1. © 2013 Chevron
KSI BP LED Valve Cycling
Repacks
Phil Johnson
Joe Marin
Rance Rogers
Michael Job
TTA
SALSA = Short Analysis Lean Sigma Activity

2. © 2013 Chevron
Lean Sigma SALSA
Short Analysis Lean Sigma Activity
Project Background
 Problem: Valves being replaced when unable to cycle without first
conducting an inspection
 Opportunity: Conducting inspection and maintenance of valves
instead of replacing. Maintenance consists of installing new packing
and cleaning the valve.
2

3. © 2013 Chevron
Lean Sigma SALSA
Short Analysis Lean Sigma Activity
Before:
 KSI Maintenance
Scheduling Work
 Scoping work: if valve fails
to cycle schedule
replacement and order new
valve
After:
 KSI Maintenance
Scheduling Work
 Scoping work: if valve
fails cycle schedule
inspection and repack
valve
3
Lessons Learned, Predicted AFB, and Scalability Summary:
 Lessons Learned: Importance of valve preventative maintenance
 AFB: $100,000
 Scalability: Promoting proper valve maintenance across the Business Unit

4. © 2013 Chevron
Lean Sigma SALSA
IPO
4
Maintenance Crews
Equipment
Valve
Replacing Valves /
Isolation
OutputsInputs
Process:
Valve Cycling
Repacks Valves ($)
Labor ($)

5. © 2013 Chevron
Process Flow Map
5
Valve Fails to
Cycle
CVX Request KSI
to Replace Valve
KSI Order Valve
from MRC
Can Valve be
repacked and
cycled?
Scheduled
Maintenance
Work
Schedule Isolation
and Replacement
Isolate and
Replace Valves
Scheduled
Maintenance
Work
Valve Fails to
Cycle
Request KSI to
Inspect Vavle
Repack Valve and
Cycle
Order New Valve
for Replacement
Isolate and Finish
Work-Order
NO
YES
Before
After

6. © 2013 Chevron
Financial Verification
6
Month Valves
# of Valves
Repacked
Capital
Avoidance
AFB
November 3,956.83$ 2 3,956.8$ 3,956.8$
December 3,000.00$ 1 3,000.0$ 6,956.83$
January 9,136.32$ 8 9,136.3$ 16,093.15$
February 5,422.30$ 1 5,422.3$ 21,515.45$
March 16,741.02$ 1 16,741.0$ 38,256.47$
April -$ 0 -$ 38,256.47$
May 35,710.90$ 9 35,710.9$ 73,967.37$
June
July
August
September
October
November
December
(3) Valve repack material is between $20-$100 depending on diameter of valve
Assumptions:
(1) Cost of repacking labor is equal to cost of replacing labor
(2) Valve Cost is qouted from MRC