Upload
wannarat-tan-arkardvipart
View
219
Download
1
Tags:
Embed Size (px)
DESCRIPTION
Management system
Citation preview
1
Understanding and Applying
Management System
2
• What is Management System?
• Plan-Do-Check-Act
• Management System vs. Tool
• Example and Application
• Presentation and Summary
Agenda
3
What is Management System?
Management System is the framework of processes and procedures for
establishing accountability, schedule for activities to be completed as well as
auditing tools to implement corrective actions to continuous improvement the
processes by which an organization defines and achieves its goals/targets
Source: ISO, Wikipedia http://www.thecqi.org/Knowledge-Hub/Knowledge-portal/Compliance-and-organisations/Management-system-standards/
Base on Principle of Plan-Do-Check-Act 4
Goal/Target
Benefit • Improve quality
• Cost savings
• Reduce environ.
impacts
• Increase
productivity
• Etc.
MS Framework Drive to Achieve Target Philosophy of Continuous Improvement and PDCA
5
Plan • Review and establish
objectives, targets, KPIs and
action plans
Do • Implement the plan
• Collect data for analysis in
the following "CHECK" and
"ACT" steps
Check • Monitoring/measure and
study the result
• compare against the
expected results (targets or
goals from the "PLAN")
Act • Request corrective
actions on differences
actual vs. planned results
• Determine whether to adopt the
change
PDCA Control to Continuous Improvement
Advantage 1) Cycle to continuous improvement 2) Force/control to cautious
6
Management System vs. Tool Different point is clearly/obvious accountability
Management System
Tool
Management System
1. Framework of processes
and procedures
2. Establish goals/objectives
3. Accountability (an
assignment of personal
responsibility)
4. Schedule for activities
5. Auditing tools to
implement corrective
actions
6. Creating an upward spiral
of continuous
improvement
Tool
• Be used to achieve a
goal
• Procedure or process
with a specific purpose
• Technology
Management System
Tool
Source: ISO, Wikipedia http://www.thecqi.org/Knowledge-Hub/Knowledge-portal/Compliance-and-organisations/Management-system-standards/
7
• Increased energy efficiency
• Reduced costs
• Improved energy performance
Definition Advantage/Benefit Industries
+
• Environmental
Management System *Base ISO9001
• All Industries,
Company, hospital, etc.
• Reduce cost of waste management
• Savings in energy and materials
• Improved corporate image
• Good
Manufacturing Practice
• Improved Product Consistency
• Helps to Lower Costs
• Legal requirement
• Quality Management System
• All Industries,
company, hospital, etc.
• Common tool for standardization
• Improves quality, employee motivation, awareness, and morale
• Energy Management
System *Base ISO9001, ISO14001
• All Industries
Especially energy business group
• Food, drug and
pharmaceutical
products
+
+
+
• Food Safety
Management System *Base PRPs, HACCP, ISO9001
• Food and food
supply chain
industries
• The product became safer
• Food quality
• Control focused on what is necessary
+ +
• Hazard analysis and critical control points
• Food safety and
biological, chemical,
physical hazards
• Food safety and quality increase
• Organizes your process to produce
safe food
+ +
+ +
+
+
+
+
+ +
Example: Application for Management System and Tool
8
• What is Management System?
• Plan-Do-Check-Act
• Management System vs. Tool
• Example and Application
• Presentation and Summary
Agenda
9
ISO50001 Energy Management System Increased energy efficiency and Improved energy performance
10
General Requirement of ISO50001
• Top Manager set Energy Policy and EnMR
- Set boundary and scope of EnMS
- Cont. improve energy performance including EE
- Aim for follow a legal and other energy requirements
• Establishing guidelines and provisions
- Review, Analyse and identify significant energy use
- Set baseline, EnPIs, Target and action plan
• Training/Communicate/Document/Control/Design
- EnM Team has adequate skills to control the EnMS
- Appropriate communicate channels should be defined
- System require the procedure and plan in place
- Operational and design to reduce energy guidelines
- Collaboration with supplier is key in becoming in ‘greener’
- Monitoring significant energy use and EnPIs
- Check effectiveness and compare with
expectation
- Revise nonconformities and find reason
- Evaluation of legal requirement and others
- Revise effectiveness and adjust
- Can be conducted as a part of
organization’s audit programme
- Examine the EnMS conform to
energy objectives and target
• Report Result
- Reassures top
management role
and responsibility
- Accelerates the
EnMS progress for
continual improve
- Understands and
recognizes the
changes made
- Evaluate people’s
effort
Energy Policy
Energy Planning
Implementation and Operation
Monitoring and Measurement
Internal Audit of EnMS
Management Review
Checking
Nonconformities and preventive action
Continual Improvement
P
D
C
A
11
Example Policy: Food Quality and Safety
Source: http://singhabeverage.co.th/index.php?route=about/about&about_id=3
12
Example Policy: Environment
Source: http://www.toyota.co.th/about.php?page=policy
13
Example Plan:
Source: TOTAL Annual Report
14
Example Plan: Energy Planning Roadmap
Source: European Industrial Initiative on bioenergy
KPIs Target
Cost of energy/product volume ($/L) 2.3 1.9 1.8 1.5 1.3 1.1
Example Do: Energy Saving Initiative
Source: http://www.enconlab.com/ve/measure.html 15
16
Example Do: HACCP Process Step: ร่อนแป้งด้วยเคร่ือง Tru Balance Sifter
Food Safety Hazards and Cause Physical อนัตรายจากเศษ ไม้ โลหะ เศษหิน ที่ติดมบัแป้ง และตะแกรงที่หลดุลอ่นจากเคร่ืองร่อน Chemical สารหลอ่ลืน่จากเคร่ืองมือ Biological Bacillus cereus
Control Measures ใช้ตะแกรงร่อนแป้ง ขนาด 850 ไมครอนจ านวน 3 ชัน้ และต้องเปลีย่นทกุ 2 สปัดาห์ถึงแม้จะไมช่ ารุดก็ตาม ตรวจสอบข้อตอ่และมอเตอร์ก่อนเร่ิมปฏิบตัิงานวา่มีลอ่งลอยของคราบน า้มนัไหลออกมาหรือไม ่ตรวจสอบเคร่ืองร่อนแป้งก่อนใช้งานวา่ที่บนัทกึการท าความสะอาด จากนัน้ตรวจสอบด้วยตาเปลา่วา่มีคราบหรือเศษแป้งติดอยูห่รือไม ่จากนัน้ใช้แอลกอฮอล์ความเข้าข้น 70% พน่และเช็ดออกด้วยผ้าแห้งก่อนใช้งานเคร่ืองมือคร่ึงชัว่โมง
CCP No. Critical /Legal Limit MONITORING PLAN CORRECTIVE ACTION PLAN
Procedures frequency Responsibility Records Procedures Responsibility Records
CCP 1 - ตรวจสอบตะแกรงห้ามมีลอยขาดหรือการช ารุดโดยเด็ดขาด - ห้ามมีคราบน า้มนัไหลออกจากเคร่ืองร่อนแป้ง
- ตรวจสอบตะแกรงเหลก็ด้วยตาเปลา่ - ตรวจสอบคราบตา่งๆตามเคร่ืองร่อนแป้ง
-ทกุๆ 1 ชัว่โมงขณะเคร่ืองร่อนแป้งท างาน
-QC operator -บนัทกึลงเอกสาร QC Daily ทกุครัง้ที่ตรวจสอบ
-หากตะแกรงขาดให้หยดุกระบวนการผลติทนัที ท าการเปลีย่นตะแกรงใหมแ่ละท าลาย โดที่เกิดจากการผลติโดยแป้งสาลีนีย้้อนหลงั 1 ชัว่โมงทิง้ทัง้หมด แล้วด าเนินการผลติตอ่
-QC supervisor -Maintenance division
บนัทกึลง Daily, Weekly and monthly report เพื่อประเมินความเสยีหายตอ่ไป
Version: 1.0 Date: xxx Completed By: QC Supervisor Checked: QC manager
17
Example Check: Monitoring Number of Students in Library
18
Example Check: Output Energy Monitoring
Source: Annual and CSR reports
19
ISO14001 Environmental Management System Prevention and control of Pollutions
20
General Requirement of ISO14001
• Top Manager set Environment Policy and EMR
- Set boundary and scope of EMS
- Cont. improve environment impact
- Aim for follow a legal and other envi requirements
• Establishing guidelines and provisions
- Identify significant environmental aspects (SEAs)
- Set KPI, Target and action plan
• Training/Communicate/Document/Control
- EM Team has adequate skills to control the EMS
- Appropriate communicate channels should be defined
- System require the procedure and plan in place
- Operational and control to reduce envi impact
- Emergency preparedness & response
- Monitoring significant energy use and KPIs
- Check effectiveness and compare with
expectation
- Revise nonconformities and find reason
- Evaluation of legal requirement and others
- Revise effectiveness and adjust
- Can be conducted as a part of
organization’s audit programme
- Examine the EnMS conform to
energy objectives and target
• Report Result
- Reassures top
management role
and responsibility
- Accelerates the
EMS progress for
continual improve
- Understands and
recognizes the
changes made
- Evaluate people’s
effort
Environment Policy
Environmental Planning
Implementation and Operation
Monitoring and Measurement
Internal Audit of EMS
Management Review
Checking
Nonconformities and preventive action
Continual Improvement
P
D
C
A
21
HACCP Hazard Analysis and Critical Control Points Food safety and increase quality
22
HACCP Plans are based on the 7 HACCP Principles
Conduct a hazard analysis
Determine the critical control
points (CCP)
Establish critical limits (CL)
Establish the corrective action
to be taken
Establish procedures for verification to confirm
Establish a system to monitor
control of the CCP
Establish documentation
concerning all procedures
• List all the hazards expected to occur at each step process • Decide which potential hazards should be addressed in plan
• Determine by using a decision-tree which facilitates a
logical approach
• Critical limits – temp, time, moisture level, pH and
sensory parameters (visual, texture) – should be scientifically
• Monitor/measure a CCP relative to its critical limits • Monitoring should be recorded
• Specific corrective actions should be developed for each CCP and ensure the CCP is brought under control
• Procedures should be established for verification
• Verification activities e.g. review HACCP system and its record
• Accurate document and record keeping are essential to the application of HACCP System
P
D
C
A
23
Example Output: Control Hazard:
- Physical: swarf
- Chemical: lubricant
- Biological: fungi
Monitoring CCP and
compare with standard
Corrective action plan
24
Plan
Do
Check
Act
• Energy policy
• Energy review
• Set objectives, targets and
action plan
• Establish baseline
• Set EnPIs
• Environmental policy
• Environmental aspects
• Set objectives, target and
programme
• Determine the critical control
points (CCP)
• Hazard analysis
• Hazard identification
• Implement energy
management action plan
• Prevention and control
of pollution • Conduct a hazard
analysis
• Establish critical limits
(CL)
• Monitor and measure
process
• Determine energy
performance vs. energy
policy and objective
• Monitoring and
measurement
• Establish a system to
monitor control of the
CCP
• Take actions to
continually improve
energy performance and
EnMS
• Take action to
continually prevent and control pollution
• Establish the corrective
action to be taken
Principle Requirement for Management System
25
Policy
KPI and Target
• Top Management shall support and drive policy to
success
• Planning shall set KPI and target to assessment
• Focus on critical point
• Corrective action and plan to adopt
Key Success Factors in Management System
Implement
Monitoring
Take action to
continuous improvement
Explanations Keys
• Implement action plan and collect data
• Measuring and monitoring to assessment and compare
with target
Achievable
Relevant
Time phased
Measurable
Specific
26
“SMART” The Five Conditions of a Good KPI and Target
• It has to be clear what the KPI exactly measures
• The KPI has to be measurable to define a standard to
make it possible to measure the actual value comparable
• Nothing is more discouraging than striving for a goal
that you will never obtain
• The KPI must give more insight in the performance of the organization in obtaining its strategy
• It is important to express the value of the KPI in time
• Every KPI only has a meaning if one knows the time dimension in which it is realized
Source: http://www.lltcorp.com/content/kpi-s-m-r-t-rule
27
• What is Management System?
• Plan-Do-Check-Act
• Management System vs. Tool
• Example and Application
• Presentation and Summary
Agenda
Learning Point
28
Key Learning ISO 50001
Learning Point
• Manage data
• How importance of KPI and monitoring
• Setting suitable baseline is importance to analyze result
• To set Boundary
• Critical control point is the most important in the process, and if
there is some problem in CCP, plant will shutdown immediately
• Understand significant data
• Use or not use
• Correct or incorrect
Key Learning HACCP
29
Exercise Workshop
Production in Ton
Ethan Propane LPG NGL
2005 9,000 12,500 47,000 8,000 76,500 76,500
2006 9,150 12,700 48,000 8,500 78,350 78,350
2007 9,100 12,800 50,000 9,000 80,900 80,900
2008 9,200 13,000 52,000 10,000 84,200 84,200
2009 9,300 13,500 53,000 10,000 85,800 85,800
2010 9,500+15,000(ESP) 14,000 55,000 11,00089,500 89,500 15000
2011 10,000+30,000(ESP) 15,000 65,000 12,000102,000 102,000 30000
2012 10,000+40,000(ESP) 15,000 65,000 12,000102,000 102,000 40000
2013 12,000+20,000(ESP) 18,000 70,000 14,000114,000 114,000 40000
Energy consumption in GJ
In GJ Hg RemovalCO2
Removal
Gas
DryerLiquid Dryer
De-
Methani
zer
De-
Ethanize
r
De-
Propemi
zer
ESP
2005 7,000 90,000 17,000 25,000 45,000 32,000 50,000 -
2006 8,000 90,000 18,000 27,000 45,000 35,000 50,000 -
2007 7,000 85,000 17,500 29,000 43,000 33,000 53,000 -
2008 8,500 10,000 19,000 28,000 50,000 36,000 57,000 -
2009 9,000 95,000 19,500 30,000 47,000 38,000 58,000 -
2010 9,500 90,000 20,000 29,000 45,000 38,000 59,000 400,000
2011 10,000 95,000 20,000 30,000 50,000 40,000 62,000 600,000
2012 10,000 95,000 20,000 30,000 50,000 40,000 62,000 700,000
2013 11,000 100,000 20,500 30,000 50,000 43,000 64,000 705,000