KAIZEN methodology is the most powerful tool in designing/redesigning a company or department. Lean kaizen can be apply any organization so time to renew yours.

1. APPLICATION OF LEAN KAIZEN TO
DRILLING SERVICES DEPARTMENT
IN DESIGN AND QUALITY
IMPROVEMENT
Abdulkadir TEK N
Mayõs 01, 2017

2. OVERVIEW
2
• Goal of Lean Thinking
• Methodology of Kaizen
• Main Objective
• Drilling Services Department Design and Organization Process
• Drilling Services Department Sample Design

3. GOAL OF LEAN THINKING
3
The Principles of “Lean Thinking System”
1. Takt time
2. Value Stream Mapping (VSM)
3. Line Balancing and Set Up Reduction (SMED)
4. Eliminate WIP (Work in Progress), implement continuous flow,
PULL System and KANBAN
5. Implement POKE YOKE systems
6. 5S
“Lean” focuses on:
The systematic elimination of waste and re-alignment of resources to deliver value to the
customer faster, better, & more consistently.
LEAN PROCESS
Eliminate Waste Add
Value
Overproduction
Waiting
Unnecessary
transport
Over processing or
incorrect processing
Excess inventory
Unnecessary
movement
Defects

4. GOAL OF LEAN THINKING
4
The 5S’s
1. SORT
• Remove what is not absolutely necessary.
2. STRAIGHTEN
• Ensure there is a space for everything and everything is
in it’s place.
• No more searching!!
3. SWEEP
• Maintain a clean and orderly space to make problems
easily identifiable.
• Eliminate rejects and scrap.
4. SIMPLIFY &
STANDARDIZE
• Always think improvement of the organization of the
Workstation.
• Be organized to reduce 3.
5. SUSTAIN
• Keep repeating 1 to 4.
LeadingtoLeadingto
Eliminate
Waste
Reduced
Cycle Times
Increased
Capacity &
Efficiency
Lean Thinking

5. METHODOLOGY OF KAIZEN
5
1
• Select Target Process
2.
• Create Team
3
• Set Project Goals and Plans
4
• Observe the Process
5
• Analyze the Process
6
• Develop a Performance Improvement Plan
7
• Implement the Project
Leadingto
Observe the
Process
Find Out
Problems in
Department
Generate Ideas,
Determine Goals
and Develop an
Action Plan
Implement The
Action Plan
LeadingtoLeadingto
Design a perfect company organization, enhance productivity through
simplified work/service system, help any organization to growth
successfully.

6. MAIN OBJECTIVE
6
Design a Drilling Services Department with Implementation of
KAIZEN Standards and Lean Process to Create a Recognized
Leader Company in the Oilfield and Geothermal Sector.

7. MAIN OBJECTIVE
7
I- Effective Personnel Hierarchy
and Duty Chart
II- Professional Management and
High Quality Service
III- Standardized Service Quality
with Process Documents and
Forms
IV- Productivity Control by Web
Based Service Lean Flow
Program and Finance
Management Program
V- Effective Inventory Control by
Web Based Storage
Management Program
VI- Perfect Working Conditions by
Workshop Lean Design
VII- Continuous Improvement

8. DRILLING SERVICES DEPARTMENT
DESIGN AND ORGANIZATION PROCESS
8

9. 9
1- Which services should be provided by the department?
2- What forms should be used to chain services together?
3- Create ideal work flow charts for each services according
to;
a- Map out process (VSM), identify value and non
value add,
b- Eliminate non value add steps,
c- Eliminate work in progress, implement continuous
flow,
d- Implement Poke Yoke system to error proof to
improvements.
5- Create personnel hierarchy and duty charts for each
services.
4- Create forms and documents for each services to
standardize work flow progress.
6- Observe the workshop needs for each services to create
lean flow charts.
DRILLING SERVICES DEPARTMENT
DESIGN AND ORGANIZATION PROCESS

10. 10
1- Create Drilling Services Department Work Organization
Charts
2- Create Drilling Services Department Personnel Hierarchy
Charts
Draw together Level I design parameters and;
3- Create Drilling Services Department Personnel Duty Charts
4- Create Workshop Lean Flow Diagram
5- Create Web Based Service Lean Flow Program
6- Create Web Based Storage Management Program
6- Create Finance Management Program
DRILLING SERVICES DEPARTMENT
DESIGN AND ORGANIZATION PROCESS

11. DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN
11
1- Definition Of The Services To Be Provided:
o Services which
will be
provided by the
department Liner Hanger
Service Redress,
Maintenance
Operation
Coring
Service
Hole
Enlargement
Service
Fishing
Service
Casing
Running
Service
BOPs and
Wellhead
Service
Welding
Application
Lathe
Application
Paint
Application
Inspection
Services
Support ServicesWorkshop Services
Drilling Tools
Redress
Drilling Tools
Inspection
Measurement
Devices
Maintenance
and
Calibration
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation and Test
Warehouse
Management
and
Transportation
Office
Administration
Performance
Drilling
Service Redress,
Maintenance
Operation
Other Duties
Visual Tube
OD Gage Tube
Ultrasonic Wall
Thickness Visual
Connection
Heat Checking
Electromagnetic
Ultrasonic Slip-
Upset Area
MPI Slip-Upset
Dimensional-
1/2/3
Elevator and Slip
Groove
Wet Visible
Contrast
Blacklight
Connection
UT Connection
Liquid Penetrant
Field Services

12. 12
1- Definition Of The Services To Be Provided:
o Support
Services that
will be
necessary to
perform the job
• Income and Expense
Report
• All Account Activities
Finance
• Equipment
transportation
• Personnel traveling
organization
Transportation
and Traveling
• Procure goods
• Warehouse
management
Purchase and
Storage
• All Personnel Services
Personel
Administration
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

13. 13
o Services linked
to each other
according to
type of work Liner Hanger
Service Redress,
Maintenance
Operation
Coring
Service
Hole
Enlargement
Service
Fishing
Service
Casing
Running
Service
BOPs and
Wellhead
Service
Welding
Application
Lathe
Application
Paint
Application
Inspection ServicesField Services Support ServicesWorkshop Services
Drilling Tools
Redress DS1 Drill
String
Inspection
Other Duties
Measurement
Devices
Maintenance
and
Calibration
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation and Test
Warehouse
Management
and
Transportation
Office
Administration
Performance
Drilling
Service Redress,
Maintenance
Operation
Other Duties
Visual Tube
OD Gage Tube
Ultrasonic Wall
Thickness
Visual
Connection
Heat Checking
Electromagnetic
Ultrasonic Slip-
Upset Area
MPI Slip-Upset
Dimensional-
1/2/3
Elevator and Slip
Groove
Wet Visible
Contrast
Blacklight
Connection
UT Connection
Liquid Penetrant
Drilling Tools
Inspection
Finance
1- Definition Of The Services To Be Provided:
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

14. 14
2- Work Flow Charts For Each Particular Services:
Liner Hanger
Service Redress,
Maintenance
Operation
Field Services
o Design work flow
chart for each
services
according to;
a- Map out process
(VSM), identify value
and non value add
b- Eliminate non value
add steps
c- Eliminate work in
progress, implement
continuous flow.
d- Implement Poke
Yoke system to error
proof to
improvements.
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

15. 15
3- Standard Forms And Documents For Each Particular Services:
o Create forms and
documents for each
services to standardize
work flow progress
Contract Forms
Customer Forms
Finance Forms
Inspection Forms
Maintenance Forms
Operation Forms
Reports
Revision Forms
Service Forms
Service Management
Liner Hanger
Service Redress,
Maintenance
Operation
Inspection
ServicesField Services Support ServicesWorkshop Services
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

16. 16
Liner Hanger Forms
3- Standard Forms And Documents For Each Particular Services:
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

17. 17
4- Personnel Hierarchy And Duty Chart For Each Particular Services:
o Create personnel hierarchy
and duty chart for each
services
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

18. 18
5- Workshop Lean Design For Each Particular Services:
o Observe the workshop
needs for each services to
create lean flow diagram
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

19. 19
6- Work Organization Charts:
o Draw together
level I design
data and
create Drilling
Services
Department
Work
Organization
Chart
Service Management
Liner Hanger
Service Redress,
Maintenance
Operation
Coring
Service
Hole
Enlargement
Service
Fishing
Service
Casing
Running
Service
BOPs and
Wellhead
Service
Welding
Application
Lathe
Application
Paint
Application
Inspection
ServicesField Services Support ServicesWorkshop Services
Drilling Tools
Redress DS1 Drill
String
Inspection
Other Duties
Measurement
Devices
Maintenance
and
Calibration
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation
Redress,
Maintenance
Operation and Test
Warehouse
Management
and
Transportation
Office
Administration
Performance
Drilling
Service Redress,
Maintenance
Operation
Other Duties
Visual Tube
OD Gage Tube
Ultrasonic Wall
Thickness
Visual
Connection
Heat Checking
Electromagnetic
Ultrasonic Slip-
Upset Area
MPI Slip-Upset
Dimensional-
1/2/3
Elevator and Slip
Groove
Wet Visible
Contrast
Blacklight
Connection
UT Connection
Liquid Penetrant
Drilling Tools
Inspection
Finance
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

20. 20
7- Personnel Hierarchy And Duty Charts:
o Draw together level I
design data and create
Drilling Services
Department Personnel
Organization and Duty
Charts
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

21. 21
8- Workshop Lean Diagram:
o Draw together level I
design data and create
Drilling Services Workshop
Lean Diagram
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

22. 22
9- Service Program:
o Draw together level I
design data and create
Drilling Services Lean
Program
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

23. 23
10- Warehouse Management Program:
o Draw together level I
design data and create
Drilling Services
Warehouse Management
Program
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

24. 24
11- Finance Management Program:
o Draw together level I
design data and
create Drilling
Services Finance
Management
Program
DRILLING SERVICES DEPARTMENT
SAMPLE DESIGN

25. 25
• Re-design your organization by KAIZEN methodology.
• Lean process and KAIZEN can be applied to create new
company or re-design any organization.
For more information send e-mail to tekin.3@osu.edu