Báo Cáo Thực Tập

Bo co Thc tp tt nghip DK09
LI CM N
L nhng sinh vin nm cui chuyn ngnh du kh, chng ti c hc nhiu
kin thc v cc qu trnh ha hc, cc thit b phc v cho cng ngh ha cht ni chung
v ngnh du kh ni ring. Nh my du nht VILUBE l mt nh my ln, c thi gian
pht trin lu di, quy m t chc khoa hc v c tm nh hng ln trn c nc. Chnh v
vy khong thi gian thc tp y thc s l mt c hi qu gi chng ti cng c,
kim tra li vn kin thc ca mnh.
Chng ti khng ch c hin thc ha quy trnh sn xut du nht hin nay, m
cn c tham gia vo quy trnh sn xut, bit cch ng dng cc cng c qun l vo trong
sn xut. Hn th na, chng ti cn c tham gia vo vic kim tra cht lng sn phm
du nht thng qua cc thit b hin i hn rt nhiu so vi nhng g chng ti tip xc
trong qu trnh hc tp ti trng. iu quan trng nht l chng ti c hc hi rt
nhiu t cc anh ch k s, cng nhn vin y v nhng kinh nghim sn xut thc t, tc
phong cng nghip, phng php lm vic khoa hc v chuyn mn ha cao. l nhng
iu ht sc qu gi m chng ti t c sau t thc tp ln ny.
V pha nh trng, chng ti xin chn thnh cm n B mn Ch bin Du kh,
khoa K thut Ha hc, trng i hc Bch Khoa TPHCM t chc cho chng ti t
thc tp b ch ny.
V pha nh my, chng ti xin dnh li cm n chn thnh ti Ban Lnh o, tp
th cng nhn vin nh my, c bit l hai b phn Sn xut v Cht lng tn tnh
hng dn, ch bo, gip chng ti hon thnh t thc tp ny.
Cui cng, xin knh gi n qu thy c, Ban lnh o, cc anh ch k s cng ton
th cng nhn nh my li chc sc khe v hnh phc.
Nhm sinh vin thc tp
Nh my du nht Vilube
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NHN XT CA N V THC TP
Nhm sinh vin thc tp bao gm 3 sinh vin sau y:

1. NGUYN THNH DANH 60900337
2. NG QUANG LC
60901453
3. NGUYN C TI
60902317
Thi gian thc tp: T ngy 18/07/2013 n ngy 16/08/2013
Ni dung thc tp:
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ti 1: Hoch nh k hoch sn xut v kim sot quy trnh
ti 2: Qun l cht lng
Nhn xt:
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Tp. HCM, ngy ...... thng ....... nm 2013
Xc nhn ca nh my
Nh my du nht Vilube
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NHN XT CA B MN
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Tp. HCM, ngy ...... thng ....... nm 2013
Xc nhn ca B mn
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MC LC
PHN I: TNG QUAN V CNG TY VILUBE ........................................................................ 10
1. Lch s hnh thnh nh my ................................................................................................... 10
2. S nt lch s hnh thnh ca MOTUL .................................................................................. 11
3. Qu trnh pht trin ca Vilube ............................................................................................. 11
4. Nng lc sn xut Kinh doanh Phn phi sn phm...................................................... 13
4.1 Nng lc sn xut ca cng ty ........................................................................................... 13
4.2 Nng lc kinh doanh ca cng ty ...................................................................................... 14
4.3 H thng phn phi sn phm ca cng ty ....................................................................... 14
5. V th ca nh my ................................................................................................................... 15
6. S b tr nhn s ca nh my .......................................................................................... 15
7. An ton Sc khe Mi trng ti nh my Vilube (HSE) ............................................. 17
7.1 Ni dung an ton (HSE) i vi khch lm vic ti nh my .......................................... 17
7.2 Ni dung an ton (HSE) i vi nh hp ng v nhn vin........................................... 17
8. X l ph thi, nc, kh thi v v sinh cng nghip .......................................................... 25
8.1 X l ph thi, kh thi v v sinh cng nghip ................................................................. 25
8.2 X l nc thi .................................................................................................................... 25
PHN II: NGUYN VT LIU SN XUT ............................................................................... 26
1. Du gc ...................................................................................................................................... 26
1.1. Tnh cht chung ................................................................................................................. 26
1.2 Mt s loi du gc nh my ang s dng ...................................................................... 27
1.3 Cc ch tiu nh gi du gc ........................................................................................... 27
2. Ph gia ....................................................................................................................................... 28
2.1. Tnh cht chung ................................................................................................................. 28
2.2. Cc chng loi ph gia ...................................................................................................... 29
3. Bao b ......................................................................................................................................... 31
4. Kh nng thay th nguyn vt liu ......................................................................................... 31
PHN III: SN PHM ................................................................................................................... 32
1. Cc loi sn phm chnh ca nh my ................................................................................... 32
2. Tiu chun i vi cc sn phm du nht ........................................................................... 32
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3. Tiu chun ca mt s sn phm thng dng ca nh my ................................................ 33
PHN IV: QUY TRNH SN XUT ............................................................................................ 35
1. Quy trnh sn xut chung ........................................................................................................ 35
2. Quy trnh pha ch ................................................................................................................... 36
2.1 S khi ........................................................................................................................... 36
2.2 M t cng vic.................................................................................................................... 37
2.3 S Gantt quy trnh pha ch ........................................................................................... 39
2.4 Thit b ................................................................................................................................. 39
2.4.1 Bn pha ch ................................................................................................................... 39
2.4.2 Bn gia cng ph gia..................................................................................................... 44
3. Quy trnh ng gi v kim tra cui cng on .................................................................... 47
3.1 Quy trnh ng gi .............................................................................................................. 47
3.1.1 S khi .................................................................................................................... 47
3.1.2 Thit b .......................................................................................................................... 50
3.2 Quy trnh kim tra cui cng on....................................................................................... 53
4. Hoch nh qun l sn xut .................................................................................................. 54
4.1 Cc cng c thng k dng trong sn xut ca nh my ................................................. 54
4.1.1 Phiu kim sot ............................................................................................................. 55
4.1.2 Lu ........................................................................................................................... 56
4.1.3 Biu nhn qu........................................................................................................... 56
4.1.4 Biu Pareto ............................................................................................................... 57
4.1.5 Biu mt phn b ................................................................................................ 58
4.1.6 Biu phn tn............................................................................................................ 59
4.1.7 Biu kim sot .......................................................................................................... 60
4.2 Qun l nng lc b phn sn xut ................................................................................... 61
4.2.1 KPI ................................................................................................................................ 61
4.2.2 ra k hoch v ti u ha nng lc sn xut ............................................................ 64
PHN V: QUN L CHT LNG ........................................................................................... 66
1. Gii thiu tng quan B phn Cht lng v Phng Ha nghim ...................................... 66
1.1 B phn cht lng............................................................................................................. 66
1.2 Phng Ha nghim ............................................................................................................ 67
2. Quy trnh kim tra cht lng ................................................................................................ 68
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2.1 Kim tra nguyn liu .......................................................................................................... 68
2.1.1 Du gc ......................................................................................................................... 68
2.1.2 Ph gia........................................................................................................................... 68
2.2 Kim tra sn phm .............................................................................................................. 69
2.2.1 Mu sau pha ch (Final blend) ...................................................................................... 69
2.2.2 Mu Filling t quy trnh cch li .................................................................................... 72
2.2.3 Kim tra mu cui ......................................................................................................... 73
3. Cc thit b trong phng Ha nghim ................................................................................... 73
3.1 My phn tch thnh phn nguyn t trong mu ICP ................................................... 73
3.2 My o ph hng ngoi FTIR ............................................................................................ 75
3.3 My o nht nhit cao HTHS................................................................................ 75
3.4 Thermoelectric Cold Cracking Simulator CCS............................................................... 76
3.5 Density meter (Auto) ........................................................................................................... 77
3.6 Automated Multi-range Viscometer ................................................................................... 78
3.7 Comparator .......................................................................................................................... 78
3.8 Chun TBN (Basic Constituents) .................................................................................. 79
3.9 Xc nh hm lng nc bng chun in th Karl Fisher ...................................... 80
3.10 Flash point - Fire Point Crackle Test............................................................................ 81
3.11 im ng.......................................................................................................................... 82
3.12 Kim tra to bt ............................................................................................................ 82
4. Thc hin 5S i vi phng Ho nghim ............................................................................... 84
4.1 Khi nim v 5S ................................................................................................................... 84
4.2 Cch thc thc hin 5S ...................................................................................................... 84
4.3 Phng Ha nghim thc hin 5S nh th no .................................................................. 84
PHN VI: TN TR V BO QUN ......................................................................................... 88
1. Thng cha ............................................................................................................................... 88
2. Bo qun trong nh.................................................................................................................. 88
3. Bo qun ngoi tri.................................................................................................................. 89
PHN VII: KIN XUT ...................................................................................................... 90
TI LIU THAM KHO .............................................................................................................. 92
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DANH MC HNH NH - S
Hnh 1: S b tr nhn s ca nh my. ................................................................................... 16
Hnh 2: S mt bng nh my v ca thot him. ................................................................... 18
Hnh 3: im tp kt trc cng nh my. ................................................................................... 19
Hnh 4: Thc hnh din tp PCCC ti nh my. .......................................................................... 24
Hnh 5: Cc thnh phn c bn ca du nhn.............................................................................. 26
Hnh 6: S Gantt quy trnh pha ch. ......................................................................................... 39
Hnh 7: Thit b khuy..................................................................................................................... 40
Hnh 8: Bn gia cng ph gia AP1.................................................................................................. 44
Hnh 9: S Gantt cho cng on ng gi. ............................................................................... 49
Hnh 10: Khu vc rt nht. ............................................................................................................. 50
Hnh 11: Khu vc ng np. ........................................................................................................... 50
Hnh 12: Khu vc rt v ng np. ................................................................................................ 51
Hnh 13: Khu vc rt nht. ............................................................................................................. 51
Hnh 14: Khu vc vn np. ............................................................................................................. 52
Hnh 15: Chuyn x. ........................................................................................................................ 52
Hnh 16: Chuyn phuy. .................................................................................................................... 53
Hnh 17: S Gantt giai on FI. ................................................................................................ 54
Hnh 18: Phiu ng gi. ................................................................................................................. 55
Hnh 19: Biu xng c. ............................................................................................................. 57
Hnh 20: Biu Pareto. ................................................................................................................. 58
Hnh 21: Biu mt phn b. .................................................................................................. 58
Hnh 22: Biu phn tn. ............................................................................................................. 59
Hnh 23: Mt s biu kim sot. ................................................................................................ 60
Hnh 24: S t chc B phn Cht lng. ................................................................................ 66
Hnh 25: My o ICP. ...................................................................................................................... 73
Hnh 26: V d v phn tch thnh phn Mn trong mu du. ..................................................... 74
Hnh 27: My o FTIR. ................................................................................................................... 75
Hnh 28: My o HTHS................................................................................................................... 76
Hnh 29: My o CCS. ..................................................................................................................... 76
Hnh 30: My o t trng. ................................................................................................................ 77
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Hnh 31: My o nht. ............................................................................................................... 78
Hnh 32: My o mu. ..................................................................................................................... 78
Hnh 33: My o TBN. .................................................................................................................... 79
Hnh 34: My o hm lng nc theo phng php Karl Fischer. .......................................... 80
Hnh 35: My o nhit chp chy. ............................................................................................ 81
Hnh 36: My o im ng. ........................................................................................................... 82
Hnh 37: My o to bt............................................................................................................. 83
Hnh 38: Mu ng ni quy nh. ............................................................................................. 85
Hnh 39: Cc mu trc khi em lu vo kho. ............................................................................. 85
Hnh 40: Mu sau pha ch c t ng v tr............................................................................ 86
Hnh 41: Ni dng c bo h. .................................................................................................... 86
Hnh 42: Khu vc lu tr h s. ..................................................................................................... 86
Hnh 43: Khu vc my mc, thit b lun c v sinh sch s .................................................. 87
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DANH MC BNG BIU

Bng 1: Nng lc sn xut ca nh my ........................................................................................ 14
Bng 2: Phn loi du gc theo tiu chun API ............................................................................ 27
Bng 3: Du gc t nh cung cp SBC Petrochemical PTE LTD ............................................... 28
Bng 4: Phn cp nht theo tiu chun SAE ........................................................................... 33
Bng 5: Sn phm du dng c thng dng hay kim tra trong nh my ................................. 34
Bng 6: Sn phm thng dng ca du thy lc hay kim tra trong nh my ......................... 34
Bng 7: Thng s ca Bn pha ch ................................................................................................. 40
Bng 8: Bng theo di ch tiu KPI ca b phn sn xut nm 2012 ......................................... 62
Bng 9: Cc ch tiu KPI b phn sn xut trong nm 2013 ....................................................... 63
Bng 10: COA ca mt loi ph gia ............................................................................................... 68
Bng 11: Cc ch tiu cn o v phng php s dng ............................................................... 69
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PHN I: TNG QUAN V CNG TY VILUBE

1. Lch s hnh thnh
Cng ty Vilube c thnh lp vo nm 1994, tin thn l cng ty TNHH Ton Tm,
ngoi vic sn xut v kinh doanh sn phm du nht mang thng hiu Vilube, cng ty cn
sn xut gia cng cho cc cng ty du nht a quc gia nh Caltex, Esso v Total. Sau ,
cng ty n lc pht trin sn phm v thng hiu Vilube tr thnh Cng ty du nht
hng u ca Vit Nam hin nay, c v tr v uy tn ring bit trn th trng du nht trung
v cao cp.
n nm 2001, sn phm ca Vilube chim ti 11 % tng th phn sn phm du
nht trong c nc.
Nm 2008, mt s kin quan trng mang tnh to bc ngot, m ra mt thi k mi
cho Cng ty: Vilube chnh thc l thnh vin trong tp on du nht Motul danh ting ca
Php. Vi s hp tc ny, Vilube khng nhng khng nh c v th trn th trng
du nht Vit Nam m cn c thm nhng c hi vn xa hn, hi nhp su hn vi th
trng quc t.
Vi t cch l thnh vin ca Motul, Vilube ng vai tr ch cht trong vic sn xut
ra cc sn phm c cht lng cao cho cc th trng trong khu vc Chu Thi Bnh
Dng, bao gm c th trng Vit Nam.
K t y, tt c cc sn phm mang nhn hiu Vilube c sn xut di s gim
st k thut ca Motul nhm cung cp cc sn phm cht lng cao cho th trng ng thi
gi ti ngi tiu dng thng ip v cam kt cht lng sn phm v n lc pht trin
thng hiu Vilube a ra phng chm sn xut cng nghip khng chp nhn cc sai st,
s c v khim khuyt.
Vilube hin nay c tr s chnh t ti Thnh ph H Ch Minh, gm c nm chi
nhnh: H Ni (phc v th trng min Bc), Nng (phc v th trng min Trung),
hai chi nhnh t ti Tp. HCM (phc v th trng cc tnh Min ng Nam B v th
trng TPHCM) v Cn Th (phc v th trng ng bng Sng Cu Long).
Nh my du nht Vilube
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2. S nt lch s hnh thnh ca MOTUL
c thnh lp hn 150 nm trc ti NewYork vo nm 1853, Motul bt u ngnh
kinh doanh ch yu bng vic sn xut du ly t m c voi dng cho n lng. S hu
Motul ln lt l Forest & Francis, tip n l Standard Oils of NJ v sau cng l Swan &
Finch (S&F). Nhng nm sau chng kin S&F tp trung v m rng kinh doanh vo th
trng Chu u vi nhiu nhn hiu v sn phm du nhn, trong nhn hiu Motul
nhanh chng khng nh c thng hiu ca mnh. Vo nm 1932, cng ty phn phi ca
Php thuc quyn s hu ca gia nh Zaugg mua li S&F nhng vn gi li thng hiu
Motul. Vo nhng nm 1960, tt c cc hat ng ca cng ty u c chuyn sang Php,
v t Motul c bit n nh mt nhn hiu v sn phm ca Php.
Tt c cc loi sn phm cht lng cao ca Motul ang c bn rng ri ti 80
quc gia trn th gii vi th phn ch yu cc phn khc xe hai bnh v -t.
3. Qu trnh pht trin ca Vilube
Nm 1994
Thnh lp Cng ty TNHH Thng mi v Sn xut Ton Tm vi nh my c cng
sut 15 000 tn/nm, t ti Th c.
Nm 1995
Cng ty ln u tin a ra th trng Vit Nam sn phm can nha 18 L phc v
cho ghe tu nh c v xe ti.
Bt u sn xut gia cng cho Esso, Total, Caltex.
Thnh lp chi nhnh ti Cn Th phc v cho th trng ng Bng Sng Cu Long.
Nm 1999
Thnh lp chi nhnh ti Nng phc v cho th trng Min Trung t Ph Yn ra
Qung Bnh.
Nm 2000
Cng ty ln u tin a ra th trng loi nht xe gn my GAMA, GAMA X v
nht xe hi du lch BLAZO, MASTER.
Nm 2001
Nh my du nht Vilube
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Khnh thnh nh my mi nm cnh khu cng nghip Hip Phc, Huyn Nh B,
TP H Ch Minh vi cng sut gn 13 000 000 L/nm, trn din tch 30 000 m2.
Nhn c 3 huy chng Vng Cht lng ti Hi ch Quc t Expo 2001 cho cc
sn phm GAMA X, STELLO, HYDROLIC AW32.
Thnh lp chi nhnh ti H Ni phc v th trng Min Bc t H Tnh tr ra.
Nm 2002
Nhn chng ch qun l cht lng Quc t ISO 9001:2000 do t chc BVQI, Vng
Quc Anh cp.
i tn thnh Cng ty TNHH Du nht v Ho cht Vit Nam (Vilube Co.).
Nm 2003
Nhn gii thng Mai vng Hi nhp do VCCI v Tng cc Cht lng Vit nam
trao tng.
Huy chng Vng Cht lng Hi ch Quc t EXPO 2003 cho nht xe gn my
GAMA X, bng khen sn phm t tiu chun cht lng cho cc sn phm khc.
Cp Vng Cht lng dnh cho cc doanh nghip c nhiu sn phm t huy chng
vng.
t tiu chun JASO MA T903 do T chc tiu chun t Nht Bn (Japanese
Automobile Standard Organization) cp.
Gii thng Sao Vng t Vit do Hi Lin Hip Thanh Nin Vit Nam v U Ban
Trung ng Hi cc nh Doanh Nghip Tr Vit Nam cp cho nhng thng hiu
mnh Vit Nam.
Nm 2004
T thng 04 nm 2004, Cng ty Vilube c c phn ha v c tn mi l Cng
ty C Phn Du Nht v Ha Cht Vit Nam (Vilube Corp).
Cng ty Vilube m rng th trng xut khu sang Campuchia v Trung Quc.
Nm 2005
Ngy 04 thng 01 nm 2005, Vilube c trao "Cp Vng Top Ten Thng hiu
Vit" ca nghnh du nht v ho cht do Trung tm Cng ngh thng tin v T vn
Nh my du nht Vilube
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qun l doanh nghip QVN (thuc Hi S hu cng nghip Vit Nam) thc hin t
chc bnh chn
Ngy 28 thng 01 nm 2005, Sn phm du nht Vilube c chng nhn l "Hng
Vit Nam Cht Lng Cao" do ngi tiu dng bnh chn trn bo Si Gn Tip Th.
Nm 2006:
c bnh chn l mt trong 500 thng hiu ni ting ti Vit Nam theo kt qu d
n kho st Thng hiu ni ting ti Vit Nam nm 2006, do Phng Thng mi v
Cng nghip Vit Nam (VCCI) cng tp ch Vietnam Business Forum, Cng ty
truyn thng Cuc sng v cng ty nghin cu th trng ACNielsen Vit Nam thc
hin.
Nm 2008:
Thng 11/2008 Vilube chnh thc l thnh vin ca tp on du nht a quc gia
Motul c tr s chnh t ti Php. nh du s tham gia ca c ng chin lc
nuc ngoi u tin. C ng nc ngoi thuc tp an du nht Motul vi 30 %
tng s vn iu l cng ty.
Nm 2009:
Nm 2009 c xem nh nm u tin Vilube hot ng vi hnh thc cng ty 100
% vn nc ngoi kinh doanh du nht ti Vit Nam.
4. Nng lc sn xut Kinh doanh Phn phi sn phm
4.1 Nng lc sn xut
Vilube vn hnh mt nh my pha ch du nht ring ca cng ty nm cnh khu
cng nghip Hip Phc, Huyn Nh B, Tp. HCM. V tr t nh my thun tin cho vic
vn chuyn nguyn vt liu v sn phm. a th v din tch hin ti ca nh my cho php
nh my tip tc m rng tng cng sut trong mt thi gian di m khng phi di di,
to nn s linh ng v chin lc sn xut ca Vilube.
Nh my du nht Vilube
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Bng 1: Nng lc sn xut ca nh my
Cng sut thit k
13 000 000 L/nm
Din tch nh my
30 000 m2
Cng sut bn cha du gc (BOT)
5 bn 750 m3 v 4 bn 650 m3
Bi cha v kho c mi che
Kho bi
dnh cho vt liu v thnh phm
C s h tng
ng b v cu cng ng thy
phc v giao nhn hang

Trang thit b
Phng ha nghim kim nghim cht lng ca nguyn
kim nh cht lng
liu, du nht thnh phm v du nht qua s dng
Kch c sn phm, bao b
Nh my c th ng gi vo phuy, can, x v chai/bnh

nha t 0.8 L, 1 L, 4 L, 5 L, 18 L, 25 L, 200 L.
4.2 Nng lc kinh doanh ca cng ty

Cng ty Vilube hot ng trong lnh vc sn xut v phn phi du nht, m bi trn
v cc loi ha cht ti Vit Nam. Cng ty nhp khu du gc v ph gia t cc nh cung
cp ni ting trn th gii nh Chinese Petroleum Corporation (Taiwan), Exxon Mobil
(Singapore), Chevron Oronite (USA), Lubrizol Asia Pacific, Afton Aisa Pacific Singapore,
Dupont Dow Elastomers (USA) v Fragrance Oils (England) Tin hnh pha ch ti nh
my theo mt quy trnh c kim sot cht ch v cht lng, sau a ra tiu th trn
th trng thng qua h thng phn phi ca cng ty.
4.3 H thng phn phi sn phm ca cng ty
Vilube phn chia th trng thnh nm khu vc chnh, phc v cho vic qun l hu
cn v qun l tip th, bn hng: Min Bc, Min Trung, Min ng Nam B, Tp. HCM v
ng Bng Sng Cu Long.
Cng ty c hai thng hiu chnh Vilube v Motul vi ba dng sn phm:
Nh my du nht Vilube
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Dng sn phm thng hiu Vilube truyn thng ch yu cung ng cho th
trng ni a v cc nc ln cn.
Dng sn phm kt hp hai thng hiu Vilube - Motul (Co-branding) p ng
knh tiu th i hi cht lng cao hn trong nc.
Dng sn phm mang thng hiu Motul l mt loi sn phm du nht tng
hp c cht lng rt cao ca Tp on m Motul Php c sn xut ti Nh
my Vilube v xut khu i tt c cc nc thuc Chu Thi Bnh Dng.
Sn phm ca Cng ty bao gm cc chng loi du nht phc v cho cc th trng
trung v cao cp:
Du nht xe gn my.
Du nht xe ua (Thng hiu Motul).
Du nht xe hi.
Du nht xe ti, tu truyn v ng c Diesel.
Du nht ngnh hng hi.
Cc loi du nht cng nghip c chng: cung cp cho cc Nh my SX, Cng
trng phc v cho cc thit b, my mc chuyn dng khc nhau nh: thy lc,
my nn, bnh rng
Cc loi sn phm c bit v cao cp khc.
5. V th ca nh my
Nh my Vilube nm cnh khu cng nghip Hip Phc, ti x Hip Phc, Huyn
Nh B, TP.HCM, cch trung tm thnh ph 18 km:
- Din tch nh my 30 000 m2, din tch xy dng 3828 m2.
- Pha ng v Ty gip cc cng ty khc trong KCN Hip Phc; pha Nam gip
sng ng in; pha Bc gip ng rung.
6. S b tr nhn s ca nh my
Nh my du nht Vilube
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Gim c nh my
Th k gim c
Tng gim st cht lng
Qun l sn xut
Qun l cht lng
Qun l k thut
Gim st sn xut
Gim st cht lng
Qun l d n
Gim st khu vc SX
Phng Ha nghim
Gim st bo tr
T trng pha ch
K s P. Ha nghim
Qun l hnh chnh
Nhn vin hnh chnh
Cng nhn v sinh
K s bo tr
Cng nhn pha ch

Cng nhn ng gi
KT. Bao b u vo
v kim tra mu cui

Nhn vin QA
KT. Cht lng QTSX
Nhn vin QC
Nh my du nht Vilube
Hnh 1: S b tr nhn s ca nh my.

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Qun l an ton
Nhn vin HSE

7. An ton Sc khe Mi trng ti nh my Vilube (HSE)
7.1 Ni dung an ton (HSE) i vi khch lm vic ti nh my
Khch n lm vic ti nh my cn nghim tc thc hin y cc th tc nh sau:
-
ng k vt dng c nhn: my chp hnh, my tnh v hng ha ti phng bo v.
i trn phn ng dnh cho ngi i b, quan st khi bang ngang qua ng.
S dng phng tin c nhn ph hp khi i vo trong nh my v trong khu vc sn

xut. Nn cng, giy an ton l yu cu ti thiu khi n nh my. Qun ngn v dp
kp khng c s dng ti nh my.
Khng tc ng vo bt c my mc thit b no khi khng c php.
Khi c tai nn hoc s c xy ra, bo ngay cho nhn vin nh my mnh ang cng
lm vic. Khi pht hin s c chy n: nhn nt bo ng gn nht, gi s ni b
thng bo s c.
Khi nghe bo ng, bnh tnh di chuyn ra khu vc an ton theo ch dn thot him,
nhanh chng di chuyn n im tp kt.
Tun theo quy nh an ton, bin bo an ton v hng dn ti mi khu vc
Cm ht thuc v n ung trong nh my, ngoi tr ng ni quy nh.
Khng c vo nhng khu vc khng cho php.
Khng chy xe qu tc an ton quy nh l 10 km/h. u xe phi ng ni nh

theo ch dn ca bo v.
7.2 Ni dung an ton (HSE) i vi nh hp ng v nhn vin

Nh my xy dng h thng qun l an ton tp trung vo 3 nhn t chnh l: con
ngi, mi trng v thit b. H thng qun l an ton da trn nn tng OHSAS 18001
v 5S.
Ni dung an ton c th hin qua cc mt sau y:
An ninh trt t.
An ton chy n.
Tnh hung khn cp, li thot him v im tp trung.
Giao thng ng b.
in thoi di ng v phng tin nghe nhn.
Nh my du nht Vilube
Trang 17
Bo h lao ng (PPE).
12 nguyn tc vng v an ton lao ng.
Hun luyn ATVSL.
7.2.1 An ninh trt t

-
Cm gy ri trt t nh my.
Cm t chc bun bn di mi hnh thc.
Cm s dng ma ty, cht kch thch, thc ung c cn.
Cm t chc c bc.
Khng n ung ti ni lm vic, khng ht thuc trong nh my.
7.2.2 An ton chy n

-
Cm ht thuc tt c khu vc trong nh my.
Ch c ht thuc ti nh ht thuc.
Cm la.
7.2.3 Tnh hung khn cp, li thot him v im tp trung

Khi c tnh hung nguy him khn cp, lp tc bo ng v thot ra bng con ng
ngn v an ton nht.
Hnh 2: S mt bng nh my v ca thot him.

Nh my du nht Vilube
Trang 18

Sau khi thot him, di chuyn n im tp trung trc cng vo nh my.
Hnh 3: im tp kt trc cng nh my.

7.2.4 Giao thng ng b
-
i ng tuyn.
i ng tc .
Khng t i li trong nh my.
Tun theo s hng dn.
7.2.5 in thoi di ng v phng tin nghe nhn khc

-
S dng in thoi v cc phng tin nghe nhn khc phi m bo an ton.
Khng c quay phim chp hnh khi khng c php.
7.2.6 Cc nguyn tc vng an ton lao ng

7.2.6.1 i vi tt c cng vic
Nhn din c cc nguy c.
m bo an ton cho chnh bn thn.
Tun th cc quy nh PPE.
Tun th quy trnh/th tc/hng dn cng vic.
Bo co tai nn, s c.
Bo h lao ng (PPE):
Nh my du nht Vilube
Trang 19

Giy bo h lao ng.
Nn bo h lao ng.
Cc trang b bo h lao ng khc.
Quy nh bo h lao ng ti cc khu vc trong nh my:
Nh my du nht Vilube
Trang 20

7.2.6.2 Khi gim st cng vic
m bo nhng ngi c gim st tun th nguyn tc vng v thc hin
cng vic an ton.
m bo nhng ngi c gim st tun th cc quy trnh/th tc hoc
hng dn cng vic/vn hnh an ton (nu c).
khc phc ngay khi nhn din ra cc hnh ng hoc cc iu kin khng an
ton.
7.2.6.3 Khi vn hnh phng tin vn chuyn
C bng cp/chng ch vn hnh phng tin.
m bo an ton khi lu thng v vn hnh phng tin vn chuyn trong nh
my, nh phi ci dy an ton v i nn bo him.
Tun th cc quy nh v tc .
7.2.6.4 Khi lm vic trn cao (>1.8m)
Phi c sn thao tc hoc s dng dy eo an ton ton thn.
Ro chn khu vc lm vic trn cao.
Phi c phng n cu h.
Nhng nhn vin lm vic trn cao phi c bit phng n cu h.
Hun luyn k thut an ton lm vic trn cao.
7.2.6.5 Cch ly my v thit b
My/thit b phi c cch ly v treo th trc khi thc hin cng vic.
Kim tra v xc nhn cch ly ng.
Nhn vin cch ly v tho g cch ly l duy nht.
Hun luyn k thut cch ly.
7.2.6.6 Khi lm vic vi my/thit b/ b phn chuyn ng
My/thit b/ chuyn ng phi c che chn.
Nghim cm tho g cc che chn.
Nhn din c cc nguy c, ri ro.
7.2.6.7 An ton in
m bo my/thit b/ dng c s dng in trong trnh trng an ton.
Nh my du nht Vilube
Trang 21

u ni an ton: khng c mi ni h, mi ni khng t yu cu..
S dng cc cm, phch cm hoc cc thit b kt ni in ph hp.
Cng vic in phi c thc hin bi nhng ngi c chuyn mn.
Hun luyn k thut an ton in.
7.2.6.8 Khi lm vic trong khng gian hn ch
Khng c vo khng gian hn ch khi cha c s cho php.
Phi c giy php vo hoc lm vic trong khng gian hn ch.
Tun th cc yu cu an ton.
Phi bit phng n cu h.
Phi c hun luyn an ton khi lm vic trong khng gian hn ch.
7.2.6.9 Nhng cng vic gy chy n
Ch c thc hin nhng khu vc qui nh v phi c giy php nu thc
hin bn ngoi khu vc qui nh.
Cc bin php an ton phi c m bo c thc hin.
Cc chai kh p lc phi c t t th ng v c buc cht vo kt cu
vng chc.
c hun luyn v an ton thc hin cc cng vic gy chy n.
c hun luyn v PCCC.
c thc hin bi ngi c chuyn mn.
7.2.6.10 Khi lm vic vi thit b nng
C bng cp/chng ch chuyn mn ph hp.
c hun luyn v an ton khi lm vic vi thit b nng.
Thit b phi c kim nh, ng kim, hiu chun theo qui nh php lut.
Bit r v khu vc v hng nng hng.
7.2.6.11 Tnh trng sc khe ph hp
Khng chu s nh hng ca thc ung c cn hoc cht kch thch.
Sc khe trong tnh trng ph hp vn hnh my/thit b.
Khng c lm vic nu tnh trng sc khe gy mt an ton.
Nh my du nht Vilube
Trang 22

7.2.6.12 in thoi di ng v thit b nghe nhn khc
Ch c s dng khi:
dng cng vic ang thc hin.
Di chuyn n mt v tr an ton.
S dng nhng khu vc cho php.
7.2.7 Hun luyn ATVSL theo yu cu php lut (TT37/2005/BLTBXH)
ATVSL chung.
S cp cu.
PCCC.
An ton chuyn mn khc: in, hn in hn hi, khng gian kn
c bit vn PCCC:
Hng nm tin hnh o to, hun luyn, din tp 1 ln/nm theo cc quy nh
v PCCC ca B Cng an.
Cc khu vc trong nh my lun c trang b h thng bo hiu, cha chy
t ng, m bo an ton PCCC.
Mt s hnh nh thc hin din tp PCCC ti nh my:
Nh my du nht Vilube
Trang 23
Hnh 4: Thc hnh din tp PCCC ti nh my.
Nh my du nht Vilube
Trang 24

8. X l ph thi, nc, kh thi v v sinh cng nghip
8.1 X l ph thi, kh thi v v sinh cng nghip
Ph thi ca nh my l cc sn phm khng t cht lng, nh my tin hnh
kim tra nht ca du ph thi, nu t nht cho php, du ny c th ti s dng, nu
nht khng nm trong khong cho php, du ph thi s c lu tr, pha trn li t
yu cu cho php.
Nh my c s dng bec t du D.O, nhng vi cng sut thp, v lng D.O ny
ch yu un ni hi v nu cc loi ph gia nn khng cn h thng x l khi thi, c
th thi trc tip ra ngoi khng kh.
V sinh cng nghip: trc v sau khi sn xut, lc lng cng nhn trong nh my
u lm v sinh, v nh k c lm v sinh bn b. Cn trong khun vin nh my c lc
lng lao cng qut dn, v trng nhiu cy xanh nn mi trng cnh quan nh my rt
thong mt m bo cho sn xut c hiu qu.
8.2 X l nc thi
Nc thi do ra cc dng c th nghim cha du trong phng Lab: c dn ra h
thng x l s b, ri tn tr trong cc phuy, nh k s c xe ch i n mt nh my
chuyn x l nc thi khc.
Nc thi do c s c trn du: iu cn quan tm l lng nc lm sch mt bng,
m lng nc thi l hn hp nc du khng c thi ra ngun m phi c tin
hnh x l trit lng du ln trong nc, v lng nc ny cng c lu tr vn
chuyn n mt nh my chuyn x l du ln trong nc.
Nh my du nht Vilube
Trang 25
PHN II: NGUYN VT LIU SN XUT

Nguyn vt liu trong sn xut du nhn bao gm: Du gc, Ph gia, Bao b. Du
gc v ph gia nhp khu t cc nh cung cp ni ting trn th gii nh Chinese Petroleum
Corporation (Taiwan), Exxon Mobile (Singapore), Chervon Oronite (USA), Lubrizol Asia
Pacific, Afton Asia Pacific Singapore, Dupont Dow Elastomers (USA) v Fragrance Oils
(England). Bao b c cung cp t cc nh sn xut trong nc c cht lng cao.
1. Du gc
1.1 Tnh cht chung
Phn on du gc c c t qu trnh chng ct su cc phn on nng ca du
th, sau khi qua qu trnh tch loi paraffin, c th c m t trong s sau:
Hnh 5: Cc thnh phn c bn ca du nhn.

Thnh phn ca du gc c th c:
Parafin mch thng v mch nhnh.
Hydrocacbon no n v a vng (naphten) c cu trc vng xyclohexan gn vi
mch nhnh parafin.
Cc hydrocacbon thm n vng v a vng ch yu cha cc mch nhnh ankyl.
Nh my du nht Vilube
Trang 26

Cc hp cht cha vng naphten, vng thm v mch nhnh ankyl trong cng mt
phn t.
Cc hp cht hu c c cha cc d nguyn t, ch yu l cc hp cht cha lu
hunh, nitv oxy.
Phn loi du gc:
- Da vo bn cht, thnh phn ca du gc: du parafin, du napthen, du aromatics
- Da vo tiu chun API:
Bng 2: Phn loi du gc theo tiu chun API
Nhm % Sunfua
% Hydrocarbon
Ch s
Phng php
bo ho
nht, VI
sn xut
> 0.03
<90
80 VI 120
Solvent refining
II
0.03
90
80 VI 120
Hydrotreating
III
0.03
90
VI 120
Hydroisomerization
IV
Poly Alpha Olefins (PAO) Du tng hp
Tt c cc loi du gc cn li khng bao gm nhm I, II, III, IV
- Da vo nht: du gc SN (Solvent Neutral), du gc BS (Bright Stock).

1.2 Mt s loi du gc nh my ang s dng
- Du gc nhm 2 (API): 600N Caltex, 150N Caltex
- Du gc nhm 3 (API): Yubase 4, Yubase 6, Mexbase
- Du gc nhm 4 (API): PAO 4, PAO 6
1.3 Cc ch tiu nh gi du gc
nh gi cht lng du gc trong qu trnh thu mua v pha ch du nht, ta cn
kim tra cc thng s sau y:
- Ngoi quan: B & C v cn.
- T trng.
- nht ng hc ti 40 oC v 100 oC.
Nh my du nht Vilube
Trang 27

- Ch s nht.
- im chp chy.
- im ng.
- Mu sc.
- Cn Carbon.
- n mn ming ng.
- TBN.
Mi loi du gc khi a v s km theo mt bng tiu chun do nh sn xut cung
cp, mi nh cung cp s c 1 tiu chun ring:
V d:
Bng 3: Du gc t nh cung cp SBC Petrochemical PTE LTD
Items
Test Method
Result
Specification
Visual
Bright & Clear
Bright & Clear
Specific Gravity, @15/4 oC
ASTM D1298
0.8415
Report
Kinematic Viscosity, @40 oC
ASTM D445
35.01
Report
Kinematic Viscosity, @100 oC
ASTM D445
6.320
6.3-6.7
Viscosity Index
ASTM D2270
132
Min. 125
Noack Volatility, wt%
DIN 51581
7.5
Max. 8
Flash Point, oC
ASTM D92
235
Min. 210
Pour Point, oC
ASTM D97
-12
Max. -12
Color, ASTM
ASTM D1500
L0.5
Max. L0.5
Con. Carbon Residue, wt%
ASTM D189
< 0.01
Max. 0.05
Copper Corrosion
ASTM D2622
<1
Report
Total Acid Number, mgKOH/g
ASTM D664
< 0.01
Report
Appearance
2. Ph gia
2.1 Tnh cht chung
Ph gia s dng cho du nhn rt a dng, c th l nhng hp cht hu c, c
kim, thm ch l cc nguyn t. Ty theo yu cu tnh nng ca tng loi sn phm m ta s
Nh my du nht Vilube
Trang 28

dng cc loi ph gia ph hp nng cao cc tnh cht ring bit cho sn phm. Thng
thng hm lng mi loi ph gia trong du nhn thay i t vi ppm n trn 10 %.
Phn ln cc loi du nhn cn nhiu loi ph gia tha mn tt c cc yu cu v
tnh nng. Cc loi ph gia khc nhau c th h tr cho nhau gy nn hiu ng tng h
hoc ngc li, chng c th tng tc vi nhau gy nn hiu ng i khng lm gim hiu
lc ca ph gia v to ra nhng sn phm ph khng tan hoc nhng sn phm c hi khc.
Do vic t hp cc ph gia i hi phi kho st k nhng tc dng qua li gia cc loi
ph gia cng nh c ch hot ng ca tng loi ph gia ring v tnh ha tan ca chng.
Ph gia c th dng ph gia thnh phn (component) hoc ph gia ng gi
(packages) trong cht mang c s dng l du khong. Hin nay khuynh hng s
dng ph gia ng gi ang rt ph bin. N c cc u im l tnh tng hp cao v rt
thun tin trong qun l tn kho v chi ph thp. Tuy nhin, khi s dng ph gia ng gi ta
cng gp phi mt s bt li nh khng th iu chnh hoc gim thiu mt tnh nng no
trong sn phm. Sn phm to ra c tnh ph cp, khng c tnh chuyn bit v s dng
ph bin cho cc sn phm thng dng nh du ng c PCMO, MCO v HDEO.
Du ng c c th cha ti mi nhm ph gia, hoc hn. Lng ph gia dng cho
du ng c chim trn 50 % tng lng ph gia c s dng trn th gii.
2.2 Cc chng loi ph gia
Mt s loi ph gia quan trng:
-
Ph gia chng oxy ha: lm tng bn oxy ha cho sn phm.

+ C ch: ph gia chng oxy ho tc dng theo mt trong ba c ch sau
c ch gc t do.
Phn hu cc peroxyt.
Th ng kim loi.
+ V d: cc dn xut phenol, amin thm, ZDDP (Km diankyldithiophotphat)
Ph gia kh hot tnh kim loi: ngn chn hiu ng xc tc ca kim loi trong qu
trnh oxy ha v n mn.
+ C ch: to thnh mng hp ph ln b mt kim loi, ngn cn s tip xc vi mi
trng.
Nh my du nht Vilube
Trang 29

+ V d: dn xut triazole, benzotriazole, thiodiazole, hp cht photphit
-
Ph gia c ch n mn: chng n mn.

+ C ch: to thnh mng bo v trn b mt kim loi, ngn cn s tip xc ca cc
tc nhn n mn ln b mt kim loi.
+ V d: dithiophotphat kim loi, c bit l Km, cc tc nhn hot ng b mt nh
cc axit bo, amin, axit ankylsuxinic, clo ho parafin
Ph gia c ch chng g: chng g.

+ C ch: to mng hu c bn vng trn b mt kim loi, ngn m thot qua.
+ V d: acid succinic, epoxylate alkyl phenols/ alcohol/ amine
Ph gia lm tng ch s nht: tng ch s nht.

+ C ch: l cc polymer tn ti dng xon cht trong du khi nhit thp do
kh nng ho tan km v khi nhit cao, cc polymer ny dui di ra lm tng
nht ca du, nh vy gim s bin i nht ca du theo nhit .
+ V d: Copolymer ca ethylene propylene, polyisobutylene, copolymer styren
isoprene, polymetacrylate, polyacrylate v cc polymer ca este styrenmaleic...
Ph gia h im ng: lm gim nhit ng c.

+ C ch: lm chm li qu trnh to thnh tinh th sp hon ho bng cc bao bc
xung quanh hoc cng kt tinh vi sp, thc y qu trnh to thnh cc tinh th sp
nh hn thay cho cc m vn xp hnh thnh khi khng c cc cht h im ng.
+ V d: Polymethacrylates, alkyl naphthalens, cc polyester c nhm styren.
Ph gia chng to bt: chng to bt.

+ C ch: bm vo bt khng kh lm gim sc cng b mt. Cc bt bong bng nh
v th m t li to thnh cc bt bong bng ln ni ln b mt lp bt v v ra lm
thot khng kh ra ngoi.
+ V d: Silicon trong dung mi pegasol.
Ph gia chng mi mn: chng li s n mn, gim ma st, ta nhit.

+ C ch: to lp mng gia cc b mt tip xc, bm trn b mt kim loi.
+ V d: cc nhm ho cht c cha hp cht photpho, hp cht lu hunh, cc dn
xut bo c kh nng bm dnh trn b mt kim loi.
Nh my du nht Vilube
Trang 30

Trn y l mt s ph gia quan trng s dng trong cc sn phm du nht. Ty vo
mi loi sn phm khc nhau s s dng cc loi ph gia khc nhau. Hin ti nh my ang
s dng 2 dng ph gia l ph gia ring r nh VM (tng ch s nht), PPD (h im
ng) v ph gia ng gi nh DI Trong ph gia ng gi ang ngy cng c s
dng ph bin nhm pht huy ti a cc tnh nng ca ph gia. ng thi ph gia ng gi
cng chnh l b mt cng ngh ca mi nh sn xut.
3. Bao b
Cc dng bao b mua trong nc gm: Phuy 200 L, can, x 18 L, can 25 L, can 4.5 L,
bnh nha 0.5, 0.7, 0.8, 1 L v thng giy carton ng hng.
4. Kh nng thay th nguyn vt liu
Kh nng thay th du gc v ph gia hin nay l rt thp, v:
o Vit Nam c nh my lc du, tuy nhin ngun du gc vn cha p ng
c mt s yu cu ca nh my.
o Cng ngh Du kh v ph gia cha pht trin.
o Cc hng ni ting bt u u t vo Vit Nam nhng vn l cc d n ang
thc hin.
Bao b c cung cp bi cc doanh nghip trong nc, v vy kh nng thay th l
rt cao.
Nh my du nht Vilube
Trang 31
PHN III: SN PHM

1. Cc loi sn phm chnh ca nh my
Hin ti nh my ang sn xut cc loi sn phm chnh sau:
- Nhm du ng c (xe my, diesel) vi cc sn phm chnh sau:
+ HTech 100 Plus 0W20
+ Htech 100 5W30
+ 3100 Gold 4T 10W40
+ 3100 Gold 4T 15W50
- Du Gear oil vi cc sn phm chnh sau:

+ Gear FI LSD 75W90
+ HDX 80W90
- Du thy lc vi cc sn phm chnh sau:

+ Hydralo AW22
+ Hydralo AW32
+ Hydralo AW46
+ Hydralo AW68
- Du ct gt kim loi:
+ Supercool
+ Biocool 3220
2. Tiu chun i vi cc sn phm du nht

Thng thng cc sn phm du nht c phn loi theo mt trong hai tiu chun l
tiu chun API (American Petroleum Institute) v tiu chun SAE (Society of Automotive
Engineers). Thc t cc sn phm ca Vilube cng c phn loi v kim tra da theo hai
tiu chun chnh ny.
Nh my du nht Vilube
Trang 32

i vi tiu chun SAE ta c bng phn loi theo cp nht nh sau:
Bng 4: Phn cp nht theo tiu chun SAE
nht nhit thp
nht ng hc nhit cao
(mPa/oC)
100 oC (mm2/s)
Cp
nht
nht khi khi ng
nht khi bm
ASTM D2602-75
ASTM D4684-89
0W
3250 max (-30 oC)
5W
Ti thiu
Ti a
30 000 max (-35 oC)
3.8
3500 max (-25 oC)
30 000 max (-30 oC)
3.8
10W
3500 max (-20 oC)
30 000 max (-25 oC)
4.1
15W
3500 max (-15 oC)
30 000 max (-20 oC)
5.6
20W
4500 max (-10 oC)
30 000 max (-15 oC)
5.6
25W
6000 max (-5 oC)
30 000 max (-10 oC)
9.3
20
5.6
9.3
30
9.3
12.5
40
12.5
16.3
50
16.3
21.9
60
21.9
26.1
3. Tiu chun ca mt s sn phm thng dng ca nh my

Mi mt sn phm du nht trong nh my u phi tun theo bng tiu chun m
cng ty a ra. Bng tiu chun ny gi tt l bng COA ca sn phm (Certificate of
Analysis). Bng COA c cng ty lp ra i vi tng sn phm l da trn cc tiu chun
quc t nh SAE, API v c tin hnh theo cc tiu chun ASTM. COA c xem nh
l thc o cht lng cho cc sn phm du nht, da vo c th bit c sn phm
t cht lng hay khng.
Sau y l COA ca mt s sn phm thng dng trong nh my:
Nh my du nht Vilube
Trang 33
Bng 5: Sn phm du dng c thng dng hay kim tra trong nh my

Tr s
%kl
TBN,
Zn, Ca,
mg
Mg
KOH/g
Sn phm
Kim
tra
kh
Cm
quan
T trng
30 oC g/l
Mu
ASTM
nht
40oC,
cSt
nht
100oC,cSt
CS
N VI
to
bt
ml/ml
Nhit
chp
chy
im
chy
GAMA M
Kh
B&C
0.87-0.89
3-4
155-190
17-19.5
114
4.5
0.21
<50/0
220
-5
GAMA X
Kh
B&C
0.87-0.92
3.5-4
155-190
17-19.5
114
7.5
0.31
<50/0
220
-5
GAMA @
Kh
B&C
0.87-0.89
2.5-4
110-145
13.5-16
120
6.5
0.32
<50/0
200
- 10
Bng 6: Sn phm thng dng ca du thy lc hay kim tra trong nh my
Nh my du nht Vilube
Sn phm
HO.VG46
Kim tra kh
Kh
Cm quan
B&C
T trng 30oC g/l
0.87- 0.89
Mu ASTM
< 1.5
nht 40oC, cSt
43.5 - 48.5
nht 100oC, cSt
6.3 - 7.2
CSN VI
95
to bt ml/ml
< 50/0
Nhit chp chy
210
Trang 34
PHN IV: QUY TRNH SN XUT

1. Quy trnh chung
Bt u
Xc bn pha ch
Bm du gc
Khng
t
Nhn ph
gia
Ly mu &
kim tra
du gc
ng gi
Ch cch
x l t QA
Ly mu &
kim tra
mu cui
Khuy trn du gc
v ph gia
Khng
t
Khng
t
Ly mu v
kim tra
bn TP
Kim tra cng on
Cch ly/ sc ra
ng ng
Khng
Kim tra
mu cch
ly
Nh my du nht Vilube
Nhp kho
Kt thc
Trang 35

2. Quy trnh pha ch
2.1 S khi
Ngi chu trch nhim
Gim st sn xut
Nhn phiu yu
cu sn xut
T trng pha ch
Lp h s pha ch
Cng nhn
Nhn v kim tra

nguyn liu
T trng pha ch
Kim tra ma
trn xc ra
Khng
Ma trn xc bn
Cng nhn
Xc ra bn pha ch
Cng nhn
Bm du gc
Cng nhn
Khuy, gia nhit
Cng nhn
Ly mu du gc
Khng
Nhn vin cht lng
Kim tra
du gc
Thc hin theo

hng dn ca
phng cht lng
Cng nhn
Cn v np ph gia
Cng nhn
Xc phuy ph gia
Cng nhn
Khuy, hon lu
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Trang 36

Ngi chu trch nhim
Cng nhn
Ly mu Final Blend
Khng
Thc hin theo

hng dn ca
phng cht lng
Nhn vin cht lng
T trng pha ch
Kim tra mu
Final Blend
Cp nht d liu v
lu h s
Kt thc
2.2 M t cng vic

1. Nhn phiu yu cu sn xut (1ngi/5 pht) : Gim st sn xut nhn, kim tra thng
tin trn phiu yu cu sn xut v phiu pha ch phi ging nhau. Chuyn phiu sn
xut cho t trng pha ch.
2. Lp h s pha ch (1ngi/5 pht): Lp phiu yu cu xut nguyn vt liu, phiu theo
di thng tin pha ch, phiu kim sot ph gia, phiu bo co pha ch hng ngy.
Lu : - Tnh ton cn thn, chnh xc.
- Lu phuy l ph gia.
- Da vo bng khi lng tm khi lng mi ph gia.
3. Nhn v kim tra nguyn liu (1ngi/10 pht): Kim tra nguyn vt liu da vo
phiu yu cu sn xut, so snh h s vi h s bn kho.
Lu : - Kim tra ng tn loi ph gia.
- Kim tra ng khi lng yu cu.
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Trang 37

4. Kim tra ma trn sc ra (1 ngi/2 pht): Kim tra du m trc v m sau c cn
phi sc ra hay khng, nu c th yu cu cng nhn tin hnh sc ra bn pha ch
theo hng dn ca ma trn sc ra bn.
Lu : - Thng thng ta khng sc ra hoc 2 ln tun theo hng dn ca ma trn
sc ra bn, mi ln 350 L du gc.
- i vi du thng sc 1 ln, mi ln 150 L du gc.
5. Sc ra bn pha ch (1 ngi/45 pht) : Bm du gc vo bn pha ch sc ra theo
hng dn ca ma trn sc ra sau tho du gc ra ngoi cha vo phuy.
6. Bm du gc (1 ngi/25 pht) : xem s liu trn phiu pha ch, ci t thng s trn
lu lng k, m van bm du gc vo bn pha ch.
7. Khuy gia nhit (1 ngi/30 pht): Trong bn cha 1 loi du gc th khng cn
khuy, nu cha 2 loi du gc tr ln th khuy gia nhit vi nhit thch hp (40 oC
60 oC).
Lu : - i vi 1 loi du gc: Khng khuy du gc, sau tin hnh cn ln ph
gia.
- i vi 2 du gc tr ln: Nu trn 4000 L th khuy 30 pht, nu t 1000 L
- 4000 L bm hon lu 60 pht.
8. Ly mu du gc (1 ngi/5 pht): Chun b dng c ly mu v l ri sau ly mu.
9. Kim tra du gc (40 pht): Thc hin trong phng QC.
10. Cn np ph gia (3 ngi/20 pht): M np phuy ph gia hi lng ri t vo v tr
a phuy ln bn ph gia, ko phuy bng dng c h tr ri vo bn, cn l ph gia
dn vo phuy ri a ln bn ph gia. Sau khuy.
Lu : - Nu ph gia c mu, mi s c trc tip vo bn pha ch.
- Nu du gc cha trong phuy sau khi s dng phi vn cht np trnh nhim
nc.
11. Xc phuy ph gia (2 ngi/5 pht) : Di chuyn phuy ti bn pha ch ri t ng dn
du vo phuy, m 2 van cho du i vo phuy, lc u phuy sau ng 1 van cho ht
du ngc li bn.
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Trang 38

12. Khuy hon lu (1 ngi/30 pht): Ph gia c khuy xong, m vang cho du gc di
chuyn sang bn ph gia, sau m van hon lu ko hn hp ph gia du gc tr
v bn pha ch. Thc hin cho n khi sch ph gia, khuy trn hon lu sn phm
khong 30 pht.
Lu : - Phi lun theo di nhit bng nhit k trn thn bn m bo nhit
trong khong quy nh.
- Thng xuyn theo di hot ng ca ch cnh khuy, cc van ng hi
lu v h thng bm m bo chng ang lm vic tt.
13. Ly mu cui (1 ngi/ 5 pht) : Chun b dng c ly mu v l sau ly mu.
14. Kim tra mu cui (40 pht) : Thc hin trong phng QC.
15. Cp nhp d liu v h s: Tin hnh cp nhp d liu v h s pha ch (tng thi
gian pha ch l 235 pht).
2.3 S Gantt quy trnh pha ch
Hnh 6: S Gantt quy trnh pha ch.

2.4 Thit b
2.4.1 Bn pha ch
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Trang 39
Hnh 7: Thit b khuy.

2.4.1.1 V tr v s lng
H thng pha ch gm 8 bn (trong c 1 bn 1000 L). Ngoi ra cn c 1 bn AP1
khuy trn ph gia.
2.4.1.2 Cu to
- Th tch thit k: 15 000 L.
- Th tch lm vic: 14 600 L.
* Cu to bn ngoi:
Bng 7: Thng s ca Bn pha ch
Thng s
Vt liu kch thc
Gia cng
CT3, dy 6 mm, ng
Thn bn
knh 2500 mm, cao 3610
mm
y bn
CT3, dy 6 mm
ng dn
CT3, ng knh 4 inches
Np bn
CT3, dy 5 mm
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c
Hn thp on tik
Hn tm
Trang 40

o Trn thn c lp nhit k o nhit pha ch.
o Thn bn v y bn c hn dnh bng hn in.
o Bn c sn trnh g st.
o Np bn c gn vi thn bn bng hn in. Np c dng trnh bi bn
trong qu trnh sn xut.
o Bn c gi trn mt sn nh 4 tai treo bng thp.
o H thng ng ng trn 1 bn BK:
H thng nhp liu: gm 11 ng bao gm du gc (8 ng), ph gia (1 ng),
hi qu nhit (2 ng):
D (du gc) = 4 inches.
D (ph gia) = 4 inches.
D (hi qu nhit) = 4 inches.
H thng tho liu:
D (tho sn phm) = 4 inches.
D (nc ngng t) = 27 mm.
o Tt c h thng ng ng u c lm bng thp v c ghp ni vi nhau.
o Du gc trc khi vo bn pha ch c nh lng bng lu lng k c iu
chnh t ng.
o H thng ng dn c iu khin bng h thng van ng - m.
o Ngoi ra h thng hon lu ca bn cn c tc dng tng cng kh nng khuy
trn du trong bn.
* Cu to bn trong: H thng khuy
o Motor khuy:
Khi lng 44 kg.
in : 220V/380V 50 Hz.
Cng sut : 5 Hp.
S vng quay 1440 v/ph.
o Hp gim tc: t s truyn 1/18.
o Trc khuy : d = 60 mm.
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Trang 41

o Trc khuy xuyn qua np v c bt kn bi hp m. Trc ca motor ni vi
trc ca cnh khuy bng mt bch.
o Cnh khuy: mi cho dk = 70 mm.
C hai tng cnh.
Khong cch gia 2 tng cnh 1500 mm.
Tc cnh khuy: 80 v/ph.
o H thng gia nhit trong bn pha ch l h thng ng xon gm 1 ng i xung
quanh thn bn v 1 ng nm pha y bn c cung cp hi qu nhit t l
hi sang.
o Trc ng ng tho liu c gn b b lc li lc cn c hc c th c
trong sn phm.
2.4.1.3 Chc nng v ch lm vic
-
Bn pha ch l mt thit b pha ch cc sn phm du nht ca nh my. Vi cc

loi sn phm khc nhau thng pha ch trong cc bn khc nhau.
Nhit lm vic: 40 60 oC.
p sut lm vic: p sut kh tri.
Cc loi nhin liu s dng:

o Ngun in 3 pha cung cp cho h thng bm, motor khuy.
o i vi tng loi sn phm khc nhau, thi gian pha ch v nhit pha ch khc
nhau dn ti lng hi nc v lng in s dng khc nhau.
2.4.1.4 Nguyn tc vn hnh

-
Trc khi pha ch sn phm mi phi kim tra bn v v sinh sch s m bo

khng cn sn phm ca ln pha trc.
Khi x du gc vo bn phi m van hi lu v gia nhit cho h thng bng hi qu

nhit, bt cnh khuy hot ng.
Khi x du gc vo bn AP1 th phi tt bm hi lu, sau khi ht ph gia v du gc

v bn BK th tip tc bt bm hi lu.
Phi tnh ton kim tra ng m chnh xc cc van khi np ph gia v du gc.
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Trang 42

-
Trong qu trnh khuy trn phi lun theo di nhit bng nhit k trn thn bn
m bo nhit trong khong quy nh.
Thng xuyn theo di hot ng ca ch cnh khuy, cc van ng hi lu v h

thng bm m bo chng ang lm vic tt.
Sau khi sn phm t yu cu ng gi th ngng khuy trn. M van ng gi, m

bm a sn phm sang khu ng gi ng thi van hi lu m mt vng.
Kt thc ng gi, phi kim tra ton b h thng, kha cc van bm.
2.4.1.5 S c v cch khc phc

S c
R r hay ng ng dn b b
Trn du do r r vt hn than
bn
C ting ng l trong my bm,
cnh khuy hoc bm ngng hot
ng
Nhit vt qu mc cho php
Nh my du nht Vilube
Khc phc
Tt my bm v bo cho k s iu hnh sn
xut v k s bo tr gii quyt
Khi c nghi ng r r phi kim tra bng cch
ch x phng ln vt hn, nu c s c th
khc phc
Tt my v bo vi k s sn xut, k s bo
tr
Ngng cp nhit v bo vi cn b qun l
Trang 43

2.4.2 Bn gia cng ph gia
Hnh 8: Bn gia cng ph gia AP1.

2.4.2.1 V tr v s lng: Ch c 1 bn gia cng ph gia.
2.4.2.2 Cu to
o Thn bn.
o Np bn.
o y bn.
o B phn gia nhit.
o Motor cnh khuy.
Thn, np v y c gia cng bng hn in.
* Thn: Hnh tr
o Vl thuyt = 10 m3 , Vthc = 8 m3 .
o Cao 2.5 m.
o D = 2.56 m.
o V gm 3 lp: Lp ngoi cng l lp nhm bao bc, lp k tip l lp bo n
lp cch nhit c lm bng si thy tinh dy 8 mm nhm hn ch s trao i
nhit gia dung dch trong bn vi khng kh bn ngoi, lp trong cng l lp
thp CT3 dy 6 mm.
* Np bn: c ch to dng np bng c ca nhp liu.
* y bn:
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Trang 44

o Hnh chm cu.
o Dy 6 mm.
o chnh gia c:
L tho liu d = 90 mm.
Mt bch c d = 200 mm.
* B phn gia nhit: dn hi t gia nhit cho nguyn liu.
o Dng ng xon: i khp b mt y bn, sau i ziczac dc thn bn.
o D = 325 mm.
o Vt liu: thp CT3 dy 10 mm.
* Cnh khuy:
o C 2 tng cnh.
o S vng quay 80 v/ph.
o Dng mi cho.
o D = 1m.
o Vt liu : thp CT3.
o Cnh khuy hot ng lin tc cho ph gia tan hon ton trong 1 h.
* Motor:
o t trn np ca l s ch.
o S vng quay 1440 v/ph.
o Cng sut 7.5 Hp.
2.4.2.3 Nguyn tc vn hnh
o Phi kim tra thit b gia cng.
o Np ht lng ph gia cn thit.
o Bt cng tc khi ng h thng l.
o M van cho du gc bn pha ch qua trn ln vi ph gia, sau ht ngc li
bn.
o Thc hin khi ht ph gia trong bn ph gia.
Lu :
Trc khi gia cng cn kim tra li:
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Trang 45

o H thng in chuyn trng thi m.
o Bn gia cng phi tho ht ph gia c.
o Cc van y v van vn chuyn phi c kha.
2.4.2.4 S c v cch khc phc
Trong lc vn hnh c th gp nhng s c sau:
o B phn nh la b h.
o Nhit tng ln t ngt: Nguyn nhn do r le khng hot ng.
o Nhit k b h.
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Trang 46

3. Quy trnh ng gi v kim tra cui cng on
3.1 Quy trnh ng gi
3.1.1 S khi
Bt u
Chun b ng gi
Sc ra ng ng
o mu
Tin hnh ng gi
o mu cui
ng gi
Khng
Ch hng x l
ca QC
V sinh dy chuyn
Bn giao sn phm qua b

phn FI
Tr bn khuy cho b
phn pha ch
Kt thc
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Trang 47

- Chun b ng gi:
B1: T trng nhn phiu ng gi t gim st.
B2: T trng chuyn phiu ng gi n NV kho lm phiu xut kho.
B3: T trng chuyn phiu xut kho n kho nguyn vt liu.
B4: Cng nhn b phn kho bi vn chuyn bao b vt t t kho v t trng kim tra
m bo s lng nhn. Lu : S lng bao b cn ly vt s lng dng
ng gi 10% b tr trng hp li bao b.
- Sc ra/Cch ly ng ng:
B1: 2 cng nhn ly s thng phuy trng da vo ma trn sc ra ng ng. Thng
phuy dng cch ly l thng dng cha ph gia ca chnh m . Nu s lng
phuy yu cu ln hn, phi lm phiu nhn thm phuy vi b phn kho bi.
B2: Bm du mi sc ra ng ng. Du cch ly xong l ph thi, phi ng
ni quy nh ch x l.
B3: Nhn vin QC tin hnh ly mu cch ly u ng (3 ln: bt u, gia v cui
qu trnh cch ly). Nu yu cu sn phm hon thnh gp, c th b qua bc ny
b qua khu o mu. Tuy nhin, phi tng s phuy cch ly ln 2 phuy so vi ma trn
cch ly.
- o mu (C th b qua):
B1: Chuyn mu v phiu ng gi n QC.
B2: QC tin hnh o mu theo cc tiu chun ASTM.
B3: Nu mu t chuyn phiu ng gi cho t trng.
B4: Trong qu trnh ch phng QC o mu, 2 cng nhn s thay khun.
- Tin hnh ng gi:
B1: T trng ci t v chnh my da vo phiu ng gi.
B2: Tin hnh ng gi. T trng c nhim v theo di hot ng ca dy chuyn,
nu c trc trc th phi khc phc hoc nh b phn bo dng khc phc.
B2a: 2 cng nhn c nhim v b lon vo dy chuyn. Cng nhn b lon/can/phuy
vo dy chuyn c nhim v kim tra s b cc khuyt tt ca lon/can/phuy.
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Trang 48

B2b: Cho sn phm vo thng. 3 cng nhn cho sn phm vo thng, 2 cng nhn dn
keo thng v xp thng.
B3: Kim tra ngu nhin 10 pht/ln (khi lng, ngoi quan ca bao b). Kim tra
ngu nhin mt s sn phm.Nu pht hin li (thiu du, li bao b, dn tem, khng
c seal) phi bo t trng chnh li my.
B4: Thi gi, vt ng ng.
- o mu cui ng gi:
B1: Ly mu cui ng gi.
B2: Chuyn phiu ng gi v mu cui n QC o mu.
B3: nh gi ngoi quan xem c cn, c hay mu l khng.
- Kt thc m ng gi:
Ba1: V sinh ton b dy chuyn, my mc, khu vc xung quanh theo OPL (One
Point Lesson) v checksheet.
Ba2: Chuyn phiu bn giao bn khuy cho b phn pha ch.
Bb1: Dn nhn cho thng sn phm.
Bb2: Chuyn phiu kim tra cht lng cui cng on cho b phn FI.
- Vi chuyn x/phuy: do dy chuyn cha c my ng np cho x/phuy nn trong giai
on tin hnh ng gi, phi thm 1 bc ng np cho sn phm, do 1 cng nhn chu
trch nhim.
- S Gantt cho cng on ng gi:
Hnh 9: S Gantt cho cng on ng gi.

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Trang 49

3.1.2 Thit b
- Chuyn trn:
+ Cu to: Bng chuyn, b phn filling, b phn ng np, b ng seal, my kim tra seal,
my phun date, cn.
Hnh 10: Khu vc rt nht.
Hnh 11: Khu vc ng np.

+ Nguyn tc hot ng: o v rt nht theo th tch My truyn ng theo bnh rng nn
m bo c s hot ng lin tc ca dy chuyn, nng sut cao hn so vi chuyn thng.
- Chuyn Serac:
+ Cu to: Bng chuyn, b phn filling, b phn ng np, my dn nhn, my ng seal,
my kim tra seal, my phun date.
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Trang 50
Hnh 12: Khu vc rt v ng np.

+ Nguyn tc hot ng: o v rt nht theo khi lng, m bo c chnh xc. My
truyn ng theo bnh rng nn m bo c s hot ng lin tc ca dy chuyn, cho
nng sut cao hn so vi chuyn thng. y hin ang l chuyn ch lc ca nh my.
- Chuyn thng:
+ Cu to: Bng chuyn, b phn filling, b phn ng np, my ng seal, my kim tra
seal, my phun date.
+ Nguyn tc hot ng: o theo th tch. Do truyn thng nn mi ln rt nht, c bng
chuyn phi dng li gy nh hng ln n nng sut.Hn na, chuyn khng c b phn
phn phi np nn cng nhn phi t np ln chai th cng.
Hnh 13: Khu vc rt nht.

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Trang 51
Hnh 14: Khu vc vn np.

- Chuyn x
+ Cu to: Bng chuyn, b phn filling, b phn ng np.
+ Nguyn tc hot ng: o theo khi lng. My truyn ng thng. Do khng c b phn
xp np nn cng nhn phi y np th cng cho x v my s ng cht np.
Hnh 15: Chuyn x.

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Trang 52

- Chuyn phuy:
+ Cu to: Bng chuyn, b phn filling, b phn ng np.
+ Nguyn tc hot ng: o theo khi lng. My truyn ng thng. Do khng c b phn
xp np nn cng nhn phi y np th cng cho phuy v my s ng cht np.
Hnh 16: Chuyn phuy.

3.2 Quy trnh kim tra cui cng on
Bt u
Khng
Kim tra cui

cng on
Tr v b phn
ng gi
Qun mng
Nhp kho
Kt thc
- Bt u: Cng nhn b phn FI nhn hng dn nhn bi nhn vin QC.

- Kim tra cui cng on:
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Trang 53

B1: Kim tra ln cui tt c cc khuyt tt trn v chai v nhn chai: v mp mo,
nhn dn sai quy cch, dn mo, dn nhn.
B2: Kim tra s lng sn phm: mi thng c s lng theo quy nh, s thng,
s x, s phuy.
B3: Dn keo thng
B4: Ghi li thng tin v l hng v lu gi ti b phn sn xut.
- Qun mng: Cng nhn qun mng theo OPL qun mng.
- Nhp kho: T trng chuyn phiu nhp kho cho b phn kho bi ngh nhp kho
- S Gantt cho giai on FI:
Hnh 17: S Gantt giai on FI.

4. Hoch nh qun l sn xut
4.1 Cc cng c thng k dng trong sn xut ca nh my
Trong sn xut, cc nh qun l thng dng 7 cng c thng k qun l quy trnh
cng nh cht lng u ra ca sn phm.Ty theo yu cu v tnh cht ca cng vic m ta
c th s dng cc loi biu thch hp. 7 cng c bao gm:
o Phiu kim sot (Checksheet).
o Lu (Flowchart).
o Biu nhn qu (Cause and Effect Diagram).
o Biu Pareto (Pareto Chart).
o Biu mt phn b (Histogram).
o Biu phn tn (Scatter Diagram).
o Biu kim sot (Control Chart).
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Trang 54

Trong thc t sn xut nh my Vilube, tt c cc loi biu trn u c p dng.
4.1.1 Phiu kim sot
- Khi nim, mc ch: Dng lu tr d liu, c th l h s ca cc hot ng trong qu
kh, cng c th l phng tin theo di cho php thy c xu hng hoc hnh mu mt
cch khch quan. Trong thc t ca cng ty, phiu kim sot c s dng lm h s cho
cc hot ng cng nh mt phng tin kim tra nh gi mc hon thnh cng vic
ca c nhn.
- V d:
Hnh 18: Phiu ng gi.

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Trang 55

4.1.2 Lu
- Khi nim: l mt s biu din mt chui cc bc cn thit thc hin mt hnh
ng.
- Mc ch: chia nh tin trnh cng vic nhm cho mi ngi bit cng vic phi
thc hin ra sao, th no. Ngoi ra n cn gip tin trnh cng vic d theo di, khuyn
khch nhn vin lm vic nhm, t c s ng nht kin trong tp th.
- Cch xy dng:
B1: Mi c nhn xut cc hot ng ring l to nn qu trnh.
B2: Lit k tt c cc hot ng theo th t.
B3: V s .
B4: Tho lun vi cc thnh vin chc chn khng sai st bt k ch no.
B5: Kim tra bng s bng vic ly v d v t ra cc gi nh c th xem xt
xuyn sut s .
Lu thng i km vi s Gantt cho bit thi gian thc hin qu trnh.
4.1.3 Biu nhn qu
- Mc ch: l mt phng php tm ra nguyn nhn ca vn , t c th a ra phng
php khc phc hiu qu. Biu nhn qu c ngha trong vic o to nhn vin.
- Cch xy dng:
B1: Xc nh cc vn cn gii quyt v xem vn l h qu ca mt s
nguyn nhn phi xc nh.
B2: Lp danh sch tt c nhng nguyn nhn chnh ca vn bng cch t nhng
cu hi 5W (Who, What, When, Where, Why) v 2H (How, How Much).
B3: Tip tc tm ra nhng nguyn nhn c th hn (nguyn nhn th cp 1) c th
gy ra nguyn nhn chnh v biu din bng mi tn hng vo nguyn nhn chnh.
B4: Nu cn phn tch su hn th lp li bc trn vi cc nguyn nhn th cp th 2
gy ra nguyn nhn th cp 1.
Mi thnh vin ca b phn phi tham gia ng gp kin vo vic xy dng
biu nhn qu.Phi nhn s vic trn gc tng th, cc kin ca cc thnh vin u
phi c lng nghe v xem xt.
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- V d:
Hnh 19: Biu xng c.

4.1.4 Biu Pareto
- Khi nim: Biu Pareto (Pareto Analysis) l mt biu hnh ct c s dng phn
loi cc nguyn nhn/nhn t c nh hng n sn phm.
- Mc ch: Tch nhng nguyn nhn quan trng ra khi nhng nguyn nhn vn vt ca
vn bit hng gii quyt.
- Cch xy dng:
B1: Lit k cc hot ng trong bng v m s ln mi hot ng trong bng
B2: Sp xp theo mc quan trng gim dn
B3: Tnh tng s ln cho c bng
B4: Tnh phn trm ca mi hot ng so vi tng
B5: V s Pareto vi trc ng th hin phn trm, trc ngang th hin hot ng.
(ng cong tch ly th hin phn trm tch ly ca tt c cc hot ng).
B6: Phn tch kt qu, nhn bit nhng yu t no cn u tin.
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-V d:
Hnh 20: Biu Pareto.

4.1.5 Biu mt phn b
- Khi nim: L mt dng biu ct n gin. N tng hp cc im d liu th hin
tn sut ca s vic.
- Mc ch: S dung theo di s phn b cc thng s ca sn phm/qu trnh. T
nh gi c nng lc ca qu trnh .
- Cch xy dng:
B1: Dng checksheet thu thp d liu
B2: Tm cc gi tr ln nht v nh nht trong tp hp cc s liu, nh rng gia
gi tr nh nht v gi tr ln nht ca tp hp cc s liu.
B3: Dng trc tung th hin tn s pht sinh ca vn . Dng trc honh th
hin nhng gi tr
B4: Gii thch biu .
- V d:
Hnh 21: Biu mt phn b.
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4.1.6 Biu phn tn
- Khi nim: l s biu din d liu bng th trong cc gi tr quan st c ca mt
bin c vthnh tng im so vi cc gi tr ca bin kia m khng ni cc im li
vi nhau bng ng ni.
- Mc ch: Da vo vic phn tch biu c th thy c nhn t ny ph thuc nh th
no vo mt nhn t khc v mc ph thuc gia chng.
- Cch xy dng:
B1: Thu thp cc s liu ca 2 c tnh, thng t 30 n 50 mu. V d mu 1 c c
tnh (X, Y) l (X1, Y1), tng t vy cho mu 2... mu N.
B2: Chm cc gi tr ln th.
B3: Da vo th, phn tch cc mi quan h gia 2 c tnh X v Y. Tuy nhin, c
2 lu chng ta cn nh khi phn tch:
Nu c mi quan h gia 2 c tnh th cha chc c tnh ny l nguyn nhn ca
c tnh kia.
Mi quan h ch da trn mt gii hn ca c tnh.
- V d:
Hnh 22: Biu phn tn.

Nh my du nht Vilube
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4.1.7 Biu kim sot
- Khi nim: L mt biu vi cc ng gii hn c tnh ton bng phng php
thng k.
- Mc ch: theo di s bin ng ca cc thng s v c tnh cht lng ca sn phm,
theo di nhng thay i ca quy trnh kim sot tt c cc du hiu bt thng xy ra khi
c du hiu di ln hoc i xung ca biu .
- Cch xy dng: Cch xy dng biu kim sot rt phc tp nn bi bo co ny khng
cp n. Trong thc t, b phn sn xut ca nh my khng xy dng biu kim sot
m xy dng cc biu ct hoc ng khng c cc ng gii hn theo di xu th
ca mt ch tiu no , ri kt hp vi KPI qun l cht lng sn xut.
- V d:
Hnh 23: Mt s biu kim sot.

Nh my du nht Vilube
Trang 60

4.2 Qun l nng lc b phn sn xut
hot ng ca nh my c hiu qu, ngoi cht lng ca sn phm (c qun l
bi b phn cht lng), nng sut cng l mt yu t rt cn c quan tm.Ti b phn
sn xut, nng sut cng nh cht lng lm vic ca cng nhn c qun l. Mt cng c
quan trng quy nh v chun ha hot ng ca b phn sn xut l KPI (Key
Performance Indicator).
4.2.1 KPI
- Khi nim: KPI l ch s o lng hiu sut, c ngha gip doanh nghip nh hnh v
theo di qu trnh tng trng theo mc tiu ra. Khi xy dng KPI cn trnh p dng
my mc, v phi chn nhng ch s KPI no c th lng ha c, v gia nhng ch s
c th o lng c, cn phi la chn ra nhng ch s tht cn thit gip doanh nghip
t mc tiu ra.
- Phn loi: B phn sn xut ca nh my phn cc tiu chun KPI theo c nhn v ca c
tp th:
+ KPI c nhn: Cc tiu chun KPI c nhn quan tm n qun l hnh vi v nng lc sn
xut ca mi c nhn, th hin qua cc ch tiu v mc hon thnh cng vic c giao,
hiu sut lm vic v k lut ca c nhn da theo ni quy cng ty.
+ KPI chung cho b phn sn xut: b phn sn xut a ra cc ch tiu KPI nhm a ra
mt ci nhn ton din, bao qut v tnh hnh sn xut ca b phn sn xut nhm gip nh
qun l c th nm bt kp thi cc vn pht sinh, t c hng gii quyt v a ra
chin lc ngn hay di hn thch hp.
- Cch tnh cc ch tiu KPI ca b phn sn xut:
K hoch sn xut tun = s l SX trong tun/tng k hoch t hng c ln
lch trong tun .
Hao ht trn thng = tng th tch nguyn liu pha ch - (tng sn lng sn phm
hon tt + lng pha ch d dang)/tng th tch nguyn liu pha ch.
Nng sut u ngi = th tch sn phm SX c/s gi cng ca CN trc tip.
Trong :
th tch SPSX c = th tch thnh phm chuyn giao qua kho.
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Trang 61

S gi cng = (s gi lm vic * s ngy cng) + tng ca dng SX c k hoch.
Hiu sut thit b ton din (OEE) = ch s sn xut (%) * hiu sut hot ng(%) *
ch s cht lng(%).
Vi: Ch s sn xut = thi gian hot ng/thi gian sn xut theo k hoch.
Hiu sut hot ng = tng lng sn xut/thi gian hot ng/cng sut thit b.
Ch s cht lng = s sn phm t/ tng lng sn phm.
Bng 8: Bng theo di ch tiu KPI ca b phn sn xut nm 2012
Ch tiu
n v
Mc
tiu
Kh nng
Thng
1
10
11
12
99.7
100
99.4
96.7
98.3
99.2
98.0
100
100
100
100
97
0.7
0.9
1.0
1.0
1.0
0.9
1.0
1.2
0.95
0.98
0.98
1.03
1.0
0.9
0.8
0.9
0.8
1.0
1.1
0.97
0.55
0.57
0.54
0.57
TB
p ng
k hoch
>= 98
sn xut
99.0
thng
Hao ht
Motul
trn tng
<= 1
sn lng
0.97
thng
Hao ht
trn tng
sn lng
<= 1
0.80
thng
Nng
135.1 135.1 139.1 142.7 139.1 135.6
sut u
ngi sn lt/ngi/gi >=135
xut hng
138.5
135.1
135
142
146
135
142
thng
Nh my du nht Vilube
Trang 62

Sai li
quy trnh
Trng hp
hng
<=3
48.2
46.2
50.2
50.0
50.4
50.2
50.0
50.1
51.5
50.1
48.4
49.2
2.7
thng
Vi phm
ni quy
Trng hp
hng
<=3
0.3
thng
Hiu sut
thit b
>=50
49.5
ton din
Ch tiu k hoch KPI nm 2013 v chin lc thc hin chng ca nh my nh sau:
Chin lc (Must win battles):
1. Tng cng cc hot ng ci thin hiu qu hot ng ca nh my.
2. Gia tng nhn thc v HSE v qun l theo nh hng An ton 5S Trc quan.
3. Tip tc trin khai cc hot ng pht trin nng lc i ng.
4. Tip tc h thng qun l cht lng bao gm HSE v d n.
Bng 9: Cc ch tiu KPI b phn sn xut trong nm 2013
Cc ch tiu
n v
Mc tiu
S c cht lng trong qu trnh sn xut
V/thng
<3
p ng k hoch sn xut thng
95
Hao ht trn tng sn lng - Motul
0.95
Hao ht trn tng sn lng - Vilube
0.85
Nng sut bnh qun u ngi sn xut
litres/man-hour
145
Hiu sut thit b ton din OEE Filling
45
Hiu sut thit b ton din OEE Blending
45
Nh my du nht Vilube
Trang 63

4.2.2 ra k hoch v ti u ha nng lc sn xut
- ra k hoch:
Trn c s l KPI, kt hp vi vic thu thp v phn tch d liu t 7 cng c thng
k, ngi qun l sn xut c th tnh ra c nng lc sn xut ca b phn cng nh tng
c nhn. Kt qu tnh ton c th c s dng kt hp vi vic phn tch cc yu t bn
ngoi (nhiu): n hng, cc i tc, nh cung cp... t a ra k hoch sn xut c
th. Cc bc ra k hoch sn xut:
B1: Thu thp d liu, thng k di dng s Gantt v cc cng c thng k khc.
B2: Phn tch v tnh ton cc d liu thu thp c, t tnh ra nng lc sn xut
ca b phn.
B3: Kt hp vi ch tiu m b phn sn xut a xung v cc yu t nhiu khc:
nh cung cp bao b, nguyn vt liu, tnh hnh bin ng nhn cng... t c th
a ra k hoch thch hp.
Cc yu t nhiu lun lun c mt tr nht nh. tr c th gy nh hng
ln n tin v kh nng sn xut ca nh my. V d khi c s bin ng tng trong n
hng, dn n s tng nhu cu sn xut, dn n tng nhu cu v bao b, nguyn vt liu
cng nh nhn cng, nh my khng th c ngay lp tc nhng nguyn liu cn m phi i
cc cng ty bao b, nh cung cp nguyn vt liu kp lm ra v cung cp, cng nh cn
thi gian tuyn thm nhn cng v o to h. Ngoi vic tuyn thm nhn cng, tng ca
cng l mt gii php tng nng sut cho nh my, c p dng khi thiu my mc v
nhn cng.
Ngc li, khi nhu cu sn xut gim, cc gii php nh gim lng nhn cng bng
cch cho ngh vic hoc ngh php, m cc lp o to c xem xt.
- Ti u ha nng lc sn xut:
Ti u ha nng lc sn xut th hin qua vic gim thi gian sn xut, ci tin quy
trnh cng nh cht lng thc hin cng vic. Vic ti u ha nng lc sn xut khng ch
c ngha tng nng sut m n cn gip gim chi ph v nhn cng, chi ph cho cc tin
ch ph tr: in, nc... cng nh chi ph x l cc li pht sinh.
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Trang 64

Cc bc cn lm ti u ha nng lc sn xut:
B1: Thu thp d liu, x l v thng k bng cc cng c thng k.
B2: Phn tch d liu trn cc cng c thng k v tm ra nhng nguyn nhn dn n
gim cht lng thc hin cng vic.
B3: Trn c s nhng phn tch nguyn nhn v cc yu t nh hng, ngi xy
dng quy trnh v k hoch sn xut cn a ra nhng ci tin quy trnh c v cch
khc phc cc nguyn nhn tiu cc nh hng n qu trnh.
Nh my du nht Vilube
Trang 65
PHN V: QUN L CHT LNG

1. Gii thiu tng quan B phn Cht lng v Phng Ha nghim
1.1 B phn cht lng
- Nhim v: kim sot cht lng ca nguyn liu, sn phm nhm p ng kp thi cho sn
xut, kinh doanh v trn ht l nhu cu ca khch hng.
- C cu t chc nh sau:
BP Cht lng
GS. Cht lng
- Kim sot chung

hot ng Phng
cht lng
- Gii quyt khiu
ni ca khch hng
- iu phi cc
hot ng nhm
khc phc s c
- Kim sot ngn
sch
Phng Ha nghim
Kim tra BB u vo
KT CLQT Sn xut
KS P. Ha nghim
NV P. Cht lng
NV KT Cht lng
- Phn tch, kim tra

cht lng nguyn
liu gm du gc,
ph gia v cht
lng sn phm
- Th nghim pha
trn, to cc cng
thc mi
- Ban hnh phiu
kim tra ng gi
sn phm
-
- Kim tra cht

lng BB u vo
- Thc hin in nhn
mc cho BB
- Pht trin v th
nghim cc BB mi
- Gii quyt cc s
c pht sinh vi BB
- Kim tra, m bo
cht lng sn phm
ca quy trnh sn
xut: pha ch, cch
li, ng gi
- Kim tra cc quy
trnh xut nhp
hng, quy trnh sn
xut
- Gii quyt cc s
c pht sinh
Hnh 24: S t chc B phn Cht lng.

- Chin lc trong nm 2013:
Vi phng chm: chnh xc, kp thi, hiu qu, an ton, tp th nhn vin b
phn cht lng phn u thc hin tt nht cc mc tiu ra, c th:
+ Quyt tm xy dng thnh mt b phn cht lng c chuyn mn cao trong lnh vc th
nghim du nht.
Nh my du nht Vilube
Trang 66

+ m bo kt qu th nghim chnh xc, trung thc, nhanh chng nhm p ng kp thi
cho sn xut, kinh doanh cng nh mong i ca khch hng vi nhng sn phm c cht
lng cao.
+ Ci thin hot ng phng th nghim theo nh hng ISO/IEC 17025 : 2005.
+ Trong giai on 2013 - 2015 s u t b sung, hin i ha thit b chuyn dng, nhm
p ng cc yu cu ngy cng cao ca vic kim nghim.
+ o to v o to li ngun nhn lc c kh nng thc hin tt cc nhim v ni trn.
1.2 Phng Ha nghim
- Nhim v chnh:
+ B phn trc tip phn tch, kim tra cht lng nguyn liu gm du gc, ph gia v cht
lng sn phm, thng qua kim sot cht lng quy trnh sn xut.
+ Tin hnh th nghim pha trn, to cc cng thc mi theo yu cu t pha nh sn xut.
+ Ban hnh phiu kim tra ng gi sn phm, kim sot quy trnh ng gi.
+ Lu mu trong vng hai nm nhm gii quyt cc s c pht sinh t pha khch hng.
- C s vt cht:
Phng Ha nghim c trang b y my mc, thit b rt hin i c th cho kt qu
chnh xc, nhanh chng, kp thi v cht lng ca nguyn liu v sn phm du nht. Cc
thit b chnh trong phng Ha nghim bao gm:
+ 1 my kim tra hm lng kim loi (thit b o ICP): Perkin Elmer.
+ 2 my kim tra nht t ng Herzog.
+ 1 my kim tra nht nhit m - CCS Cannon.
+ 1 my kim tra t trng t ng - Anton Paar.
+ 1 my quang ph hng ngoi FTIR Shimadzu.
+ 1 my chun in th TBN - Metrohm & Schott.
+ 1 my xc nh hm lng nc bng chun in th - Metrohm.
+ 1 my o to bt Koehler.
+ 1 my o nht nhit cao HTHS.
Phng php phn tch da vo tiu chun quc t ASTM American Society for Testing
& Materials.
Nh my du nht Vilube
Trang 67

Tt c cc tiu chun ca nguyn liu v sn phm u c phn tch, nh gi theo cc
tiu chun quc t nh API, SAE
2. Quy trnh kim tra cht lng
2.1 Kim tra nguyn liu
2.1.1 Du gc
* Cc ch tiu cn kim tra ngay khi nhn du gc v:
-
T trng.
nht ng hc (KV @40 v KV @100).
Kim tra nc (crackel test).

Nu cc ch tiu ny t, QC bo li cho b phn kim sot nhp hng cho php nhp
du gc vo cc bn BOT.
Lu mu, tip tc kim tra cc ch tiu cn li trong COA.
* Cc ch tiu cn kim tra trc khi pha ch:
- Nu ch c mt loi du gc c s dng th khng cn kim tra.
- Nu l hn hp cc loi du gc th mu du gc hn hp sau khi pha trn s c em i
kim tra cht lng:
+ KV @100.
+ T trng.
+ Kim tra nc (crackel test).
Nu t th mi tip tc pha ch.
2.1.2 Ph gia
Mi nh sn xut s cung cp mt COA cho tng loi ph gia, v d:
Bng 10: COA ca mt loi ph gia
Characteristics
Specification
Minimum
Typical
Maximum
Result
0.850
0.870
0.885
0.869
Viscosity @100, cSt
950
1125
Oil Blend Vis @100, cSt
12.5
12.75
13.00
12.72
Specific Gravity, @15.6
Nh my du nht Vilube
Trang 68

Ph gia s c tin hnh kim tra t trng, nht v o FTIR (ph hng ngoi)
xc nh cc gc chc c ph hp vi ph chun cung cp hay khng.
2.2 Kim tra sn phm
2.2.1 Mu sau pha ch (Final blend)
Sau khi bn sn xut pha ch xong mu Final Blend, mu s c em qua phng
QC kim tra cht lng sn phm nhm kim tra qu trnh pha ch c t hiu qu hay
khng. Cc ch tiu cn c ca mt mu Final Blend m phng QC ti nh my c th tin
hnh kim tra c tng hp bng sau:
Bng 11: Cc ch tiu cn o v phng php s dng
Tiu chun
Ngoi quan (B&C, cn)
Phng php
Bng mt
Mu sc
ASTM D1500
Khi lng ring 15 oC (20 oC)
ASTM D4052
nht ng hc 100 oC (@100)
ASTM D445
nht ng hc 40 oC (@40)
ASTM D445
Ch s nht
ASTM D2270
nht ti nhit m (CCS)
ASTM D5293
im chp chy
ASTM D92
im ng
ASTM D97
Tng hm lng kim (TBN)
ASTM D2896
nht ti nhit cao (HTHS)
ASTM D5481
to bt
+ Cp I
ASTM D892
+ Cp II
+ Cp III
Thnh phn kim loi (ICP)
Kim tra nc
nh lng hm lng nc
Nh my du nht Vilube
ASTM D4951
Crackel test
Chun in th Karl Fischer
Trang 69

ngha tng ch tiu:
-
Ngoi quan: kim tra sng, trong (Bright & Clean) v kim tra cn bng mt
thng nhm s b nh gi hiu qu ca qu trnh khuy trn.
Mu sc: kim tra mu sc ca mu du va pha ch c ph hp vi ch tiu ca nh

sn xut hay khng.
Khi lng ring 15 oC (20 oC): l t l gia trng lng ring ca du v trng
lng ring ca nc, ti 15 oC (hoc 20 oC). T trng c ngha quan trng trong
nh gi s b sn phm v trong chit rt sn phm, giao dch, bun bn (theo khi
lng, th tch).
nht ng hc ti 40 oC v 100 oC (KV @40 v @100): l lc ma st trong ca

cc phn t ca cht lng, xc nh da vo thi gian chy ca mu du, ti iu kin
40 oC (nhit thng thng khi khi ng my) v 100 oC (iu kin lm vic ca
ng c). nht l thng s c trng nht ca cc sn phm du nht, cho thy
kh nng bi trn ca cc sn phm ny.
Ch s nht: l s bin thin ca nht ng hc theo nhit . Ch s nht

cng cao th du cng n nh, t bin i theo nhit .
nht ti nhit m (CCS Viscosity): l nht ng lc hc ca sn phm, c

trng cho kh nng lm vic nhit thp ca sn phm, c bit l cc sn phm
xut khu sang th trng ngoi c iu kin thi tit lnh
im chp chy: l nhit m ti hi to ra b t chy tc th khi c ngn la

xut hin trn b mt cht lng. Kim tra thng s ny nhm mc ch m bo vn
an ton chy n khi lm vic, trnh tht thot, ng thi c th nh gi mc
ln ca nhin liu vo du nht.
im ng: l nhit m ti du bt u xut hin hin tng ng c, ch tiu

ny cn thit khi cn kim tra mu du xut khu sang th trng c iu kin hot
ng nhit thp.
Tr s TBN: l kim trong du bi trn cho bit lng Acid Percloric (HClO4)
c quy i tng ng lng KOH (tnh bng mg) cn thit trung ha ht cc
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Trang 70

hp cht mang tnh kim c trong 1 gram mu du nhn nhm chng li s n mn
ha hc ca nhin liu diesel c hm lng lu hunh cao.
-
HTHS: xc nh nht ca mu du ti nhit cao. Php kim tra ny rt khc so

vi phng php xc nh nht ng hc (cSt) c xc nh thng qua thi gian
chy, php th ny xc nh nht ng lc hc (cP) ca mu du thng qua s cn
tr s quay ca ng c.
to bt: bt do khng kh trn mnh vo du nhn nh hng xu ti tnh cht

bi trn, lm tng s xy ha ca chng, lm du b tn tht, ngn cn s lu thng
ca du trong s tun hon, gy ra hin tng bi trn khng y . ng thi bt
cng c th gy ra hin tng va p thy lc, gy nh hng ln hot ng ca
ng c. Do cn phi gii hn to bt ca sn phm.
nh tnh nc: nhm s b kim tra nh tnh s c mt nc trong mu du thng

qua ting n lch tch khi un nng mu trn ngn la th.
Hm lng nc: lng nc trong du nht phi khng ch mc thp nht (< 100
ppm) v nc gy ra nhiu tc hi ln cho sn phm du nht, c xc nh bng
phng php chun in th.
Th tc kim tra cht lng mu Final Blend:

Trong vng 45 pht k t khi nhn mu, b phn QC phi lp tc tin hnh kim tra
mu v gi kt qu v cho bn sn xut tin hnh bc sn xut tip theo. Do c nhiu
tnh cht cn kim tra nh ni trn nn kim tra ht s mt kh nhiu thi gian. V
th QC s tin hnh kim tra trc nhng ch tiu no tht s quan trng v thi gian bo
kt qu nhanh. Cc ch tiu thng thng s l:
-
Ngoi quan: B & C v cn.
Mu sc.
KV @ 100 v @ 40 (nu c).
CCS.
T trng 20 oC.
Kim tra nc (Crackel test).
Nh my du nht Vilube
Trang 71

Mi mu Final Blend s km theo mt phiu pha ch v phiu cht lng (COA)
km theo. QC sau khi tin hnh kim tra cc thng s k trn s so snh vi cc thng s
trong COA ca nh cung cp. Nu ph hp th mu t, b phn sn xut sau s tin
hnh sc ra ng ng hoc cch ly ty theo tnh hnh sn xut. Nu khng ph hp trong
COA (hoc cc gi tr gn st vi cc gii hn) th s bo vi b phn sn xut c hng
iu chnh li cho m sn phm .
Kim tra full test sau s tin hnh cho cc ch tiu cn li, v d: VI, HTHS, to
bt, TBN
2.2.2 Mu Filling t quy trnh cch li
- Chc nng quy trnh cch li:
Cch li: l th tc tin hnh nhm lm sch ng ng, bng cch dng sn phm chun b
chit rt y ht sn phm c cn li trong ng ng chit rt ra. Cch li s c tin hnh
theo mt ma trn cch li. Ma trn cch li l mt bng gm nhiu hng v nhiu ct m da
vo ta xc nh s phuy cn tin hnh y sn phm c ra khi thit b chit rt bng
bng sn phm mi. Hng u tin ca ma trn th hin danh sch cho sn phm trc, ct
u tin s th hin danh sch cc sn phm chun b chit rt. Ty vo m sn xut trc
v hin ti, ta xc nh con s tng ng trn ma trn, t xc nh s phuy cn s dng.
V d minh ha:
Sp Trc
X1
X2
X3
X4
Y1
Y2
Y3
Y4
Sp Sau
- Kim tra cht lng:

Vi mu filling ch cn kim tra mt s ch tiu sau:
+ Ngoi quan (B&C).
Nh my du nht Vilube
Trang 72

+ KV @ 100 v @ 40 (nu c).
+ Mu sc.
+ Kim tra nc (crackel test).
Nu t tiu chun cho trc th qu trnh cch li tin hnh t yu cu. Sau b
phn sn xut s tin hnh khu cui cng l chit rt sn phm.
2.2.3 Kim tra mu cui khu ng gi
Cng tin hnh kim tra tng t nh mu Final Blend, tuy nhin ch yu vn l
kim tra ngoi quan (B & C) kim tra quy trnh ng gi c m bo hay khng, cc ch
tiu cn li hu nh khng thay i.
3. Cc thit b trong phng Ha nghim
3.1 My phn tch thnh phn nguyn t trong mu ICP
- Tn gi: Optima 7000 DV ICP - OES
Hnh 25: My o ICP.

- Chc nng: dng xc nh thnh phn cc nguyn t kim loi (c trong ph gia) trong
mu du da trn phng php quang ph pht x nguyn t.
- Tiu chun: ASTM D4951.
- Nh cung cp: cng ty Perkin Elmer M.
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Hnh 26: V d v phn tch thnh phn Mn trong mu du.

- Nguyn tc hot ng:
Thit b hot ng da trn vic o ph pht x nguyn t ca cc thnh phn kim
loi trong mu du. y l phng php ph da trn vic o bc sng, cng v cc
c trng khc ca bc x in t c pht ra t cc nguyn t hay ion trng thi hi khi
c s thay i trng thi nng lng ca cc nguyn t. Thit b quang ph ICP l h thng
gm 3 khi chc nng chnh l h thng chiu sng, h thng tn sc v h thng ghi ph.
+ H thng chiu sng: c nhim v to ra ngun kch thch quang ph vch, bao
gm ngun pht ra snh sng cng, mt hoc ba thu knh hi t lm nhim v chuyn
chm nh sng phn k thnh chm tia song song. Ngun kch thch ph c chc nng
chuyn mu kho st t trng thi rn hoc lng thnh trng thi hi v chuyn trng thi
hi sang trng thi kch thch. a s cc ngun kch thch u c th thc hin ng thi cc
chc nng trn v c th l mt trong cc ngun sau y: ngn la n kh, ngun h quang
in, tia la in, n plasma Vi thit b ny s dng n plasma, nhit c th ln n
5000 10 000 oC, phng php rt hin i ny c th kch thch hu nh tt c cc cht.
+ H thng tn sc: c nhim v thu nhn cc quang ph vch pht ra v to thnh
cc tia n sc ring l a vo bung nh. Cu to theo th t gm khe quang ph, thu
knh phn k hoc gng cu li, b phn tn sc, cc vt knh chun trc v bung nh.
+ H thng ghi ph: c nhim v thu nhn cc tn hiu n sc t h thng tn sc v
chuyn thnh tn hiu ph trn mn hnh, da trn nguyn l quang ph k (hin tng
quang in).
Nh my du nht Vilube
Trang 74

3.2 My o ph hng ngoi FTIR
- Tn gi: FTIR 8400S- Shimazu.
Hnh 27: My o FTIR.

- Chc nng: xc nh nhm chc ca ph gia da trn phng php xc nh quang ph
hng ngoi.
- Nh cung cp: cng ty Shimazdu Nht.
- Nguyn tc hot ng:
Thit b hot ng da trn phng php o ph hng ngoi ca cc nhm chc c
trong ph gia. Mi nhm chc s c mt tn s hp thu hng ngoi c trng. Da vo cc
tn hiu quang ph thu nhn c ta xc nh s c mt cc nhm chc c trng c trong
mu du.
My hot ng da trn nguyn tc nh sau: chm tia hng ngoi pht ra t ngun
c tch thnh hai phn, mt i qua mu v mt i qua mi trng o (dung mi), sau
c b giao thoa k (b to n sc) tch thnh tng bc x c tn s khc nhau v chuyn
n Detector. Detector s so snh cng hai chm tia v chuyn thnh tn hiu in c
cng t l vi phn bc x b hp thu bi mu. Dng in ny rt nh do phi nh
b khuch i tng ln nhiu ln trc khi a vo my tnh x l s liu ri in ra ph.
3.3 My o nht nhit cao HTHS
- Tn gi: TBS 2100 E.
Nh my du nht Vilube
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Hnh 28: My o HTHS.

- Chc nng: Xc nh nht ng lc hc (cP) ca mu du nhit cao (150 oC).
- Tiu chun: ASTM D 5481.
- Nh cung cp: TANNAS Co., USA.
- Nguyn tc hot ng:
Mu du cn xc nh s c cho vo gia roto v stato ca thit b ti nhit 150
C. Sau cho ng c hot ng, da vo moment cn m mu du gy ln roto, t
bin i cho ra nht tng ng. HTHS cng cao chng t mu du cng bn ti iu kin
th nghim, do kh nng bo v ng c cng ln. chy mt mu du bt k trc ht
cn chy vi dung dch chun, sau mi tin hnh trn mu. HTHS l thng s nh gi
cht lng mu du trong iu kin ng c ang hot ng, ng thi th hin tnh kinh t
v mt nhin liu v hiu qu s dng ca ng c.
3.4 Thermoelectric Cold Cracking Simulator CCS
- Tn gi: CCS 2050.
Hnh 29: My o CCS.

Nh my du nht Vilube
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- Chc nng: o nht nhit m.
- Nh cung cp: Hoa Co., Ltd.
- Nguyn tc hot ng:
Nhit m c xc nh bng cch ly gi tr u tin ca k hiu mu du cng
cho -35, gi tr thu c chnh l nhit m cn xc nh nht.
V d: Mu du c k hiu 5W30, CCS s o ti nhit : 5 + (-35 oC) = -30 oC.
Nguyn tc o CCS cng ging nh o HTHS, xc nh nht ng lc hc ca
mu du da vo s cn tr s quay ca rto ti mt nhit xc nh. Khc nhau ch
HTHS tin hnh nhit cao (150 oC) trong khi CCS cn phi lm lnh mu xung n
nhit m.
3.5 Density meter (Auto)
- Tn gi: DMA 4500 M
Hnh 30: My o t trng.

- Chc nng: o t trng (khi lng ring) ca mu du ti nhit xc nh.
- Nh cung cp: Anton Paar o.
- Nguyn tc hot ng:
Mt lng th tch nh ca mu (khong 0.7 ml) s c ht vo trong mt ng dao
ng, t xc nh chu k dao ng ca ng cha mu ti iu kin nhit ci t.
Thit b c sn d liu v chu k dao ng ca ng cha nc, cha khng kh, ng thi
c khi lng ring ca nc v khng kh ti nhit ci t. Sau , da vo chu k
dao ng ca mu va xc nh c, tin hnh tnh ton t ng theo cc cng thc c sn
cho ra kt qu cui cng l gi tr khi lng ring (g/cm3) ca du.
Nh my du nht Vilube
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3.6 Automated Multi-range Viscometer
- Tn gi: Herzog HVM 472.
Hnh 31: My o nht.

- Chc nng: xc nh nht ng hc ca mu du ti 2 gi tr nhit khc nhau l 40
o
C v 100 oC.

- Nh cung cp: PAC LP, USA.
- Nguyn tc hot ng:
Xc nh nht ng hc (cSt) thng qua o thi gian chy ca mu qua hai vch
xc nh. Cc qu trnh ly mu, o c, sc ra v sy u c tin hnh t ng, tng
thi gian tin hnh o cho mt mu l 45 pht, v vy y l thng s cn phi kim tra
trc tin c th kp thi gian bo kt qu li cho b phn sn xut.
3.7 Comparator
- Tn gi: Lovibond P.O. Comparator.
Hnh 32: My o mu.

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- Chc nng: Xc nh mu ca mu du theo phng php so mu.
- Nguyn tc hot ng:
Thit b ny c tn gi l sc k (hay thit b so mu). Nguyn tc hot ng l s so
snh mu ca mu cn o so vi mu ca hai mu chun. C ba mu s c chiu sng
cng lc trong mu cn o mu s c t gia hai mu cn li s chiu sng l
i xng. Sau bng mt thng ta quan st mu ca ba mu qua knh. iu chnh hai
nm xoay iu chnh mu ca hai mu chun cho n khi chng c mu trng hoc gn
trng vi mu trung tm. Trn nm xoay s c cc con s t 0.5 n 8 tng ng vi cc
cp mu m dn. Sau khi iu chnh, nu mu trung tm trng vi mt trong hai mu
chun th mu ca mu s tng ng vi gi tr trn nm xoay ca mu chun. Nu
khng c mu trng th chn pha mu chun c mu hi m hn, c gi tr trn nm
xoay tng ng v thm ch L (light) pha trc, ta c mu ca mu.
3.8 Chun TBN (Basic Constituents)
- Tn gi: Metrohm.
Hnh 33: My o TBN.

- Chc nng: phng php ny nhm xc nh tng hm lng kim c trong cc sn phm
du m ni chung v sn phm du nht ni ring bng phng php chun vi acid
pecloric trong acid acetic bng.
- Tiu chun: ASTM D2896 rt thng dng i vi du ng c Diesel.
- Nh cung cp: Metrohm, Switzerland.
- Nguyn tc hot ng:
Nh my du nht Vilube
Trang 79

Mu s c ha tan trong mt lng xc nh ca hn hp dung mi chlorobenzene
v acid acetic bng, sau c tin hnh chun in th vi dung dch chun l hn
hp gia acid pecloric v acid acetic bng. Php chun c tin hnh trn in cc thy
tinh v in cc calomel chun, c cho vo trong mu v c kt ni vi nhau bng mt
cu mui. Kt thc qu trnh chun ta thu c ng cong biu din s thay i in
th o c gia hai in cc theo th tch chun , da vo ng cong ny xc nh
c im cui ca qu trnh. T thc hin cc tnh ton cn thit quy i v tng
hm lng kim trong mu.
3.9 Xc nh hm lng nc bng chun in th Karl Fisher
- Tn gi: Titrino Metrohm.
Hnh 34: My o hm lng nc theo phng php Karl Fischer.

- Tiu chun: theo phng php chun in th Karl Fischer.
- Nh cung cp: Metrohm, Switzerland.
- Nguyn tc hot ng:
Da trn mt mu ca iot. nhit thng, iot kt hp vi nc v SO2 thnh
HI khng mu, theo phn ng:
I2 + SO2 + 2H2O 2HI + H2SO4
Phn ng trn l phn ng thun nghch, mun cho phn ng theo mt chiu, Fischer
cho thc hin phn ng trong mi trng c piridin.
Phng php ny c th pht hin c ti vt nc (lng nc rt nh) bng h
thng chun in th.
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Thuc th Fischer l hn hp vi th tch xc nh ca Methanol, Iot, Pyridine
c bo ha SO2. Cc thnh phn ca thuc th ny phi c kh nc trc khi tin
hnh pha ch.
Tin hnh chun : u tin pha long thuc th Fischer (thuc th Fischer :
methanol : n-butanol = 1 : 3 : 8 v/v/v) ri cho vo my o vi piridin v mu th, sau
trn ln vi nhau v xy ra phn ng, trong c cha cp in cc ghi nhn s thay i
th trong sut qu trnh chun . Ban u nh tng git thuc th Karl Fischer vo bnh
vi vn tc 1 git/giy. Khi kim ca microampe k bt u dao ng mnh, thm thuc
th vi vn tc 1 git /5 giy, v gn im tng ng vi vn tc 1 git/10 giy. Tin
hnh chun cho n khi kim ca microampe k t c vch chia nht nh ca thang
o, khc rt nhiu so vi im 0 v gi vch vch chia trong khong thi gian 30 giy,
khi vic thm 1 - 2 git thuc Karl Fisher s khng lm thay i v tr ca kim. V tr
ca kim ng h microampe k ch r im kt thc chun . T xc nh th tch thuc
th s dng v tin hnh tnh ton cn thit a ra kt qu hm lng nc trong mu.
3.10 Flash point - Fire Point Crackle Test
- Tn gi: Cleverland Open Cup Test System
Hnh 35: My o nhit chp chy.

- Chc nng: dng xc nh im chp chy cc h v xc nh xem c s xut hin ca
nc trong mu du nht hay khng.
- Nh cung cp: cng ty Captair Malaysia.
- Nguyn tc hot ng:
Nh my du nht Vilube
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+ Flash point v Fire point (im chp chy v im bc chy): gia nhit t t mt
lng mu xc nh trong cc h cho n lc xut hin chp chy khi cho ngn la nh c
kch thc tiu chun ngang qua ming cc. Nhit thp nht m ti hi trn b mt
cht lng bt chy c ghi nhn l nhit chp chy. xc nh im bc chy, th
nghim tip tc cho n khi ngn la th lm mu trong cc bc chy v ngn la duy tr
hn 5s.
+ Crackel test: tin hnh un nng mu di ngn la. Nu pht hin c ting n
lch tch th mu c ln nc. Php th nhm kim tra nh tnh s ln nc trong mu.
3.11 im ng
Hnh 36: My o im ng.

- Chc nng: xc nh im ng ca mu du.
- Nh cung cp: cng ty Normalab Php.
- Nguyn tc hot ng:
Mu c t trong thit b tiu chun v tt c c cho vo b lm lnh h nhit
xung t t. Sau mi ln gim xung 3 oC, kim tra mu bng cch: t mu nm ngang,
nu trong vng nm giy mu khng cn dch chuyn th im ng l gi tr nhit trn
hin th trn nhit k tr i 3 oC.
3.12 Kim tra to bt
- Tn gi: K43092 Dual-Twin Foaming Characteristics Apparatus.
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Hnh 37: My o to bt.

- Chc nng: kim tra to bt ca sn phm.
- Nh cung cp: cng ty Koehler M.
- Nguyn tc hot ng:
Thit b cho php kim tra to bt ca sn phm du nht ti 24 oC v 93.5 oC,
nhm nh gi kh nng to bt v bn bt i vi tng mu du. u tin mu s c
tin hnh nhit 24 oC bng cch thi khng kh vo trong mu vi tc khng i
trong nm pht, sau ghi nhn th tch bt to thnh. Tip theo yn mu trong vng
mi pht v ghi nhn th tch bt cn li (Seq I). Tin hnh qu trnh tng t ti nhit
93.5 oC v ghi nhn cc gi tr th tch bt (Seq II). Sau ph bt v h nhit t 93.5 oC
xung 24 oC v cng tin hnh 2 bc thi kh v yn nh cc ln trc, ghi nhn cc gi
tr th tch (Seq III). Mi sn phm khc nhau s c nhng tiu chun ring cho 3 Seq ny.
Nh my du nht Vilube
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4. Thc hin 5S i vi phng Ho nghim
4.1 Khi nim v 5S
5S l mt cng c qun l ang c p dng rt ph bin hin nay nhm p ng h
thng qun l cht lng ca mt t chc. Khi ngun t Nht Bn, 5S hin nay thc s
nh mt nn tng p dng h thng qun l cht lng, trong tp trung vo trit l
Con ngi l trung tm ca mi s pht trin.
5S l t vit tt ca vic tin hnh nm qu trnh: Sng lc (Serie), Sp xp (Seiton),
Sch s (Seiso), St sng (Seiketsu) v Sn sng (Shitsuke) theo ng trnh t. Tin hnh 5S
cn phi c s quyt tm v s ng lng thc hin ca tt c cc thnh phn trong mt t
chc. Chnh v th thi im ban u c th gp i cht kh khn v thi gian, cng sc
tuy nhin hiu qu mang li t 5S l rt ln.
4.2 Cch thc thc hin 5S
- S1 - Sng lc (Serie):
+ Phn loi nhng th cn thit v khng cn thit.
+ Loi b nhng th khng cn thit.
- S2 - Sp xp (Seiton):
+ Sp xp nhng th cn thit theo th t ngn np.
+ D dng s dng.
- S3 - Sch s (Seiso): gi gn v sinh sch s ton b Cng ty, dng c, trang thit b
- S4 - St sng (Seiketsu): duy tr 3S mi lc mi ni.
- S5 Sn sng (Shitsuke):
+ Thc hin nhiu ln to thnh thi quen.
+ o to mi ngi tun th 3S mt cch t gic t nguyn.
4.3 Phng Ha nghim thc hin 5S nh th no
- Vic tin hnh 5S ti Phng Ha nghim lun din ra mt cch thng xuyn v t gic.
Vi vic kim tra mu nguyn liu, sn phm mt cch lin tc, nu khng tin hnh thng
xuyn 5S s rt d dn n cc s c nhm mu, tht thot mu, ng thi gy mt khng
gian lm vic v tnh trng ln xn, tn thi gian khi lm vic. Chnh v th, phng lun tin
hnh 5S mi lc mi ni nhm to mt mi trng lm vic hiu qu nht.
Nh my du nht Vilube
Trang 84

- Mt s hnh nh v 5S trong phng Ha nghim:
Hnh 38: Mu ng ni quy nh (c dn nhn r rng v vch phn chia khu vc).
Hnh 39: Cc mu trc khi em lu vo kho c lu trc ti phng kim tra li

khi cn thit.
Nh my du nht Vilube
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Hnh 40: Mu sau pha ch c t ng v tr.
Hnh 41: Ni dng c bo h.
Hnh 42: Khu vc lu tr h s.

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Hnh 43: Khu vc my mc, thit b lun c v sinh sch s,

cc t ng dng c c nhn mc r rng.
Nh my du nht Vilube
Trang 87
PHN VI: TN TR V BO QUN

Cc loi du nht c sn xut p ng cc yu cu s dng khc nhau, do
chng c nhng tnh cht hon tan khc nhau. V vy, nu khng c bo qun mt cch
hp l v thch ng, chng c th b hng hoc nhim bn, gy lng ph v i hi phi x
l phc tp.
Nguyn nhn thng thng v s h hng, nhim bn nu trn l do: Thng cha b
h hi, s ngng ng hi m, thit b chit rt bn, tip xc trc tip vi mi trng bi
khi, ha cht hay hi nc, trn ln cc loi du nht khc nhau, tn tr trong mi trng
qu nng hay qu lnh, thi gian tn tr qua lu.
Sau y l mt vi kinh nghim v vn ny:
1. Thng cha
Chn kch thc bao b ph hp vi yu cu s dng.
S dng cc phng tin nng khi bc ti hng, c bit l cc bao b phuy 200 L.
Trong qu trnh ln phuy, phi kim tra b mt, trnh nhng vt rn lm thng v
thng.
Phn loi cc sn phm v a vo khu vc tn tr theo tng chng loi trnh
nhm ln.
Cc sn phm trong bao b 18 L hoc thng giy phi c bc d cn trng, gi tnh
trng bao b ngoi tt trc khi a vo kho.
2. Bo qun trong nh
Bo qun trong nh c mi che l thch hp nht cho cc loi du nht, c bit bt
buc i vi cc bao b bng nha.
i vi cc sn phm 18 L v 25 L, tt nht nn xp vo gi k. Nu khng c gi
k, khi cht chng ln nhau m bo khng qu nm lp.
i vi thng giy, phi c k pha di trnh thm nc, cht chng ti a
khng qu bn lp.
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Nhng sn phm s dng cha ht phi phi sit cc np y tht cht trnh hin
tng nhim bn khi tn tr.
Sp xp v tr thch hp m bo nguyn tc hng vo kho trc s s dng trc.
3. Bo qun ngoi tri
Ch c p dng cho cc loi bao b phuy 200 L bng st. Nu c th nn c nhng
mi che tm.
Cc phuy phi c cht nm ngang vi v tr cc np y phi ngp trong mc nht
m bo hi m khng hp thu vo bn trong c khi nhit mi trng thay i.
Trong trng hp phi t theo chiu ng, cn t phuy nghing c ming k di
y m bo cc nt song song vi cc khi gi nc cch xa np phuy.
Tt c cc trng hp u cn m bo np c sit tht cht.
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PHN VII: NHN XT V KIN NGH

1. u im ca nh my
- Pha Nam ca nh my gip sng ng in nn thun li cho vic nhp cng nh xut
sn phm vi chi ph thp.

- i ng cn b cng nhn vin nh my tr trung, nng ng, c tinh thn trch nhim
cao, lm vic nhit tnh, on kt.
- Nh my lun cao vic m bo an ton lao ng cho i ng cng nhn v k s, cung
cp y trang phc bo h. ng thi vic tin hnh p dng cng c 5S trong nh my,
phng Ha nghim c thc hin hiu qu, m bo mi trng lm vic thun li cho
mi thnh vin trong nh my.
- Phng Ha nghim c trang b y cc thit b hin i, m bo kt qu chnh xc,
kp thi v m bo tin sn xut.
2. Hn ch
Tuy nhin nh my cn mt s mt hn ch cn khc phc:
- Nh my ch c mt bn khuy trn ph gia AP1 trong khu sn xut, nn tng thm t nht
mt bn na m bo nh my vn hot ng lin tc v hiu qu khi cn tng nng sut.
- H thng x l nc thi ca nh my cn kh n gin, ch l x l s b v cha c
u t nhiu.
- b phn pha ch nn thit k dng c h tr vic x l cc phuy ph gia sau khi pha
ch, trnh vic nm phuy xung sn v kh nguy him.
- Khu vc sn xut keo nn u t che chn k cng hn, v sau mi t ma ln keo rt
thng xuyn b ln nc, buc phi kim tra nc cho keo v phi tin hnh tch nc, do
kh tn thi gian v cng sc. Do , cn thit nn u t xem xt vn ny.
- Phng Ha nghim trong thi gian gn y cha c trang b iu kin lm vic tt nht,
h thng my lnh ca phng gn nh khng hot ng. V th khng kh lm vic trong
phng kh ngt ngt v nng, c bit l phng pha ch mu. Do , nn nhanh chng sa
cha hoc thay mi h thng ny to iu kin cho nhn vin ha nghim c th lm vic
hiu qu nht.
Nh my du nht Vilube
Trang 90

- Hin nay, cc phuy thnh phm ca Vilube khng c mi che, rt d lm h hng bao b
v c th s nh hng n cht lng sn phm (sn phm b bin tnh do nhit ) Cn
xy dng thm h thng mi che m bo cho vn tn tr v bo qun sn phm v
nguyn liu.
Nh my du nht Vilube
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TI LIU THAM KHO

[1]. Ti liu Kha o to K thut Sn phm Vilube, Vilube, 2011.
[2]. Ti liu Chng trnh hun luyn tng qut dnh cho nhn vin mi lm vic ti nh
my Vilube.
[3]. Ti liu An ton Sc khe Mi trng (HSE) ti nh my Vilube.
[4]. Ti liu Hun luyn cn bn v du nht, Cng ty c phn p Si Gn Du kh, 2012.
[5]. Phm Ngc Tun, m bo cht lng, NXB i hc Quc gia Tp.HCM, 2005.
[6]. Ti liu Thc hnh 5S, Phng Cht lng Vilube, 2012.
[7]. Ngun tiu chun ASTM t Internet.
Nh my du nht Vilube
Trang 92

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Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Nhm sinh vin thc tp bao gm 3 sinh vin sau y:

ti 1: Hoch nh k hoch sn xut v kim sot quy trnh

ti 2: Qun l cht lng

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

DANH MC BNG BIU

Bo co Thc tp tt nghip DK09

PHN I: TNG QUAN V CNG TY VILUBE

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

13 000 000 L/nm

Cng sut bn cha du gc (BOT)

dnh cho vt liu v thnh phm

phc v giao nhn hang

Phng ha nghim kim nghim cht lng ca nguyn

kim nh cht lng

liu, du nht thnh phm v du nht qua s dng

Kch c sn phm, bao b

Nh my c th ng gi vo phuy, can, x v chai/bnh

4.2 Nng lc kinh doanh ca cng ty

Bo co Thc tp tt nghip DK09

Bo co Thc tp tt nghip DK09

Tng gim st cht lng

Qun l cht lng

Gim st cht lng

Qun l hnh chnh

Nhn vin hnh chnh

Cng nhn v sinh

Cng nhn pha ch

v kim tra mu cui

KT. Cht lng QTSX

Hnh 1: S b tr nhn s ca nh my.

Nhn vin HSE

Bo co Thc tp tt nghip DK09

ng k vt dng c nhn: my chp hnh, my tnh v hng ha ti phng bo v.

S dng phng tin c nhn ph hp khi i vo trong nh my v trong khu vc sn

Khng tc ng vo bt c my mc thit b no khi khng c php.

Tun theo quy nh an ton, bin bo an ton v hng dn ti mi khu vc

Cm ht thuc v n ung trong nh my, ngoi tr ng ni quy nh.

Khng c vo nhng khu vc khng cho php.

Khng chy xe qu tc an ton quy nh l 10 km/h. u xe phi ng ni nh

7.2 Ni dung an ton (HSE) i vi nh hp ng v nhn vin

Tnh hung khn cp, li thot him v im tp trung.

in thoi di ng v phng tin nghe nhn.

Bo co Thc tp tt nghip DK09

12 nguyn tc vng v an ton lao ng.

Hun luyn ATVSL.

7.2.1 An ninh trt t

Cm t chc bun bn di mi hnh thc.

Cm s dng ma ty, cht kch thch, thc ung c cn.

Khng n ung ti ni lm vic, khng ht thuc trong nh my.

7.2.2 An ton chy n

Cm ht thuc tt c khu vc trong nh my.

7.2.3 Tnh hung khn cp, li thot him v im tp trung

Hnh 2: S mt bng nh my v ca thot him.