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LEAN_Construction_Tools_and_Methods_PATTY.ppt
1.
2. Dr. Robert M. Patty, MBA, PE
Performance Improvement Facilitator / Consultant
832-717-7027 rmpatty@sbcglobal.net
Former KBR Sr. Project Manager
Lean-Constructability Program Manager
& Consultant
Lean Operations for FEL and EPC
Lean EPC Facilitator
Shorten Cycle Time, Eliminate Error, Improve Quality, Reduce Cost
3. Overview
Define lean facility delivery service
– including lean construction
Benefits and examples
– Business case
Implementation
– Getting started
Key take away
– Differential success
• i.e. benefits using lean
– Requires differential sponsorship
• by executives
4. The 20,000 ft View of Lean
Extract & align vision – top priorities
– Of Client / EPC / Supplier executives
Engage employees
– Of Clients / EPC / Supply chain
Extend – ultrahigh safety & quality focus
– With principles and emergent change tools
– To achieve downward spiraling cost & time
Different – the way the team works together
– To improve performance for Clients
• With mutual stakeholder benefit
5. Traditional vs. Lean Project Delivery
Assessment of initial impact on pilot projects
– Major oil company, senior project managers
• & value improving practices team
ERA
Traditional Project
Design
Basis
Project Proposal
Bid
Procurement, Fabrication & Delivery
Detailed Design
OS
Construction Start Up
MC
Lean Project Delivery
Project
Criteria
WRLP
Procurement, Fabrication & Delivery
Detailed Design
ERA
Construction Start Up
OS
MC
System
Criteria
Component
Criteria
Construction
Planning
6. Why – What Happens
TIC - logistics & operations savings
– ~4.5% to 15%
• used in balance with other VIPs
Raising task completions as planned
– from 20 to 80%
Example on Mega PreFEED project
– Increased national content 28%
– Avoided scope growth 2.5%
– Schedule-assurance avoided revenue loss 41%
– Saved CAPEX 0.5%
– Reduced OPEX 0.5% /year
7. Core Performance Enhancing Strategies
Enhance
– Voice-of-the-customer in decisions
– Workface level productivity
Engage an emergent change tool set
Extract & manage by standards
– Task-level
– Manager-performer aligned
Sequence standards
– For flow optimization & reliability
8. All work
should be planned
in work packages
developed from standards
ITP – Q/A Requirements
Safety Requirements
Construction Equipment
Scaffold Builds
Planned Value - Manhours
Timesheet Cost Code
System Designation
Material Status
IFC Drawings
Activity ID & dates
3D snap shots of work
FIWP
Field
Installation
Work
Package
Field Work Package
FEL Work Package
Eng. Work Package
Manuf. Work Package
9. Leadership Strategies
Transparent-status
– Execution control boards
– Balanced scorecards
Better fitness for outcomes
– Aligned commitment
– Task level operational excellence
More robust response to
– Near misses
– Performance breeches
– Creative voices
10. Management by Lean Work-task-level Standards
• If any standard does not cause
– the right things to happen
» consistently and reliably
– it is not considered lean
• It must be improved until it does
– the standard itself and/or
– the standard’s deployment policy
– workface progress visibility & control
Project Critical Chain Schedule
Front End Planning Standards EPC Planning Standards
Detailed Engineer, Procure, Construct Phase
FEED - Select & Define Phase
PreFEED- Appraise
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Design
Basis
4 to 6 Week moving work-task package execution plan
11. Engineering
Workface Sampling
:15 :30 :45
:05 :15 :30 :45 :15 :30 :45 :15 :30 :45 :15 :30 :45
6 7: 8: 9: 10: 11:
:15 :30 :45
:05 :15 :30 :45 :15 :30 :45 :15 :30 :45 :15 :30 :45
12 1: 2: 3: 4: 5:
:15 :30 :45 12:
:15 :30 :45 6:
23
Home
25
24
5
15 15
16 16
27 27
21
23
25 25
24 24
5 5 30 30 5
21 21
Title 5
Title 4
Title 2
Title 1 23
23
5
21
25
24
5
Direct Value Added Work -
PreFEED
1 Criteria Extraction
2 PreFEED Appraise
FEED (Front End Engineering Design)
3 FEED Select
4 FEED Define
Detailed Engineering & Procurement
5 Detailed Design
6 Procurement
7 Documenting Asbuilt
Contributory Work -
Effective Task Setup
8 Task programming
9 Project programming
10 Alignment
Contributory Task Process
11 ReScheduling
12 Re-Review
13 Field measure
14 Inspection and Testing
15 Late technical criteria resolution
Administrative Delay
16 Clean Up
17 Maintenance and Troubleshooting
18 Transit within Operating Center
19 Transit between Operating Centers
20 Personal Time
Waiting, Noncontributory & Rework -
Workface Waiting
21 Waiting – for self
22 Waiting – for own discipline
23 Waiting – for other engineering
24 Waiting – for field
25 Waiting – for vendor
26 Waiting – for Client
27 Waiting – Discretionary
Ineffective Work
28 Ineffective Meeting Time
29 Ineffective Work
30 Unnecessary design
Redesign
31 Redesign – error, omission
32 Redesign – Other disciplines
33 Redesign – Field
34 Redesign – Vendor
35 Redesign – Client
12. Urgency Justifies Executive Sponsorship
Alignment of work-process excellence
– clients, EPC departments & supply chain
Remove comfort zone
– If it doesn’t get worse
• We will be ok
– If it gets worse
• We are victims of circumstance, still ok
Executive demand-to-improve
– Render traditional cost & schedule
• ‘Not-good enough’
– Figure out how to apply lean here
13. Results of Workface Sampling
Chemical Plant Construction, Jan 14-24, 2008
Non Contributory, Waiting &
Non Value Added Work
25.2%
Direct Value Added Work
35.8%
Contributory Work 39.0%
14. Results of Workface Sampling
Chemical Plant Construction, Jan 14-24, 2008
Fabrication &
PreAssembly, 5.8%
Dismantle, 1.9%
Excavating &
Backfilling, 2.8%
Placing, 0.4%
Final Assembly
11.4%
Effective Setup
13.5%
Direct
Value
Added
Work
35.8%
Non Contributory, Waiting &
Non Value Added Work
25.2%
Contributory
Work 39.0%
15. Results of Workface Sampling
Chemical Plant Construction, Jan 14-24, 2008
Non Contributory, Waiting &
Non Value Added Work
25.2%
Direct
Value Added Work 35.8%
Contributory
Work
39.0%
Safety Work, 3.8%
Rigging & Flagging, 1.3%
Inspection & Testing; 0.5%
Material and Equipment
Loading, Unloading
& Storage, 1.6%
Clean Up, 3.2%
Maintenance & Repair, 1.0%
Personal Time, 1.3%
Move Self, 8.9%
Move Tools & Materials
14.8%
Locating & Positioning 2.2%
Holding Materials or
Equipment, 0.4%
16. Results of Workface Sampling
Chemical Plant Construction, Jan 14-24, 2008
Direct
Value Added Work 35.8%
Contributory Work 39.0%
Non-Contributory,
Non-Value
Added
Work
&
Waiting
25.2%
Idle - Crew Balance; 6.2%
Idle - Interference; 2.6%
Idle - Talk; 0.4%
Idle - Over Manning; 2.5%
Idle - Late Start or
Early Quit; 3.2%
Idle - Discretionary; 3.2%
Idle - Institutionalized
Standby; 4.2%
Ineffective Work; 1.5%
Rework; 1.5%
17. Situation-at-a-Glance
LeJeune® Bolt
Metallurgy of twist-off end
– Limits bolt size
– ≤ 1.125” Diameter max
Friction–dependent tension indication
– Dirt or rust
– Causes premature twist-off
Cannot be removed once installed
Ergonomic
– Non-impact
– Single side/operator installation
Operator must stop
– to check washer
compression
Inspector
– must use feeler gage
Not ergonomic
– 2 operators
– Impact tool required
Direct Tension Indicating
Washer
18. Implementation
Visual Red Squirt Material
– occurs upon advent of Proper Tension
Is just what installer needs to know
Altered metallurgy
– So serrated end does not twist off
Results
Installer tightens
– without stopping
Inspection is Visual
– or with feeler gage
Non-impacting wrench
– used from one side
No size limits
– reduces number of bolts
Friction independent
– rust & dirt irrelevant
Easily removed
– and reinstalled if needed
19. Executive Sponsorship
of Chief Improvement Officer
Differentiation now & future dominance
– individuals professionally
• project teams & companies
– is achievable by real executive commitment
• of time, resources
– and intellect to learn and implement
Call or send email for primer of new handbook
Patty, Robert M; Denton, Michael A; Lean Operations for Front-end-
loading, Engineering, Procurement, and Construction: Shorten Cycle
Time, Eliminate Error, Improve Quality, Reduce Cost, Universal-Publishers,
500+ pgs, being typeset for 2009.
Editor's Notes
Many of you are very successful now without using lean.
10 to 15 years ago that was also true in shipbuilding, aerospace, automotive, insurance and a host of other industries.
In those and many other industries today, one decade after the introduction of lean the prevailing opinion is that it is nearly impossible to make any more money without being lean.
Industries are littered with implementation failures linked to lack of effective executive sponsorship.
Extract & align Client/EPC/Supplier executives’
vision to become & do to prosper against the storm
Engage employees of Clients/EPC/Supply chain
in accelerated improvement toward that vision
Always high among executive’s top priorities
Prior focus – ultrahigh safety & quality of deliverables
Lean extension – downward spiraling cost & time
Same – many members of the team, principles
Different – the way the team works together
To improve performance w/ mutual stakeholder benefit