CODE ORGANISATION TEAMm3b6c2m2.stackpathcdn.com/wp-content/uploads/2018/11/... · 2018-11-15 ·...

CODE ORGANISATION TEAM

B01 NIPPON WIPER BLADE P1

B02 PERUSAHAAN OTOMOBIL NASIONAL SDN. BHD. (PROTON) DQ

B03 PETRONAS CHEMICALS LDPE SDN. BHD. DSS PRO

B04 PERUSAHAAN OTOMOBIL NASIONAL SDN. BHD. (PROTON) MY LULUS

B05 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. THE RHODIUM

B06 INSTRUMENT TECHNOLOGY JOHOR SDN. BHD. GOLDEN PHOENIX

B07 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. ANARAIZA

B08 PROTON TANJUNG MALIM SDN. BHD. SOLUTIONS

B09 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. eyeNsee

B10 HICOM TECK SEE MANUFACTURING (M) SDN. BHD. TEAM ABC

B11 PROTON TANJUNG MALIM SDN. BHD. BERSATU

B12 PETRONAS CHEMICALS DERIVATIVES SDN. BHD. LABYRINTH

B13 VALE MALAYSIA MINERALS THE BLEX

B14 PROTON TANJUNG MALIM SDN. BHD. QME

B15 PETRONAS DAGANGAN BERHAD CLASH OF LPG

B16 VALE MALAYSIA MINERALS THE BATTERY

B17 PETRONAS DAGANGAN BERHAD BORD

B18 PETRONAS GAS BERHAD EFFECT

CODE TEAM CODE

B19 PETRONAS DAGANGAN BERHAD ERAT SEPAKAT

B20 HICOM TECK SEE MANUFACTURING (M) SDN. BHD. GB5

B21 PETRONAS DAGANGAN BERHAD BLUE FLAME

B22 INOKOM CORPORATION SDN. BHD. RYUGA

B23 ROBERT BOSCH (M) SDN. BHD.SUKSES MELALUI

TEAMWORK

B24 CIBA VISION JOHOR SDN. BHD. PIP BEYOND 2017

B25 PETRONAS CHEMICALS MTBE SDN. BHD. THE OPTIMUS

B26 PETRONAS PENAPISAN (TERENGGANU) SDN. BHD. PROTECH

B27 CIBA VISION JOHOR SDN. BHD. ALCOA

B28 PETRONAS CHEMICALS MTBE SDN. BHD. GPRS

B29 VALE MALAYSIA MINERALS GILA GOLD

B30 PETRONAS PENAPISAN (TERENGGANU) SDN. BHD. D'GEAR

B31 INOKOM CORPORATION SDN. BHD. SKYACTIV

B32 PETRONAS CHEMICALS MTBE SDN. BHD. MY-INNOTECH

B33 INOKOM CORPORATION SDN. BHD. PAINT INSCRIPTION

B34 PETRONAS CHEMICALS OLEFINS SDN. BHD. DECLOGGANT

B35 MALAYSIAN NPK FERTILIZER SDN. BHD. INNOTECH

ABORANG ABSTRAK

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

Projek telah memenangi hadiah tempat ke-2 dalam Konvensyen ICC peringkat Syarikat.Dan mendapat anugerah EMAS dalam konvensyen TEAM EXCELLENCE Peringkat MINI

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

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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]

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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 : The Rhodium

ORGANISASIORGANISATION : Petronas Chemicals Derivatives Sdn. Bhd.

TAJUK PROJEKPROJECT TITLE : Catalyst Transfer Pump Mechanical Seal Leakage

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

: RM 2,299,889.10(Sila huraikan dalam Bahagian 2 – Borang D)

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

1. Catalyst Transfer Pump is equipped with open loop seal system. The system allowedemissions (catalyst) from process side to flow out from mechanical seal to Butanol Flare Headerthrough seal water return line.2. Catalyst circulating in LPO Reaction System via Vaporizer Catch Pot leak out to Butanol FlareSystem from Catalyst Transfer Pump’s mechanical seal system. Water quality at Kertih River willbe effected if overflowing polluted water from Process Sewer to PCOGD plant perimeter ditch.3. Based on the graph trending, catalyst concentration has showed significant decrease in 4weeks from 75 ppm (June 2016 Week 1) to 33 ppm (June 2016 Week 4)4. Impact from the issue, LPO Reaction was unstable due to less of reactivity in the system.5. Normal Butanol product purity showed off spec due to low catalyst in the system.

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

Pump’s mechanical seal with open loop seal system not satisfy with pump process condition.

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

Modify existing mechanical seal open loop to close loop seal system.

iv.TANDA ARAS :BENCHMARK :

G-6772 / G-6773 Glycol Feed Pump at EOG Plant, PC Glycols Sdn. Bhd.

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

1. After project implementation, catalyst concentration maintains at its optimum level, LPOreaction was stable and product quality was maintained as per specification.2. No water pollution detected at Kertih River due to overflowing of polluted water.3. Catalyst loss cost avoidance is RM 886,437.404. Manpower for pump’s maintenance cost avoidance is RM 9,954.605. Total revenue loss avoidance due to plants shutdown event is RM 1,403,497.10

ABORANG ABSTRAK


1. Focus recognition from Butanol Operation Engineer and Manager for successful project inorder to align with department KPI to generate cost saving2. Focus recognition from PCOGD CEO on project innovation for company profit andenvironmental care3. Recognition and award from ‘Kerajaan Negeri Terengganu’ and Chemical Industries Council ofMalaysia (CICM) related to environmental Care on year 2016/20174. Recognition from PC Derivatives Sdn. Bhd. (BA & BGE Unit) in conjunction sustain NormalButanol product flow feeding to their plants5. Recognition from Kertih Terminals Sdn. Bhd. (KTSB) in order meet product specificationagreement for storage6. Recognition from Sanggul Emas Sdn. Bhd. & Sundyne (Catalyst Transfer Pump Vendor) dueto successful innovation project on their pump7. Gold Award Winner in PCOGD Speaks Academy 20188. Gold Award in East Coast Regional Mini Team Excellence Convention (MTEx) 20189. Gold Award in Central Regional Team Excellence Convention (RTEx) 2018


Mechanical Seal Close Loop Seal System Project Real Project Modification

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

NAMA KUMPULANTEAM NAME : ANARAIZA

ORGANISASIORGANISATION : PETRONAS CHEMICALS DERIVATIVES SDN BHD

TAJUK PROJEKPROJECT TITLE : HIGH TOTAL ORGANIC CARBON (TOC) ANALYZER MEASURE IN WASTE

WATER CHECK BASIN


:

RM 198,400

(Sila huraikan dalam Bahagian 2 – Borang D)


All waste water generated from manufacturing units must be treated in the wastewater treatment plant(WWTP). There are 4 water discharge points managed by Utilities:

a) North West (NW) Check Basin: Storm water runoff and non-contact cooling water from Olefins,Derivatives and Utilities

b) South West (SW) Check Basin: Storm water runoff and non-contact cooling water from EOG, Butanoland Utilities

c) Lot N Check Basin: Storm water from Lot N, not including Kerteh Terminal Station (KTSB) they havea separate outfall

d) W-5: Wastewater treatment plant effluent

All four (4) discharge points have on-line analysers for monitoring. They are ”serious per HSE 7.06(requiresalternate protection if not working). The Total Organic Carbon (TOC) analyser in check basin is to measurethe waste water conditioned before release to outside river. Department of Environmental (DOE) has statedin standard B limit of TOC value must below 50 parts per milion (ppm) before release to river. In the wastewater normal operating procedure stated the check basin sluice gates should be closed if TOC measurementis more than 30 ppm.

The analyser must measure continuous representative sample and it required good sampling system andsample line such as pneumatic pump, composite hose and floating ball. One end of hose connection isconnected to pump and other end is wire mesh screen to trap sludge and foreign materials. The ball float balldepend on the check basin level to ensure the tip is not touch surface of the check basin.


Total organic Carbon (TOC) analyser repeatedly measured high TOC reading. This has caused waste waterin check basin will be not release to river and require immediate verification by analyzer technicians to confirmthe measurement values are actual or false. Finding from the rectification founded:

a) Composite hose occasionally stuck/immovable at certain level inside wet well and it is too heavy.b) Algae formation inside composite hose and sampling system.c) Wire mesh tip clogged and contaminated with algae

All of the above failures/problems causing the TOC measurement high and unreliable.

ABORANG ABSTRAK


Solution has been identified durng the brainstorming session among team member. Team recommendationas below:

NO Problem Recommendation1 Rough surface skin of the hose

causing it stuck inside wet well.Replace to polyethylene hose. This hose is lighter and it’soutside surface skin is seamless. This will prevent hose stuckat wet well

2 Wire mesh clogged Design and fabicated new stainless steel wire screen basket3 Algae formation inside hose and

sampling systemDesign and install air purging at the suction point of pneumaticpump for flushing purposes. This will ease of maintenancewithout cleaning the wire screen tip by pulling out the hose fromwet well and remove algae inside hose.


Benchmark of the design:

a) Polyethylene hose. The hose has been used in the Olefins plant for sucking the waste water insidethe wate water basin contain of 1000 ppm Total Organic Carbon (TOC).

b) Stainless steel wire mesh basket. The wire screen basket is design previously in Olefins waste waterbasin. However for the check basin the design is improved on the screen size and basket connection.

Algae formation. Flushing with air benchmark from the utilities plant in the waste water collection tankpump.


Improvement on the high TOC reading provide continously and true measurement of TOC reading. Thus,increasing the capability for environmental compliance discharge monitoring. The improvement has beencommunicated to DOE as part of corrective action plan related to the prevent NCR/incident. The projecthas achieve it target and objectives:

a) TOC analyser continuous measuring low TOC value for past 1 month.b) Less maintenance and reduce cost of man-hours and material for cleaning and repair.c) Comply with DOE standard B limit for TOC measurement.

Achievement sustain plant production at high rate without interruption due to waste water issues.


1) Gold medal awards and top ten the National Convection Team Excellent 20162) Gold medal awards in the International Convection On Quality Control Circle (ICQCC) 2017.3) Awards as Best Project of the year 2017 in PETRONAS Chemicals Derivatives for a low cost

materials used and high impact to comply and a digitalize technology implementer.


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ABORANG ABSTRAK

1. Layout of the waste water sample from the check basin into TOC analyzer measure the TOC value.

1. Impact of high TOC to densadeg and aeration basin, unable to release the water into river.

Check Basin Wet Well & Floating ball

Pneumatic PumpPrimary Sample System

Analyzer House TOC Analyzer

ABORANG ABSTRAK

2. Wire mesh screen frequent clogged and improper installation and it’s connection to floating balle.Thefloating ball condition is bad.

3. New design of seamless floating ball & hose used polyethylene material. Design and fabricate wire meshbasket. The connection of the basket is proper attach to one end of the hose.

Maklumat Penting:

Polyethylene Ball Wire mesh Basket Polyethylene Hose

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NAMA KUMPULANTEAM NAME : SOLUTIONS

ORGANISASIORGANISATION : PROTON TANJUNG MALIM SDN. BHD.

TAJUK PROJEKPROJECT TITLE : MENGATASI MASALAH PENINGKATAN PENGGUNAAN CUTTER BLADE DI

BODY ASSEMBLY


:

RM50,620.00 SETAHUN



Tip dressing adalah alat untuk mengasah Tip (spot weld gun) supaya mengikut standard diameter yangditetapkan. Cutter blade yang terdapat pada Tip dressing berfungsi sebagai mata pengasah untuk Tip (spotweld gun). Peningkatan penggunaan ‘Cutter blade’ yang berlaku dikesan dari kekerapan membuat Tipdressing sehingga mengakibatkan ketajaman ‘Cutter blade’ menjadi tumpul yang telah menyebabkan koskerugian masalah sebanyak RM11,570 (89unit) dalam tempoh 3 bulan Januari hingga Mac 2017. Pemilihanmasalah ini adalah seiring dengan objektif, misi dan visi serta matlamat kumpulan, jabatan dan syarikat.


Analisis melalui faktor SQCDM (Safety, Quality, Cost, Delivery & Morale) Terdapat unsur unsafe act kerana pekerja mengasah Cutter Blade secara manual menggunakan

Grinder. Selepas pekerja melakukan Tip dressing, didapati Tip yang diasah tidak menepati standard diameter

yang ditetapkan, ini boleh menyebabkan berlakunya Spot point no fusion. Penggunaan Cutter Blade didapati meningkat setiap bulan disebabkan proses mengasah

mengunakan Grinder yang menyebabkan mutu asahan tidak tepat (kadang kala terlebih asahan)dan penukaran Tip (spot weld gun) yang kerap dan banyak digunakan kerana Tip yang diasah tidakmengikut standard diameter.

Masalah ini juga kerana ianya telah menyebabkan kelewatan untuk menyiapkan sesuatu proseskerja kerana kekerapan untuk melakukan Tip dressing.

Pekerja mengalami tekanan disebabkan bebanan kerja kerana perlu kerap melakukan proses Tipdressing untuk memenuhi standard diameter Tip.


Terdapat 2 punca utama yang menyumbang kepada permasalahan Proses mengasah Cutter Blade sukar dan merbahaya dan tidak mencapai standard yang ditetapkan

Cadangan : Menggunakan alat pengasah yang mudah dikendalikan untuk proses mengasah CutterBlade bagi memenuhi standard dan SQCDM.

Cutter Blade rosak semasa diasahCadangan : Menukar proses cara mengasah Cutter Blade bagi memenuhi standard dan SQCDM

Kedua-dua cadangan disatukan menjadi satu tindakan iaitu mencipta sebuah mesin khas untuk mengasahCutter Blade supaya proses mengasah cutter blade menjadi mudah, selamat dan memenuhi standardserta SQCDM.

SQ

DM

C

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Tanda aras projek adalah KPI jabatan Body Assembly (Cost) sebagai Benchmark sasaran projek. Konsep alat pengasah pensil sebagai benchmark tindakan projek kami, kerana mendapati konsep

tersebut mudah dilaksanakan, serta mendapat asahan yang konsisten. Kumpulan telah melakukan servey pada syarikat yang berkaitan (OEM). Syarikat tersebut hanya

mengunakan konsep pakai buang untuk kegunaan Cutter Blade. Disebabkan itu kumpulan hanyaboleh melakukan benchmark di atas sahaja. (sasaran projek KPI dan tindakan projek iaitu konsepalat pengasah pencil)


Perbandingan pareto sebelum dan selepas projek menunjukkan penurunan peratus masalahsebanyak 80% (data kerugian 4 masalah utama sebanyak RM25,855 ke RM5,285)

Data pembelian cutter blade dari segi ringgit dan unit/kuantiti menunjukkan penurunan dan mencapaisasaran yang ditetapkan.Sebelum tindakan : RM11,570 = 89 unit 3bulan(Jan-Mac)Selepas tindakan : RM520 = 4 unit 3bulan (Julai-Sept)Sasaran kumpulan : RM780 = 6unit sebulan

Hasil dari projek ini juga telah berjaya membuat penjimatan keseluruhan melebihi RM50,000 setahun Keunikan projek ini adalah menggunakan 100% bahan-bahan terpakai & sedia ada. Mesin pengasah Cutter Blade mempunyai kepelbagaian kegunaan antaranya digunakan untuk

mengasah pelbagai alat memotong. (mata dril, pisau, parang dan sebagainya) Menerima maklum balas yang positif dari pekerja yang sangat berpuas hati dengan cara proses

asahan Tip dan Cutter Blade serta masalah Spot No Fusion dapat diatasi.


Kumpulan Solution juga turut menerima surat pengiktirafan dari pihak pengurusan Body Assembly ataskejayaan projek.Pihak pengurusan Body Assembly & Continuous Improvement Management PTMSB telah menjalankanaudit pada hasil tindakan yang dibuat oleh Kumpulan Solutions dan mengesahkan hasil ciptaan telah berjayadilaksanakan.Pencapaian terbaik yang diperolehi kumpulan adalah tempat ke-3 Konvenyen Team Excellent PeringkatAkhir PTMSB 2017/18.Anugerah Emas Wilayah Tengah 2018 (MPC)


LAKARAN MESIN PENGASAH CUTTER BLADE PEMEGANG (BLOCK)CUTTER BLADE

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ABORANG ABSTRAK

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MESIN PENGASAH = MP-17

PEMEGANG (BLOCK) CUTTER BLADE

CARA PROSES ASAHAN DIJALANKAN

PENAMBAHBAIKAN

PENAMBAHBAIKAN

PEMUTAR UNTUK DIJADIKAN SUIS

PENAMBAHBAIKAN TINDAKAN PENGKOMERSILAN

SUIS

PLUG

MESIN MP-17 :SEBELUM : SISTEM ANGINSELEPAS : TENAGA ELEKTRIK

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

NAMA KUMPULANTEAM NAME : EyeNSee

ORGANISASIORGANISATION : PETRONAS Chemicals Derivatives Sdn. Bhd.

TAJUK PROJEKPROJECT TITLE : High Temperature In VPH Reactor


: RM 14,792,405.68



PC Derivatives is one of petrochemical plant owned by PETRONAS. It has 5 plants namely Olefins, Glycols, Derivatives, Butanol andUtility. Butanol plant is producing N-butanol and isobutanol for various customers. VPH reactor is the heart of Butanol operation. In theprevious years, VPH reactor is experiencing frequent trips causing the production to stop. Our team aim is to get into the root cause ofthe problem and come out with the solution.


VPH reactor is tripped due to temperature spike. We found out the water ingress into the thermowell causing the sensor to give falsereading and tripping the plant.


To fabricate protection chamber that prevents water ingress into thermowell. This protection incorporates single construction designthat prevents any possible water ingress which could hamper the performance of the thermocouple.


Zero VPH reactor trip


Zero trip were reported after the protection chamber was installed.


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NAMA KUMPULANTEAM NAME : TEAM ABC

ORGANISASIORGANISATION : HICOM TECK SEE MANUFACTURING (M) SDN BHD

TAJUK PROJEKPROJECT TITLE : PENJIMATAN KOS PACKAGING UNTUK MODEL BARU


:

RM 108,534.22



Apabila Jabatan ” Business Development’’ memaklum mengenai propjek baru, Jabatan ” IndustrialEngineering” perlu membuat kajian mengenai ”packaging” yang diperlukan, seperti ’’box’’ dan ’’trolley’’


Kos pembuatan ”packaging” pula agak tinggi kerana beberapa faktor iaitu harga ditentukan berdasarkankeadaan ekonomi semasa, harga bahan mentah yang sentiasa berubah, dan peningkatan kos buruh.


1. Kitar semula ’’box’’ yang lama tapi masih dalam keadaan baik2. Kitar semula ’’trolley’’ yang lama tapi masih dalam keadaan baik3. Penyusunan ’’packaging’’ secara bertingkat untuk menampung beban barang yang banyak4. Membuat ’’adjustable trolley’’


Kos pengeluaran yang tinggi


1. Syarikat berjaya melahirkan pekerja yang berfikiran kreatif dan inovatif untuk penjimatan syarikat2. Harga jualan produk dapat dikurangkan3. Menghapuskan tempat pembiakan nyamuk Aedes di dalam ’’trolley’’ atau ’’box’’ yang bertakung air


Kumpulan ini menjadi Juara ICC dalam HTS SGA ICC/HCDP Konvensyen Akhir FY1718 pada 7 April 2018

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NAMA KUMPULANTEAM NAME : BERSATU

ORGANISASIORGANISATION : PROTON TANJUNG MALIM SDN.BHD

TAJUK PROJEKPROJECT TITLE : MENGURANGKAN DOWNTIME BAIK PULIH BOLT STUD OFFSET


:

RM987,050.00 SETAHUN



Jabatan tf tidak dapat mencapai sasaran pengeluaran disebabkan berlaku line stop akibat masalah bolt studoffset di line trim 2.Masalah bolt stud offset telah menyebabkan kesukaran kepada pekerja untuk memasangpart selector assy(gear lavel).Pekerja terpaksa melakukan proses baik pulih bolt stud offset dengan caramengetuk bolt stud menggunakan penukul dan menjadikan actual part sebagai panduan.cara kerja ini telahmenyebabkan berlaku secondary defect dan telah menyebabkan peningkatan part reject iaitu selector assy.Hasil data yang dikumpul selama tiga bulan ( feb 2017 ~ Apr 2017 ) mencatatkan part reject sebanyak 59kes dan downtime line stop sebanyak 472 minit.pemilihan masalah ini seiring dengan objektif,misi dan visisyarikat serta mempunyai hubungkait dengan matlamat kumpulan,jabatan dan syarikat.


Hasil dari analisis yang dijalankan terdapat 5 punca utama masalah dikenalpasti.

1. Tiada guide untuk check bolt stud menyebabkan proses pemeriksaan bolt menjadi lambat (purata140 saat).

2. Pekerja menggunakan cara visual check menyebabkan hasil pemeriksaan tidak konsisten.

3. Tiada alatan tangan yang sesuai untuk baik pulih masalah bolt stud offset.

4. Pekerja mengetuk bolt stud dengan penukul menyebabkan peningkatan part reject.


Terdapat 3 punca utama menyumbang kepada permasalahan.

rekacipta special gauge mengikut data part sebenar iaitu selector assy untuk dijadikan arassemasa baik pulih bolt stud.gauge tersebut dinamakan GBS ONE( Guide Bolt Selector ).

Merekacipta special tool yang berfungsi 3 dalam 1 yang memudahkan pekerja melakukan prosesbaik pulih bolt stud offset tanpa merosakan thread bolt.Special tool tersebut dinamakan TuningStud Tool (TST).

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Tanda aras sasaran projek adalah KPI Jabatan Body Assembly ( Delivery ). Tanda aras tindakan merekacipta special gauge adalah data sebenar part selector assy. Tanda aras tindakan merekacipta special tools adalah dari pemerhatian kumpulan di laman

sesawang PINTEREST.COM dan Pusat Servis PROTON.


Masalah downtime baik pulih bolt stud offset Berjaya diselesaikan 100%. Hasil projek ini telah memberi kesan yang positif kepada keselamatan dan kesihatan pekerja. Pengurangan masalah empat downtime tertinggi sebanyak 92%. Keunikan hasil penciptaan boleh digunakan oleh semua jabatan pengeluaran di kilang PROTON

untuk baik pulih masalah bolt stud offset. Hasil ciptaan juga boleh digunakan di syarikat pengeluar kereta lain dan vendor PROTON. Hasil ciptaan projek telah dipatenkan dan dikomersilkan di kilang SUZUKI INDOMOBIL MOTOR

(SIM) dan syarikat vendor ( PHN DAN INGRESS )


Johan Konvensyen Team Excellence Proton Tanjung Malim 2018 Naib johan Konvensyen ICC Proton Holding 2018 Penerima Anugerah Best Innovation di konvensyen ICC Proton Holding 2018. Pemenang Best Of The Best Kaizen Proton Tanjung Malim 2018 Anugerah Emas konvensyen ICC wilayah utara 2018


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GBS ONE

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Maklumat Penting:




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Tuning Stud Tool (TST)

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NAMA KUMPULANTEAM NAME : LABYRINTH

ORGANISASIORGANISATION : PETRONAS CHEMICALS DERIVATIVES SDN BHD

TAJUK PROJEKPROJECT TITLE : FAILURE OF ELECTRONIC PNEUMATIC CONTROLLER, GAS

CHROMATOGRAPHY


: RM 1.283 million per year



Gas chromatography units at Laboratory found problem to achieve desire pressure and flow since 2015,according to Equipment reliability record 2016, 18 units Gas chromatography recorded breakdown due toElectronic pneumatic controller (EPC) problem. The biggest potential of problem is due to moisture trap inline system to Gas Chromatography. As a result to the breakdown, PETRONAS Chemical Derivatives SdnBhd contribute to average RM900K Price of non-Conformance (PONC) per year involving spare partreplacement and maintenance troubleshooting.

Equipment Reliability Record and Price of non-conformance (PONC) has triggered Laboratory toperform improvement on Gas Chromatography line system. Lab Labyrinth team volunteers to initiate newproject with objective to reduce number of breakdown and increase of Price of conformance to Section,Department and company suit with Company OPERATIONAL EXCCELENCE Pillar

Lab Labyrinth successfully build new filter to trap moisture in Gas Chromatography system, whichsaving approx. RM 900K price of conformance ,minimize the Gas Chromatography breakdown andincreased Equipment reliability to support Laboratory Operation.


1. Moist Hydrogen gas introduce into EPC system Gas Chromatography2. Moist Zero air introduce into EPC System Gas Chromatography3. Hydrogen generator failure due cartridge saturated.


1. Add new filter for hydrogen and nitrogen gas before entering module EPC at gas chromatography.2. Establish preventive maintenance program for hydrogen and zero air generator3. Create new Standard Operating Procedure for Hydrogen and zero air Equipment Bacis Care (EBC) and

Preventive maintenance (PM)

ABORANG ABSTRAK


To reduces less or below 2 units Gas chromatography breakdown due to Electronic pnemumaticcontroller problem per year


1. Expenditure Gas Chromatography Spare part reduces to RM 54,000 FY 2017 compared to

RM 972,000 FY2016

2. Cost saving RM 1,283,000 per year 2017

3. ZERO (0) Service Interruption

4. 98.5% analysis on time reported without any delay of production and shipment,

5. ZERO (0) Non Conformance related to Company demurrage

6. Equipment availability and reliability increased to 99.48% (Overall)

7. ZERO (0) Customer Complaint

8. 100% Service Availability without Interruption for Chromatography analysis


1. Department Recognition2. Bronze Award – SPEAK Academy (PETRONAS)3. Gold Award – KONVENSYEN MINI TEAM EXCELLENCE WILAYAH PANTAI TIMUR 20184. ICC Muda Terbaik – KONVENSYEN MINI TEAM EXCELLENCE WILAYAH PANTAI TIMUR

20185. Gold Award - KONVENSYEN TEAM EXCELLENCE PERINGKAT WILAYAH (RTEx) 2018

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Belt damage commonly occurs in belt conveyor systems, in which it’s repairing consumes a lot of time andtherefore will cause a significant loss of production. Belt repair process consists of a series of stepscontributing to it’s long repair duration. One of it is the positioning time. This project is about reducing thepositioning time by using a device to automatically positioning the belt, also reducing the risk by keepingmaintenance personnel away from the conveyor.


Long time taken for belt positioning due to limitation of human sensory.


Create an automated positioning device which detects the marked part on belt and stopping the conveyorin the correct time and place.


The device should help to reduce the positioning time by around 1 to 2 hours.


Time saving for belt positioning;2 hours (before) – 0.5 hours (after) = 1.5 hours

Manpower cost saving;1.5 hours x 5 person x 58 RM/hour = RM 435.00

Reduced production loss (considering 70USD/ton);1.5 hours x 8000 ton/hour x 270 RM/ton x 30%(OEE) = RM 972,000.00

Potential Annual Saving (considering 8 belt repairs per year);(RM 972,000 + RM 435) x 8 repairs = RM 7,779,480.00


3rd place in Vale Malaysia QCC Competition Gold Award in Regional Team Excellence 2018

NAMA KUMPULANTEAM NAME : The BLEX

ORGANISASIORGANISATION : Vale Malaysia Minerals Sdn Bhd

TAJUK PROJEKPROJECT TITLE : Smart Conveyor Positioning System (SCOPS)


: RM 7,779,480.00


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Maklumat Penting:




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

NAMA KUMPULANTEAM NAME : QME

ORGANISASIORGANISATION : PROTON TANJUNG MALIM SDN BHD

TAJUK PROJEKPROJECT TITLE : NOMBOR CHASSIS TIDAK SAMA ANTARA BAHAGIAN HADAPAN DAN LANTAI

KERETA.


:

RM115,450/ SETAHUN(Sila huraikan dalam Bahagian 2 – Borang D)


Aduan dari pihak JPJ dan puspakom mengenai nombor chassis body yang meragukan.Kereta tidak boleh ditukar milik kepada penama lain.Pembaikan memerlukan skill yang mahir dan melibatkan kosKesan sampingan (secondary defect) bila buka part pada kereta.


Mesin pencetak nombor chassis tidak dapat mengenal pasti nombor chassis yang telah di buat sebelum ini, dan juga mesin boleh mencetak nombor chassis yang telah dibuat sebelum ini secara operasi manual.


Penambahbaikan pada system computer iaitu system buzzer dan alarm supaya nombor chassis body yangsama dapat di kesan awal sebelum proses percetakan chassis nombor dilakukan.Mesin juga akanmengenal pasti nombor chassis yang telah dibuat sebelum ini


KPI jabatan


Dapat memastikan kualiti berada pada paras spesifikasi yang ditetapkan.Dapat mengurangkan work in proses (WIP).Mengurangkan runggutan pelanggan dan kereta dapat ditukar milik kepada penama baru.Pencapaian ahli dalam ICC meningkat.Kualiti kereta dapat ditingkatkan.


Anugerah Emas ( Bulan Julai 2018 Peringkat Wilayah Utara )Wakil jabatan ke ICC peringkat akhir (PROTON TGM Bulan January 2018)Pengiktirafan dari Head of Body Shop PTMSB 5hb Ogos 2017

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Sebelum tindakan dilakukan pada mesin Selepas tindakan dilakukan pada mesin

Terima data nomborchassis dariPALC

Proses selesai

Data nombor chassisditerima oleh mesin

Parts diletakan padamesin.

Parts dikeluarkan

Punching nomborchassis body

bermula.

Terima data nomborchassis dariPALC

Proses selesai

Data nombor chassisditerima oleh mesin

Parts diletakan padamesin.

Punching nomborchassis body

bermula.

Parts dikeluarkan

Mesin menilainombor

chassis body

NG(berulang )

a)Error akan displayjika nombor chassisberulang.*Buzzer alarm akanberbunyi

b)Manual operationturut dinilai jika nomborchassis yang samadibuat.

akan berhentiMesinserta merta denganmengeluarkan

Aktiviti yang KumpulanQME jalankana) Membuatpenambahbaikan padasistem program mesin"PLC program"

b)menambah memoryhistory data nomborchassis supaya bolehmengenal pasti datayang telah di punchingsebelum ini.

c)Mesin juga tidak bolehberopersi jika mesinmencetak nomborchassis yang sama

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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 di

bawah 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]

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NAMA KUMPULANTEAM NAME : Clash Of LPG

ORGANISASIORGANISATION : Petronas Dagangan Berhad, Prai LPG Terminal

TAJUK PROJEKPROJECT TITLE : Pengujian Alat Kesan Kebocoran Silinder Gas Petroleum Cecair (Electronic Leak

Tester) Yang Mengambil Masa Yang Lama


:

RM1.34 Juta Setahun



Bagi setiap silinder Gas Petroleum Cecair (LPG) yang siap diisi, injap silinder perlu diuji untuk memastikanianya tidak bocor sebelum dijual kepada pelanggan. Bagi menguji kebocoran injap ini, terdapat 12 alatpengesan kebocoran (Electronic Leak Tester – ELT) yang dipasang bersama – sama mesin pengisiansilinder LPG. Setiap ELT haruslah diuji dan ditentukur (calibration) pada setiap pagi sebelum operasipembotolan LPG bermula yang mengambil masa 1 jam. Semasa ujian ELT dijalankan, operasi pembotolanLPG tidak dapat dimulakan. Syarikat mengalami keuntungan terlepas sehingga RM2.68 juta setahun apabilasetiap hari 1 jam terpaksa digunakan untuk menguji ELT.


Menggunakan Rajah Ishikawa sebanyak 6 punca awal yang dikenalpasti, namun setelah verifikasi lanjuthanya 1 punca utama masalah yang ternyata menyumbang kepada masalah pengujian ELT yang mengambilmasa yang lama. Punca masalah itu adalah reka cipta bentuk asal alat pengujian ELT itu sendirimelambatkan proses pengujian ELT. Ini termasuklah:

i) Reka bentuk alat pengujian ELT asal hanya mampu menguji 1 unit ELT pada suatu masa (setiapELT mengambil masa 5 minit x 12 ELT = 1 jam).

ii) Alat pengujian ELT sedia ada amat berat (23 kg) dan sukar dikendalikan di ruang sempit atasmesin pembotolan LPG.


Setelah membuat analisa SWOT terhadap setiap cadangan penyelesaian, kami bersepakat untukmerekacipta satu alat baru yang boleh mempercepatkan proses pengujian ELT, Maka, HEXA LEAKTESTER telah direka & dibina dengan ciri – ciri berikut:

i) Berupaya menguji 3 ELT sekaligusii) Ringan (6kg sahaja) namun stabil dan senang dikendalikan di ruang sempit.iii) Kos pembinaan yang murah dan senang untuk direplikasikan.iv) Rekacipta asal dalaman yang boleh didaftarkan hakmilik dan dikomersilkan.


Aktiviti tandaaras (benchmarking) dijalankan terhadap 2 lokasi dibawah sistem pengisian LPG di Prai(berkapasiti 5,400 silinder/jam) yang mirip iaitu:

Kuwait (berkapasiti 7,200 silinder/jam) – Ujian ELT 1 jam 45 minit purata Bangladesh (berkapasiti 6,600 silinder/jam) – Ujian ELT 1 jam purata PETRONAS Prai LPG (berkapasiti 5,400 silinder/jam) – Ujian ELT 1 jam purata

Disebabkan masa pengujian adalah lebih kurang sama, kumpulan kami menggunakan kaedah nisbahmudah untuk menentukan arah tuju kumpulan kami. Daripada kiraan nisbah mudah sekiranya 3 ELT diujiserentak, ianya cuma memerlukan 30 minit maksimum untuk kesemua 12 ELT.

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HEXA LEAK TESTER berjaya mengurangkan masa pengujian ELT dari 1 jam kepada 30 minit sahaja,dimana masa yang telah dijimatkan boleh digunakan untuk operasi pembotolan LPG yang seterusnyamemberikan keuntungan lebih RM1.34 juta setahun kepada pihak syarikat.Di samping itu, Hexa Leak Tester juga memberi manfaat kepada perkara berikut:

i) Menyingkirkan sebarang risiko ergonomik ketika bekerja di ruang sempit antara mesin pengisianLPG.

ii) Memastikan silinder LPG yang dijual kepada pelanggan bebas dari sebarang kebocoran.


- Pemenang Anugerah Emas Konvensyen Regional Team Excellence ( Wilayah Tengah ) 2018.- Pemenang Keseluruhan & Anugerah EMAS bagi kategori ICC peringkat PETRONAS Downstream

Continuous Improvement Convention 2017.- Pemenang Tempat Ke-3 peringkat syarikat PETRONAS Dagangan Berhad.

Pemenang & disenarai pendek mewakili Operasi Terminal LPG & Minyak Wilayah Utara & Timur,PETRONAS Dagangan Berhad.


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



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NAMA KUMPULANTEAM NAME : THE BATTERY

ORGANISASIORGANISATION : VALE MALAYSIA MINERALS SDN BHD

TAJUK PROJEKPROJECT TITLE : ACCESS LADDER


: RM 559,200,000



Existing design for operator to change shift/duty which required to stop the operation by moving Operatorcabin to exchange point. This condition consumed 8 minutes per changed. The process required 8 timeswhich total losses of 64 minutes operating times per day for each ship unloader.(3 ship unloader with total of192min/day). Another reason, having difficulties in case of emergency in situation of the cabin in operatingpoint for operator to evacuated out from the cabin it self.


1. Loosing operating hours due to stop for operator exchange.2. Unproper/unsafe evacuation route in case of emergency at boom operating point


1. Design/Fabricate dedicated route(ladder) for operator to go down to Operator cabin without stopthe operation.

2. Safer working condition and evacuation route during emergency.


1. Eliminate 100% downtime for operator change.2. Fastest evacuation route in case of any emergency..


Project AchievementExplained below the gain via this ELIMINATION of “Change of Operator”

8 minutes safe per cycle for one Ship-Unloader = 8 Minutes1 day have 8 cycles of for one Ship-Unloader = 64 Minutes3 Ship-Unloader works simultaneously everyday = 192 Minutes (3.2 hours)20 days of operation per month = 64 Hours12 months of operation per year = 768 Hours saved

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Value Creation Vale’s Value ”Life Matter Most” applied here to priotize operators working condition are well taken

care. Reflection theme of the year been proposed by our CEO Fabio Schvartsman which is ”Workplace

Incident Prevention Is A War We Can Win”. Our implementation creates the positive window tosupport this campaign.

Increase of OEE of the year upon the implementation of this Access Ladder which giving positivegain in Gross Saving Revenue.


1) 1ST RUNNER-UP QCC VALE MALAYSIA COMPETITION.


1)

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2)

3)

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NAMA KUMPULANTEAM NAME : BORD

ORGANISASIORGANISATION : PETRONAS Dagangan Bhd

TAJUK PROJEKPROJECT TITLE : Operasi Top up Bowser Tidak Ergonomic


:

RM 150,000. (Penjimatan dari CAPEX)


Operasi ’top up’ bowser dijalankan selepas bowser membuat pengisian minyak kapal terbang dan operasitop up menggunakan hose dalam panjang 5m dan coupler yang berat. Ini menyebabkan kerja kerja top upbowser tidak ergonomic dan memakan banyak tenaga unutk operasi tersebut. Ini menyebabkan pekerjapenat dan terdedah kepada risiko sakit belakang.


1. Hose dan coupler yang berat.2. Operasi top up perlu dilakukan secara manual.3. Hose yang panjang menyukarkan pergerakan pekerja untuk memasang kepada bowser.


Kumpulan BORD telah membuat penambahan roda dan pemegang hose supaya dapat mengurangkanpenggunaan tenaga manusia semasa membuat operasi top up.


1. Loading Arm2. Intake coupler dari lori dispenser


1. Penjimatan RM150 ribu untuk membeli dan memasang ’loading arm’2. Pengurangan tenaga manusia semasa operasi top up, kerja tidak letih.3. Cara kerja yang lebih ergonomic.4. Jangka hayat hose boleh diperpanjangkan.


1. Dalam process pendaftaran permohonan baru paten.2. Pengiktirafan dari OGCF, vendor Aviation Equipment supplier.3. Pengiktirafan dari institusi.4. Penghargaan dari pihak pengurusan PETRONAS Dagangan Bhd

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NAMA KUMPULANTEAM NAME : ERAT SEPAKAT

ORGANISASIORGANISATION : PETRONAS DAGANGAN BERHAD

TAJUK PROJEKPROJECT TITLE : KERJA PENUKARAN PIN RANTAI MENGAMBIL MASA YANG LAMA


:

RM 2.7 JUTA SETAHUN


Erat Sepakat telah ditubuhkan pada 11hb April 2016 dengan visi untuk menyelesaikan masalah penyelenggaraaan diTerminal Gas Petroleum Cecair (GPC) Melaka. Masalah utama yang berlaku ialah kerja penukaran pin rantaimengambil masa yang lama.Untuk meyelesaikan masalah ini, satu kumpulan yang diwakili oleh 6 juruteknik telah dibentuk untuk mencari jalanpenyelesaian yang paling sesuai. Penyelidikan, pengumpulan data dan kajian telah dilakukan to mengenal pastilangkah terbaik dengan mengambil kira juga kos alat yang murah.Setelah beberapa bulan selepas mengunakan kaedah kaji selidik dan analisis data, Badang X telah dicipta dan dikenalpasti sebagai alatan yang paling sesuai untuk menyelesaikan masalah ini.Selain itu, kumpulan ini juga telah berjaya memupuk semangat berpasukan yang begitu tinggi dengan menyemarakkanbudaya kerja Petronas Cultural Beliefs (PCB) dan 5QPs demi menghasilkan projek yang berkualiti dan menepatikehendak syarikat.

ii. PUNCA UTAMA MASALAH :MOST POSSIBLE CAUSE(s) :Berikut ialah punca masalah utama :

1) Kesukaran untuk membuka dan memasanag pin rantai yang baru2) Penggunaan peralatan yang boleh merosakkan pin rantai3) Kaedah mengetuk pin rantai yang merbahaya4) Kendalian peralatan yang memerlukan lebih dari seorang pekerja


Cadangan penyelesaian ialah menghasilkan alat penekan hidraulik yang ergonomik dan lebih efisyen.

iv.TANDA ARAS :BENCHMARK :Tanda aras ialah seperti berikut :

1) Kapasiti pembotolan tong silinder gas2) Masa yang digunakan untuk kerja penukaran pin rantai3) Jumlah pekerja untuk kerja penukaran pin rantai

v. PENCAPAIAN PROJEK & PENCIPTAAN NILAI :PROJECT ACHIEVEMENT & VALUE CREATION :Pencapaian projek ialah sepeti berikut :

1) Kos projek hanya melibatkan RM 400 sahaja dengan jumlah keuntungan produksi sebanyak 2.7 juta setahun.2) Jumlah penjimatan masa selama 20 minit ( masa dikurangkan dari 30 minit kepada 10 minit )3) Tenaga pekerja hanya seorang sahaja ( pekerja dapat dikurang dari 2 orang kepada 1 orang )

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vi. ANUGERAH, PENGHARGAAN & PENGIKTIRAFAN :AWARD, REWARD & RECOGNITION :Berikut ialah anugerah dan pengiktirafan untuk projek ini :

1) 21hb September 2016 @ Petronas Dagangan Berhad (PDB) Downstream Continous Improvement Conventionat Kuala Lumpur Convention Centre (KLCC) – Hadiah Utama ( 1st Prize)

2) 9hb Oktober 2017 @ DOWNSTREAM CONTINOUS IMPROVEMENT CONVENTION 2017 (DCIC 2017) atKuantan, Pahang – Hadiah Tempat Ke-2 ( SILVER AWARD )


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NAMA KUMPULANTEAM NAME : GB5

ORGANISASIORGANISATION : HICOM TECK SEE MANUFACTURING (M) SDN BHD

TAJUK PROJEKPROJECT TITLE : REDUCE REJECTION FOR HONDA MODEL (TSAA REAR LICENSE GARNISH)


:

RM 322,397. 20



-Total rejection cost at HTS for Jan’17 – Jun ’17 was RM 2.42 mil-RM 2.35 mil of internal rejection cost was contributed by Injection Moulding, Electroplating, Painting &Secondary Process-57% of the internal rejection (RM 1.34 mil) came from Injection Moulding process


-Injection Moulding rejections such as warping, flow mark, oily mark, and sink mark)


-Mold repair


High rejection at Injection Moulding process


-The solution horizontally replicated to other new model ( T9AX Upper Moulding Front Grille)


This team was the winner for HTS ICC/HCDP SGA Final Convention FY1718

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NAMA KUMPULANTEAM NAME : BLUE FLAME

ORGANISASIORGANISATION : PETRONAS DAGANGAN BERHAD

TAJUK PROJEKPROJECT TITLE : Inisiatif Penapisan Air Mesin Basuhan Silinder

(Cylinder Washing Machine Water Filteration Initiative)


:

RM 960,000.00

RM PER YEAR


Mesin basuhan silinder di Terminal GPC Pasir Gudang menggunakan “closed loop water system”,pembersihan silinder adalalah satu proses yang wajib dilakukan sebelum silinder-silinder dipasarkan.Penerimaan silinder yang kotor dan berminyak adalah tinggi dan berdasarkan rekod, penyelenggaraanmesin basuhan telah dilakukan amat kerap berikutan masalah tekanan air rendah (pressure loss) akibatdari saluran air pada nozzle tersumbat. Masalah ini menyebabkan proses basuhan serta operasitergendala dan produk @ silinder kotor boleh terlepas ke pasaran.Inisiatif projek ini adalah untuk mengatasi masalah kekerapan penyelenggaraan mesin basuhan yangtersumbat dan mengurangkan kos akibat dari masalah ini berlaku. Projek ini akan menambah baikkankerja-kerja pembersihan penapisan air menggunakan prinsip “Backwash” serta penambahan “Filter Bank”bagi memudahkan serta mempercepatkan kerja-kerja pembersihan disamping menjadikan cara kerja lebihergonomik serta menjimatkan kos.


Sistem penapisan basuhan kerap tersumbat akibat daripada lepasan kotoran halus melepasi strainer danmenyebabkan air di dalam sistem mesin basuhan cepat kotor disebabkan tahap kotoran selinder terlalutinggi. Sistem mesin basuhan yang agak ringkas (simple) tidak dapat menampung tahap kotoran yang tinggi.


Menggunakan sistem penapis air yang menpunyai sistem backwash selepas strainer di mesin basuhansilinder.


a.Menggunakan kaedah dual bank untuk sistem penapis air.b.Menggunakan sistem penapis air rumah yang biasa.


a.Mengurangkan downtime disebabkan mesin basuhan tersumbat.b.Meningkatkan kecekapan operasi dan tempoh menangani masalah.c.Memperkenalkan cara kerja yang ergonomik dan efisyen.d.Menyelesaikan masalah dengan jimat dan kos terendah.e.Meningkatkan mutu pengeluaran dan keyakinan pelanggan

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Memenangi Naib Johan PDB Mini Downstream Continuous Improvement Campaign (DCIC 2016)


Maklumat Penting:




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


NAMA KUMPULAN TEAM NAME

: PIP BEYOND 2017

ORGANISASI ORGANISATION

: CIBA VISION (JOHOR) SDN. BHD.

TAJUK PROJEK

PROJECT TITLE : REDUCE DOWNTIME STATION-01 AT ATS#7

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

:

38K USD = CALCULATION


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

Ats#7 is a primary packaging lines consist of 12 station which is to package contact lenses along conveying system (supertrack) Station01 is sub line for ATS#7 which is to transfer the blister from the conveyor belt into the pallet I supertrack system.

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

Possible Root cause 1.Bowl Feeder area (1st solution) 2.HOLD back area (2nd Solution) 3.PNP & LTU area (3rd solution) 4.Escapement Area (Final solution).

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

Solution 1 : Bowl Feeder : 1.1 Re-adjust and standardize pressure air flow range. 1.2 Re-adjust the Vibration speed (Controller) for stability. Solution 2 :Hold Back Area : 2.1 Re-position stopper 2.2 Re-setting sensor detection Solution 3 :PNP & LTU Area 3.1 Re-viewed and make new position range for S-bot 3.2 Do Position Pont Marking for PNP Solution 4 :Escapement Area 4.1 Re-viewed and new change O-ring into double O-ring type.. Others:- - Mini Maintenance Manual- - Maintenance Server Manual (Viewer) – KIOSIK (Downtime Data Monitoring)

iv. TANDA ARAS :

BENCHMARK :

Reduce Downtime from 980 min/hours into 688 min/hours. (Data collection Downtiime APR – JUN 2017) which target 30% reduction of Downtime

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

-Downtime reduce from 980 min/hours into 541 min/hours (actual) which 55.2% reduce downtime Group target plan reduce :- 30% reduction of Downtime Actual results :- 56.2% reduction of Downtime

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

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1.Internal QCC winner ALCON JOHOR - JULY 2017 2. GOLD - CONVENSYEN TEAM EXCELLENCE SOUTHERN REGION 10-11 JULY 2018.

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

SYSTEM COMPONENT:

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SOLUTION:

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]




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: The Optimus


: PDH Plant Department, PCMTBE

TAJUK PROJEK

PROJECT TITLE : Steam Optimization: Reactor Effluent Drier (RED) Management


:

RM 493,560/ SETAHUN


Steam is the most expensive utility cost in PDH Plant. From January 2014 until December 2015, PDH Plant recorded higher monthly steam specific consumption (SC) against the budgeted number (17 out of 24 months, 71%). They are 5 major steam users in PDH. In March 2016, PDH Plant set up a team to look into high steam SC issue.


Higher RED regeneration frequency


Prolong RED adsorption (online) time to reduce RED regeneration frequency hence reducing steam consumption.

iv. TANDA ARAS :

BENCHMARK :

25% steam reduction for RED regeneration activity in a month.


Lower steam SC against budgeted number from October 2016 until December 2017 (14 out of 15 months, 93%).

- 33% steam reduction during RED regeneration

- Recorded RM 493,560/year cost saving (details as per Borang D) -


Focused Regocnitoin from PCMTBE Management in succesfully implemented and sustained one of the optimization project registered under Business Excellence Management (BEM) Committee.

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: GPRS


: PCMTBE

TAJUK PROJEK

PROJECT TITLE : LIVE LOADED PACKING RELIABILITY STRATEGY


:

RM 13, 806,784.70



Live loaded packing for control valve is identified as one of the reliability threats in PCMTBE where it leads to loss of production and causing long recovery period due to equipment damage. Both plants ( PDH & MTBE) has to shutdown the Continous Catalyst Regenaration (CCR) Unit whenever there is major fire in order to avoid catastrophic damage towards the equipment and environment. GPRS team proactively take initiative to identify the root cause of this issue. The combination of expertise within the team members which includes engineer and experienced technical personnel has investigate and assisted the plant to resolve this issue by improving the reliability program of selected CCR control valves.


No detailed preventive maintenance program on live loaded packing condition while plant onstream.


1) Improvise existing M-Plan (Maintenance Plan) by monitoring height, torque and physical condition of live loaded packing.

2) Introduce special tool as to improve further efficiency on overall work process.

iv. TANDA ARAS :

BENCHMARK :

1) Zero Plant Incidents Report (PIR) 2) Zero CCR Unit Shutdown due to fire incidents at control valve cause by packing

leak. 3) To develop baseline database on gland packing performance monitoring 4) To enhance staff capability and awareness towards the gland packing monitoring

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v.

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

1) TANGIBLE PROJECT ACHIEVEMENT & VALUE CREATION :

1) TOTAL MTBE PRODUCTION : USD 916,335 TOTAL PDH PRODUCTION : USD 541,800 TOTAL PRODUCTION LOSS : 1 458,135 Total/day (USD) LOSS Running at 54.4% load of production : 664, 909.56 (USD) Estimated 5 Days : USD 664, 909.56 x 5 days : USD 3 324,547.8 ~ RM 13, 805184.74 * 5 Days – No of days for the plant to be fully operational after a shutdown 2) REDUCE MAN HOUR UTILIZATION FOR PM EXECUTION FROM 30

MINUTES TO 20 MINUTES PER CONTROL VALVE. SAVINGS = 16 HOURS /YEAR FOR PM EXECUTION EQUAL TO 16 HOURS/YEAR X RM100/ MAN HOUR = RM1600

TOTAL COST SAVING = RM 13, 806,784.70

2) INTANGIBLE PROJECT ACHIEVEMENT & VALUE CREATION :

Reduce frequency of Hydrogen leakage at CCR (Continous Catalyst Regeneration) Unit

Improve control valve performance for Hydrogen service

Increase understanding among the staff towards the important of live loaded packing for control valve.

Inculcate above the line culture

Nurturing PETRONAS Cultural Beliefs


1) GOLD Award – RTEx 2018 (RTEx Tengah) 2) Focused Recognition by Head of Department Maintenance 3) Third place in PCMTBE Technical Sharing (THESIS) Forum 2017 4) Presented in Instrument Forum 2017

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

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NAMA KUMPULANTEAM NAME : Gila Gold

ORGANISASIORGANISATION : Vale Minerals Malaysia Sdn. Bhd.

TAJUK PROJEKPROJECT TITLE : Improvement of Vulcanizing Table & Vulcanizing Press at Vale Malaysia


:(About 1.7 MTPY – Million Tons Per Year (Total of MYR 501.7 M – gross savingrevenue) + Around MYR 5820.9 K saving per year).

Overall = MYR 507.6 M



Belt conveyor is the most important asset in Vale’s Terminal due to the highest cost production and thehandling complexity especially the belt replacement procedure. Vale Minerals Malaysia (VMM) consist of 28KM conveyor belts. In 2018, VMM’s belt conveyor materials cost is around 40% from the overall materialscost and the vulcanizing services cost (laggings and splices mainly) is 24% from the overall services cost.

VMM with the capacity of 30 MTPY (Million Tons Per Year) of iron ore production has a huge historical ofsplicing (belt joining) activity. Last year, VMM carried out around 170 belt interventions (more than 70 splices)and in Sept 2018 VMM carried out more than 165 belt interventions (more than 80 splices). Each splicingactivity at the open area in VMM require at least 36 hours to complete. Even at the biggest Vale port in Brazilwith 230 MTPY of production, consisting more than 120 KM of conveyor belt, the number of splicing activitiesjust around 45 splices/ year. This large difference due to the Vale Project Team flawed that failed to complywith the Vale Belt Conveyor Standard on determined and finalized the operation features and assetscalculation.

Our project goals is to improve the performance of VMM’s vulcanization activities. Focusing on health, safety,productivity and sustainability and fully utilized the recycle resources to minimize risks and reduce the impactof vulcanizing splicing activity intervention and to reduce one of VMM biggest cost.


Splicing activity requires scaffoldings which is high in cost and during shutdowns the vulcanizing team facedmajor issue with the lack of resources. It caused the higher number of time frame interventions. Besides that,scaffolding’s erect and dismantle process takes between 6 to 7 hours. Hours of heavy execution process willaffect the production and cause fatigue to the executors.

Previously, vulcanizing team used the sectional press for splicing activity. They faced huge safety issuessuch as fatigue and ergonomic problem when handling the sectional press due to the longer time to set eachpiece of this heavy equipment. It caused low productivity, low quality of work that require them to redo the36 hours process and delayed on the process.


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Design and fabricate the multi-function splicing table to support the vulcanizing team to execute all steps ofthe vulcanizing splices activity at the steel cord belts conveyor and introduce the compact vulcanizing pressinstead to use the sectional press with more than 60 pieces and 3,000 kg in total.


To reduce overall time to execute the vulcanizing splice activity at open area from 36 hours to 29 hours withthe high productivity, high quality of work, increase in safety compliance and reducing the fatigue issues ofexecutors.


This project succeed to achieve our main goals which is to reduce overall time to execute the vulcanizingsplice activity at open area from 36 hours to an average of 25.15 hours and we also able to achieve:

1) Cost reduction2) High quality of work (no rework)3) Increase safety4) Reduce fatigue, and most important;5) Recognition for the vulcanizing team


Champion of 2018 QCC Conference in Vale Malaysia Minerals Sdn. Bhd.

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: myINNOTECH


: PETRONAS CHEMICALS MTBE SDN. BHD.

TAJUK PROJEK

PROJECT TITLE : SOFT SOLUTION FOR CLEAN AIR MANAGEMENT


:

RM 2.24 Million



Project selection is based on sustenance of PCMTBE Sdn. Bhd. HSE Excellence pillar. As a company that is highly committed to the wellbeing of society and surroundings, PCMTBE strives to comply to all mandatory regulation that is subjected to it. From our identification, the company has yet to comply to the new Environmental Quality (Clean Air) Regulation 2014. This project addresses the regulatory non-compliance the company is facing for Clean Air Regulation 2014 (CAR 2014) in terms of monitoring emissions from affected plant equipment continuously with the outcome of potential non-conformance avoidance of RM100,000.


Company does not comply to new Clean Air Regulation 2014.


Predictive Emission Monitoring System (PEMS)

iv. TANDA ARAS :

BENCHMARK :

1. 100% compliance to Environmental Quality (Clean Air) Regulation 2014 2. Zero Price of Non-conformance associated with Environmental Quality (Clean Air) Regulation 2014


1. 100% compliance to Environmental Quality (Clean Air) Regulation 2014 2. Zero Price of Non-conformance associated with Environmental Quality (Clean Air) Regulation 2014

3. Cost optimization of RM 1.84M with additional of RM 135K per year when compared to other possible solution


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1. PEMS project received recognition from Department of Environment Malaysia as a valid emission

monitoring system 2. PEMS project team received Focused Recognition from Head of Manufacturing, Petronas

Chemicals Group 3. PEMS team leader also received Focused Recognitions from CEO Petronas Chemical MTBE,

Occupational Health & Environment Manager and Process Optimization Manager 4. PEMS project have submitted technical paper internally and externally and received recognition as

below a. Best presenter for Thesis 8 competition (Internal)

b. 3rd best presenter in Regional Olefin Producer Technical Conference 2018 (External)


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NAMA KUMPULANTEAM NAME : DECLOGGANT

ORGANISASIORGANISATION : PETRONAS CHEMICALS OLEFINS SDN BHD (PCOSB)

TAJUK PROJEKPROJECT TITLE : PROLONGED DURATION OF COMPRESSOR PRESSURE

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

:



In November 2016, PCOSB CGC 2nd stage pressure transmitter data (tag no. PT-1701-09)was found to be irresponsive to the DCS as normal and anti-surge controller need to be switchedto manual by panel operator. Maintenance was on-called to rectify the reading; however theproblem remains unresolved after calibration was performed. Further investigation was done atsite, and it was found that there were accumulation of polymer inside the transmitter tapping.Team decided to do steaming at the transmitter tapping for de-plugging purpose. Team wassuccessfully solved the problem after steaming; however, the duration for this activity took about2 days to remove polymer accumulation inside the transmitter.

In March 2017, once again the same problem happened and team required 2 days of steamingat the same pressure transmitter tapping for rectification.

In conclusion, both cases had caused production load reduction from 100% to 85% capacity andalso impacted PCOSB production planning strategy as well as stakeholder planning.


Hard solid polymer accumulated inside pressure transmitter root valve and cause plugging.Formation of hard solid polymer material in the cracked gas compressor system is due to natureof the chemical process reaction.


To design a special tools which can solve the problem occurred. The tool must be safely to beused during system online and pressure still exist to avoid any safety incident and environmentalissues.


To reduce duration of deplugging activity by less than 8 hours (allowable duration of surgeprotection for compressor can be disable) compared to previous method which is required 48hours to solve the problem.

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The project have positively impacted on the HSE, operational excellence & value creation.Transmitter root valve plugging issues successful can be de-plugged within 2 hours compared toprevious method and Cracked Gas Compressor surge protection can be normalized less 8 hoursas maximum duration allowable for surge protection disable.


i) Successful of the project recognized by Head of PC Olefins Departmentii) GOLD AWARD MEDAL on Konvensyen Mini Team Excellence 2018 at Kuala Terengganuiii) MOST PROMISING CIRCLE AWARD on Konvensyen Mini Team Excellence 2018 at Kuala

Terengganuiv) GOLD AWARD MEDAL on Konvensyen Team Peringkat Wilayah (Selatan) 2018

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

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NAMA KUMPULANTEAM NAME : INNOTECH

ORGANISASIORGANISATION : MALAYSIAN NPK FERTILIZER SDN BHD

TAJUK PROJEKPROJECT TITLE : MENGATASI MASALAH CORONG ”BAG CLAMP” DI MESIN PEMBUNGKUSAN

YANG MUDAH KOYAK


:

RM 202,120.00/SETAHUN



Corong “bag clamp” di mesin pembungkusan sentiasa koyak. Corang “bag Clamp yang koyak menyebabkan tumpahanproduk. Preventive maintenance kerap dilakukan dan memerlukan kos yang tinggi. Analisa dilakukan untuk melihatpermasalahan ini dan penambahbaikan dilakukan dengan menggantikan bahan penahan produk iaitu inner liner sebagaialat untuk menahan produk daripada tumpah. Cara ini berkesan tetapi rubber inner liner tidak boleh bertahan lamadisebabkan oleh suhu produk yang panas dan tindakbalas bahan kimia. Innovatif yang dibuat adalah menukar rubberinner liner dengan stainless steel plate yang lebih tahan lama dan tidak mudah koyak disebabkan oleh tindakbalas kimia.


Corong ”bag Clamp” di mesin pembungkusan yang mudah koyak


Menukar bahan penahan pada corong bag clamp dengan stainless steel plate yang lebih tahan lama dan tidakmudah koyak serta membuat penambahbaikan pada bentuk corong.


Corong mengisi minyak tanah yang memudahkan pengisian minyak kedalam botol.


Pencapaian Projek:1. Mengurangkan kos penyelenggaraan2. Mengurangkan tumpahan produk

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

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1. Tempat kedua - Konvensyen ICC Malaysian NPK Fertilizer Sdn Bhd 2018.2. Anugerah Emas - Konvensyen Team Excellence Peringkat Wilayah (Rtex) 2018


Corong bag clamp yang mudah koyak

Inovasi yang dilakukan dengan menukar menukar rubber inner liner dengan stainless steel plate yang lebih tahan lebihlama dan tidak mudah koyak

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Inner liner darimaterial “rubber”

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