Title: APPLYING DMAIC TO REDUCE FAILURE OF ELECTRICITY PRODUCTION PROCESS AT THE FACTORY OF HA SONG PHA 1 HYDROPOWER JOINT STOCK COMPANY 2.. ABSTRACT The topic “Applying DMAIC to reduc
LITERATURE REVIEW 5 PIN vo a9
Quality Definition 2.1.2 Prneiples ofbuilding a quality sysfem ccc eee cetera cena ete ce cena ae 5 2.1.3 Characteristics, Roles, and Issues of Qualify Q.2 n2 2122211121 12221221122222 2 6 PS cà Pn 2.2.2 History of Šix ŠIgima - L2 02121121121 121 1111121111111 111111 1151010111111 1112111111111 11 x0 2.2.3 Level of Six Sigma - 2.2.4 Significance of Six Š1ỉIa - à 2 2212121 12111111 1111510111 111111211211 111111 11111111111 Xz 2.2.5 Benefits of Six SIgma cece cece 00 1111211112111111 1111110111111 211111111 11011111111 1110111111 E2, 2.3 The Six Sigma Methodology ven
The European Organization for Quality Control defines quality as “the suitability of a product to consumer requirements”
Quality, according to Philip B Crosby, is defined as: (Total Quality Management, 2007, financial publishing house) “Quality is compliance with requirements”
Quality, as defined by ISO 8402, is the collection of characteristics of an entity that enables it to fulfill both stated and implied needs (Dr Luu Thanh Tam, 2003, Vietnam National University Publishing House, Ho Chi Minh City).
The International Organization for Standardization (ISO) defines quality as the capability of a product, system, or process to fulfill the requirements of customers and other stakeholders, as outlined in the draft DIS 9000:2000.
Quality is the degree to which a product meets established requirements and standards from a manufacturer's perspective, while from the consumer's viewpoint, it refers to the product's fitness for its intended use.
Quality varies by organization and individual, but it can be defined as the capacity to consistently meet and surpass customer expectations across all products and services.
2.1.2 Principles of building a quality system
To effectively implement a quality management approach, it is essential to adhere to fundamental guidelines that ensure the production of high-quality products that align with client expectations The final result is derived from a series of interconnected procedures, each comprising multiple sub-steps that contribute to the overall output.
The quality of a product is fundamentally influenced by the effectiveness of its quality management system, which involves multiple processes in the development of product features Therefore, a robust quality management system is essential for ensuring high product quality, as it directly impacts the final outcome.
Process management is essential if we are to produce a high-quality end result
Prevention is better than correction, emphasizing that avoiding mistakes is crucial for organizations Quality management experts highlight that errors in production and business processes can severely affect a company's revenue, profit, and reputation By prioritizing prevention, businesses can save costs and uphold their good standing in the market.
Utilizing statistical techniques is essential for identifying and analyzing the root causes of faults in product or service quality generation By pinpointing these causes, we can effectively implement preventive measures to enhance overall quality and performance.
To achieve optimal results, it is essential to establish a quality management system that emphasizes excellence from the outset High-quality output from each process simplifies subsequent steps, ensuring that consistent and reliable input leads to products that meet the required standards Consequently, delivering exceptional products relies on maintaining error-free inputs throughout the production cycle.
2.1.3 Characteristics, Roles, and Issues of Quality
Meeting customer demands is essential for evaluating product quality A product deemed unacceptable, regardless of its advanced technology, is considered low quality This understanding is vital for quality-focused companies in shaping their corporate policies and strategies.
Because quality is judged by the satisfaction of requirements, and wants are continually changing, so quality changes with time, space, and use conditions
To assess an object's quality effectively, it is essential to evaluate all features that meet specific demands, encompassing not only customer needs but also the requirements of stakeholders.
Needs can be expressed through norms and standards, but some remain indescribable and can only be sensed during use Quality extends beyond mere attributes of everyday products; it encompasses both systems and processes.
To effectively meet customer needs, businesses must invest in costs both prior to and after the product is delivered A crucial measure of a company's quality management performance is the reduction of product costs.
Quality costs, as defined by ISO 8402, encompass the expenses associated with maintaining product and service quality, along with the losses incurred when quality standards are not met.
We categorize quality expenses as follows based on the functions and features of various categories of costs:
To ensure quality meets demands, businesses incur costs related to raw materials, resources, trained employees, and management Conversely, failing to meet quality standards results in losses, including waste, recycled materials, and returned goods Quality losses stem from not maximizing resource potential, leading to wasted talent, ineffective management, diminished credibility, and reduced trust.
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Histograms
A histogram, commonly referred to as a bar chart or density distribution histogram, visually represents the variability of a metric This graphical format enables a clearer understanding of statistical patterns compared to traditional numerical tables.
Kaizen (Continuous Improvement) 17 2.4.6 Benchmarking
The Kaizen technique is an effective strategy for driving continuous business improvement, particularly in the manufacturing sector By consistently monitoring processes, identifying inefficiencies, and implementing enhancements, businesses can reduce waste and swiftly address even the smallest inefficiencies This commitment to collective and ongoing improvements fosters a culture of efficiency and responsiveness.
Benchmarking is a measurement technique that allows businesses to assess their performance by comparing it with other organizations This process can include internal benchmarking, which focuses on comparing different departments within the same company, functional benchmarking, which looks at similar functions in industry leaders, and competitive benchmarking, which evaluates products and services against competitors.
Pareto Chart
The 80/20 rule, also referred to as the Pareto Principle, suggests that 80% of costs are attributed to just 20% of potential causes Juran was among the first to explore the significance of focusing on "a few vital things" as opposed to "many unimportant things."
A Pareto chart is a bar graph that organizes data from highest to lowest, highlighting priority issues that need immediate attention It visually identifies common failure patterns and establishes a clear order of priority for resolving these issues, ultimately guiding process improvement initiatives By leveraging the Pareto principle, organizations can swiftly identify problems and concentrate their improvement efforts on areas that yield the greatest impact.
A scatter plot, often referred to as a relational or distribution histogram, is an invaluable tool in frequency analysis for exploring the relationship between two variables Essentially, it illustrates how a change in one characteristic can predict a corresponding change in another.
Histograms provide an overview of data variations, allowing us to assess the general state of the process through visuals, making evaluation easier
In 1943, Professor K Ishikawa from the University of Tokyo developed the cause-and-effect diagram, widely recognized as the fishbone diagram, to facilitate process analysis This chart illustrates the relationship between causes and their effects, with the problem represented as the effect and its influencing factors as the causes By utilizing causal diagrams, organizations can effectively identify and eliminate issues at their source, enhancing their understanding of the interactions among various process elements.
Collaborating on a cause-and-effect diagram is more effective than creating one individually, as it enhances brainstorming efforts This valuable tool can be categorized into various types, making it versatile for different applications.
- The 5M cause-and-effect diagram, commonly known as 5MIE, includes the following factors that cause difficulties in the operating process:
- Cause-and-effect diagram by process: contains the production process
Understanding the process and its key drivers offers valuable insights at each step, enabling the identification of areas that require improvement Additionally, this approach helps establish functional authority, ensuring clarity in responsibilities Training team members on the entire process fosters familiarity and enhances overall efficiency.
Weaknesses include the tendency to get overwhelmed by certain causes, challenges in handling lengthy and intricate operations, and the potential for recurring issues to arise from the same underlying reasons.
Stratified cause-and-effect diagram:
Benefits: o Give groups of possible causes of the problem to help guide the solution o Graphs are less complicated
Weaknesses in the analysis may lead to the oversight of important causes, making it challenging to identify smaller groups contributing to the issue A comprehensive understanding of the various causes is essential, along with in-depth knowledge of relevant products and processes to effectively address the problem.
Control Charts
Product heterogeneity arises from two primary factors: general process causes and specific reasons The purpose of a control chart is to identify the presence of special causes within the process, ultimately leading to system stability.
A control chart can help estimate future time periods when a process is stable and does not need adjustments, while also assisting in identifying and eliminating special causes of instability.
Control charts are classified into several types:
- Control chart attributes: p chart, np chart, c chart, u chart
Variable control charts, including R charts, X and s charts, and M and R charts, are essential statistical tools for effective data collection, synthesis, and analysis Each organization may utilize different tools based on their specific circumstances This article focuses on a few key tools, such as column charts, Pareto charts, and cause-and-effect charts, to provide a comprehensive yet straightforward analysis of data.
The Six Sigma DMAIC methodology is widely applied across various manufacturing sectors, including automotive parts, metal processing, glove production, file manufacturing, laser mouse production, semiconductor fabrication, grinding operations, and rolling mills One study highlights the use of Six Sigma for enhancing safety levels, where the author shares insights on Six Sigma and the DMAIC approach Additionally, the author introduces tools designed to facilitate the steps of the DMAIC process, which will be utilized in this thesis.
METHODOLOGY 20 3.1 C00000 An
Qualitative research tools 21 1 Observation à 21
Observation is a qualitative research method that involves gathering data by closely watching individuals' behaviors or events in their natural environments Overt observations are generally favored, as conducting research without participants' awareness or consent can lead to ethical concerns.
Observations are most useful when:
- You are trying to understand an ongoing process or situation
- You are gathering data on individual behaviors or interactions between people
- Collecting data from people is not realistic If respondents are unwilling or unable to provide data through questionnaires or interviews, observation is a method that requires little from participants
An atypical focus group typically consists of 6 to 12 participants, and conducting at least three focus group discussions (FGDs) is recommended Engaging with multiple groups facilitates the gathering of more in-depth and diverse information.
A focus group discussion (FGD) should ideally last between 60 to 90 minutes to ensure effective exploration of the topic Sessions shorter than 60 minutes may hinder in-depth discussion, while those exceeding 90 minutes can lead to participant fatigue and reduced productivity, ultimately encroaching on their time.
Focus groups are most useful for:
- Pre-testing topics or ideas to sharpen the research questions
- Identifying program strengths, weaknesses, and recommendations
- Learning people’s thoughts on project outcomes and impacts
Qualitative research employs various interviewing techniques inspired by clinical and diagnostic interviews in fields like medicine and psychology Beyond simple questioning, qualitative interviewers utilize methods such as probing, clarification requests, paraphrasing, reflection, laddering, and active listening to thoroughly investigate the subject matter.
Qualitative interviews typically utilize a topic list, often referred to as a guide or agenda, which may range from a broad overview of key issues to a detailed set of open-ended questions The primary goal is to gather specific information rather than to adhere to a rigid set of standardized questions.
Brainstorming aims to generate a multitude of ideas on a specific topic However, incorporating evaluation during this process can hinder creativity, as participants may judge each other's contributions Therefore, it is crucial to postpone any evaluative feedback To guide the creative process effectively, we utilize written instructions that provide clear direction.
Effective interaction should focus on enhancing each participant's creative thinking Once the brainstorming session concludes, an evaluation can be conducted to assess the ideas generated, either through written instructions or criteria developed by the participants themselves.
3.2.5 Open-ended Surveys and Questionnaires
Open-ended surveys and questionnaires enable participants to provide detailed, unrestricted responses instead of selecting from predefined options For instance, an open-ended question such as "Why don’t you eat ABC brand pizza?" encourages in-depth feedback and insights.
Encourage participants to express their thoughts in a narrative format instead of limiting them to predefined options such as "I'm a vegan," "It's too expensive," or "I don't like pizza." This approach fosters more meaningful engagement and richer insights.
Implementation process
Sigma, DMAIC and Information supporting tools
Define the problem in production process
Measure all of the factor related to the problem and Analyze the root causes of them
Supporting tools (Pareto chart, VOC, )
Fishbone, control chart, flowchart, check sheets,
Propose some solutions to improve and control the process
Evaluate the effectiveness of the given proposals
In summary, Six Sigma serves as a strategic methodology for consistently measuring results, establishing new baselines for enhanced performance, and driving organizations toward operational excellence By adopting this philosophy across their enterprises, organizations can transform their manufacturing operations into world-class leaders in their industry.
This chapter introduces the theory of quality management, focusing specifically on the DMAIC process It outlines the implementation steps and supporting tools that will be utilized in the thesis to enhance process improvement through the DMAIC methodology.
COMPANY BACKGROUND 25 4.1 GENERALITNTRODUCTION 2 00.21121121 101111111111111110111 21211111 111111 11 E411 cay 25 4.1.1 Information about the Company
Information about the Company's hydropower factory
The Ha Song Pha hydroelectric power complex consists of two plants, Ha Song Pha 1 and Ha Song Pha 2, boasting a combined capacity of 15.75 MW and generating around 69.51 million kWh of electricity annually The operational principle of these plants involves harnessing the energy of flowing water to produce sustainable power.
The upstream water flows into the factory's lake, creating a high-pressure stream that travels through the canals This powerful water column is then directed into the factory's turbine, driving the energy generation process.
- Strong running water with high flow and pressure rotates the coaxially attached turbine, transforming mechanical energy into electricity
- The generated electricity is sent through the step-up transformer, which produces high- voltage current
- The high voltage current will be connected to the 110kV national power transmission network and will convey consumption loads a Ha Song Pha 1 factory:
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Figure 4.6 Ha Song Pha I's factory (Source: Internal Information of Company)
The Ha Song Pha Hydropower Plant, operated by the Ha Song Pha Hydropower Joint Stock Company in Ninh Thuan province, consists of two facilities in Lam Son commune The Ha Song Pha 1 plant, which began operations in November 2013, features two 5.4MW units, including one unit with a capacity of 2.7MW, and has a flow rate of 28 m³/s An additional 2.7MW unit is set to be added in 2018, increasing the total capacity to 8.1MW The plant achieves a maximum generation capacity of 42 m³/s and produces approximately 35.31 million kWh annually.
The Ha Song Pha 2 Hydropower Plant, developed by the Ha Song Pha Hydropower Joint Stock Company in Lam Son commune, Ninh Son district, Ninh Thuan province, is a significant energy project initiated in 2014 The plant operates in two phases, with the first phase commencing in July 2015, featuring two units of 5.1MW capacity (one unit at 2.55MW) An additional unit is set to be constructed in 2018, raising the total installed capacity to 7.65MW The plant boasts a flow rate of 28 m3/s, achieving a maximum generating capacity of 42.1m3/s and an impressive annual production of approximately 34.2 million kWh.
Figure 4.7 Ha Song Pha 1’s factory (Source: Internal Information of Company)
Main Product: -c- c 2 2211212112111111 11181 1121222
The company's primary offering is energy produced by its two hydroelectric power plants, HSP1 and HSP2 This energy is transmitted to the national power grid at a voltage of 110 kV, facilitating efficient distribution to consumers.
Electricity is a unique product, and regulations mandate that all customers purchase it solely from the Electricity of Vietnam (EVN), which is responsible for transmitting and selling electricity to consumers.
Company Structure
Figure 4.8 Ha Song Pha Company Structure
(Source: Internal Information of Company)
The General Meeting of Shareholders is the highest decision-making authority in the Company, comprising all voting Shareholders This annual meeting must occur within four months after the fiscal year ends, although the Board of Directors can extend it by up to six months if necessary In addition to the annual meeting, extraordinary meetings may also be convened The location of the General Meeting is determined by the chairperson, ensuring it takes place on Vietnamese territory.
The Supervisory Board is responsible for overseeing the Company's management and administration, guided by the Board of Directors and the Director Comprising three members, the Supervisory Board members serve a maximum tenure of five years, with the option for unlimited re-elections.
The Board of Directors serves as the primary management body of the company, holding full authority to make decisions and exercise the company's rights and responsibilities, except for matters reserved for the General Meeting of Shareholders Comprising five members, the Board's term is limited to a maximum of five years, with the possibility of unlimited re-elections.
The Director serves as the company's legal representative, overseeing daily operations and reporting directly to the Board of Directors This role entails accepting responsibility for the execution of assigned rights and obligations, ensuring compliance with legal standards and accountability to the Board.
Assist the Director in overseeing and guiding the Company's operations as assigned, taking accountability for the performance outcomes in designated areas of responsibility.
As a production unit, it is in charge of arranging and running the plants! electrical output
Taking the responsibility for the following tasks:
- Work in finance and accounting
- Human resources, human resource training and development, labor and salary, emulation and reward, company culture, administration, legal, contract management, and procurement
Taking the responsibility for the following tasks:
Effective technical management encompasses the operation and repair of equipment, information technology, and SCADA systems, while prioritizing environmental considerations and enhancing production and technology It also focuses on safety measures, disaster prevention strategies, fire prevention protocols, and search and rescue operations, along with the management of dam and reservoir safety.
- Create the execution of short and long-term production and business plans
Financial Performaice + 12 1121121121121 111111111111111111111 111110111111 11 1111111011111 11 1120 30 “900v Sẽ S
Below is a table of the Company's production and business results in 2020 and 2021: Table 4.4 Company’s Financial Statement
Average selling price of electricity Wh VND/k 1,175.36 1,190.26
4.4 Outsourcing Services VND 1,581,126,796 1,647,007,079 4.5 Expenses by cash VND | 13,150,039,850 | 13,425,621,220 4.6 Long-term Liabilities VND | 22,341,451,673 | 21,761,203,169 Profit by producing electricity VND | 16,322,245,793 | 19,562,406,534
Profit on exchange rate difference VND 0
(Source: Internal Information of Company)
The company has a team of young, dynamic, well-qualified and skilled leaders and technicians Professional and friendly working environment s* Threats
Power generation operators’ knowledge and professional expertise in terms of optimal calculation 1n operation are fairly limited
The company's headquarters and two factories are situated outside Phan Rang, approximately 50 kilometers from the city center Due to the distance of around 400 kilometers from Ho Chi Minh City, training programs for enhancing the professional skills of the operational staff are challenging This geographical barrier also complicates the retention of highly trained technical personnel for long-term employment in Ho Chi Minh City.
In Chapter 4, the author presents an overview of Ha Song Pha Hydropower Joint Stock Company, covering key aspects such as its production and business sectors, organizational structure, historical background, product offerings, as well as its strengths and weaknesses Additionally, the chapter analyzes the company's business performance over the past two years, providing a solid foundation for understanding the challenges faced by the organization.
FINDINGS 32 5.1 Flowchart of Electricity Productlon Process .- cà 2.2.2.1, 212121121212212212112112222 2122 32 5.2 DMAIC Process 33
Analyze
After analyzing statistics and data, it was found that the damage severity varies significantly among different error types Consequently, the team decided to prioritize the selection criteria based on the severity of damage caused by each fault They will then conduct a secondary evaluation based on the frequency of occurrence of these errors The DMAIC team has also agreed to utilize the fishbone diagram (Ishikawa cause and effect) to pinpoint the root causes of the three identified issues.
Did not check carefully, did not detect errors of the device
Flood brought small garbage, blocking the cooling system
Operators must constantly’ monitor computer screens, which causes fatigue
Inadequate maintenance and repair in accordance with regulations
Incorrect technique or n , den operation
The equipment is not maintained and p repaired according to regulations
Operation when safety precautions are Rain, flooding, and power grid problems not fully implemented in transmission lines all had an impact on objective conditions
Figure 5.15 P14's Fishbone analysis (Source: Author's analysis and collection result)
The first error we choose is P14 - Incidents due to equipment failures causing sudden stoppage of generating sets or units that cannot generate electricity - with the huge lost (230.000.000 VND)
The second error we choose base on the lost is D8 (Rain, flood carry mud, earth, stone do water fill heart lake so cause stop machine)
It cause total 193 400 000 VND for our company
Do not timely forecast the amount of flood discharge to the lake ewe
Working outside in the hot sun
Mud, soil, and rock fill obstructing the flow of water into the unit is not enough
Forecast not timely the amount of mud, soil, rock to fill the lake bed
Stop the machine to’ dredge mud, soil, rock
Working in rainy conditions, so the risk’ of errors is high
Untimely opening of the sand discharge sluice causes a large amount of sedimentation
Inadequate operation, inability to open the sand Not enough water to run the machine discharge culvert "
Slow operation, inability to open the sand drain in a timely manner
The amount of soil, rock mixed in the water, which is highly likely to damage the unit
Figure 5.16 D8's Fishbone analysis (Source: Author's analysis and collection result)
The R2 fault at the Da Nhim hydropower facility, located upstream of the Lower Song Pha, has significantly diminished its capacity or caused it to cease operations, leading to minimal or absent water flow This issue has critically impacted the plant's performance at the tank step.
Water to the lake is not enough, so’ the generating capacity of the generating units has to be reduced
The amount of water changes’ on a regular basis, the operators becomes fatigued
No water in the lake, so the units have to be stopped
Reduces capacity due to the reduced amount of water running the machine Reduce the capacity of the units
Machine stops due to running out of water Stop the units
Figure 5.17 R2's Fishbone analysis (Source: Author's analysis and collection result)
Additionally, this problem occurs quite frequently The two causes mentioned above result in R2 mistake, which results in the company's greatest overall loss — 687 750 000 VND
The author conducted interviews with three staff members from the dam, plant, and reservoir divisions, along with two DMAIC team experts, to identify the root causes of three critical problems Their insights highlighted the significance and urgency of each issue, providing a comprehensive analysis essential for addressing these challenges effectively.
The author provides strategies to address the high index in each error's causes in the table below, helping the improvement project to achieve the highest results
Due to insufficient water levels in the lake, the generating capacity of the units must be reduced, necessitating their temporary shutdown.
Reduce the capacity of the units
Reduces capacity duc to the reduced amount of water running the machine
Machine stops due to running out of water
The amount of water changes on a regular basis, the operators become fatigued
(Source: Author's analysis and collection result)
Tran Nguyén Tran Anh Sử Trường Phạm Đức Thông Trường Tiên Tuân Quang Hoàng Khôi
The improvement team made its decision after analyzing all the causes to choose:
- P14: Workers did not check carefully, did not detect errors of the device
- D8: Do not timely forecast the amount of flood discharge to the lake
Forecast not timely the amount of mud, soil, rock, to fill the lake bed
The DMAIC team held meetings, brainstoming to come up with solutions for the 8 causes identified in the Analysis step:
“+ SOLUTION FOR ERROR P14: Incidents due to equipment failures causing sudden stoppage of generating sets or units that cannot generate electricity
One significant cause of equipment errors is the lack of timely inspections by workers To address this, it's essential to assign technical managers to conduct regular checks and inspections of all devices, following a detailed maintenance plan aligned with the manufacturer's guidelines Ensuring adherence to this maintenance plan is crucial for optimal equipment performance Additionally, to mitigate mistakes arising from missed inspections, researchers are exploring the implementation of reminder software to enhance oversight and compliance.
Incorrect techniques or operations can lead to significant issues To address this, it is essential to implement annual professional training for the operating force and conduct regular inspections of their performance This includes providing thorough training and operating instructions for new equipment before use, as well as reinforcing compliance with operating procedures and labor discipline among the workforce.
SOLUTION FOR ERROR D8: Rain, flood carry mud, earth, stone do water fill heart lake so cause stop machine
To effectively manage flood risks, it is crucial to implement timely forecasting of flood discharge into the lake This can be achieved by developing comprehensive guidelines for flood forecasting and conducting annual training sessions to enhance the skills of reservoir managers Additionally, regular inspections of flood forecasting practices should be organized to ensure adherence to these guidelines Furthermore, researching and integrating advanced flood forecasting software will significantly improve the accuracy and reliability of predictions for the lake.
To address the issue of untimely forecasts regarding the accumulation of mud, soil, and rock in the lake bed, it is essential to develop comprehensive guidelines for accurate forecasting This includes organizing training sessions to enhance the forecasting skills of the annual operation shift leaders Additionally, implementing annual inspections of these leaders will ensure accountability and improve the accuracy of forecasts related to mud, soil, and rock accumulation in the lake bed.
Research and implement software solutions to forecast the necessary materials, such as mud, soil, and rock, for filling the lake bed The Da Nhim hydropower facility, located upstream of Lower Song Pha, has experienced a decrease in capacity or complete shutdown, leading to minimal or absent water flow.
To effectively manage the transmission grid in Ninh Thuan province, it is essential to regularly monitor and update the overload situation, allowing for optimal adjustments in the capacity of generating sets Additionally, reducing the capacity of the Da Nhim hydropower plant or halting operations can lead to significant water shortages in the reservoir Therefore, it is crucial to conduct research and calculate the economic efficiency of expanding reservoirs to enhance water storage for power generation, particularly during instances of grid overload.
Excessive noise in the workplace can significantly impact operators' performance and well-being To mitigate this, it is essential to provide noise-cancelling earplugs and enforce their regular use Additionally, installing soundproof cabins in the machine room can create a quieter environment for operators Furthermore, limiting exposure to equipment noise and thoughtfully scheduling working hours within the operator's machine space can enhance comfort and productivity.
Next, DMAIC team continue evaluating the feasibility, implementation time and investment capital for each solution
5 weeks (Source: Company internal documents)
Base on team’s evaluation, we decide to deploy 4 solutions
FEASIBILITY High Medium Medium Mdium Low High Low High High
- Create a detailed plan for the inspection and maintenance of each piece of equipment in line with the manufacturer's instructions Verify that the plan for equipment maintenance 1s being followed
Regular monitoring and timely updates of the transmission grid's overload status in Ninh Thuan province are essential This proactive approach enables the development of optimal strategies for adjusting the capacity of generating sets, ensuring efficient energy management and reliability in power supply.
- Equip noise-cancelling earplugs for operators and require frequent use to reduce the impact of noise
- Limit exposure to equipment noise and arrange the working hours in the operator's machine space sensibly
€ improvement of the operation system
The factory's capacity was greatly enhanced in April 2023 after the aforementioned improvement measures were put in place
Table 5.14 Electricity production capacity after improve
Date Quantity (kwh) Average flow per day (m3/s) Capacity
(Source: Company internal documents) d Estimated cost savings
The factoryt's average capacity has improved by 8% during the course of one month of improvement The sales data for the factory demonstrate this
Cost savings = Increase in revenue + Outsourcing expense
Based on the anticipated water volume to the lake, the improvement team created an operation plan and a maintenance schedule for the plant's machiner
Table 5.16 Machine maintenance plan for 2023
2_ | Hệ thông điều tốc TC TC TC TC
5 Thiét bi dong cắt điện áp D D máy phát (MC,DS )
6_ | Cáp 6,3kV và giá đỡ cáp D D
Máy biến áp kích từ và
7 _ | máy biến áp tự dùng p Đ
Hệ thống tự dùng 400 Vac Đ D D BD
9_ | Hệ thống nén khí TDC TDC TDC TDC
10 | Hệ thông nước kỹ thuật DC ĐC ĐC BC
Hệ thông bảo vệ, đo lường,
Mạng máy tính và mạch
14 | Hệ thông báo cháy tự động T T
15 | Cầu trục gian may TDC TDC
16 | Dorung, dé đảo 2 tổ máy TC | Tc | TC | Tc | Tc | TC | TC |] Te | Tc | Te | Te | TC
17 | Thiết bị cửa nhận nước TDC TDC
Month sTT Name 1 2 3 4 5 6 7 8 9 10 HW 12 Notes
18 Thiết bị cửa hạ lưu TĐ,C TDC
19 _ Hệ thống bơmtiêu TDC TDC
20 Vệ sinh trần gian máy Cc C
21 Tram dién 22kV TD TD TD TD
2 _ Thí nghiệm dầu bôi trơn
Sỉn lượng Chish CT | Sinlumg | Sie lugng | hon
43 HS? (kWh) ay) ‘i FA GW) | HS(kW) | H6 GW) tu lưng
Figure 5.19 Operation plan base on the amount of water (Source: Company internal information)
The Song Pha Hydropower facilities, located in Lam Son commune, Ninh Son district, Ninh Thuan province, Vietnam, are a vital part of the Pha-Ong river system The Lower Song Pha Hydropower Factory, operational since 2020, features three levels and boasts an installed capacity of 18 MW, generating approximately 102 million kWh of electricity annually This article will explore the project execution at the Lower Song Pha facility, utilizing the Six Sigma technique and the DMAIC implementation process to enhance the efficiency of its power generation operations.
As aresult, the author offers suggestions for improvement, addition, and correction
The author used a number of tools learned during the actual working process, including the DMAIC method, quality management tools, and the Six Sigma theory, to achieve the aforementioned goal
The factory faced widespread failures across all levels, leading to reduced plant capacity and unsatisfactory performance To address this challenge, the DMAIC method was implemented to improve the productivity of the production line.
Following its completion, the project produced the following outcomes:
- Discovered fifteeen significant failures that often arise in three stages of the production line
- Measure each failure and determine its root causes
- Provide improvement strategies for the three failuress that have the most effects on performance
- Putting into practice four potential solutions while carrying out the project, and assessing the project's effects on the business
- Make suggestions to the business on how to continue and increase production in the future
My attachment experience has significantly enhanced my understanding by allowing me to apply theoretical knowledge from university to practical situations through various thesis-related activities This process has not only provided me with valuable insights and hands-on experience but also taught me important lessons from the real working environment The thesis served as a comprehensive assessment of my strengths and weaknesses, helping me identify the skills I need to improve for my future career.