Structural Weld Overlay CPNPP

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  • 1. Structural Weld OverlayKAIZENTime CompressionthroughApplication of Lean Thinking"Value Stream Mapping &Tools ofQuality"
  • 2. 2RF10 Refueling Outage Structural Weld Overlay130 People involved in 25 Small and Large Group KAIZEN activitiesProcess Pressurizer Structural Weld OverlayNuclear/LeanPrinciples andPracticesAppliedVALUE,, FLOW, PULL, VALUE STREAM, Level Loading, Constraint ManagementValue Stream Mapping, FMEA, C/E Matrix, Poka Yoke, Operating Experience,Lessons Learned, Eng. Technical Reviews, Risk Assessments, Safety evaluationsProduct A Performance Demonstrated Initiative inspectable Structural Weld Overlay with NOrejectable indications / defectsCustomers Plant Operations, NRCProcess ValueAddWelding the Correct amount of weld overlay material no more / no less than requiredto create a weld overlay with zero defectsResults: 5.5 Day reductionBreaker’s Open to Acceptable FINAL PDI Inspection = 15 DaysZERO Safety Incidents + ZERO Indications/DefectsSafe and Reliable 27% Cycle Time Improvement
  • 3. Event 1: Strawman of VSM, Define Process, Define VA, ID Customers,
  • 4. Event 2 Communication and AlignmentKick Off: End to End VSM Evaluation – End to End Walkdown
  • 5. Final ProductWIPVisual ManagementDuring implementation
  • 6. Measurements of Process PerformanceContinuous MetricsDelivery: (Schedule Adherence) Ahead, On , Behind ScheduleRESULT: 12 hours ahead of planned schedule.Quality: Zero Indications during all welding stepsRESULT: Zero Indications /DefectsBinary MetricsQuality: Zero Indications at Final NDE testingRESULT: Zero Indications / Zero Rework / Defect Free final Non Destructive ExaminationSafety:RESULT: Zero OSHA Recordables / 1 First AidWorld Record in NuclearWe owe all successto these people