Chin lc bo tr" (Maintenance Strategy) v ngng my phi c xem nh l mt phn trong chin lc kinh doanh tng th ca cng ty (Business-Centred Maintenance).
Cc chin lc bo tr cn c xem xt nh gi lin tc v nh k khi c s thay i v mi trng kinh doanh ti cc khu vc v trn ton cu hay nh my ang c s thay i nh n ang gi i v cc nguyn vt liu c ch bin c th thay i. Nu phm vi ca ngng my c xc nh theo cch lm truyn thng hoc cc gi nh sai s dn ti vic ngng my qu nhiu. Ti mt nh my cn nhm m anh bn ti l Trng phng Bo tr, vic ngng my c thc hin vo mi Ging sinh. Nhng ngi lao ng trc tip vn hnh sn xut i ngh l, khng c lin quan cc s kin ny. Cc nhn vin bo tr lm vic thng c thi gian cc k ngh l, nn rt kh c c lao ng c k nng tt, v nhiu ngnh cng nghip dch v ng ca trong khong thi gian ny v rt kh khn c c ph tng thay th nu c yu cu. Khi chin lc c thay i, v c cc t ngng my ngn ngy c t chc thng xuyn hn, cc hot ng vi n lc t mc tiu khng phi ngng my vo Ging sinh hng nm. Nhng thay i trong chin lc gim s gin on sn xut ra sn phm v m bo cc nhu cu cho cc cng ty, nh cung cp v khch hng xy dng hng tn kho, cng vi cc chi ph ca ngng my, cch lm ny lm li hn 30 triu la. Mc ch chnh ca doanh nghip l to ra li nhun cho cc ch s hu, nhng thnh cng ca n l kh nng sn xut hng ha hay dch v vi mt chi ph cnh tranh v vi mt thi gian v s lng p ng nhu cu ca cc khch hng tt hn so vi cc i th cnh tranh. Nu khng c mt nh my m bo tin cy th khng c k hoch sn xut c ngha, vic ny s nh hng bt li n kh nng dch v ca cc cng ty theo cc i hi ca khch hng. Mt chin lc l cn thit duy tr hoc ci thin tin cy ca cc thit b c lp v cho tng th nh my. Ngng my sa cha ton nh my l mt chin lc bo tr, chng khng phi ch l mt s kin k thut, c thc hin nh l mt chc nng bo tr, m cn l mt phn ca mt chin lc trong k hoch kinh doanh ca cng ty. 1.4 Ti sao phi ngng my Mc tiu chnh khng phi l c ngng my, v iu ny nn lun lun l mc tiu. Nu iu ny l khng th t c sau khi gia tng khong thi gian trung bnh gia cc ln ngng my, nn tip tc c tng ln.
Nu khng c s gia tng khong thi gian gia cc ln ngng my c th tin cy b mt i. Thng thng mt phn ca thit b s xc nh khong thi gian gia cc ln ngng my. Ngng my ch yu ri vo mt trong nhng l do sau: Nhu cu th trng: Cc nhu cu v sn phm c th mang tnh chu k, cc nh my ng l mt v d tt, mi nm h c thi gian khng c nhu cu. Cc sn phm mi hoc nng lc mi: Khi nh my c yu cu c ngng chy cho mt thay i trong sn phm hoc mt tng vn u t m rng nng lc, c th l c hi thi im thng xuyn hay khng thng xuyn khi thc hin cc hot ng bo tr. Nhu cu bo tr: nhiu hot ng bo tr khng th thc hin trong khi nh my ang hot ng v khi c cc h hng ca thit b s cn phi xc nh thi im ngng my. Yu cu ca lut php: Mt s chnh quyn hoc ngnh cng nghip xc nh bao lu th nh my phi ngng kim tra hay thay mi. H thng l hi p lc l mt v d.
bt u tin hnh cng vic v bit trc nhng g mnh phi lm v chun b sn sng p ng cng vic ca mnh theo k hoch.
Hnh 3:Tiu chun con ngi cho sa cha ngng my 16) Thng xuyn hp nhanh vi tt c nhng ngi ch cht vo bo co v tin , c bit l cng vic quan trng, bo co tin cho tt c cc nhm lm vic. 17) Bit lm th no s tin c chi tiu trong thi gian thc t v gim st chi tiu so vi k hoch. 18) Cc k hoch lm vic c hon thnh kp tin , ng d ton ngn sch. 19) Cc thit b chnh thc bn giao tr li cho do bn qun l vn hnh. 20) Nh my t ti cng sut to sn phm vo thi im mong mun. 21) Hin trng c lm sch, tt c cc vt t ph tng c tr li cho cc kho vt t v cc thit b c a i sa cha. 22) Hon thnh cc bo co Turnaround v cc qun l ti hin trng chp nhn nhng xut ci tin. 2.2 Cc iu chnh cho ngng my Cc iu chnh cn c tin hnh tng t nh i vi bt k cc d n ln v cc kim tra cn phi cng k cng. Mt s iu chnh cho ngng my nn bao gm: Tm lc li s iu hnh bao gm ti sao phi ngng my, cc cng vic ln, cc li ch v ri ro. M t v cc cng vic s c thc hin. Cc kt qu mong i v kh nng cung cp nh l mt kt qu ca vic ngng my. L do ti sao cng vic phi c thc hin v l do ti sao cc cng vic ch c th c thc hin khi nh my ngng chy.
Ti sao vic ngng my li xy ra ngay by gi, ti sao n khng th hiu qu nh cng mt thi im trong tng lai? Trong khong thi gian ngng my theo k hoach v ri ro c bit i vi k hoch. Ngn sch d kin cho vic ngng my, v cc ri ro i vi khon ngn sch . Php tnh Thu hi vn u t (Return On Investment - ROI) l tt c cc chi ph bao gm c chi ph mt c hi ci thin v lm gim cc nguy c ri ro. Cc thng tin khc bao gm c kh khn thch thc, cc gi thit v lch s trong qu kh. Xem xt cc ri ro v s kin xy ra ngu nhin. C bao nhiu ngy c sn phm chi tr cho nhng tng chi ph ngng my?.
Sa i mc tiu hoc cc chnh sch, nu c chng minh l cn thit. 3.3 Giai on 2 Lp k hoch Trng ban qun l Tumaround nn ch nh mt t lp k hoch, t ny s chu trch nhim vi trng qun l Turnaround cho cc k hoch cng vic chi tit v s chun b mi phng din ca d n. Trong sut giai on lp k hoch, cc thnh phn sau y cn phi c quan tm: a) Phm vi cng vic Phm vi cng vic l nn tng m trn cc Turnaround c xy dng. Khi pht trin sm phm vi cng vic (scope of work), iu quan trng l ly tt c cc hng mc chnh hoc cc hng mc c th l quan trng, chuyn vo trong danh sch cng vic. Chng c th c phn on cc cng vic ln, cng vic nh. b) Gi tr hiu lc ca phm vi cng vic L xc nh cc phm vi cng vic thch hp v "lc b" cng vic khng cn thit. Trong qu trnh xc minh, bt k ri ro cho con ngi hoc mi trng nn c xc nh. Khi hiu lc cng vic hon tt, cn c mt mc chc chn rng l cng vic s c thc hin K hoch Turnaround v s sch ti chnh c th c pht trin. c) Cc cng vic trc ngng my Mc ch cc cng vic ny l xc nh mt giai on u trong qu trnh lp k hoch, trong thi gian d phng, cng vic c lm sn hay cc nhu cu i hi v thi gian ca chuyn gia lm vic. Mt s cng vic nn c a ra giai on ny nh cc dch v hu cn, ch v cc phng tin. d) Cc gi thu cng vic: Cc quyt nh trc tin trong giai on ny l bao nhiu cng vic c thc hin hay nhng cng vic no s c thc hin bi nh my v cc cng vic no s c thu ngoi. Qun l v thc hin ton b cc cng vic Turnaround c th thu ngoi vi cc ngun lc ni b ch yu hot ng nh l nh thu ph. S thm nh v la chn nh thu nn c thc hin, cc gi cng vic c th c chia ra, gip h lp k hoch tin cho cng vic v ti chnh. e) K hoch Turnaround i hi s tham gia ca mt nhm ngi- t lp k hoch, t nh my, i din k thut, i din nh thu, t an ton v t chnh sch. Trnh t cc s kin i hi phi lp k hoch,
xem xt v ti u ha cho n khi lp k hoch c th cung cp cc mc tiu ca cng vic v cc kh khn. K hoch Turnaround cng phi c phng php i ph vi nhng bt ng, c th n t cng vic khn cp hoc cc s kin ngoi k hoch. Cn c mt quy c cho cc lin h vi cc cng vic b sung ny.
Hnh 4: Lp k hoch tin cng vic f) S t chc cho Turnaround Mc d n c th l mt t Turnaround l nhng ngi m lp k hoch v thc thi cc cng vic Turnaround, s t chc cho Turnaround cc cng vic khng c s ngang hng m l rt nhiu th bc, mt ngi kim sot v c chu trch nhim v mc chu trch nhim duy nht. Khng c t chc no hon ho v mt t chc c thit k dnh cho cc Turnaround s l mt pha trn ca cc k nng, kin thc v tnh sn sng. Mt im ng ghi nh c gi tr l Turnaround c nh ngha nh l "mt qu trnh thc hin cc hot ng theo mt chui logic", do iu quan trng l bit c tt c cc chui cc s kin v vai tr ca n v s nh hng. Mi ngi nn hiu c t chc v ni h phi bo co. g) K hoch v hu cn ti Site Mc ch ca K hoch Hu cn l c ng th cn thit cho ng ni vo ng thi im v trong cc iu kin ng thc hin cc chc nng yu cu. Cng tc hu cn trong Turnaround l sp xp vic tip nhn ti hin trng, lu tr vt t phng tin hoc ch , bo tr v cung cp ca tt c cc mc cn thit cho s kin ny. Hu cn ti hin trng phi c lp k hoch nghim tc nh cc hot ng khc ca Turnaround. h) S sch ti chnh
Tnh chnh xc ca chi ph ca cc s kin i vi ngn sch ph thuc vo tnh chnh xc ca cc phm vi cng vic v c bao nhiu n v gi cho hng ha v dch v c bit. Ngn sch Turnaround b hn ch vi mc khng chc chn. Thng thng mt k hoch chi tiu c pht trin thng c gi l ng cong ch S v gn nh l " thi gian thc "ca ph tn thc t c th c theo di st so vi k hoch, thng th gi lm vic cng c lp biu so snh vi k hoch. i) K hoch an ton: Mt Turnaround l mt t chc s kin nhiu ri ro, n a vo mt s lng ln ngi vo mt khu vc gii hn, thc hin cc nhim v khc nhau thng s dng cc thit b nhiu ri ro nguy him v lm vic di p lc thi gian. K hoch an ton m bo rng cc cng vic c nh gi trc khi thc hin d on tim nng ri ro v mi nguy him hoc gim thiu nhng nguy him hoc kim sot ra vo gim thiu mc lan truyn. K hoch an ton s bao gm cc k hoch o to v k hoch vo ca cho tt c nhng ngi i vo cc cng trng v cng c th cc cng vic trong cc lnh vc m c th khng quen thuc vi h. N phi bao gm mt mng li thng tin lin lc v quy trnh th tc trong trng hp xy ra mt s c hay mt tai nn. k) K hoch cht lng K hoach cht lng tt nht l mt trong nhng k hoch c xy dng trn qu trnh ca tt c cc giai on ca Turnaround hn l kim sot kt qu, nh l kt qu ca cng vic. H thng cht lng tp trung vo u vo, gim thiu nhu cu kim tra cc kt qu u ra. V d nh kim tra nng lc cc Th hn, trc khi bt u cng vic s gim thiu cng vic lm li v tip tc kim tra cht lng ca cc mi hn. l) K hoch thng tin lin lc y l mt k hoch tch hp ca cc bui hp v thng tin lin lc cho tt c mi ngi bit v hiu tin ca cc s kin nh th no v bt c s thay i no trong k hoch m c th c mt s nh hng n h. Cng cn phi c kim sot cht lng ti ch m bo rng mi ngi nhn c thng tin chnh xc. 3.4 Giai on 3 Thc thi Nhng c gng v p lc trong vic qun l thc thi cng vic ph thuc trc tip vo tnh nghim ngt ca k hoch c a ra. Cc thnh phn chnh ca qun l thc thi cng
vic l tun th cc l trnh v Qun l cc cng vic pht sinh ngoi mong i. Trong sut giai on thc thi, cc cng vic sau y s c qun l: 1) Ngng nh my Thng c thc hin bi nh qun l nh my v nhn vin vn hnh. N phi c thc hin ph hp vi k hoch chung ca nh my. Cc bc lm ngui, gim p, cch ly, c lp, kh nhim v lm sch. Cn c mt bn giao chnh thc ca cc ngi qun l nh my cho nh qun l Turnaround, trong lu tun th vic bn giao nh my ti mt thi gian tho thun v vi cc iu kin tho thun.
Hnh 5: Cc cng vic bo tr ton nh my 2) L trnh l mc tiu ca cc l trnh kim sot cc s kin v bit khi no c sai lch. L trnh k hoch hng ngy bao gm kim tra tt c cc vn quan trng v d nh an ton, tin trnh thc hin, chi ph, kim tra tt c cc i ch cht trong khu vc lm vic, tham gia vo cc cuc hp. H tr cc i c hiu qu trong phi hp k hoch cng vic. 3) Cc pht sinh khng mong mun Pht sinh xy ra cc s c v tai nn v cc iu tra sau v cng vic khn cp m i hi phi kim sot hay n c th nh hng bt li n ton b Chng trnh Turnaround hoc kt qu trong mt chi ph.
Bao gm tr li cho ngi lao ng lm vic bnh thng. Tho b tt c cc thit b, cng c, vt t, xe cu, gin gio, v.v 2) Kim tra v bn giao cui cng y l tha thun vi Manager ca Nh my rng cc nh my quay tr li iu kin hot ng y . 3) Hu turnaround Trc khi cc t gii tn h phi xem xt mc thnh cng ca cc s kin ny nh th no so vi cc mc tiu, qua mt lot cc ch s vn hnh chnh v cc chi ph thc t cui cng ca Turnaround. Mt danh sch cc c hi ci thin k tip cho s ngng my nn c pht trin. 4) Cc Bo co v Turnaround Tt c cc ch Turnaround cn c xem xt li v cc th mnh v im yu lm ni bt cc c hi t hiu qu hay ci tin. Bn bo co cn chnh thc v cn c xem xt li vi cc t chnh sch v qun l. 5) C hnh bui l tng kt Khng bao gi nh gi thp tm quan trng ca nhng l tng kt ny, n cng l s kt thc cho s kin ny. Li kt Turnaround l mt nhim v phc tp v kh khn, cng l mt trong nhng th thch v cc s kin ng lm m bn s phi qun l. S thnh cng ca s kin ny thng c xc nh trc, lp k hoch v s chun b chu o cho Turnaround l thi gian, cng sc v tin bc. Turnaround l mt s kin c mong i, vi cc hot ng bo dng phng nga v t c tin cy mong mun.