CN112348382A - Asset integrity management system and method based on PDCA process management - Google Patents
Asset integrity management system and method based on PDCA process management Download PDFInfo
- Publication number
- CN112348382A CN112348382A CN202011264730.4A CN202011264730A CN112348382A CN 112348382 A CN112348382 A CN 112348382A CN 202011264730 A CN202011264730 A CN 202011264730A CN 112348382 A CN112348382 A CN 112348382A
- Authority
- CN
- China
- Prior art keywords
- management
- submodule
- planning
- module
- equipment
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Images
Classifications
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0635—Risk analysis of enterprise or organisation activities
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/06—Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
- G06Q10/063—Operations research, analysis or management
- G06Q10/0639—Performance analysis of employees; Performance analysis of enterprise or organisation operations
- G06Q10/06393—Score-carding, benchmarking or key performance indicator [KPI] analysis
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/10—Office automation; Time management
- G06Q10/103—Workflow collaboration or project management
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/20—Administration of product repair or maintenance
Landscapes
- Business, Economics & Management (AREA)
- Human Resources & Organizations (AREA)
- Engineering & Computer Science (AREA)
- Strategic Management (AREA)
- Entrepreneurship & Innovation (AREA)
- Economics (AREA)
- General Business, Economics & Management (AREA)
- Marketing (AREA)
- Operations Research (AREA)
- Quality & Reliability (AREA)
- Tourism & Hospitality (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Theoretical Computer Science (AREA)
- Development Economics (AREA)
- Educational Administration (AREA)
- Game Theory and Decision Science (AREA)
- Data Mining & Analysis (AREA)
- Management, Administration, Business Operations System, And Electronic Commerce (AREA)
Abstract
The invention has proposed an asset integrality management system and method based on PDCA process management, the system includes administrative layer, asset integrality management database and analysis tool; the management layer comprises a plan strategy module, an execution module, a check summary module and an improvement management module; the plan strategy module is used for making a plan strategy according to the asset integrity management database; the execution module is used for executing enterprise risk classification, asset life cycle management, training and performance indexes according to the plan strategy; the inspection summary module is used for evaluating the management system and analyzing the faults of the equipment; the improved management module is used for correcting various deviations of the enterprise in the asset integrity management and improving the enterprise management process. Based on the system, the invention also provides an asset integrity management method. The invention carries out closed-loop management on equipment management, covers the management of the whole life cycle of the equipment, forms a systematic management idea and can improve the efficiency of enterprise equipment management.
Description
Technical Field
The invention belongs to the technical field of enterprise asset management, and particularly relates to an asset integrity management system and method based on PDCA process management.
Background
Asset integrity management systems are a management system that ensures the integrity of assets throughout their life cycle in process manufacturing facilities, and are now being used and agreed upon by the various petroleum, petrochemical and hazardous chemical manufacturing facilities of the world in order to obtain the necessary and sufficient life-cycle attention to equipment that is involved in hazardous or toxic chemicals, thereby minimizing the risk of hazardous consequences that may result from the release of such chemicals. PDCA refers to Plan, Do, Check, and Action to embody different management phases.
The implementation methods published in the prior art include equipment integrity management informatization system research of oil refining chemical industry, Liushufen and the like, scientific management [ J ], No. 7 of 2020, and patent document, namely a risk-based equipment integrity management system of oil refining enterprises, with the application number of 201510264512.3. The implementation modes in the prior art have the following characteristics respectively: firstly, technical management software is installed on a central database of a management system, and the technical management software comprises a system management module, a risk management module, an execution management module, a quality management module, an ITPM management module, a fortification management module, a defect management module, a change management module and an integrity strategy module for management. Secondly, the integration of equipment state monitoring data is realized by using a portal technology, a key equipment continuity and reliability analysis method is applied to equipment classification in an equipment maintenance stage, factors such as equipment fault root cause, occurrence frequency, fault distribution and trend are analyzed by using a quality assurance analysis method, and a preventive maintenance list is formed by using a maintenance decision modeling and state monitoring technology. However, in the implementation mode of the existing integrity management system, the closed-loop management of an integrity system to equipment is not embodied, the missing closed-loop management causes the problems which are not eradicated and can continuously occur, and the management level can not be improved through improvement. The existing integrity management platform mainly focuses on management in the equipment maintenance stage, and is not sufficient for early-stage attention of equipment, but actually, the early-stage management of the equipment has a considerable influence on the reliability of the equipment. The existing integrity management platform mainly relies on historical fault data of equipment to carry out modeling calculation, and a big data system and an artificial intelligence algorithm are not utilized to carry out auxiliary correction.
Disclosure of Invention
In order to solve the technical problems, the invention provides an asset integrity management system and method based on PDCA process management, which adopts a plan strategy module, an execution module, a check summary module and an improved management module to carry out closed-loop management on equipment management, forms a systematic management thought, can improve the efficiency of enterprise equipment management, reduces the risk loophole of the equipment management, and covers the management of the whole life cycle of the equipment.
In order to achieve the purpose, the invention adopts the following technical scheme:
an asset integrity management system based on PDCA process management comprises a management layer, an asset integrity management database and an analysis tool;
the management layer comprises a plan strategy module, an execution module, a check summary module and an improvement management module; the planning strategy module is used for making planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes according to the asset integrity management database; the execution module is used for executing enterprise risk classification, asset full life cycle management, training and performance indexes according to the planning strategy; the inspection and summary module is used for evaluating the management system based on the execution results of risk classification management and control and asset full life cycle process management, evaluating performance indexes based on the execution of training and performance indexes, analyzing equipment faults in asset full life cycle management through an analysis tool, and checking the loopholes of equipment management in a backward pushing mode; the improvement management module is used for correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the vulnerability of equipment management; finally, the management of the enterprise equipment forms closed-loop management;
the analysis tool provides a management layer with a tool for analyzing the risk and the fault of the asset integrity management database;
the asset integrity management database provides an enterprise asset basic database and a real-time database for the management layer module; the real-time database is combined with a big data system, and the analysis and judgment of the enterprise equipment by the basic database are corrected in real time through an artificial intelligence algorithm.
Further, the basic database comprises an enterprise equipment basic information database, a failure mode and mechanism information database, a position responsibility information database and a legal regulation standard information database.
Further, the real-time database comprises an enterprise device operation real-time database, an online and offline equipment state monitoring database, a material analysis system database and other management software databases.
Further, the analysis tool includes a hazard and operability analysis submodule, a sheath analysis submodule, a safety integrity level submodule, a reliability-centric repair submodule, a fault tree analysis submodule, and 5 cause submodules.
Further, the plan strategy module comprises a risk grading strategy submodule, a full life cycle process planning submodule, an inspection detection and preventive maintenance planning submodule, a defect planning submodule, a change planning submodule, a spare part planning submodule, a third-party service planning submodule, a post duty planning submodule, a training planning submodule and a performance planning submodule;
the risk classification strategy submodule is used for firstly planning an equipment risk classification flow and then customizing a risk classification criterion;
the whole life cycle process planning submodule is used for selecting corresponding laws, regulations, specifications, standards, company management regulations and excellent management modes of enterprises according to the risk grade of the risk grading strategy submodule, and planning various working processes and control measures of equipment in the whole life cycle in design, manufacture, installation, test run, operation, maintenance, update and disposal;
the inspection detection and preventive maintenance planning submodule is used for planning the engineering flow of inspection detection and preventive maintenance and the range and type of equipment needing to carry out inspection detection and preventive maintenance according to the risk level of the risk grading strategy submodule;
the defect planning submodule is used for planning the management flow of the defects, the criteria of defect identification and risk evaluation and the acceptance criteria of the defects according to the risk level of the risk grading strategy submodule;
the change planning submodule is used for planning the changed management flow and the change identification and risk evaluation criterion according to the risk level of the risk grading strategy submodule;
the spare part planning submodule is used for planning a spare part management flow, a quality acceptance standard, a storage requirement and a safety stock according to the risk level of the risk grading strategy submodule;
the third-party service planning submodule is used for planning the management flow, qualification requirement, training requirement and field service requirement of a third party related to the equipment;
the post responsibility planning submodule is used for planning the post responsibility which is supposed to be undertaken by the enterprise equipment management personnel and the internal related party;
the training planning submodule is used for planning a management process of training;
and the performance planning submodule is used for selecting a proper index according to the goal of asset integrity management, determining the weight of the proper index and planning the acquisition requirement of the index.
Furthermore, the execution module comprises a risk grading execution sub-module, a full life cycle process execution sub-module, an inspection detection and preventive maintenance execution sub-module, a defect execution sub-module, a change execution sub-module, a spare part execution sub-module, a third party service execution sub-module, a post duty execution sub-module, a training execution sub-module and a performance execution sub-module;
after the risk classification planning submodule is completed, the risk classification execution submodule carries out risk classification on various devices in the asset integrity management range according to the basic database and inputs a classification result into the platform;
the full life cycle process execution submodule is used for executing various working processes and control measures of the equipment after the full life cycle process planning submodule is completed;
the inspection detection and preventive maintenance execution submodule is used for executing the working process of inspection detection and preventive maintenance after the inspection detection and preventive maintenance planning submodule is finished, determining the plan of different types of equipment needing to execute inspection detection and preventive maintenance tasks according to the formulated inspection detection and preventive maintenance scheme, and finishing the inspection detection and preventive maintenance tasks according to the plan;
the defect execution submodule is used for executing a defect management process after the defect planning submodule is finished, identifying the defects, carrying out risk evaluation on the defects, and selecting a proper maintenance mode for processing according to the risk level of the defects;
the change execution submodule is used for executing the management flow of the change after the change planning submodule is finished, identifying the change and carrying out risk evaluation on the change, wherein the change with allowable risk can be executed, and the change with unallowable risk can not be executed until the risk is allowable;
the spare part accessory execution submodule is used for performing warehousing quality acceptance according to the quality acceptance standard of the planned spare part accessories after the spare part accessory planning submodule is finished, storing the spare part accessories according to the storage requirement and ensuring that the number of the spare part accessories is not lower than that of the safety warehouse;
the third-party service execution submodule is used for supervising the qualification, training condition, on-site operation evidence development and on-site service completion condition of service personnel of a third-party contractor after the third-party service planning submodule is completed;
the post responsibility execution submodule is used for executing different authorities of each post at each process node after the post responsibility planning submodule is finished, and recording the completion condition of each post worker;
the training execution sub-module is used for carrying out training requirement investigation, training plan arrangement, training implementation and examination on each post personnel after the training planning sub-module is completed;
and the performance execution submodule is used for collecting various established indexes and recording a collection result after the performance planning submodule is finished.
Furthermore, the inspection and summary module comprises an equipment fault accident analysis sub-module, a management system evaluation sub-module and a performance index evaluation sub-module;
the equipment fault accident analysis submodule carries out root cause analysis on equipment faults recorded in the fault execution submodule and other accidents caused by the equipment faults by adopting an analysis tool, and detects equipment management bugs in a backward pushing mode;
the management system evaluation submodule is used for evaluating a management system based on risk classification management and control, asset full life cycle process management, inspection detection and preventive maintenance management, defect management, change management, spare part management, third-party service management, responsibility and training management, personnel training and performance management;
and the performance index evaluation submodule is used for automatically calculating and comparing with the index requirement standard according to each acquired and recorded index after the performance execution submodule is finished, and generating an analysis report.
Further, the improvement management module comprises an equipment fault accident improvement submodule, an enterprise management improvement submodule and a performance index improvement submodule;
the equipment fault accident improvement submodule is used for respectively improving inspection detection, preventive maintenance and defects according to an execution result of the equipment fault accident analysis submodule;
the enterprise management improvement submodule is used for improving risk classification, improving whole life cycle process, changing, improving spare parts, improving third-party service, improving post responsibility and improving training in the enterprise management process.
And the performance index improvement submodule is used for improving the performance index according to the analysis report generated by the performance index evaluation submodule.
Further, the defect of the defect execution submodule is automatically recorded in a platform failure mode and mechanism database.
The invention also provides an asset integrity management method based on PDCA process management, which comprises the following steps:
firstly, establishing an asset integrity management database, and then developing risk grading plan on enterprise equipment; the database comprises a basic database and a real-time database;
after the risk classification planning is finished, planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes are made according to the asset integrity management database;
executing enterprise risk classification, asset full life cycle management, training and performance indexes according to the planning strategy;
evaluating a management system based on execution results of risk classification management and control and asset full-life-cycle process management, evaluating performance indexes based on training and performance index execution, performing fault analysis on equipment faults in asset full-life-cycle management through an analysis tool, and checking loopholes of equipment management in a backward mode;
correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the vulnerability of equipment management; and finally, forming closed-loop management for the management of the enterprise equipment.
The effect provided in the summary of the invention is only the effect of the embodiment, not all the effects of the invention, and one of the above technical solutions has the following advantages or beneficial effects:
the invention has proposed an asset integrality management system and method based on PDCA process management, the system includes administrative layer, asset integrality management database and analysis tool; the management layer comprises a plan strategy module, an execution module, a check summary module and an improvement management module; the planning strategy module is used for making planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes according to the asset integrity management database; the execution module is used for executing enterprise risk classification, asset life cycle management, training and performance indexes according to the planning strategy; the inspection summary module is used for evaluating the management system based on the execution results of risk classification management and control and asset full life cycle process management, evaluating performance indexes based on the execution of training and performance indexes, analyzing equipment faults in asset full life cycle management through an analysis tool, and checking the loopholes of equipment management in a backward mode; the improvement management module is used for correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the loophole of equipment management; and finally, forming closed-loop management for the management of the enterprise equipment. The analysis tool provides a tool for analyzing the risk and the fault of the asset integrity management database for the management layer; the asset integrity management database provides an enterprise asset basic database and a real-time database for the management layer module; the real-time database is combined with a big data system, and the analysis and judgment of the enterprise equipment by the basic database are corrected in real time through an artificial intelligence algorithm. Based on the system, the invention also provides an asset integrity management method based on PDCA process management. The planning strategy module, the execution module, the inspection summary module and the improvement management module carry out closed-loop management on equipment management, form a systematic management idea, can improve the efficiency of enterprise equipment management and reduce the risk loophole of the equipment management. All modules are organically combined through flow circulation, and finally, the performance index evaluation, the equipment fault accident analysis and the management system review are carried out for inspection and summary, so that the improvement is realized, and the aim of continuously updating the equipment management is fulfilled.
The invention covers the management contents of the whole life cycle of the equipment, including the management contents of each stage of design, purchase, manufacture, installation, test run, operation, maintenance, update and disposal, and comprehensively controls the quality of each link of equipment management.
The invention not only utilizes the historical fault data of the equipment, but also records the defect and fault data of the platform during the operation period, so that the database is continuously updated by self. And automatically recording the defect execution of the defect execution management module to a platform failure mode and mechanism database, and continuously enriching and correcting the contents of the failure mode and mechanism database. Meanwhile, the accuracy of analyzing and judging the equipment fault by the platform is improved by combining a big data system and an artificial intelligence algorithm.
Drawings
Fig. 1 is a schematic diagram of an asset integrity management system based on PDCA process management according to embodiment 1 of the present invention;
fig. 2 is a schematic diagram of a management layer system in process management based on PDCA in embodiment 1 of the present invention;
fig. 3 is a flowchart of an asset integrity management method based on PDCA process management according to embodiment 2 of the present invention.
Detailed Description
In order to clearly explain the technical features of the present invention, the following detailed description of the present invention is provided with reference to the accompanying drawings. The following disclosure provides many different embodiments, or examples, for implementing different features of the invention. To simplify the disclosure of the present invention, the components and arrangements of specific examples are described below. Furthermore, the present invention may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. It should be noted that the components illustrated in the figures are not necessarily drawn to scale. Descriptions of well-known components and processing techniques and procedures are omitted so as to not unnecessarily limit the invention.
Example 1
The embodiment 1 of the invention provides an asset integrity management system based on PDCA process management. Fig. 1 is a schematic diagram of an asset integrity management system based on PDCA process management according to embodiment 1 of the present invention, where the system includes a management layer, an asset integrity management database, and an analysis tool.
The asset integrity management database provides an enterprise asset basic database and a real-time database for the management layer module; the real-time database is combined with a big data system, and the analysis and judgment of the enterprise equipment by the basic database are corrected in real time through an artificial intelligence algorithm.
Wherein the base database comprises: the system comprises an equipment basic information database submodule, a failure mode and mechanism database submodule, a post responsibility database submodule and a legal regulation standard database submodule.
The real-time database includes: the device runs a real-time database submodule, an online and offline equipment state monitoring database submodule, a material analysis system database submodule and other management software database submodules. The real-time database also combines the assistance of a big data system and an artificial intelligence algorithm.
The Analysis tools of the present invention relate primarily to risk and failure Analysis tools, including the HAZOP (Hazard and Operability Analysis) tool, the LOPA (Layer of Protection Analysis) tool, the SIL (Safety Integrity Level) tool, the RCM (Reliability Centered Maintenance) tool, the FTA (Fault Tree Analysis) tool, and the 5why (5 reasons) tool.
Fig. 2 is a schematic diagram of a management layer in PDCA-based process management according to embodiment 1 of the present invention. The management layer comprises a plan strategy module, an execution module, a check summary module and an improvement management module. The planning strategy module is used for making planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes according to the asset integrity management database; the execution module is used for executing enterprise risk classification, asset full life cycle management, training and performance indexes according to the planning strategy; the inspection and summary module is used for evaluating the management system based on the execution results of risk classification management and control and asset full life cycle process management, evaluating performance indexes based on the execution of training and performance indexes, analyzing equipment faults in asset full life cycle management through an analysis tool, and checking the loopholes of equipment management in a backward pushing mode; the improvement management module is used for correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of the enterprise and the performance evaluation flow based on the result of the performance index evaluation and improving the management of the equipment fault based on the vulnerability of the equipment management; and finally, forming closed-loop management for the management of the enterprise equipment.
The planning strategy module comprises a risk grading strategy submodule, a full life cycle process planning submodule, an inspection detection and preventive maintenance planning submodule, a defect planning submodule, a change planning submodule, a spare part planning submodule, a third-party service planning submodule, a post duty planning submodule, a training planning submodule and a performance planning submodule.
The risk classification strategy submodule is used for firstly planning an equipment risk classification flow and then customizing a risk classification criterion; this includes ranking criteria for the severity of the consequences of a device failure and the likelihood of a device failure, as well as ranking criteria for the risk in a risk matrix where the severity of the consequences and the likelihood of failure constitute two dimensions.
The whole life cycle process planning submodule is used for selecting corresponding laws, regulations, specifications, standards, company management regulations and excellent management modes of each enterprise according to the risk grade of the risk grading strategy submodule, and planning various working processes and control measures of equipment in the whole life cycle in design, manufacture, installation, test run, operation, maintenance, update and disposal; the process settings and control measures may differ for different risk levels of the device.
The inspection detection and preventive maintenance planning submodule is used for planning the engineering flow of inspection detection and preventive maintenance and the range and type of equipment needing to carry out inspection detection and preventive maintenance according to the risk level of the risk grading strategy submodule; different inspection tests and preventive maintenance protocols are determined for different equipment types, the protocols including how to use the data from the failure mode and mechanism database and the real-time database for calculations. The process settings and schemes may differ for devices of different risk levels.
The defect planning submodule is used for planning the management flow of the defects, the criteria of defect identification and risk evaluation and the acceptance criteria of the defects according to the risk level of the risk grading strategy submodule; the process settings and criteria may differ for devices of different risk levels.
The change planning submodule is used for planning the changed management flow and the change identification and risk evaluation criterion according to the risk level of the risk grading strategy submodule; the process settings and criteria may differ for devices of different risk levels.
The spare part planning submodule is used for planning a spare part management flow, a quality acceptance standard, a storage requirement and a safety stock according to the risk level of the risk grading strategy submodule; the process settings and criteria may differ for devices of different risk levels.
The third-party service planning submodule is used for planning the management flow, qualification requirement, training requirement and field service requirement of a third party related to the equipment; process settings and requirements may differ for third parties involved in servicing equipment at different risk levels.
The post responsibility planning submodule is used for planning the post responsibility which the enterprise equipment manager and the internal related party should undertake; and planning the post responsibilities to be undertaken by the enterprise equipment management personnel and the internal related parties.
The training planning submodule is used for planning a management process of training; the skills that the personnel of each post should have and the training courses that should be accepted in order to achieve the skills.
And the performance planning submodule is used for selecting a proper index according to the goal of asset integrity management, determining the weight of the index and planning the acquisition requirement of the index.
The execution module comprises a risk grading execution sub-module, a full life cycle process execution sub-module, an inspection detection and preventive maintenance execution sub-module, a defect execution sub-module, a change execution sub-module, a spare part execution sub-module, a third-party service execution sub-module, a post duty execution sub-module, a training execution sub-module and a performance execution sub-module.
And after the risk classification planning submodule is completed, the risk classification execution submodule carries out risk classification on various devices in the asset integrity management range according to the basic database and inputs a classification result into the platform.
The full life cycle process execution sub-module is used for executing various work processes and control measures of the equipment after the full life cycle process planning sub-module is completed;
the inspection detection and preventive maintenance execution sub-module is used for executing the work flow of inspection detection and preventive maintenance after the inspection detection and preventive maintenance planning sub-module is finished, determining the plan of different types of equipment needing to execute the inspection detection and preventive maintenance tasks according to the formulated inspection detection and preventive maintenance scheme, and finishing the inspection detection and preventive maintenance tasks according to the plan.
And the defect execution submodule is used for executing the defect management process after the defect planning submodule is finished, identifying the defects, carrying out risk evaluation on the defects and selecting a proper maintenance mode for processing according to the risk level of the defects.
The change execution submodule is used for executing the management flow of the change after the change planning submodule is completed, identifying the change and carrying out risk assessment on the change, wherein the change allowed by the risk can not be executed, and the change allowed by the risk can not be executed until the risk is allowed.
And the spare part accessory execution submodule is used for performing warehousing quality acceptance according to the quality acceptance standard of the planned spare part accessories after the spare part accessory planning submodule is completed, storing the spare part accessories according to the storage requirement, and ensuring that the quantity of the spare part accessories is not less than that of the safety warehouse.
The third-party service execution submodule is used for supervising the qualification, training condition, on-site operation evidence development and on-site service completion condition of service personnel of a third-party contractor after the third-party service planning submodule is completed;
and the post responsibility execution submodule is used for executing different authorities of each post at each process node after the post responsibility planning submodule is finished, and recording the completion condition of each post worker.
And the training execution sub-module is used for carrying out training requirement investigation, training plan arrangement, training implementation and examination on each post personnel after the training planning sub-module is completed.
And the performance execution submodule is used for collecting various established indexes and recording a collection result after the performance planning submodule is finished.
The inspection and summary module comprises an equipment fault accident analysis sub-module, a management system evaluation sub-module and a performance index evaluation sub-module.
And the equipment fault accident analysis submodule adopts an analysis tool to carry out root cause analysis on the equipment fault recorded in the fault execution submodule and the accident caused by other equipment faults, and inspects the vulnerability of equipment management in a backward pushing mode.
The management system review sub-module is used for reviewing the management system based on risk classification management and control, asset full life cycle process management (design, manufacture, installation, test run, operation, maintenance, update, disposal), inspection detection and preventive maintenance management, defect management, change management, spare part management, third-party service management, responsibility and training management, personnel training and performance management.
And the performance index evaluation submodule is used for automatically calculating and comparing with the index requirement standard according to each acquired and recorded index after the performance execution submodule is finished, and generating an analysis report.
The improvement management module comprises an equipment fault accident improvement submodule, an enterprise management improvement submodule and a performance index improvement submodule;
the equipment fault accident improvement submodule is used for respectively improving the inspection, detection, preventive maintenance and defects according to the execution result of the equipment fault accident analysis submodule;
the enterprise management improvement submodule is used for improving risk classification, improving whole life cycle process, changing, improving spare parts, improving third-party service, improving position responsibility and improving training in the enterprise management process.
And the performance index improvement submodule is used for improving the performance index according to the analysis report generated by the performance index evaluation submodule.
The invention automatically records the defects of the defect execution submodule to the platform failure mode and mechanism database.
Example 2
Based on the asset integrity management system based on PDCA process management provided by the embodiment 1 of the invention, the embodiment 2 of the invention also provides an asset integrity management method based on PDCA process management. Fig. 3 is a flowchart of an asset integrity management method based on PDCA process management according to embodiment 2 of the present invention.
In step S301, a base database in the asset integrity management database is established; inputting an enterprise equipment basic information database, a failure mode and mechanism information database, a post responsibility information database and a legal rule specification standard information database.
In step S302, a real-time database in the asset integrity management database is established; the system comprises a real-time database for logging in the operation of the enterprise device, an online and offline equipment state monitoring database, a material analysis system database and other management software databases.
In step S303, a risk stratification plan is developed. Firstly, an equipment risk classification flow is planned, and then the risk classification rules are customized, wherein the risk classification rules comprise the classification rules of the severity of the consequences caused by the equipment failure and the classification rules of the possibility of the equipment failure, and the severity of the consequences and the possibility of the failure form the classification rules of the risks in a two-dimensional risk matrix.
In step S304, a full life cycle flow plan, an exhibition inspection and preventive maintenance (ITPM) plan, a defect plan, a change plan, and a spare part plan are developed according to the risk classification category in the risk classification plan.
In step S305, a third party service plan, a post job plan, a training plan, and a performance index plan are developed.
In step S306, after the planning strategy is completed, risk classification execution, full lifecycle process execution, inspection detection and preventive maintenance (ITPM) execution, defect execution, change execution, spare part execution, third party service execution, post work execution, training execution, and performance indicator collection are performed in sequence.
In step S307, after the execution is completed, the management system is evaluated based on the execution results of the risk classification management and control and the asset full-life-cycle process management, the performance index is evaluated based on the execution of the training and performance indexes, the equipment failure in the asset full-life-cycle management is analyzed by the analysis tool, and the vulnerability of the equipment management is checked by adopting a backward pushing mode.
In step S308, correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the loophole of equipment management; and finally, forming closed-loop management for the management of the enterprise equipment.
In the asset integrity management method based on PDCA process management, the plan strategy, the execution, the inspection summary and the improvement management carry out closed-loop management on equipment management, a systematic management thought is formed, the efficiency of enterprise equipment management can be improved, and the risk loophole of the equipment management is reduced. All modules are organically combined through flow circulation, and finally, the performance index evaluation, the equipment fault accident analysis and the management system review are carried out for inspection and summary, so that the improvement is realized, and the aim of continuously updating the equipment management is fulfilled.
The invention covers the management contents of the whole life cycle of the equipment, including the management contents of each stage of design, purchase, manufacture, installation, test run, operation, maintenance, update and disposal, and comprehensively controls the quality of each link of equipment management.
The invention not only utilizes the historical fault data of the equipment, but also records the defect and fault data of the platform during the operation period, so that the database is continuously updated by self. And automatically recording the defect execution of the defect execution management module to a platform failure mode and mechanism database, and continuously enriching and correcting the contents of the failure mode and mechanism database. Meanwhile, the accuracy of analyzing and judging the equipment fault by the platform is improved by combining a big data system and an artificial intelligence algorithm.
Although the embodiments of the present invention have been described with reference to the accompanying drawings, the scope of the present invention is not limited thereto. Various modifications and alterations will occur to those skilled in the art based on the foregoing description. And are neither required nor exhaustive of all embodiments. On the basis of the technical scheme of the invention, various modifications or changes which can be made by a person skilled in the art without creative efforts are still within the protection scope of the invention.
Claims (10)
1. An asset integrity management system based on PDCA process management is characterized by comprising a management layer, an asset integrity management database and an analysis tool;
the management layer comprises a plan strategy module, an execution module, a check summary module and an improvement management module; the planning strategy module is used for making planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes according to the asset integrity management database; the execution module is used for executing enterprise risk classification, asset full life cycle management, training and performance indexes according to the planning strategy; the inspection and summary module is used for evaluating the management system based on the execution results of risk classification management and control and asset full life cycle process management, evaluating performance indexes based on the execution of training and performance indexes, analyzing equipment faults in asset full life cycle management through an analysis tool, and checking the loopholes of equipment management in a backward pushing mode; the improvement management module is used for correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the vulnerability of equipment management; finally, the management of the enterprise equipment forms closed-loop management;
the analysis tool provides a management layer with a tool for analyzing the risk and the fault of the asset integrity management database;
the asset integrity management database provides an enterprise asset basic database and a real-time database for the management layer module; the real-time database is combined with a big data system, and the analysis and judgment of the enterprise equipment by the basic database are corrected in real time through an artificial intelligence algorithm.
2. The PDCA process management-based asset integrity management system of claim 1, wherein the base database comprises an enterprise equipment base information database, a failure mode and mechanism information database, a position responsibility information database, and a legal regulation specification standard information database.
3. The PDCA process management-based asset integrity management system of claim 2, wherein the real-time database comprises an enterprise device operation real-time database, an online and offline equipment status monitoring database, a material analysis system database, and other management software databases.
4. The PDCA process management-based asset integrity management system of claim 1, wherein said analysis tools comprise a hazard and operability analysis submodule, a sheath analysis submodule, a safety integrity level submodule, a reliability-centric maintenance submodule, a fault tree analysis submodule, and 5why submodules.
5. The asset integrity management system based on PDCA process management of claim 1, wherein the plan policy module comprises a risk classification policy sub-module, a full life cycle flow planning sub-module, an inspection detection and preventive maintenance planning sub-module, a defect planning sub-module, a change planning sub-module, a spare part planning sub-module, a third party service planning sub-module, a post responsibility planning sub-module, a training planning sub-module, and a performance planning sub-module;
the risk classification strategy submodule is used for firstly planning an equipment risk classification flow and then customizing a risk classification criterion;
the whole life cycle process planning submodule is used for selecting corresponding laws, regulations, specifications, standards, company management regulations and excellent management modes of enterprises according to the risk grade of the risk grading strategy submodule, and planning various working processes and control measures of equipment in the whole life cycle in design, manufacture, installation, test run, operation, maintenance, update and disposal;
the inspection detection and preventive maintenance planning submodule is used for planning the engineering flow of inspection detection and preventive maintenance and the range and type of equipment needing to carry out inspection detection and preventive maintenance according to the risk level of the risk grading strategy submodule;
the defect planning submodule is used for planning the management flow of the defects, the criteria of defect identification and risk evaluation and the acceptance criteria of the defects according to the risk level of the risk grading strategy submodule;
the change planning submodule is used for planning the changed management flow and the change identification and risk evaluation criterion according to the risk level of the risk grading strategy submodule;
the spare part planning submodule is used for planning a spare part management flow, a quality acceptance standard, a storage requirement and a safety stock according to the risk level of the risk grading strategy submodule;
the third-party service planning submodule is used for planning the management flow, qualification requirement, training requirement and field service requirement of a third party related to the equipment;
the post responsibility planning submodule is used for planning the post responsibility which is supposed to be undertaken by the enterprise equipment management personnel and the internal related party;
the training planning submodule is used for planning a management process of training;
and the performance planning submodule is used for selecting a proper index according to the goal of asset integrity management, determining the weight of the proper index and planning the acquisition requirement of the index.
6. The asset integrity management system based on PDCA process management according to claim 4, wherein said execution modules comprise a risk classification execution sub-module, a full life cycle flow execution sub-module, an inspection detection and preventive maintenance execution sub-module, a defect execution sub-module, a change execution sub-module, a spare part execution sub-module, a third party service execution sub-module, a post duty execution sub-module, a training execution sub-module and a performance execution sub-module;
after the risk classification planning submodule is completed, the risk classification execution submodule carries out risk classification on various devices in the asset integrity management range according to the basic database and inputs the classification result into the platform
The full life cycle process execution submodule is used for executing various working processes and control measures of the equipment after the full life cycle process planning submodule is completed;
the inspection detection and preventive maintenance execution submodule is used for executing the working process of inspection detection and preventive maintenance after the inspection detection and preventive maintenance planning submodule is finished, determining the plan of different types of equipment needing to execute inspection detection and preventive maintenance tasks according to the formulated inspection detection and preventive maintenance scheme, and finishing the inspection detection and preventive maintenance tasks according to the plan;
the defect execution submodule is used for executing a defect management process after the defect planning submodule is finished, identifying the defects, carrying out risk evaluation on the defects, and selecting a proper maintenance mode for processing according to the risk level of the defects;
the change execution submodule is used for executing the management flow of the change after the change planning submodule is finished, identifying the change and carrying out risk evaluation on the change, wherein the change with allowable risk can be executed, and the change with unallowable risk can not be executed until the risk is allowable;
the spare part accessory execution submodule is used for performing warehousing quality acceptance according to the quality acceptance standard of the planned spare part accessories after the spare part accessory planning submodule is finished, storing the spare part accessories according to the storage requirement and ensuring that the number of the spare part accessories is not lower than that of the safety warehouse;
the third-party service execution submodule is used for supervising the qualification, training condition, on-site operation evidence development and on-site service completion condition of service personnel of a third-party contractor after the third-party service planning submodule is completed;
the post responsibility execution submodule is used for executing different authorities of each post at each process node after the post responsibility planning submodule is finished, and recording the completion condition of each post worker;
the training execution sub-module is used for carrying out training requirement investigation, training plan arrangement, training implementation and examination on each post personnel after the training planning sub-module is completed;
and the performance execution submodule is used for collecting various established indexes and recording a collection result after the performance planning submodule is finished.
7. The asset integrity management system based on PDCA process management of claim 6, wherein the inspection summary module comprises an equipment failure accident analysis sub-module, a management system review sub-module and a performance index evaluation sub-module;
the equipment fault accident analysis submodule carries out root cause analysis on equipment faults recorded in the fault execution submodule and other accidents caused by the equipment faults by adopting an analysis tool, and detects equipment management bugs in a backward pushing mode;
the management system evaluation submodule is used for evaluating a management system based on risk classification management and control, asset full life cycle process management, inspection detection and preventive maintenance management, defect management, change management, spare part management, third-party service management, responsibility and training management, personnel training and performance management;
and the performance index evaluation submodule is used for automatically calculating and comparing with the index requirement standard according to each acquired and recorded index after the performance execution submodule is finished, and generating an analysis report.
8. The PDCA process management-based asset integrity management system according to claim 7, wherein the improvement management module comprises an equipment failure incident improvement submodule, an enterprise management improvement submodule and a performance indicator improvement submodule;
the equipment fault accident improvement submodule is used for respectively improving inspection detection, preventive maintenance and defects according to an execution result of the equipment fault accident analysis submodule;
the enterprise management improvement submodule is used for improving risk classification, improving whole life cycle process, changing, improving spare parts, improving third-party service, improving post responsibility and improving training in the enterprise management process.
And the performance index improvement submodule is used for improving the performance index according to the analysis report generated by the performance index evaluation submodule.
9. The PDCA process management-based asset integrity management system according to claim 6, wherein the defect of the defect performing submodule is automatically recorded in a platform failure mode and mechanism database.
10. An asset integrity management method based on PDCA process management, which is implemented based on the asset integrity management system based on PDCA process management of any one of claims 1 to 9, and is characterized by comprising the following steps:
firstly, establishing an asset integrity management database, and then developing risk grading plan on enterprise equipment; the database comprises a basic database and a real-time database;
after the risk classification planning is finished, planning strategies related to enterprise risk classification, asset life cycle management, training and performance indexes are made according to the asset integrity management database;
executing enterprise risk classification, asset full life cycle management, training and performance indexes according to the planning strategy;
evaluating a management system based on execution results of risk classification management and control and asset full-life-cycle process management, evaluating performance indexes based on training and performance index execution, performing fault analysis on equipment faults in asset full-life-cycle management through an analysis tool, and checking loopholes of equipment management in a backward mode;
correcting various deviations of the enterprise in the asset integrity management based on the result evaluated by the management system; improving the management flow of enterprise management and performance evaluation flow based on the result of performance index evaluation and improving the management of equipment faults based on the vulnerability of equipment management; and finally, forming closed-loop management for the management of the enterprise equipment.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011264730.4A CN112348382A (en) | 2020-11-12 | 2020-11-12 | Asset integrity management system and method based on PDCA process management |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202011264730.4A CN112348382A (en) | 2020-11-12 | 2020-11-12 | Asset integrity management system and method based on PDCA process management |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN112348382A true CN112348382A (en) | 2021-02-09 |
Family
ID=74363506
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202011264730.4A Withdrawn CN112348382A (en) | 2020-11-12 | 2020-11-12 | Asset integrity management system and method based on PDCA process management |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN112348382A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116452209A (en) * | 2023-03-06 | 2023-07-18 | 北京三维天地科技股份有限公司 | Product closed-loop management method based on service |
| CN118134242A (en) * | 2024-01-12 | 2024-06-04 | 广东腐蚀科学与技术创新研究院 | Management platform and method for small takeover of refining enterprise and informationized management system |
-
2020
- 2020-11-12 CN CN202011264730.4A patent/CN112348382A/en not_active Withdrawn
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN116452209A (en) * | 2023-03-06 | 2023-07-18 | 北京三维天地科技股份有限公司 | Product closed-loop management method based on service |
| CN116452209B (en) * | 2023-03-06 | 2023-10-20 | 北京三维天地科技股份有限公司 | Product closed-loop management method based on service |
| CN118134242A (en) * | 2024-01-12 | 2024-06-04 | 广东腐蚀科学与技术创新研究院 | Management platform and method for small takeover of refining enterprise and informationized management system |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| Sultana et al. | Identifying safety indicators for safety performance measurement using a system engineering approach | |
| CN107798479B (en) | Knowledge management system based on full life cycle integrated knowledge experience information | |
| US8521676B1 (en) | System to build, analyze and manage a real world model in software of a safety instrumented system architecture for safety instrumented systems in a facility | |
| US8639646B1 (en) | System to build, analyze and manage a computer generated risk assessment model and perform layer of protection analysis using a real world model in software of a safety instrumented system architecture | |
| CN112348382A (en) | Asset integrity management system and method based on PDCA process management | |
| Jafarpisheh et al. | A hybrid reliability-centered maintenance approach for mining transportation machines: a real case in Esfahan | |
| CN110598878A (en) | Maintenance plan TIER4 assessment technology based on refinery device shutdown overhaul | |
| Ferreira et al. | Guidelines for life extension process management in oil and gas facilities | |
| US8732106B1 (en) | Computer instructions to build, analyze and manage a real world model in software of a safety instrumented system architecture for safety instrumented systems in a facility | |
| Vinnem et al. | Generalized methodology for operational risk analysis of offshore installations | |
| Mohammadi et al. | Risk analysis and reliability assessment of overhead cranes using fault tree analysis integrated with Markov chain and fuzzy Bayesian networks | |
| Khan et al. | Maintenance management of aging oil and gas facilities | |
| Prochazkova et al. | Risk Management at Technical Facilities Designing, Building and Commissioning | |
| Aven et al. | Methodology for incorporating human and organizational factors in risk analysis for offshore installations | |
| Kolios et al. | Risk-based maintenance strategies for offshore wind energy assets | |
| Priyanta et al. | The development of a risk-based maintenance flowchart to select the correct methodology to develop maintenance strategies of oil and gas equipment | |
| Noman et al. | A new integrated risk-assessment model for minimizing human-machine error consequences in a preventive maintenance system | |
| Romano et al. | Lean Maintenance model to reduce scraps and WIP in manufacturing system: Case study in power cables factory | |
| US8954369B1 (en) | Method to build, analyze and manage a safety instrumented model in software of a safety instrumented system architecture for safety instrumented systems in a facility | |
| Rangra et al. | On the study of human reliability in transportation systems of systems | |
| CN112819262A (en) | Memory, process pipeline inspection and maintenance decision method, device and equipment | |
| CN110874712A (en) | Modeling method of equipment integrity management system | |
| Hadidi et al. | A Markov-based model to mitigate human errors occurrence during maintenance activities in petrochemical systems | |
| Bellamy et al. | AVRIM2, a Dutch major hazard assessment and inspection tool | |
| US8732105B1 (en) | Method to build, analyze and manage a real world model in software of a safety instrumented system architecture for safety instrumented systems in a facility |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| WW01 | Invention patent application withdrawn after publication | ||
| WW01 | Invention patent application withdrawn after publication |
Application publication date: 20210209 |