Risk analysis and improvement for plant facility incidents
事故風險 ； 危害分析 ； 風險量化 ； 廠務系統 ； 玻璃基板 ； Accident risk ； hazard analysis ； risk quantification ； factory facility system ； glass substrate
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國內薄膜電晶體液晶顯示器的上、中、下游體系日趨完整，其中玻璃基板是平面顯示器的關鍵材料。為了達到供貨需求。不間斷供應成為玻璃基板公司的營業目標。然而玻璃基板製造屬於高溫製程，且透過溫度在掌控玻璃成型，因此，製程設備需搭配廠務公用設備來達到穩定的溫度控制，稍一不慎極易產生製程設備的損壞，對企業造成重大影響。 依據個案工廠幾年的事故資料，廠務供應系統發生問題，大部分發生的原因相似且重複，是由於系統上的風險並沒有被識別，導致問題重現。如何做好風險管控，管理廠務供應系統設施、製程危害分析非常重要。 本研究探討廠務事故並分析風險及改善成果。首先整理事故原因，大致為設備不當設計導、缺乏保養及測試、緊急應變計畫不周全、人員操作錯誤等。藉著瞭解製程與廠務系統的關係，進一步做危害分析，找出關鍵危害並提出改善建議。 研究結果顯示，建立事故資料分析系統可以提供管理回饋機制，了解風險及改善後的成效。分析結果指出，風險項目共204項，改善前資產損失為87.9百萬美元，改善後降為20.8百萬美元。針對危害使用分析工具來量化風險，結果可做為工廠重要的危害關鍵指標，預防事故的發生。
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.
工程學 > 工程學總論
社會科學 > 管理學