الفهرس 
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Abstract
The six-sigma method based on DMAIC principle is a helpful method to understand the problem through the define phase of the MED/TVC and determine that most of the variations of the outputs of the system comes from the lack of maintenance of the system and the calibration of devices not maintained. Further data and measures were collected in the measure phase by means of operation output measures, which led to the estimation of the performance baseline of the operation process. In the analyze phase of DMAIC approach, a set of studies, including DOE, were conducted to identify the root causes of variation of the measures. Some of the relevant causes had origin in calibration of the devices itself, but others had origin in downstream operations where maintenance of equipment not obtained. The improve phase involved the development and implementation of a set of improvement actions that were grouped around four areas of action. Each action shall apply in the philosophy of IQAP, not each action applied alone. The results after apply the four actions the results showed that the behavior of MED/TVC unit improved, the Reliability and the Availability of the MED/TVC unit increased. The effectiveness of the improvement actions were also confirmed by the significant enhancement on the values of the operation parameters.
Developing Integrated Quality Assurance Program for maitainence of desalination plants and using the Reliability Centered Maintenance (RCM) for the (MED/TVC) desalination unit type, to improve the performance of desalination unit and increase the life time of its components. By applying the Six-Sigma method, to enhance the Desalination unit performance and increase the operation lifetime, the critical systems in the unit is specified based on the operation experience. The critical systems to safety and to the operation are: Chemical Dosing System (CDS), Sea Water System (SWS), and Evaporators System (ES). Designing an Integrated Quality Assurance Program (IQAP) for maintenance of MED/TVC unit, by using the application of the Six Sigma, defines, measure, analyze, improve, and control (DMAIC) problem-solving methodology in MED/TVC Unit, aimed to increase the Reliability, availability and increase the unit lifetime. from the operation logbook, the low performance of the MED/TVC unit was discovered, also from the maintenance logbook, the lifetime of the evaporator components decreased and not matched with replaced components schedule.
The results of the MED/TVC illustrate a successful practical application of a Six Sigma project in maintenance program for Desalination Unit.
Sea Water System - for sea water system by applying the scientific method (four step method) plus the PDCA cycle, it means we apply the Six Sigma philosophy. To improve the performance of the multi effects Desalination unit and increase the operational lifetime, one of the critical systems in the Multi-effects desalination/thermo vapor compression MED/TVC unit is Sea Water System (SWS). By using the Six Sigma philosophy, define measure, analyze, improve, and control (DMAIC) method for problem-solving methodology in MED/TVC Unit, to improve the Reliability and Availability of the MED/TVC Unit.
The operation and maintenance staff discovered that the low performance of the MED/TVC unit, the availability and reliability not match with the operation objectives, also the lifetime of the components for the evaporator decreased and not matched with replaced components as schedule. So, the Reliability Centered Maintenance will apply.
The results of the SWS illustrate a successful practical application of a Six Sigma project in maintenance program for MED/TVC Desalination Unit.
The Integrated Quality Assurance for the MED-TVC desalination unit shall contain the following aspects:
• Organization,
• Quality Management System,
• Quality Assurance in Procurement of Items and Services,
• Management Procedures and Work Instructions,
• Documentation Management system,
• Identification and Control of Items,
• Control of Special Processes,
• Control of Measuring and Test Equipment,
• Handling, Storage, Shipping, and Housekeeping,
• Inspection, Test and Operating Status,
• Control of Nonconformances,
• Corrective Action Program,
• Quality Assurance Records,
• Quality Assurance Assessments,
• Indoctrination, Training and Qualification of Personnel, and
• Statistical Techniques.
By applying all the requirements under each section of the quality assurance program, the performance, reliability, and availability are improved.
The organization structure shall contain whole roles and responsibilities of the desalination unit. The unit manager, sectors heads &general managers are responsible for the implementing of the IQA program. Also, all levels of the unit organization involved in quality affecting activities have unique and specific responsibilities to assure that MED-TVC unit operated in safe and reliable.
The QAP shall meet the Internal and External Providers that provide equipment, materials, and services to MED unit to assure that appropriate quality requirements are addressed according to related Management procedures. The Provider’s QAP shall, as a minimum, meet the requirements established in this IQAP.
The IQAP described here is the policy level program. The integrated program providing administrative controls of quality assurance is incorporated in many lower level documents. Each department involved in performing quality affecting activities shall develop implementation level management procedures- according to related Management procedure, and instructions to the extent necessary to implement the requirements of this policy level program in order to attain and verify specified quality levels.
Procurement activities shall be performed in accordance with the approved management procedures/ work instructions. Organizational units’ General managers shall be responsible for developing, implementing and maintaining management procedures/work instructions affecting their activities.
Quality program requirements for the Internal and External Providers may be specified directly in the procurement documents or by reference to a standard specification. Quality program requirements for Internal and External Providers and sub-contractors shall utilize a graded approach, i.e., the program requirements shall be based on the nature, complexity & the relative importance to safety of the Items, processes or services being procured. QAP requirements shall have the cognizant quality assurance organization’s concurrence. The quality control organization may be delegated this responsibility for field procurement.
Internal and External Providers have the responsibility for the quality of their work and for having an inspection and documentation system that provides confidence that their work meets the quality requirements specified in procurement documents and applicable codes and standards.
Technical documents (e.g., drawings, specifications, analyses, computer codes, design manuals, procurement documents), and information shall be produced and processed in a standardized manner, according to previously approved procedures.
To prevent the use of incorrect or defective items, the purchased, field fabricated and installed items shall be identified and controlled in accordance with management procedures.
An appropriate system shall be maintained for assuring that records of special process operations are traceable to the work performed, when required by codes and standards.
Measures shall be established and documented to assure that M&TE used in inspection or testing activities affecting quality are of the range, type, accuracy and precision required to satisfy the measurement or test tolerance parameters, the types and frequency of use.
Controlled written management procedures shall define the method of calibration, recognized standards, means of identification, recalibration frequency, and controls for the handling, preservation, storage, and use also other requirements of the applicable codes and/or specifications. The procedures shall also provide for issuance control and recall of suspect or damaged M&TE.
Packaging, marking, labeling, receiving, shipping, handling, storage, and housekeeping activities shall be performed in accordance with documented management procedures or requirements, including special requirements specified by Internal and External Providers.
Activities related to identification of Inspection, test, and operating status shall be defined and performed only in accordance with approved management procedures.
Inspection &test records shall identify the inspection organizations or the individual
responsible for verifying conformance to requirements for the control of the status of items at whatever points in the process the inspection & test has taken place.
Contractors or sub-contractors performing inspections and tests shall develop procedures and implement controls identified in this Section.
The contractors and Internal and External Providers shall be required to develop interface management procedures to report significant deficiencies as required and resulting corrective action to the organization.
The specific corrective action program pertaining to a life cycle activity such as design, procurement, etc. shall be covered in the specific life cycle QA program based on the guidelines provided in this QA Document.
Each functional organization producing quality assurance records shall in accordance with related procedures that identify what records shall be maintained, the minimum retention period for each category of records and the method of record retention (i.e., hard copy, microfilm, electronic file, etc.).
Assessments of Internal and External Providers of equipment and services shall be scheduled and performed by the cognizant procurement organization to ensure compliance with the procurement documents. On a case-by-case basis, quality assurance organization may participate in assessments of Internal and External Providers or when there is a concern about an Internal and External Providers performance.
On a case-by-case basis, the organization personnel may participate in those assessments and surveillance of Internal and external providers of the turnkey contractor.
Independent assessment includes internal audits, external audits, surveillance and reviews, checks, inspections and tests.
The indoctrination and training, and qualification/certification requirements in this Section are applicable to the organization, the turnkey contractor and other Internal and External Providers.
Statistical techniques shall be used when necessary and to the extent appropriate to demonstrate that processes are in control and resulting in satisfactory end product.
The cognizant functional organization managers shall identify the need for statistical techniques required for establishing, controlling and verifying process capability.
Approved management procedures shall be developed and used when statistical techniques are implemented to monitor and control processes.