This document outlines a project to reduce the cycle time and cost of masking a 13-5/8" double BOP. The current masking process takes an average of 2 hours at a cost of $200 per job, with a goal of reducing costs by 50% to less than $100 per job. Key aspects of the project include defining the problem and goals, measuring the current process, analyzing sources of waste and inefficiency, improving the process through standardization and new tools/methods, and controlling the process on an ongoing basis. The team conducted a time study that found the improved process took 35 minutes to complete. Upcoming work includes reviewing additional data, setting up controls, and completing the project.

1. Project: 13” Double BOP Masking Process Cycle Time
Improvement
ETS Project Number:
Brian Jordan
Thomas Rd.
April 2014

2. T
A
R
G
E
T
Team Members
Aftermarket Drilling Systems – Pressure Control
Houston – Thomas Road
Cycle Time
Cost Reduction
Customer Experience
HSE
Black Belt: Sindhura Bikki
Green Belt: Brian Jordan
Master Black Belt: Srikanth Sarathy
Champion: Myron Brooks
Process Owner: Brian Jordan
Finance Manager: Veronica Oliveira
Team Members: Brian Jordan, Mickerin Gresham

3. DEFINE MEASURE ANALYZE IMPROVE CONTROL 3
Problem From past twelve months, the average cycle time for masking a 13-5/8 U
BOP was 2 hours costing $200/job. A gap of $100 from our Business
Objective target of less than $100/job exists. This represents an
opportunity of $100 savings per masking job. This project will focus to
reduce the masking process cost by 50% from the BSL.
Goal Masking cost reduction
Scope 13-5/8 U BOP masking process
Problem, Goal and Scope

4. Voice of the Customer
DEFINE MEASURE ANALYZE IMPROVE CONTROL
Paint/Sandblast Employees:
Masking a BOP most of the time takes longer to complete than blasting.

5. Strategic Alignment
DEFINE MEASURE ANALYZE IMPROVE CONTROL
TRIR
OTD
REWORK
COGS
OTD – On time delivery: The reduction in cycle time will help improve the
chances of on time delivery.
COGS – Cost of goods sold: the reduction in man hours directly effect the
cost of goods sold.
Cycle Time
Cost
Reduction
Customer
Experience
HSE
3 C Alignment
Cycle time: is the goal = cost reduction = customer experience

6. D – the factors that are the root cause of the undesired cycle time
M – The current cycle time by way of time study
A – Data before and after standardizing process
I – (IMPROVE – brief explanation)
C – (CONTROL – brief explanation)

7. Current Process Map
PARTARRIVESAT
PAINTAREA
Collectmasking
tools
5min
Coverlockscreww/
3layersnonstick
tape
5min
Coverringgrooves3
layersofstickytape
25min
Rollnonsticktapeto
createplugfor
bonnetliftholes
8min
Rollnonsticktapeto
createplugfor
bonnetweeping
holes
2min
PARTMOVEDTO
BLASTINGTABLE
YES
THOMASRDPAINTMASKINGPROCESSMAP
Coverlockscreww/
3layersofsticky
tape
10min
Userazorbladeto
removeexcessfrom
ringgroove
2min
Coverstudsw/
3layersnonsticky
tape
35min
Coverstudsw/3
layersstickytape
25min

8. DEFINE
MEASUR
E
ANALYZ
E
IMPROV
E
CONTRO
L
THOMAS RD PAINT MASKING PROCESS
The previous process contained waste in the
following X of 8 wastes:
Defects Sometimes tape is blast through striking
protected surfaces.
Overproduction
Waiting • Takes longer to mask than to blast (Bottle
Necks Process at Times) also unmasking
Non-standard or
Over processing
• Every paint shop employee has his own way
and level of quality of the masking process
Transportation
Injuries • Excessive use of blades increase the chance
for injury
Motion • Lots of repetitive motion when masking and
unmasking
Excess
Inventory
• Tape must be ordered by the case load
8

10. PICK Chart
PositiveImpactOnGoal
Difficulty To Implement
High
Low
HardEasy
I-Implement C-Challenge
K-KillP-Plan
Plugs
Drying booth
Mechanical
Masking
(write here)
Ring groove
sized stickers
For quick
masking,
Stud caps
DEFINE MEASURE ANALYZE IMPROVE CONTROL

11. Masking Tools

12. Time Study Post Improvements
Total Time 00:35:25
00:03:35 Wipe areas to be
taped with thinner
00:08:26 Apply stud strips
00:03:17 Shrink wrap locking screws
00:01:19 Plug holes
00:08:53 Cover ring groove
00:02:16 Add stud covers
00:07:10 Tape locking screw and tags

14. 14
Project
.
CURRENT WEEK REVIEW
END-GAME WATCH
UPCOMING SCHEDULE (1-2 WEEKS)
• Accomplished this week: data collection and analyses
• .
• Outcomes from weekly meeting need process broken down in to sectors, must insert raw
data, correct liars with time study and standardized S.A.P. data.
• .
PROJECT OVERVIEW
Champion meeting DONE
Kick off meeting DONE
Baseline DONE
DONE
• Review more new sap data
• Control set up
•