Risk analysis and improvement for plant facility incidents

• Main Authors: Chih-ChingWu, 吳志清
• Other Authors: Andrew S. Chang
• Format: Others
• Language: zh-TW
• Published: 2016
• Online Access: http://ndltd.ncl.edu.tw/handle/uncw8r

碩士 === 國立成功大學 === 工程管理碩士在職專班 === 104 === The supply chains of the materials to produce TFT-LCD are getting complete. One key raw material to produce the TFT-LCD is glass substrate. Uninterruptable supplies of glass substrate are vital to the manufacturing process. Process equipment needs to be associated with the facility system to achieve a stable temperature control. If there is any interruption to the plant facility system, it would damage the process equipment system and affect the manufacturing business. According to the yearly plant compiled in the incident data of case plant, repeated interruption happens quite often to the facility system. It is a risk in the system that has not been identified. How to effectively control and manage the risk for the facility system are by performing risk assessment and process hazard analysis are very important. This research studied the incidents occurred in the facility system, risk analysis and improvement. With the data compiled and analyzed, the incidents to the facility system were mainly caused by improper equipment design, lack of maintenance ＆ testing, emergency response plan, and incomplete ＆ human operation errors. After understanding the relationships between the manufacture process and facility system, detailed hazard analysis was performed to identify the main hazard and proper corrective actions. The research results show that with proper and detailed accident data analysis it can improve and evaluate the risk to the plant management. A total of 204 incidents was analyzed in which US$87.9M was lost. The cost was reduced to US$20.8M after risk analysis and improvement measures were taken. The hazard/risk analysis tools used are important to the plant to display the risk and accident hence reduce incidents from happening.