Improving the quality of cleaning the surface of the ahield by high pressure water jetting method at vivablast (vietnam) CO LTD

MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS INDUSTRIAL MANAGEMENT IMPROVING THE QUALITY OF CLEANING THE SURFACE OF THE SHIELD BY HIGH-PRESSURE WATER JETTING METHOD AT VIVABLAST (VIETNAM) CO.,LTD SUPERVISOR: NGUYEN THI MAI TRAM, ME STUDENT: PHAM NGOC DUY SKL 0 Ho Chi Minh City, October, 2022 MINISTRY OF EDUCATION AND TRAINING HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING THESIS IMPROVING THE QUALITY OF CLEANING THE SURFACE OF THE SHIELD BY HIGH-PRESSURE WATER JETTING METHOD AT VIVABLAST (VIETNAM) CO., LTD Student’s name : PHAM NGOC DUY Student ID : 17146012 Major : INDUSTRIAL MANAGEMENT Advisor : NGUYEN THI MAI TRAM, ME Ho Chi Minh City, October 2022 COMMENTS OF ADVISOR ………………………………………………………………………………………… ………………………………………………………………………………………… …………………………………….…………………………………………………… …………………………………………………… …………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… HCM city, day … month … year 2022 Advisor Nguyen Thi Mai Tram I COMMENTS OF REVIEWER ………………………………………………………………………………………… ………………………………………………………………………………………… …………………………………….…………………………………………………… …………………………………………………… …………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… ………………………………………………………………………………………… HCM city, day … month … year 2022 Reviewer II ACKNOWLEDGEMENTS Dear: Board of Management of Vivablast (Vietnam) Co., Ltd Mrs.Nguyễn Thị Mai Trâm – Lecturer at Ho Chi Minh City University of Technology and Education My name is Pham Ngoc Duy (student ID: 17146012) - a graduate thesis student in the first semester of the academic year 2022-2023 First of all, allow me to thank Vivablast (Vietnam) Co., Ltd for allowing me to practice and complete my graduation thesis this semester with the topic: Improving the quality of cleaning the surface of the shield by high-pressure water jetting method at Vivablast (vietnam) Co., Ltd I would also like to express my sincere thanks to Ms Nguyen Thi Mai Tram - my direct advisor for this graduation thesis In more than two and a half months of working on my graduation thesis, I have been guided in detail about the outline, presentation, and detailed content suggestions for this topic Thanks to her dedicated help, I can not only complete my graduation thesis better but also have a better overview of the topic I am writing about That helps to lay the foundation for building and defending this thesis before the committee In the end, although I have tried to this graduation thesis as best as possible, I will inevitably make mistakes I hope that Vivablast company, Mrs.Tram, and readers understand Above all, I would be happy to receive further feedback from Vivablast, Ms Tram, and readers to improve this report Sincerely Thanks and Best regards HCM city, day … month … year 2022 Student Pham Ngoc Duy III LIST OF ABBREVIATION Abbreviation Explanation AHP Analytic Hierarchy Process FDI Foreign Direct Investment ISO International Organization for Standardization NACE National Association of Corrosion Engineers International OEE Overall Equipment Effectiveness PPE Personal Protective Equipment QCVN National technical regulation 40:2011/BTNMT on industrial wastewater (vietnam) QMS Quality Management System TBM Total Productive Maintenance TNHH Vietnamese: Trách Nhiệm Hữu Hạn / English: Company Limited TPM Tool Box Meeting UHP Ultra High Pressure WJ-1 Water Jetting level WJ-2 Water Jetting level WJ-3 Water Jetting level WJ-4 Water Jetting level IV LIST OF TABLE Table Quality standards for cleaning the surface of the shields 15 Table 2 Traditional AHP pairwise comparison matrix 18 Table Normalised Pairwise Comparison Matrix 18 Table The random index corresponds to the number of selection criteria considered 19 Table Popular types of water jetting machines on the Vietnamese market 26 Table Criteria for evaluating the quality of cleaning the surface of the shield 37 Table 3 Alternatives affecting the quality of cleaning the surface of the shield 37 Table Pairwise Comparison Matrix of criteria 39 Table Normalised Pairwise Comparison Matrix of criteria 39 Table Pairwise Comparison Matrix of alternatives according to Surface Roughness 40 Table Normalised Pairwise Comparison Matrix of alternatives according to Surface Roughness 41 Table Pairwise Comparison Matrix of alternatives according to Initial Condition of the Surface 42 Table Normalised Pairwise Comparison Matrix of alternatives according to Initial Condition of the surface 42 Table 10 Pairwise Comparison Matrix of alternatives according to Degrees of Cleaning 43 Table 11 Normalised Pairwise Comparison Matrix of alternatives according to Degrees of Cleaning 44 Table 12 Alternative Weights of criterion 45 Table 13 Criteria Weights 45 Table 14 Alternative Score 46 Table Reference table of risk levels 47 Table Hierarchy of control over the secure implementation .49 V Table Compare the investment cost and risk cost of rotating shifts solution 50 Table 4 Compare the investment cost and risk cost of equipping headphones solution 52 Table Levels of roughness according to quality standards for cleaning the surface of the shield 62 Table Some suggested hand symbols 63 Table Cost effectiveness of the solution 68 VI LIST OF FIGURE Figure 1 Logo of Vivablast (Vietnam) Co., Ltd Figure The organizational structure of Vivablast Co., Ltd .7 Figure High-pressure water jetting process and final product at First Solar's production department Figure The internal steel structure is broken during traditional hand drilling 11 Figure 2 The internal steel structure is preserved when performing high-pressure water jetting 11 Figure The high-pressure water jetting system 12 Figure Cleaning quality of Class C surfaces at each level 15 Figure General structure of the hierarchy 17 Figure Fishbone diagram of the quality of cleaning the surface of the shield 21 Figure A rusted surface after UHP cleaning (left) compared with standard surface water jetting type WJ1 (right) 22 Figure 3 Certificate of Hughes' high-pressure water jetting technique 23 Figure A basic theoretical training class on water jetting techniques at Vivablast training center – Binh Chieu construction site 24 Figure Occupational safety card of a water-jetting technician 24 Figure Vivablast’s high-pressure water jetting machine 25 Figure Some accessories come with the high-pressure water jetting machine 25 Figure Position of the nozzle on the gun and its rotation amplitude 27 Figure A water jetting machine and its accessories are being transported to another site .27 Figure 10 Standard performance posture .28 Figure 11 A TBM (Tool Box Meeting) at the beginning of a shift 29 Figure 12 Some risks of occupational accidents during high-pressure water jetting 30 Figure 13 Limited area of high-pressure water jetting at Binh Chieu construction site VII 31 Figure 14 A Standard Personal Protective Equipment model when performing highpressure water jetting 31 Figure 15 Safety information boards in the high-pressure water jetting area 32 Figure 16 Emergency first aid supplies and fire extinguishers in the high-pressure water jetting area 32 Figure 17 Two waste water tanks at Binh Chieu construction site 33 Figure 18 Process of mixing abrasive particles into the high-pressure water stream 34 Figure 19 The surface of the shield (level WJ2) is scratched by large abrasive particles 34 Figure 20 Cost structure of a typical high-pressure water jetting system 35 Figure 21 The AHP hierarchical structure for the quality of cleaning the surface of the shield 38 Figure Hearos 5826 Xtreme Protection Series UF Foam Ear Plugs (NRR 33) 48 Figure Peltor Sport Tactical 100 Electronic Hearing Protector, Ear Protection, NRR 22 dB 48 Figure Maintenance workers are repairing a high-pressure water jetting machine at the Binh Chieu construction site 65 VIII APPENDIX APPENDIX A: INITIAL CONDITIONS OF THE SURFACE BEFORE CLEANING Type Initial condition A Description Standard image The surface is completely covered with adherent mill scale; little or no rust visible Initial The surface is covered with both condition B mill scale and rust The surface is completely covered Initial condition C N/A with rust; little or no pitting visible The area includes an example of a discoloration caused by heat (Rust Grade C) The surface is completely covered Initial with rust; pitting visible The area condition D includes an example of foreign matter (Rust Grade D) Previously painted the surface; Initial light-colored paint applied over condition E blast-cleaned surface; paint mostly intact 73 N/A Previously painted the surface; Initial zinc-rich paint applied over blast- condition F cleaned surface; paint mostly intact Painting system applied over mill Initial scale bear-ing surface; System condition G thoroughly weathered, thoroughly blistered, or thoroughly stained Degraded painting system applied Initial over surface; system thoroughly condition H weathered, thoroughly blistered, or thoroughly stained Source: The Society for Protective Coatings/NACE International (2001) 74 APPENDIX B: SURVEY TABLE OF PRIORITY OF FACTORS AFFECTING THE QUALITY OF CLEANING THE SURFACE OF THE SHIELD IN VIVABLAST CO., LTD Introduction: Dear Experts of Vivablast Co., Ltd, My name is Pham Ngoc Duy - a research student in the Industrial Management class at Ho Chi Minh City University of Technology and Education I am studying the thesis about Improving the quality of cleaning the surface of the shield by high-pressure water jetting method at Vivablast (Vietnam) Co., Ltd Please take a moment to answer a few questions about the factors affecting the quality of cleaning the surface of the shield by the high-pressure water jetting method at Vivablast (Vietnam) Co., Ltd The opinions of experts will help me determine which factors have the most influence on the quality of cleaning the surface of the shield by the high-pressure water jetting method at Vivablast (Vietnam) Co., Ltd Sincere thanks to the experts Filter part: Q1 Please indicate whether you are an officer of the following departments or not? (QA/QC department, Operation department, HSE department, Maintenance department, Accounting department) ° Yes (Continue) ° No (Stop Thank you) Q2 Please indicate if you have or are you working on a project with a high-pressure jetting process? ° Yes (Continue) ° No (Stop Thank you) Main part: Evaluate the intensity of importance of factors together Instruction: Please use the Fundamental scale of AHP (Saaty, 1980) to score the intensity of importance of factors together in the questions below: 75 Intensity of Definition importance Explanation Two activities contribute equally to Equal importance the objective Moderate importance of Experience and judgment strongly one over another favor one activity over another Essential of strong Experience and judgment strongly importance favor one activity over another Very strong importance An activity is strongly favored and its dominance demonstrated in practice The evidence favoring one activity Extreme importance over another is of the highest possible order of affirmation Intermediate values 2,4,6,8 between the two adjacent When compromise is needed judgment For example: If factor A is weak important than B, score Note: You can skip questions that are not in your understanding Symbols: C1: Surface Roughness C2: Initial Condition of the Surface C3: Degrees of Cleaning M1: Man M2: Machine M3: Method 76 M4: Material M5: Money Q1 Score the intensity of importance of criteria together: Intensity of importance Compare 1/9 1/8 1/7 1/6 1/5 1/4 1/3 1/2 C1 with C2 C1 with C3 C2 with C3 Q2 Score the intensity of importance of alternatives together according to Surface Roughness: Intensity of importance Compare 1/9 1/8 1/7 1/6 1/5 1/4 1/3 1/2 M1 with M2 M1 with M3 M1 with M4 77 M1 with M5 M2 with M3 M2 with M4 M2 with M5 M3 with M4 M3 with M5 M4 with M5 Q3 Score the intensity of importance of alternatives together according to Initial Condition of the Surface: Intensity of importance Compare 1/9 1/8 1/7 1/6 1/5 1/4 1/3 1/2 M1 with M2 M1 with M3 78 M1 with M4 M1 with M5 M2 with M3 M2 with M4 M2 with M5 M3 with M4 M3 with M5 M4 with M5 Q4 Score the intensity of importance of alternatives together according to Degrees of Cleaning: Intensity of importance Compare 1/9 1/8 1/7 1/6 1/5 1/4 1/3 1/2 M1 with M2 M1 with 79 M3 M1 with M4 M1 with M5 M2 with M3 M2 with M4 M2 with M5 M3 with M4 M3 with M5 M4 with M5 Other part: Do you have any other suggestions for the quality of cleaning the surface of the shield by high-pressure water jetting method at Vivablast (Vietnam) Co., Ltd? Please provide the information below ………………………………………………………………………………………… ………………………………………………………………………………………… THANK YOU VERY MUCH FOR YOUR COOPERATION 80 APPENDIX C: REFERENCE TABLE FOR LEVELS OF HAND ARM VIBRATION WHEN PERFORMING HIGH-PRESSURE WATER JETTING Source: Rebecca & Elizabeth (2005) APPENDIX D: REFERENCE TABLE OF NOISE POLLUTION LEVELS WHEN PERFORMING HIGH-PRESSURE WATER JETTING Source: Rebecca & Elizabeth (2005) 81 APPENDIX E: COMMON TYPES OF ABRASIVE PARTICLES Source: Thai (2015) 82 APPENDIX F: THE PDCA CYCLE (PLAN - DO - CHECK - ACT) OF ISO 9001:2015 Source: David (2015) 83 APPENDIX G: MAINTENANCE CHECK LIST FOR UHP Items Description Level Working Total hours cost (h) (VND) 0.5 17,250 Frequency Monitor UHP Pump head for Heat Gain Monitor readings on Control System Everyday Check the condition of the plunger guides Check the correct function of the boots pump drive Check coolant level engine (if fitted) Low Check the oil level engine (if fitted) Check the diesel fuel level Once engine (if fitted) Check oil level UHP Pump every three days Check oil level Boost Pump (Red Color) Visual check of the complete 10 34,500 unit with attention to the UHP pump, connectors, 84 hoses, and Jetting Gun 11 12 Check the condition of outlet valves, seats, and springs Correct torque of the Tie 0.5 Rod Nuts/150 lbf/ft 17,250 Once a 13 Drain condensate from the week air receiver and filter Test run the jetstream to 14 check the amount of water in 1.5 51,750 103,500 an hour Check the condition of water 15 filters and change them as Once a necessary month 16 Change earthing wire Ø 100 165,000 836,000 mm2 (3 meters) 17 Change UHP plunger seal and backup rings (Add: 1set) every three Medium 18 19 20 21 Change LP plunger seals Change outlet valve and seats (1 set) Once N/A 780,500 months Twice a Change outlet valve springs if needed (Add: Europa) Change pump 85 979,500 1,555,980 year crankcase/gearbox oil and filter (if fitted) (Add: 60 liter Diesel) 22 Change inlet valves & springs (Add: set) 3,117,900 276,000 396,500 Check the correct tension of 23 compressor drive belts (if fitted) Twice a year Jetstream body welding 24 (Add: 30 soldering wands & grindstone) Change boost pump seals 25 and bearings (Add: seal, Once a High 911,750 1,561,390 5,129,728 year pump) 26 Change plunger guides (Add: TE-CO 54305X) The machine is 95% hot due 27 to the failure of the foot valve (Add: Taiyo foot Unlikely valve) Source: Hieu (2022) Note: hour = 34,500 VND (because the average basic salary of a maintenance worker in a month is 8,300,000 VND) 86 S K L 0