code organisation teamm3b6c2m2.stackpathcdn.com/wp-content/uploads/2018/11/... · 2018-11-15 ·...

CODE ORGANISATION TEAM

A01 PETRONAS CHEMICALS LDPE SDN. BHD. LOGISTIC TAG TEAM

A02 NIPPON WIPER BLADE D'SOLUTION

A03 PROTON TANJUNG MALIM SDN. BHD. MOTIF

A04 PETRONAS CHEMICALS LDPE SDN. BHD. THE 'X' TEAM

A05 PETRONAS GAS BERHAD GESET

A07 HONG LEONG YAMAHA MOTOR SDN. BHD. DISTRIBUTION KING

A08 PETRONAS GAS BERHAD ARROW

A09 HONG LEONG YAMAHA MOTOR SDN. BHD. RAPTOR 2

A10 PETRONAS GAS BERHAD REVOLUSI

A11 MALAYSIAN REFINING COMPANY SDN. BHD. INNERSAVE

A12 PETRONAS GAS BERHAD AFFINITY

A13 MALAYSIAN REFINING COMPANY SDN. BHD. TREX8

A14 PERUSAHAAN OTOMOBIL NASIONAL SDN. BHD. (PROTON)

Q-TEAM

A15 PETRONAS CHEMICALS MTBE SDN. BHD. BE.LIVE

A16 MALAYSIAN REFINING COMPANY SDN. BHD. HSEF

A17 PERUSAHAAN OTOMOBIL NASIONAL SDN. BHD. (PROTON)

MY INSPIRA

A18 PETRONAS CHEMICALS MTBE SDN. BHD. CHIMAERA

A19 PETRONAS GAS BERHAD MOLECULES

A20 PETRONAS CHEMICALS MTBE SDN. BHD. THE ENGINEERS

A21 PETRONAS GAS BERHAD BILAH

A22 INSTITUT PENYELIDIKAN DAN KEMAJUAN PERTANIAN MALAYSIA (MARDI)

QTARA

A23 MALAYSIAN NPK FERTILIZER SDN. BHD. THE INVERTER TEAM

A24 CTRM AERO COMPOSITES SDN. BHD. THE MACHINIST

A25 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. CATALYZER

A26 CTRM AERO COMPOSITES SDN. BHD. THE CAPTIVATORS

A27 PETRONAS CHEMICALS GLYCOLS SDN. BHD. METEOR

A28 PETRONAS PENAPISAN (TERENGGANU) SDN. BHD. I'CARE

A29 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. ROTATUNED

ABORANG ABSTRAK

ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018

KATEGORI : √ ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : D'SOLUTION

ORGANISASIORGANISATION : NIPPON WIPER BLADE (M) SDN.BHD

TAJUK PROJEKPROJECT TITLE : MASA BEKERJA TINGGI BAGI PROSES OFFLINE WIP DI LINE NT30

PENJIMATAN PROJEK(RM /SETAHUN)PROJECT SAVINGS(RM /PER YEAR)*catatan: Penjimatan kos sebenar,masa & ruang yang terlibat)

: RM 97K

(Sila huraikan dalam Bahagian 2 – Borang D)

i. LATAR BELAKANG PROJEK : (MAKSIMUM 10 BARIS AYAT)PROJECT BACKGROUND: (MAXIMUM 10 LINE SENTENCES)

BERDASARKAN TEMA PROJEK YANG DIBERI OLEH KETUA JABATAN,PENILAIAN MELALUI KAEDAH MATRIK : MASALAH MASA BERKERJA YANG TINGGI BAGI PROSES OFFLINE WIP DI LINENT30 MENDAPAT MARKAH TERTINGGI.ANALISA REKOD DATA CYCLE TIME BAGI OFFLINE WIP MULAI SEPTEMBER HINGGA OKTOBER 2016 MENCATAT BACAANDIBAWAH GARIS PURATA.INI MENUNJUKKAN TERDAPAT PEMBAHAGIAN PROSES KERJA YANG TIDAK SERAGAM DAN MENYUMBANG KEPADAWAKTU KERJA YANG TINGGI KEPADA PROSES TERTENTU.

ii. PUNCA UTAMA MASALAH :MOST POSSIBLE CAUSE(s) :

1) MAN : AGIHAN WAKTU KERJA YANG TIDAK SELARAS ANTARA PROSES KERJA2) METHOD : ‘CYCLE TIME’ PROSES ONLINE TIDAK SERAGAM3) MATERIAL : WIP PART YANG TERKUMPUL MEWUJUDKAN PROSES OFFLINE WIP4) MILIEU : SUSUN ATUR MEJA KERJA YANG TIDAK SISTEMATIK

iii.

CADANGAN PENYELESAIAN INOVATIF & KREATIF :PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

1) MAN : MEMBUAT GABUNGAN PROSES KERJA2) METHOD : MENYELARASKAN ‘CYCLE TIME’ BAGI SETIAP PROSES3) MATERIAL : MEMINIMA DAN MENYELARASKAN MASA MENGIKUT PROSES ONLINE4) MILIEU : MEYUSUN ATUR MEJA KERJA DENGAN LEBIH EFEKTIF

iv.

TANDA ARAS :BENCHMARK :

”CYCLE TIME” PROSES ONLINE IAITU SEBANYAK 32sec.INI MEMBOLEHKAN PENGELUARAN PART LEBIH EFISYEN APABILA ”WAITING TIME” DIPROSES OFFLINE DAPAT DIHAPUSKAN.

ABORANG ABSTRAK

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI :PROJECT ACHIEVEMENT & VALUE CREATION :

1) PENGGUNAAN MANPOWER BERKURANG DARI 4 KEPADA 3 ORANG2) PROSES OFFLINE WIP DIMANSUHKAN3) PENJIMATAN KAWASAN KERJA SEBANYAK 9m²4) WAKTU KERJA LEBIH EFISYEN DENGAN ANGGARAN PENJIMATANMELEBIHI RM11,00 / SETAHUN

vi.

ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :AWARD, REWARD & RECOGNITION :

MENERIMA PENGHARGAAN DARIPADA PENGURUS TIE DAN PIHAK PENGURUSAN JABATAN BLADE NT30.

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA)PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

1) MAN

MEMBUAT PENGGABUNGAN PROSESKERJA

3)MATERIAL

MENGHAPUSKAN PROSES OFFLINEWIP

Muka 1/2

X

ABORANG ABSTRAK

4)MILIEU

MEMBUAT SUSUN ATUR MEJAKERJA YANGLEBIHEFEKTIF

Maklumat Penting:

1. Borang abstrak perlu dihantar selewat-lewatnya 15 Oktober 2018 (Isnin).

2. Sila kembalikan borang (dalam bentuk Microsoft Word) kepada Sekretariat APIC 2018 seperti dibawah melalui email atau faks (03-7955 1824) :

i. Mohd Khairul Nazir Nawi [email protected]. Nik Haneez Amizan Nik Rosdi [email protected]. Afiqah Liyana Abd Razak [email protected]. Norliza Rosli [email protected]

ABORANG ABSTRAK


KATEGORI : ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : MOTIF

ORGANISASIORGANISATION : PROTON TANJUNG MALIM SDN. BHD.

TAJUK PROJEKPROJECT TITLE : MENGURANGKAN MASALAH PART REJECT DI SEBABKAN TAIL GATE DENTED


:

RM38,100.00 SETAHUN



Masalah Part Reject di sebabkan Tail Gate Dented adalah kerosakan tertinggi yang dicatitkan oleh ahlikumpulan, ia berlaku semasa proses transfer dari stage ke stage. Part reject (rosak) tidak dapat di baik pulihlagi. Kos kerugian masalah sebanyak RM7,647.27 (75 kes) dalam tempoh 3 bulan Januari hingga Mac 2017.Pemilihan masalah ini adalah seiring dengan objektif, misi dan visi serta matlamat kumpulan, jabatan dansyarikat.


Analisis melalui faktor SQCDM (Safety, Quality, Cost, Delivery & Morale)

S Unsafe Act semasa pekerja memasuki kedalam kawasan hamming (pagar merah) dan kawasanrobot untuk membetulkan kedudukan part.

Q Defect Tail Gate dented menyebabkan DPU (defect per unit) tidak mencapai sasaran apabila TailGate Assy terlepas ke Fitting Line. Target 1.5 DPU, Actual 2.5 DPU

C Pembaziran pada kos pertukaran part yang reject (rosak) 75 unit dalam tempoh 3bulan purata25kes sebulan

D Kelewatan penghantaran kepada pihak pelanggan dalaman kerana proses pengeluaranterganggu dengan Tail Gate Dented (Fitting Line dan Jabatan Painting).

M Pekerja sering mengeluh kerana terpaksa membuat part untuk di assykan secara berlebihan daripermintaan asal kerana Tail Gate reject sering berlaku.

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF :PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

Terdapat 3 punca utama yang menyumbang kepada permasalahan Punca pergerakan part tidak stabil dan part berat semasa proses pergerakan dari stage ke stage.

Cadagan : Mencipta Guide untuk memudahkan pergerakan part supaya part lebih stabil semasaproses pergerakan part assy melalui conveyor dari stage ke stage dan secara tidak langsungmengatasi part berat.

Punca belting conveyor yang mana jarak belting jauh Antara satu sama lain menyebabkan parttidak bergerak secara konsisten.Cadagan : Membuat penambahan support roller diantara conveyor supaya pergerakan partbergerak secara konsisten.

Hasil dari 2 tindakan penyelesaian dari 3 punca masalah, hasil tindakan diberi nama M.G.R (Motif GuideRoller)

Muka 1/3

ABORANG ABSTRAK

iv.TANDA ARAS :BENCHMARK :

Tanda aras projek adalah KPI jabatan Body Assembly (Cost part reject) sebagai Benchmark sasaranprojek.

Konsep tindakan projek yang telah diguna oleh kumpulan adalah syarikat pembuatan minyak sawitdengan cara mereka mengelakkan buah sawit jatuh kebawah ketika conveyor bergerak, manakalauntuk part berat konsep beg beroda dimana ia mudah ditarik walaupun muatannya berat.denganroda itu beg yang berat menjadi ringan.


Pareto sebelum dan selepas menunjukkan penurunan kes Part Reject Tail Gate Dented sebanyak100% manakala penurunan kes reject sebanyak 55%.

Pengurangan ketara masalah ‘Part Reject Tail Gate Dented’ 100% di Body Shop. pengurangan iniberjaya setelah tindakan penambahbaikan dilakukan oleh ahli kumpulan Motif.

Hasil dari projek ini juga telah berjaya membuat penjimatan keseluruhan melebihi RM38,100 setahun Keunikan projek ini adalah menggunakan 100% bahan-bahan terpakai & sedia ada. Guide juga telah diguna pakai di Trim & Final Shop untuk mengelakkan seat jatuh kebawah dan

support roller juga digunakan bagi menggerakkan mesin C02 di Fiiting Line. Menerima maklum balas yang positif dari pekerja yang sangat berpuas hati dengan alat ciptaan yang

berjaya memudahkan kerja disamping dapat mengelakkan kemalangan.

vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :AWARD, REWARD & RECOGNITION :

Kumpulan Motif juga turut menerima surat pengiktirafan dari pihak pengurusan Body Assembly atas kejayaanprojek.Pihak pengurusan Body Assembly & Continuous Improvement Management PTMSB telah menjalankanaudit dengan melihat sendiri alat ciptaan kumpulan Motif dan berjaya merangkul gelaran PERAK.Pencapaian terbaik yang diperolehi kumpulan adalah Naib Johan Konvenyen Team Excellent PeringkatAkhir PTMSB 2017/18.Anugerah Emas Wilayah Tengah 2018 (MPC)


Muka 2/3

ABORANG ABSTRAK

GUIDE CONVEYOR

SUPPORT ROLLER

Muka 3/3

ABORANG ABSTRAK


KATEGORI : / ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : ARROW

ORGANISASIORGANISATION : PETRONAS GAS BERHAD (TANJUNG SULONG EXPORT TERMINAL)

TAJUK PROJEKPROJECT TITLE : LOW PRESSURE OF INSTRUMENT AIR HEADER


:

RM702,067 (NOV17 – DEC17) = 98.34%

EQUAL TO RM 4,212,402/YEAR



TSET have Instrument Air system which the main function is to produce and supply instrument airfor operating control valves and other uses throughout the plant, to keep plant automation in place.

Normal operating for instrument air header pressure is 6.5 barg – 8 barg, however, record of theoccurence of pressure header drop below from the pressure setting on early 2017 was around 205times.

The situation cause the operating hour of the air compressor higher than normal due to unnecessarycycle and increased run time which reduce service life and increase maintenance cost of supplyequipment.

in addition, there is one major incident where TSET experience total plant trip due to the aircompressor supply pressure low.

From the team survey conducted, 139 point found leak out of 169 tagged location of control valvesin 5 area in plant.

The high number of Instrument air leak points contribute high value of Price of Non Conformance(PONC) to the company as well as reduce the reliability and efficiency of Air Compressor System.

The troubleshooting had been conducted by Maintenance team in reducing the number of InstrumentAir leak points.

ABORANG ABSTRAK


Ineffectiveness of Instrument air leak identification and rectification Low grade paint used


Review PM frequency on instrument air related equipment Operation to perform comprehensive instrument air leak survey by using Instrument Air Leak Size

Guideline Review paint specification and update in documentation


Management target setting to reduce instrument air leak issues by 80%, which is from 139 leak pointsto 28 leak points.

Support one of the PETRONAS Quality Principles, which is Price of Non Conformance (PONC) aswell as Cost Saving Frenzy, an initiative by the PETRONAS President & Group CEO.


Successfully reduced number of Instrument Air Leak point from 139 points to 26 points Reducing number of Instrument Air Leak point resulting in high cost saving achieved – 94.33% PONC

saving The occurence of Instrument Air Pressure Header drop below the pressure setting is reduced

drastically. Steady Instrument Air Pressure Header maintain in the system. Increase process stability High plant reliability which reduce the interruption of product supply to the customers. Increase air compressor reliability Reducing on air compressor major overhaul activities. Contribute to PGB 3ZERO100Beyond Align with Petronas 5QP Reduce repair cost regarding accessories and parts replacement Extend air compressor life span Align with Department KPI to maximize efficiency of plant equipment Reduce black smoke emission due to unexpected flaring Protect environment from any explosion incident and comply with process safety requirement. Prevent process upset and interrupted process activity Prevent production slowdown from gas processing plant. Reduce possibility of tank top condition at gas processing plant Continuous product supply to customer without any complaints and demurrage


Gold Award in GPU Innovative & Creative Circle (GICC) 2018 The Most Outstanding Presentation in GICC 2018 Focused Recognition by TSET Management. Acknowledgement from TSET Operation Manager Acknowledgement from TSET Senior Process Executive Acknowledgement from UMW Industrial Power Sdn Bhd

Muka 1/2

ABORANG ABSTRAK


Operation team perform routine structuredround

SNOOPY has been used as a medium toidentify the presence of leak

Instrument Air leak found at fitting Instrument Air leak found at flanges

Maintenance team performedtroubleshooting to eliminate the leak.

ABORANG ABSTRAK

Maklumat Penting:




Muka 2/2

Discussion with Inspection team toreview back the PTS requirement for

painting specification.

Enforcement of new paint standard in plant

Implementation of new paint standardby vendor on piping at TSET

Piping condition after the implementation of new paintstandard

ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : Team Innersave

ORGANISASIORGANISATION : Malaysian Refining Company Sdn Bhd

TAJUK PROJEKPROJECT TITLE : Lengthy Execution Time for Partial Discharge Preventive Maintenance


:

RM / SETAHUN : RM 30,478.00

RM PER YEAR



Smart PD Sensor Stick is an innovative design with its main purpose to shorten the readiness time forPartial Discharge preventive maintenance at Electrical Transformer and cost saving to the company dueto termination of using scaffolding to access high area. With the utilization of this Smart PD Sensor Stick, inreturn would resulting in good HSE practice for reducing working at height


To perform Transformer Partial Discharge preventive maintanance it require assembling of scaffoldingsurrounding the area so technician could perform the preventive maintenance using special sensor atthe body of transformer. The job step to place the sensor on the body require minimal time but theprogress of scaffolding erection might take a lot of time. The factor including manpower, weather andtransportation for scaffolding material to be located at that area.


Using SWOT analysis, the team have design a holder for the PD sensor also known as Smart PD SensorStick. This tool can be used at any height or location of the transformer. The readiness of performing themaintenance activitiy is greatly reduced due to elimination of scaffolding usage to perform the job.


Time for preventive maintenance process from 6 Hours to 10 minutes per Transformer.


1. Value creation : Cost Savings of RM 30,478.00/year2. Quality : Timely and precise results (from 14 hours to 2 hours)3. HSE : Reduce fall and long term side effect for working at height4. Lean : Simplify work process and reduce working time

ABORANG ABSTRAK


- DCIC Gold Award

- RTEx 2018 Gold Award

ABORANG ABSTRAK


BEFORE:

ABORANG ABSTRAK

AFTER:

ABORANG ABSTRAK

Maklumat Penting:




ABORANG ABSTRAK


KATEGORI : X ICC QE/5S LEAN TRIZ LAIN-LAIN

NAMA KUMPULANTEAM NAME : T-REX8

ORGANISASIORGANISATION : MALAYSIAN REFINING COMPANY SDN BHD

TAJUK PROJEKPROJECT TITLE : INEFFICIENCY OF GRASS CUTTING MANAGMENT


:

RM 474,000.00



CES DEPARTMENT HAD BEEN FACING ISSUE ON GRASS CUTTING MANAGMENT. LIMITEDMANPOWER AND LARGE AREA TO BE COVERED ARE THE MAIN CONTRIBUTING FACTOR THATEFFECT THE MONTHLY PLANNING. THIS PROJECT CAN IMPROVE THE EFFICIENCY OF GRASSCUTTING MANAGMENT THROUGH INNOVATIVE SOLUTION PROPOSAL


ACTUAL GRASS CUTTING ACTIVITY IS NOT PERFORMED ACCORDING TO MONTHLY SCHEDULEPLAN


REFURBISH AND MODIFICATION EXISTING FARM TRACTOR TO ROTARY GRASS CUTTERTRACTOR


BASE ON CURRENT CYCLE OF 3 MONTH, MRCSB ESTABLISH OWN COMPANY STANDARD OFGRASS CUTTING COVERAGE AREA. THREE MONTH TO TWO MONTH.


- COST REDUCTION BY RM474,000.00 PERYEAR- GRASS CUTTING CYCLE REDUCTION BY 33% (2MONTH)- MANPOWER REDUCTION FROM 40 TO 31 PERSONS


ABORANG ABSTRAK

- FOCUSED RECOGNITION FROM MANAGMENT- APPRECIATION FROM CEO


Maklumat Penting:




Muka 1/2

A

BORANG ABSTRAK

ANNUAL PRODUCTIVITY & INNOVATION CONFERENCE AND EXPOSITION (APIC) 2018 KONVENSYEN TEAM EXCELLENCE PERINGKAT KEBANGSAAN (NTEx) 2018


NAMA KUMPULAN TEAM NAME

: BE LIVE

ORGANISASI ORGANISATION

: PC MTBE SDN BHD

TAJUK PROJEK

PROJECT TITLE : REACTOR FLANGES JOINT RELIABILITY IMPROVEMENT

PENJIMATAN PROJEK (RM /SETAHUN)

PROJECT SAVINGS (RM /PER YEAR) *catatan: Penjimatan kos sebenar, masa & ruang yang terlibat)

:

RM837,018.30 per year from reduction of Fire/LOPC Incidences at Reactor


i. LATAR BELAKANG PROJEK : (MAKSIMUM 10 BARIS AYAT) PROJECT BACKGROUND: (MAXIMUM 10 LINE SENTENCES)

Our project selection is based on one of the plant reliability threat in PCMTBE which is the Oleflex Reactor which leads to high reactive maintenance cost and loss of production. It is also one of the factors that had affected PC MTBE Health,Safety and Environment (HSE) Excellence Key Performance Indicator (KPI) Pillar. PCMTBE Reactor is one of Oleflex’s main high temperature equipment and designed to be operated at high temperature range. This equipment usually equipped with large diameter flanges. Due to the nature of process with large thermal expansion and thermal differences, these mating flanges can easily lost its minimum clamping force and leak if were not addressed properly. Oleflex’s operating process medium is auto-igniting when exposed to atmosphere environment and causing fire at the specific problematic joints for both MTBE and PDH plant. A special attention or focus and effort are required to mitigate and resolve these issues. In view of this, BeLive team was established to identify the root cause of this issue, proposed new and innovative solutions and assist in implementing the solutions to the plant. The overall objective to this project is to reduce numbers of Fire incidents caused by hydrocarbon leak at Reactor Flanges Joint which is alligned with our ”Zero Fire Zero Leak” operational target.

ii. PUNCA UTAMA MASALAH : MOST POSSIBLE CAUSE(s) :

Reactor Flange Bolt and Gasket creep

iii. CADANGAN PENYELESAIAN INOVATIF & KREATIF : PROPOSED INNOVATION & CREATIVE SOLUTION (s) :

The proposed solutions to address the hydrocarbon leak issue at Reactor Flanges Joint are:

To conduct analysis on Reactor Joints bolt and gasket behaviour

To establish new torque value for Reactor Joints tightening

To establish new torqueing method for Reactor Joints

To introduce new type of gasket material for Reactor Joints Flanges

A

BORANG ABSTRAK

iv. TANDA ARAS :

BENCHMARK :

New innovative solution that have yet to be applied by other industry

Reduction in number of unit shutdown/slowdown

Reduction in number of Plant Incident Report (PIR) on Reactor Flanges

Reduction in number of Fire and Loss of Primary Containment (LOPC)

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI : PROJECT ACHIEVEMENT & VALUE CREATION :

Project Achievement & Value Creation:

Reduce number of Fire/LOPC incidents for Reactor Flanges

Reduce number of PIR on Reactor Flange leak incidents

Improve Reactor performance

Improve staff capability on crtitical and non critical joint tightening

Improve and create standardization for current work practise on joint tightening for both MTBE and PDH plant in PC MTBE

Inculcate ”Above the Line” culture

Nurturing PETRONAS Cultural Belief

vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN : AWARD, REWARD & RECOGNITION :

GOLD MEDAL in Regional Team Excellence Convention 2018 (RTEx) Sabah & Sarawak

Received Focus Recognition from MD/CEO of PCG in completing MTBE TA2017 Turnaround flawlessly without any major leak

Received Focus Recognition from Maintenance Head of Department in demonstrating Focus Execution for the successful project.

vi. GAMBAR PROJEK: (MESTI JELAS DAN BERWARNA. 2 MUKA SURAT DIBENARKAN SAHAJA) PROJECT PICTURE(s) : (MUST BE CLEAR AND COLORED. 2 PAGES ONLY ALLOWED)

Muka 1/2

A

BORANG ABSTRAK

Maklumat Penting:


2. Sila kembalikan borang (dalam bentuk Microsoft Word) kepada Sekretariat APIC 2018 seperti di bawah melalui email atau faks (03-7955 1824) :

i. Mohd Khairul Nazir Nawi [email protected]

ii. Nik Haneez Amizan Nik Rosdi [email protected]

iii. Afiqah Liyana Abd Razak [email protected]

iv. Norliza Rosli [email protected]

mailto:[email protected]




A

Open

BORANG ABSTRAK



NAMA KUMPULANTEAM NAME : HSEF

ORGANISASIORGANISATION : MRCSB

TAJUK PROJEKPROJECT TITLE : Extended duration of time to reduce High Level of Toxic Gas in Confined Space


: RM 5,459,387.40



The project was performed in 2017, affecting process area of Malaysian Refining CompanySdn Bhd (MRCSB), due to extended duration of time to reduce high level of toxic gas inconfined space. The time taken to reduce toxic gas to the level that is allowable for humanto work in, known as permissible exposure limit (PEL), was on average of 32 days. Thisimpacting the cost of delay, cost of extra working hour and personal protective equipment(PPE) required and cost of the respective tank not operating. This project focusing onreducing the toxic gas to PEL while performing work inside storage tank. The activitiesincludes repairing, maintaining, inspecting and cleaning. This project was done usingPDCA tool, which is targeting to reduce the time taken for at least 3 days, which is enoughto save millions of ringgit.


Using Ishikawa method, the most possible causes was listed, which are no properventilation plan and desludging in the tank was performed using manual technique. Fromthere, further improvement was done to enhance the ventilation plan.


Solution proposed are to develop and prepare a ventilation form for confined space entry.This form will ensure that workers will analyze dimension of the storage tank by providingthe measurement of the tank. Based on that, numbers of ventilators and location to bepositioned at the entry of manhole will be properly managed to ensure the toxic gasremoval from the tank can be done at the very optimum level.Secondly, a new technique of removing the sludge from the tank was introduced. A semi-automated sludge extractor will require only one person to handle but can improve theproductivity of sludge removal to 200 drums per day compared to 100 drums per day with60 manpower.

A

Open

BORANG ABSTRAK


Benchmarking was done at three places, Petronas Chemical Olefin, Glycol andDerivatives (PCOGD), Petronas Penapisan Terengganu Sdn Bhd (PPTSB), TerengganuCrude Oil Terminal (TCOT) and KNM company. Based on the benchmarking, PPTSBtook 40 days to reduce toxic gas from confined space while PCOGD and KNM havedifferent type and dimension of tank which cannot be compared directly.


This project was successfully reducing the time for toxic gas removal from confinedspace, from average 32 days to average 27 days. This has saved the cost of managingthe tank maintenance. This project also managed to improve the productivity in managingthe waste (sludge from the tank), which avoiding the cost of non-compliance toDepartment of Environment. Also, cost on delay transfer of crude oil into the tank can beavoided, saving of RM500, 000. With tank maintenance complete on time, has improvedthe productivity of operation, profit of RM1 million per day. This project has also improvedthe capability of team members, other than the cooperation and collaboration among thesections within the department. The success of this project was also shared with theother operating unit in PETRONAS to improve the profitability.


Team has receive Focus Recognition for successfully improving the confined space entryin MRCSB. Company has also received an International Safety Awards recognition byBritish Safety Council.

Muka 1/2

A

Open

BORANG ABSTRAK


Maklumat Penting:




A

BORANG ABSTRAK




: CHIMAERA


: PETRONAS CHEMICALS MTBE SDN BHD

TAJUK PROJEK

PROJECT TITLE : GEN-H MOISTURE KILLER

PENJIMATAN PROJEK (RM /SETAHUN) PROJECT SAVINGS (RM /PER YEAR) *catatan: Penjimatan kos sebenar, masa & ruang yang terlibat)

:

RM 284,140.00



In most of Industrial Laboratory, Hydrogen is widely used as carrier gas for Gas Chromatography application. As a norm the gases are purchased in big cylinder which lead to multiple issues. An initiative was done to improve the gas cylinder management, The team had introduced a system for generating Hydrogen gas so called Gen-H Hydrogen Generator whereby the gas is produced within the laboratory itself. However along the way, during the operational of the Gen-H, few incidences took place where abnormality of test results occurred affecting lab results integrity and lead to increment of OPEX for the GC consumables. Team had generate a new innovative solution to kill the unwanted contaminants.


High OPEX Cost For Troubleshooting of Equipment which affected the integrity of results leading to difficulties in monitoring plant process and adjustment.


Fabrication of an innovative tool or consumable that can trap the contaminants especially moisture in Hydrogen gas that generated by the Hydrogen Generator (Gen-H) before entering the equipment.

iv. TANDA ARAS :

BENCHMARK :

To Reduce OPEX of consumable by 10%


Tangible Project Achievement & Value Creation Potential Cost Saving = RM 284,140 Intangible Project Achievement & Value Creation

1- Support PETRONAS CACTUS project

A

BORANG ABSTRAK

2- Reduce frequency of GC breakdown 3- Improve Reliability of Analysis Result 4- Improve Staff Competency In GC Maintenance 5- Creating New Experience To Achieve R2 6- Improve relationship with customer 7- Increase work satisfaction among lab staff 8- Nurturing PETRONAS Cultural Beliefs 9- Inculcate Above The Line for PETRONAS working culture 10- Improve Team Capability


• Gold Award in Downstream Continuous Improvement Convention 2015 (DCIC). • 2ndPlace in PC MTBE Technical Sharing Forum 2015 • 1stPlace in Analytical Technology Forum 2016 • Recognition during PCMTBE We CARE Camp 2016 • Silver Award in Downstream Continuous Improvement convention 2016 • Focused Recognition & Appreciation by PDH Operation Manager • Gold Award in Mini Convention Team Excellent 2017 • Focused Recognition & Appreciation by President of PETRONAS & CEO of PC MTBE • Gold Award in East Coast Regional Convention Team Excellent 2017 • Gold Award APIC Convention Team Excellent 2017 • Gold Award in ICC Central Region Team Excellence Convention 2018


Muka 1/2

A

BORANG ABSTRAK

Slave Slave Master

Ultrapure Water Reservoir

HYDROGEN GENERATOR

GEN-H MOISTURE

KILLER

GAS CHROMATOGRAPHY

ELECTRONIC PNEUMATIC

CONTROL

A

BORANG ABSTRAK

Maklumat Penting:







Muka 2/2





A

BORANG ABSTRAK




: THE ENGINEERS


: PETRONAS CHEMICALS MTBE SDN BHD

TAJUK PROJEK

PROJECT TITLE : FLANGE JOINTS MANAGEMENT

PENJIMATAN PROJEK (RM /SETAHUN) PROJECT SAVINGS (RM /PER YEAR) *catatan: Penjimatan kos sebenar, masa & ruang yang terlibat)

:

COST SAVING: RM 1,201,301.00

(RM 400,00.00 / year)

COST AVOIDANCE: RM 13, 688,320.00


In PETRONAS Chemicals MTBE Sdn Bhd, we have more than 10, 000 bolted joints. From 2013-2015 we have lost in terms of maintenance cost approximately RM1.2M averaging RM400k per financial year. A total of 48 Incident related to ”leak” were reported in Plant Incident Reporting (PIR) system and a total of 104 notifications on ”leak” was recorded in System Application Product (SAP) system. This was a major concern as bolted joints are primarily used as a method of connecting flanges and provide seal to avoid leak or lost of primary containment (LOPC) which could potentially lead to HSE catastrophy. Flange Joints Management (FJM) is a concerted effort from various disciplines to tackle this issue and eventually improve plant performance.


Incomprehensive flange joints management in PC MTBE Sdn Bhd. No coordinated efforts or collaboration between relevant parties.


Development of Flange Joints Managements (FJM) Establishment of structured work process

iv. TANDA ARAS :

BENCHMARK :

1. Reduction of Maintenance Cost related to ”leak” by 30%, 3 years after implementation. 2. Reduction of SAP Notifications related to ”leak” by 50%, 3 years after implementation. 3. Reduction of PIR Incident reported related to ”leak” by 50%, 3 years after implementation. 4. Benchmarking from Best Practices of Joint Integrity by NEIL FERGUSON, Joint Integrity Leaders: Americas, Hydratight, Inspectioneering Journal, March/April 2014 Volume 20, Issue 2. 5. Benchmarking from Flange Integrity Management paper by Halliburton.


HSE Reduced ”Leak” incidents reported in PIR by 70.1% (reduction of 34 incidents reported) COST Reduced reactive Maintenance cost for ”leak” by 94% (reduction of RM 1.2M)

A

BORANG ABSTRAK

PRODUCTIVITY Achieved TA KPI – Zero Leak, Zero Rework and safe start-up for TA PDH 2016, MTBE 2017 and TA completion ahead of schedule. QUALITY Improved work-process and integration between relevant parties (Maintenance, QAQC, Operation & Inspection)


1. Focused Recognition by PCG Managing Director, Dato’ Sazali Hamzah on flawless TA Execution for PC MTBE.

2. Focused Recognition by CEO PC MTBE for successfully execute Flange Joint Management program.

3. Focused Recognition by PC MTBE Operation Management Manager, M Azman Omar on reducing the number of ”leak” incidents reported in PIR System.

4. Focused Recognition by TA Manager, M Mustapa Kalil to QAQC Team for flawless execution. 5. Focused Recognition by QAQC Manager, Noraini Othman to QAQC Team for focused execution

and meeting TA KPI. 6. Received Gold Award during Konvesyen Wilayah Team Excellence (RTEx) Peringkat Wilayah

Tengah 2018.


Muka 1/2

A

BORANG ABSTRAK

A

BORANG ABSTRAK

Maklumat Penting:











ABORANG ABSTRAK C



NAMA KUMPULANTEAM NAME : QTARA

ORGANISASIORGANISATION : MARDI

TAJUK PROJEKPROJECT TITLE : Kadar Serangan Tikus Yang Tinggi Di Sawah Padi


:

5 Juta / semusim penanaman padi

10 juta / setahun (2 kali penanaman setahun)(Sila huraikan dalam Bahagian 2 – Borang D)


Tikus merupakan salah satu makhluk perosak yang boleh menyebabkan kerugian yang besar kepadapetani seandainya kawalan tidak dilakukanSerangan boleh berlaku di pada semua jenis tanaman termasukpadi, koko, kelapa sawit, jagung, ubi dan tebu. Peratus serangan tikus boleh mencapai sebanyak 50-80%di kawasan padi seandainya tidak dikawal. Serangan tikus di sawah boleh bermula pada peringkat awalpertumbuhan (semaian) sehingga peringkat padi masak. Semasa tanaman padi berada pada peringkatberanak, tikus akan memotong anak-anak padi dan makan sebahagian daripadanya. Kaedah palingmudah yang sering digunakan oleh petani adalah menggunakan racun tikus. Penggunaan racun secaratidak terkawal boleh membahayakan alam sekitar serta membunuh pemangsa semulajadi. Pendekatanmenggunakan perangkap boleh membantu menjaga alam sekitar serta menjamin kesihatan yang baikkepada petani. Usaha perlu dilakukan bagi mengatasi masalah ini agar petani mendapat satu kaedah yangberkesan selain mengurangkan kebergantungan kepada racun kimia


Perangkap yang berada di pasaran hanya mampu menangkap seekor tikus dalam satu masa. Penggunaanumpan baru perlu diberikan bagi memastikan keberkesanan perangkap konvensional. Kospenyelenggaraan bagi pemasangan umpan meningkat bagi mendapat hasil tangkapan yang tinggi.


Perangkap tikus yang mudah dan berkesan yang dinamakan RodentCARE telah direka bagi meningkatkankeberkesanan kawalan tikus sawah. Hasil kajian mendapati perangkap ini mampu mengurangkan populasitikus di sawah padi. Ianya sebuah perangkap yang mudah dibawa serta boleh dilipat serta tahan karat.Penyelenggaraan untuk meletak umpan dapat dikurangkan kerana ianya tidak sempat dimakan oleh tikusdan terlindung daripada cahaya matahari


Kaedah lama menggunakan perangkap tikus (single) sebagai alat menangkap tikus dengan hasiltangkapan seekor pada satu masa. Manakala dengan penghasilan alat perangkat RodentCARE mampuuntuk menangkap tikus dengan bilangan melebihi satu ekor.

ABORANG ABSTRAK C


Kelebihan teknologi yang dijana• Peningkatan bilangan tangkapan tikus sebanyak 3-5 ekor bagi satu perangkap• Mudah alih, ringan serta mesra pengguna• Boleh dilipat bagi menjimatkan ruang penyimpanan• Mempunyai ciri keselamatan kepada pengendali• Penjimatan penggunaan umpan - Pengunaan umpan yang lebih lama disebabkan tidak dimakan olehtikus• Tahan karat

PERKARA KONVENSIONAL RodentCARE PENCAPAIAN PERATUSPENCAPAIAN (%)

Penjimatan Masa 24 jam / ekor 4.8 jam / ekor Pengurangan 19.2jam /ekor 80 %

Hasiltangkapan/ ha(hari) 24 ekor / ha 120 ekor / ha Peningkatan

96 ekor / ha1:5

Hasiltangkapan /ha(bulan) 96 ekor 480 ekor Peningkatan

384 ekor / bulan

BilanganPekerja(ha) 6 pekerja /ha 3 pekerja /ha Pengurangan

3 pekerja /ha 50 %

Kos UpahSebulan(RM) RM 1,080.00 RM 540.00 Penjimatan

RM 540 50 %

Kos bagikeluasan9,655.8 ha (10%) 10 juta/semusim 5 juta/semusim Penjimatan

5 juta /semusim 50 %

RodenCARE juga boleh digunapakai di kawasan bangunan, pasar basah, pasar malam serta kawasanternakan bagi mengatasi masalah tikus.


1. Johan Pertandingan Konvensyen Kumpulan Inovatif & Kreatif, Hari Inovasi MARDI 2017 pada 18-19September 2017 MAEPS

2. Emas : Konvensyen Team Excellence Peringkat Wilayah Utara (RTEx) 20183. Perlindungan Harta Intelek : Utility Innovation 2018

Muka 1/2

ABORANG ABSTRAK C


ABORANG ABSTRAK C

Maklumat Penting:




Muka 2/2

ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : THE INVERTER TEAM

ORGANISASIORGANISATION : MALAYSIAN NPK FERTILIZER SDN BHD

TAJUK PROJEKPROJECT TITLE : MENGURANGKAN ”REWORK MATERIAL” DISEBABKAN MASALAH

”CONVEYOR MISALIGNMENT”


:

: RM405,526.00/ 6 BULAN

RM715,976.00 /SETAHUN



Projek ini telah dijalankan oleh gabungan dua jabatan iaitu Engineering dan Production di dalam usahamengurangkan kos “Rework Material” (bahan mentah atau produk yang terpaksa diulang guna). Analisadilakukan dan didapati “Rework Material” berlaku disebabkan tumpahan dari conveyor yang tidak sejajar(misalignment). Conveyor misalignment juga mengakibatkan “plant downtime” dan meningkatkan kos operasikilang.


Conveyor misalignment


Inverter Roller Conveyor dicipta untuk memastikan conveyor berada diposisi yang betul.


Mengambil contoh@tanda aras daripada roda sokongan basikal kanak-kanak yang berfungsi sebagaipelaras.


Pencapaian Projek:1. Mengurangkan kos “Rework Material”2. Mengurangkan kos penyelenggaraan

Penciptaan Nilai:1. Penambahbaikan operasi kilang2. Meningkatkan ilmu pengetahuan pekerja3. Mewujudkan daya innovatif dan kreatif pada pekerja4. Pengurangan risiko pencemaran alam sekitar

Muka 1/2

ABORANG ABSTRAK


1. Tempat pertama - Konvensyen ICC Malaysian NPK Fertilizer Sdn Bhd 20182. Anugerah Emas - Konvensyen Team Excellence Peringkat Wilayah (Rtex) 2018


Pemasangan Inverter roller

Conveyor misalignment (tidak sejajar))denganTail pully

TAIL PULLEY HEAD PULLEY

BELT ADJUSTER

KAWASANPEMASANGANINVERTERROLLER

ABORANG ABSTRAK

Maklumat Penting:




Muka 2/2

ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : The Catalyzer

ORGANISASIORGANISATION : PCOGD

TAJUK PROJEKPROJECT TITLE : Refining Column High Head Pressure


: RM 1 956 347.00 /trip


Refining Column is the main distillation column in Refining Section which use steam through Calandria as aheating medium for distillation process. We need to meet recommended operating pressure to ensure goodseparation. Our main product, N-Butanol with Japan Spec grade is derived from the process of RefiningColumn and Isomer Column. In the event of upsets it is imperative that these column maintains theiroperation to prevent from product off- spec.This projects highlight the improvements on providingimmediate additional venting for the system (opening bypass valve) to flare by using AOV instead ofmanual valve operated by field operator. The AOV is quicker and remotely operated from DCS.


When high head pressure over 150mbarg occurred it will disturb the operation of Refining Column and thedistillation process itself and lead to column trip. When this happen operator need to manually open thebypass valve which located at level 5 of process structure and delaying to do so will results to headpressure increasing higher and column on high base level because of changing the boiling point (the highhead pressure prevents the vaporization thus the level increase) and panel man need to cut off steam tothe calandria for equipment protection and result to column shutdown and loss of production.

The worst case is tray collapse and damage. This will require unit total shut down for a long period of timefor cleanup and maintenance.


Installation of AOV at bypass valve which can be remotely activated from Control Room..


Dow Chemicals Plant Refining Column operating pressure.


1. Able to operate Refining Column head pressure within range and no column trip incident due to highhead pressure since AOV installation.

2. Prevent from revenue lost at RM 1 956 347.00 (Butanol + stakeholder) for 12 hours due to Refiningcolumn trip.

ABORANG ABSTRAK


SPEAK Academy Pertonas Chemicals Olefin Glycol Derivative Champions 2017.

Konvensyen Team Excellence (ICC) Wilayah Pantai Timur Gold Medalist (2017)

Konvensyen Team Excellence (RTEx) Wilayah Selatan Gold Medalist (2018)


Muka 1/2

ABORANG ABSTRAK

Maklumat Penting:




Muka 2/2

ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : METEOR

ORGANISASIORGANISATION : PETRONAS CHEMICALS GLYCOLS SDN BHD

TAJUK PROJEKPROJECT TITLE : UNRELIABLE CHLORIDE INJECTION SYSTEM


:

RM 27,344,582.60(Sila huraikan dalam Bahagian 2 – Borang D)


PC Glycols Sdn Bhd faced a challenge, whereby chloride injection system is unreliable, where chloride

pump is not able to inject chloride at desired rate.

This is calculated through Z factor deviation, to identify the reliability of the chloride system.

If chloride is not injected at desired rate, the production’s ability to produce products are lowered, and

eventually cause the plant to shut down.

When the system is unreliable, maintenance need to attend the issue, hence high maintenance cost.

There is also environment issue, where the system sometimes leak, and causing exposure of

carcinogen chemical to environment and human.


1. Black particle carryover from tank

2. Chemical attack


1. Establish new chloride system without tank

2. Change piping to other material


0.3 Z Factor Deviation


1. No plant shutdown, PC Glycol achieved highest production, and RM 27 million saved compared toprevious year.

2. Maintenance cost reduced to RM 31,286 compared to RM 99,905 previous year3. Electricity cost saving RM 192,9604. Zero safety incident, and no chemical leak to environment5. Increased plant reliability to 99.5%6. Customers, achieved highest production as well due to continuous supply of product from PC Glycols


ABORANG ABSTRAK

1. CICM Responsible Care Award2. Recognition from CEO, En Zamri Japar3. Gold Medal in RTEx Regional


Muka 1/2

ABORANG ABSTRAK

Maklumat Penting:




Muka 2/2

ABORANG ABSTRAK



NAMA KUMPULANTEAM NAME : ROTATUNED

ORGANISASIORGANISATION : PETRONAS CHEMICALS DERIVATIVES SDN BHD

TAJUK PROJEKPROJECT TITLE : HIGH VIBRATION ON G-3871 ETHYLENE TRANSFER PUMP


:RM 202,837.89



G-3871 Ethylene Product pumps was experiencing high vibration problem since Dec 2015. The pump ranwith high vibration approximately 20.78 mm/s peak versus ISO 5199 where allowable limit is 7.1 mm/s rmsor 10.04 mm/s peak. Due to this high vibration problem, pumps had to be pulled out for maintenance activityand had resulted to plant slowdown. This high vibration problem can also lead to mechanical seal failure thatcould result to vapor cloud incident.


The main cause is resonance problem. Resonance occurs when a forcing frequency coincides with asystem natural frequency. In this case, pump operating speed is 2975 RPM (49.58 Hz) which very closes topump natural frequency of 49 Hz. Thus, it is higly indicated that resonance phenomenon taking placeduring pump operation.


To install tuned absorber, a device designed to have same resonate frequency which, through its vibratoryforce, will counteract the initial exciting force.


ISO 5199 Technical Specification for Centrifugal Pump.Maximum values of r.m.s vibration velocity mm/s is 7.1 mm/s rms equivalent to 10.04 mm/s peak.


1. Successfully reduce the vibration value to below 10 mm/s peak.2. RM 202,837.89 cost saving of overhaul work including spare part and manpower cost.3. RM 2653501.09 cost avoidance.4. Increased plant reliability and availibilty to 99%


1. Gold Award in the Konvensyen Mini Team Excellence 2017 Wilayah Pantai Timur.2. Bronze Award in the ICC presentation for DCIC (Downstream Continuous Improvement Convention

2017).3. Gold Award in the Regional Team Excellence Convention 2018 Wilayah Selatan.

ABORANG ABSTRAK


Muka 1/2

ABORANG ABSTRAK

ABORANG ABSTRAK

Maklumat Penting:




Muka 2/2

code organisation teamm3b6c2m2.stackpathcdn.com/wp-content/uploads/2018/11/... · 2018-11-15 ·...

Documents