XXI World Energy Congress September 2010 "MONTREAL 2010" Case 3.3: WORK PLAN FOR EFFICIENT ENERGY POLICY

Transcription

1 XXI Wrld Energy Cngress September 2010 "MONTREAL 2010" Case 3.3: WORK PLAN FOR EFFICIENT ENERGY POLICY Jb Title: ANALYSIS OF PROBLEMS IN THE IMPLEMENTATION OF MANAGEMENT SYSTEMS OF QUALITY IN THE ENERGY INDUSTRY, OIL AND GAS Name f Authrs: Authr: Ing Juan Carls Brhi Institutin represented: Energy Studies Grup (GESE) f the Universidad Tecnlgica Nacinal, Facultad Reginal General Pachec. Pstal Address: Hiplit Yrigyen 288, (CP: 1617) Buens Aires, Argentina TEL FAX gese@frgp.utn.edu.ar / juancbrhi@htmail.cm

2 MR. JUAN CARLOS Brhi Mechanical Engineer degree frm the Facultad Reginal General Pachec f the Natinal Technlgical University in Quality Engineer degree frm the Technical University f Clgne, Germany (Fachhchschule Köln) in Specializatin Curses: Curse n "Use f Alternative Energy", University f Buens Aires, Schl f Engineering Quality Auditr DGQ (German Sciety fr Quality) Specializing in Systems Auditr Quality Management at TÜV - Rheinland, Germany Envirnmental Cnsultant at the Technical University f Clgne, Germany. Meetings: Lecturer at the XV Pan American Cngress f Mechanical Engineering, Electrical and Related Branches, held in Panama n the theme "Statistics f Ratinal Energy Use in Industry" Lecturer at the XVI Pan American Cngress f Mechanical Engineering, Electrical and Related Branches, held in Santiag, Chile, n "Ratinal Use f Energy" Speaker in the 8th. Argentine Cngress n the Ratinal Use f Energy and Envirnment Lecturer at the XVII Pan American Cngress f Mechanical Engineering, Electrical, Industrial and Related Branches, held in El Salvadr Speaker at the Seventh Natinal Cngress f Mechanical Engineering and Electrical CONIN Buens Aires, Argentina Lecturer at the XVIII Pan American Cngress f Mechanical Engineering, Electrical, Industrial and Related Branches, held in Quit, Ecuadr Speaker at the IX Natinal Cngress f Mechanical Engineering and Electrical CONIN Buens Aires, Argentina. Prfessinal Activities:

3 t 1998: Frd Mtrs in Argentina, in areas f Prduct Engineering, Plant Engineering, and Training : Frd Mtrs in Germany, in the area f Quality Engineering t present: Systems Lead Auditr Quality Management TÜV Rheinland Grup t present: Cnsultant Engineer Quality Management Systems and Envirnment. Teaching Activities: - Frm 1989 t present: Crdinatr f the Study Grup n Energy (GESE) Reginal Faculty General Pachec, Natinal Technlgical University. - Teaching and Research n energy and envirnment f the Reginal Faculty Gral Pachec, Natinal Technlgical University..

4 ANALYSIS OF PROBLEMS IN THE IMPLEMENTATION OF MANAGEMENT SYSTEMS OF QUALITY IN THE ENERGY INDUSTRY, OIL AND GAS INTRODUCTION. Since its emergence in 1987 f ISO 9000, mdel fr implementatin f a system f quality management, has had a widespread wrldwide and is applicable t all activities. This rule, which actually cnstitute a "family" f standards are reviewed peridically t suit the cntinuus demands f the market, s that in 1994 had its secnd versin in 2000's third versin, and is currently current 2008 versin. A defining quality, mentin that the definitin f it has varied ver time, see the definitins f sme key thinkers wh have made majr cntributins t the subject: Shewart: "Quality as a result f the interactin f tw dimensins: subjective dimensin (what the custmer wants) and bjective dimensin (what is ffered). Deming: "Quality is custmer satisfactin. Juran "Quality is fitness fr use f the custmer." Ishikawa: "Philsphy, culture r management style f an undertaking accrding t which peple in the same study, practice, participate, and encurage." Feigenbam: "Meeting custmer expectatins. Taguchi: "Quality is the least pssible lss t sciety". Crsby: "Quality is meeting requirements" In turn the ISO 9001:2008 defines it as fllws: "Quality: the degree t which a set f inherent characteristics fulfills requirements"

5 Here are the statistics n the number f ISO 9001 certificatins issued. The first 10 cuntries with mre firms certified t ISO 9001:2008 CHINA ITALIA REINO UNIDO JAPON ESPAÑA USA FRANCIA ALEMANIA AUSTRALIA INDIA ISO 9001:2008 certified cmpanies in Nrth America Dic-01 Dic-02 Dic-03 Dic CANADÁ MEXICO USA

6 ISO 9001:2008 certified cmpanies in Central America and Suth Dic-01 Dic-02 Dic-03 Dic BRASIL BRASIL ARGENTINA ARGENTINA COLOMBIA COLOMBIA CHILE CHILE URUGUAY URUGUAY VENEZUELA VENEZUELA CUBA CUBA PERU PERU COSTA COSTA RICA RICA BOLIVIA BOLIVIA As we said at first that rule cnsists f a family f standards which highlight the key that makes the assembly f a system f quality management: System Standard ISO 9001:2008-Quality Management-Requirements.- System Standard ISO 9000:2005-Quality Management-Cncept and vcabulary.- System Standard ISO 9004:2000-Quality Management-Guidelines fr perfrmance imprvement.- ISO 9001:2008 defines the requirements fr a management system and is the standard that is certified, the thers are additinal rules fr the management system, are nt unique but are the main armed at the time f a system.

7 The schema that represents it: And these are the chapters that cmprise: Chapters ISO 9001: Purpse and scpe. 1.1-General. 1.2-Implementatin. 2-Nrmative References. 3-Terms and definitins.

8 4-Quality management System. 4.1-General requirements. 4.2-Dcumentatin requirements. 5- Management Respnsibility. 5.1-Management Cmmitment. 5.2-Custmer fcus. 5.3-Quality plicy. 5.4-Planning Quality bjectives Quality management system Planning. 5.5-Respnsibility, authrity and cmmunicatin Respnsibility and authrity Management representative Internal cmmunicatin. 5.6-Management review. 6-Resurces management. 6.1-Prvisin f resurces. 6.2-Human resurces. 6.3-Infrastructure. 6.4-Wrk envirnment. 7-Prduct Realizatin. 7.1-Planning f prduct realizatin. 7.2-Custmer-related prcesses.

9 7.3-Design and develpment. 7.4-Purchasing. 7.5-Prductin and service prvisin. 7.6-Cntrl f mnitring and measuring equipment. 8-Measurement, analysis and imprvement. 8.1-General. 8.2-Mnitring and measurement. 8.3-Cntrl f nncnfrming prduct Analysis f data. 8.5-Imprvement. DEVELOPMENT. Here we fcus n thse aspects that are cnsidered the main factrs as difficulty f develping a gd system f quality management in the il and gas industry, althugh many f them als culd be extended t ther activities. This first f this present general statistical graph: Frm where cme 10 chapters, with the incidence f each, as the mst critical. They are: Nncnfrmities per pint f ISO 9001 Surce: DGQ - German Assciatin fr Quality ISO 9001:2008 Chapter Quality Management System Number f Nn-cnfrmities Instrument Cntrl (7.6) 22 (%) Prcurement (7.4) 13 Quality system (4) 11

10 Cntrl Dcument (4.23) 11 Management Respnsibility (5-5.6) 10 Internal audits (8.2.2) 9 Cntrl f recrds (4,2,4) 8 Training (6.2) 6 Prcess cntrl (7.5) 5 Inspectin and testing ( / 4) 5 In turn this culd regrup as fllws ISO 9001:2008 Chapter Quality Management System Number f Nncnfrmities (%) Cntrl Dcument (4.23) + Cntrl recrds (4,2,4) = 24 Quality system (4) Instrument Cntrl (7.6) 22 Prcurement (7.4) 13 Management Respnsibility (5-5.6) 10 Internal audits (8.2.2) 9 Training (6.2) 6 Prcess cntrl (7.5) 5 Inspectin and testing ( / 4) 5 The grupings reflect the fact that sme deviatins in this area is alltted t a pint in general all have the same rigins: failures in cntrl f dcumentatin, make dcuments mre recrds, adding t sectin 4 here is very general and makes general requirements and dcumentatin.

11 Furthermre we present a statistical picture f deviatins frm the standard chapter f cmpanies in il and gas heading: Number f cmpanies evaluated: 30 ISO 9001:2008 Quality Management System Nncnfrmities General requirements Dcumentatin requirements Management cmmitment Custmer Fcus Quality Plicy Planning-Objectives Respnsibility, authrity and cmmunicatin Management review Prvisin f resurces Human Resurces Infrastructure Wrk envirnment Planning the perfrmance f wrk Custmer-related Prcesses Design & Develpment Purchasing Prductin and service prvisin Cntrl f mnitring and measuring equipment

12 General Mnitring and measurement Cntrl f nncnfrming prduct Analysis f data Imprvement (cntinuus imprvement, crrective actin and preventive) Chapters regrup again if we eliminate thse with n deviatins, and rdered by criticality, we have the fllwing: ISO 9001:2008 Quality Management System Nncnfrmities Prductin and service prvisin Cntrl = 63 f mnitring and measuring equipment -7.6 Dcumentatin requirements Mnitring and measurement (internal audit) Imprvement (treatment f nncnfrmities, 34 crrective and preventive actins) -8.5 Human resurces (training) Planning-Objectives Wrk envirnment Management review Purchasing Design & Develpment Cntrl f nncnfrming prduct Quality Plicy-5.3 2

13 Respnsibility, authrity and cmmunicatin Infrastructure Gruping the chapters 7.5 and 7.6, is that in this area mst f 7.5 failures are due t the way f measuring the variables, which are linked the tw issues and fall within the field f metrlgy. In the final analysis f the statistics we can cnclude that the main prblems fr the prper implementatin f a system f quality management are: 1-Cntrl and measuring instruments, which may be summarized as prblems related t metrlgical cncepts. 2-Cntrl f dcumentatin. 3-Internal audits. 4-Treatment f nncnfrmities, crrective and preventive actins. 5-Training. 6-Gals. Lack f clear bjectives and / r mnitr them. 7-Wrk envirnment. 8-Management review. 9-Purchasing. PROPOSAL. A prpsal utlined critical chapters discuss and prpse alternatives t imprve the management f them: 1-Metrlgical cncepts: -Fr the purpse f trying t find a slutin t the large number f departures t Chapter equipment cntrl, calibratin, etc.., Based n the wrding f ISO 9001 in its Chapter 7.6 states: "Chapter 7.6- Cntrl f mnitring and measuring equipment:

14 "The rganizatin shall determine the mnitring and measurement t make, and measuring and mnitring devices necessary t prvide evidence f prduct cnfrmity with the requirements identified.... Nte: see ISO (ISO :1992-metrlgical cnfirmatin system fr measuring equipment), and ISO (ISO :1997-Guide fr the cntrl f the measurement prcess) as guidance. " We must say that since the revisin f the requirements f the standard is 2000, refers t and ISO , but is currently in effect that ISO 10012:2003 is a very gd tl fr addressing the subject matter and als changed and expanded the fcus n this aspect s repeatedly generates deviatins when audits f management systems. This rule pses a change f fcus: It passed the ISO 9001 traditinal apprach based n "Cntrl f calibratin equipment- Plan" and replace with the fllwing: Fcus ISO10012: 2003 MANAGEMENT MEASUREMENTS Definitin: This standard specifies generic requirements and prvides guidance fr the management f measurement prcesses and metrlgical cnfirmatin f the measuring equipment used t supprt and demnstrate cmpliance with metrlgical requirements. It mentins that: Fllw the requirements described in this internatinal standard t facilitate cmpliance with the requirements fr measurement and cntrl f measurement prcesses specified in ther standards, fr example, sectin 7.6 f ISO 9001:2008 and f the standard ISO 14001:2004

15 That chapters are: Chapters ISO 10012: Purpse and scpe. 2-Nrmative References. 3-Terms and definitins. 4-General requirements 5-Management Respnsibility. 5.1-Functin metrlgical 5.2-Custmer Fcus 5.3-Quality Objectives 5.4-Management review 6-Resurces management. 6.1-Human Resurces 6.2-Infrmatin Resurces 6.3-Material Resurces 6.4-Party vendrs 7-Metrlgical cnfirmatin and implementatin f prcess measurement. 7.1-Metrlgical Cnfirmatin 7.2-Prcess Measurement 7.3-Uncertainty f measurement and traceability 8-Analysis and imprvement f the management system f measurements 8.1-General

16 8.2-Auditing and Mnitring 8.3-Cntrl f nncnfrmities 8.4-Imprvement In turn, this rule leads t the use f ther standards such as: 1-ISO 3534:1993-Statistics. Vcabulary and symbls. 2-ISO 5725 "Accuracy f results and measurement methd. 3-ISO / TR Guidance n statistical techniques t the ISO9001: ISO/TR 13425:1995-Guide fr the selectin f statistical methds in standardizatin and specificatin. 5-ISO/IEC 17025:1999-General Requirements fr the cmpetence f testing labratries / testing and calibratin. 6-GUM :1995-Guide fr the expressin f uncertainty in measurement. 7-OIML D 10:1984-Guidelines fr the determinatin f recalibratin intervals f measuring equipment used in testing labratries. (OIML: Internatinal Organizatin f Legal Metrlgy). 8-VIM Internatinal Vcabulary :1993-basic and general terms used in metrlgy. S that the implementatin and enfrcement f it is cnsidered a gd tl t address the tpic that always generates the same deviatins. 2-Cntrl f the dcumentatin: "He must centralize cntrl ver it, in central ffices and plants and imprve training and auditing t be carried ut in this regard. 3-Internal audits: -The perfrmance f the same shuld be dne mre ften and meeting the requirements f ISO 9001 in paragraph 8.2.2, states that "shuld be planning an audit prgram taking int cnsideratin the status and imprtance f the prcesses and areas t be audited, and the results f previus audits.

17 It wuld be desirable t have a very gd squad f auditrs, with emphasis n cntinuus training and caching them. Using as reference the ISO Guidelines fr auditing management systems f quality and / r envirnmental. 4-Treatment f nncnfrmities, crrective and preventive actin: "In this issue culd be said that is smetimes felt afraid t raise nn-cnfrmities, a prduct that in sme cases taken against thse invlved, which is a bad practice that des nt cntribute t establishing a gd management system. On the ther hand wuld have t insist n greater use f quality tls such as: Techniques fr imprving quality r reslutin f prblems: - Q7: The seven basic tls f Ishikawa - M7: The seven new tls Q7: - Flwchart - Data Cllectin Sheet - Histgram - Letters f quality cntrl - Paret Chart - Cause-effect diagram - Diagram f crrelatin M7: - Affinity Diagram - Graph f relatinships - Tree diagram - Matrix Diagram - Diagram prtfli - Diagram f arrws - Diagram f decisin prcess Mrever, there are few preventive actins, and in this particular is generally nt defined a tl t address the issue in a systematic way, fr which I recmmend using the FMEA methd.

18 FMEA FMEA Failure Mdes and Efects = Analysis "FMEA." Technical analysis is a systematic, cmprehensive and bjective, based n the participatin f a team r an fficial wh cnsulted all affected services, which aims t ensure that ptential failure mdes are cnsidered (TESTED ) and directed (minimized). 5-Training: "They shuld put mre emphasis n cntinuus training f defining bjectives and annual training hurs t verify cmpliance with training plans. 6-Objectives: "Fr a better definitin f bjectives and indicatrs as well as better mnitring f these recmmended the applicatin f the methdlgy Balanced Scre Card (BSC). The BSC is a management tl that allws yu t "mnitr" using indicatrs, cmpliance with the strategy develped by management, while enabling rapid and accurate decisins t achieve the bjectives. Part f the ratinale fr defining the visin and strategy f the cmpany fr the purpse f defining indicatrs intangible nnfinancial t financial results, and this defines 4 perspectives: Financial Custmers Internal prcesses Learning and grwth Frm which defines bjectives and indicatrs f the management system and defines a mnitring mechanism that allws greater integratin f management and staff twards meeting the verall bjectives f the rganizatin. 7-Wrk Envirnment: "T deal with the same recmmended the implementatin f envirnmental management systems based n ISO and management f ccupatinal health and safety based n

19 OHSAS Management review: "The cmpany management must shw greater cmmitment t the develpment f management systems, and t that end the prpsed methd f Balanced Stre Card is a gd tl fr this. 9-Purchasing: "They shuld develp assessment systems mre efficient suppliers. CONCLUSION. The applicatin f the tls described are cnsidered the best tls fr develping an efficient management system and help t meet the cntinuus imprvement made as requirements in ISO 9001:2008.

20 REFERENCES: Statistics DGQ (Deutsche Gesellschaft für Qualität-German Sciety fr Quality).- System Standard ISO 9001:2008-Quality Management-Requirements.- System Standard ISO 9000:2005-Quality Management-Cncept and vcabulary.- System Standard ISO 9004:2000-Quality Management-Guidelines fr perfrmance imprvement.- ISO 10012:2003-Management System Measurements-Requirements fr measurement prcesses and measuring equipment.- ISO Survey ISO Survey SIMCE (Additinal infrmatin n metrlgy, calibratin and testing).-. ISO-Internatinal Standardizatin Organizatin CENAM-Natinal Metrlgy Center.- AADECA-Argentina Autmatic Cntrl Assciatin.-