The document discusses a process improvement project to reduce the waiting time to energize high bay lighting in pot rooms from 6 months to 3 months. Currently, there is a 6 month delay between needing the lighting and its availability. The project aims to reduce this to 100 days by April 2012, saving $408k by avoiding temporary lighting costs. Key activities contributing to delays include material availability, construction implementation, and receiving permanent power. The document outlines the problem statement, objectives, metrics, process mapping, data analysis, improvement recommendations and team involved.

1. High Bay Lighting Energisation

2. Background
Work in the Pot Line area – Mc Connell Dowell & Brasco
Ferretti is critical to FHM. These contractors will need to
work in night shift in order to meet schedule. Currently
the high bay lighting will not be ready to support this night
shift work.
We need to help Kentz get permanent high bay lighting
operational in time to support this work in order to save
the cost of temporary lighting and gain the benefit of
better illuminated work environment.
Hence this PIP was selected to utilize the six sigma tools
to improve the process.

3. High bay Lighting Plan
for North Pot Line – 1

4. Problem Statement
Currently there will be a six months waiting period
between need date and availability date of High bay
Lighting Energisation in Pot Rooms.
Lighting Energisation
Y
Panel Board
Transformer Cables
X’s

5. Problem Objective
Reduce the waiting time from June 2012 (180 days)
to April 2012 (100 days) to achieve our target/desire
time schedule to energize the High Bay lightings in Pot
Rooms phase by phase.
COPQ for this process will be the cost avoidance of
Temporary Lighting arrangement cost approximately
US$ 408 K

6. High level Block Diagram

7. Primary Metric
Energisation duration
70
60
60
120
190
35
40
45
65
100
0 20 40 60 80 100 120 140 160 180 200
Cables
Distribution Boards
Lighting Transformers
Construction Work
Energisation
(Materials + construction )
MaterialsConstruction
No of Days
High Bay Lighting Energisation
Actual # of days Target # of days
Acitivities
Actual # of
days
Target # of
days
Cables 70 35
Distribution Boards 60 40
Lighting
Transformers 60 45
Construction Work 120 65
Energisation
(Materials +
construction ) 190 100

8. Secondary Metric - Job hours / month
0
2000
4000
6000
8000
10000
12000
14000
16000
Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12
JOBHOURS
MONTHS
High bay Lighting Energisation
*SAMPLE DATA*

9. Process Map

10. Customer Identification
Internal External
Direct
Bechtel
Reduction Area
Manager
Brasco Ferretti - Pot lining
Mc Connell Dowell - Mechanical
Reduction Area contractors
Secondary
Bechtel
Reduction Area
Superintendent /FE
Ma'aden Area Manager
Indirect N/A KENTZ E&I contractor

11. RUMBA
RUMBA - Customer Valid Requirements Matrix
Customer
Perceived Valid
Requirements R U M B A Y/N
Reduction Area Manager
Sequential and
completion in time Y Y Y Y Y Y
Bechtel Area Superintendent &
Area Field Engineer
Meets standards and
specification Y Y Y Y Y Y

12. Fishbone

13. XY Matrix
Material
availability
Delay
Permanent
power
receiving
delay
Construction
Implementatio
n CT delay
Approved
documents &
Mobilization
CT delay
Equipments
Mobilization
delay
Schedule
delay
Rating 170 162 134 108 102 92
Cum % 22.14% 43.23% 60.68% 74.74% 88.02% 100.00%
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
20
40
60
80
100
120
140
160
180
Rating
PARETO Chart - HB Lighting Energisation

14. Supply – Input – Process
Output - Customer
C – Controllable ( Inputs can be adjusted or controlled while process is in running)
SOP – Site Operating procedures
N – Noise ( Things that cannot be controlled or too expensive or too difficult)
Materials available
in time at site
Permanent power
Available in sub
station
Review for
Permanent
power
receiving
Document
Approval &
Mobilization
Review
CT for approval of
Documents &
Date for mobilization
Materials take off quantity
Material Approval documents
Intending for procurement
Expedite on time delivery
Preparation of required documents
Submission for approval
Manpower planning as scheduled
Equipment planning as scheduled
GIS Energisation
Main 34.5 KV SS Energisation
Cable work to Pot Room SS
MV/LV Testing and commissioning
C
C
C
C
C
C
C
C
C
SOP
C
C
Bechtel
Planner
Bechtel
Area
Supd.
Construction
Completion to
handover
Expedite
Material
availability
Analysis for
Construction
Implementation
Plan work schedule
Site clearance and access permit
Materials, Tools & Equipments
Skilled manpower
SOP
C
C
C
Bechtel
Field
Engineer
Bechtel
Area
Supd.

15. Specifications of Outputs & Inputs
Y's - Outputs Specification
High bay Lighting Energisation 180 Days
by Temporary Power 90 days
by Permanent Power 30 days
X's - Inputs Specification
C Materials take off quantity 25457-4200-SR2-E00Z-0001ee
C Material Approval documents MM/DD/YYYY
C Intending for procurement No of Materials
C Expedite on time delivery MM/DD/YYYY
C GIS Energisation MM/DD/YYYY
C Main 34.5 KV SS Energisation MM/DD/YYYY
C Cable work to Pot Room SS No of days
C MV/LV Testing and commissioning No of days
SOP Preparation of required documents No of documents & days
C Submission for approval MM/DD/YYYY
C Manpower planning as scheduled MM/DD/YYYY
C Equipment planning as scheduled MM/DD/YYYY
C Plan work schedule Number of Days
SOP Site clearance and access permit SWPP 4MP-T81-03303 TO 03305
C Materials, Tools & Equipments Quantity in Numbers
C Skilled manpower No of Man hours

16. Upstream & Outcome Indicators
Customer
Valid
Requirements
Customer
Specification(s)
Outcome (Y)
Indicators
Upstream (X) Indicator
Completion in
Time
90 days
Number of days
to High bay
Lighting
Energisation
X1 - Approved documents & Mobilization CT delay
X2 - Material availability CT Delay
X3- Construction Implémentation CT Delay
Meets
standards &
Specification
Zero
Deviation
Number of
Deviations
X4 – Number of Items in poor quality
X5- Number of items fails in Inspection checklist

17. Process Management System (PMS)

18. Conclusions & Recommendations
Improvements
Mobilize Manpower & Equipment on time – In Progress
Discuss the High Bay Lighting Materials availability issues in contractor weekly meetings
Develop a level 5 schedule of High bay Lighting activities from main schedule
Display High bay Lighting Energisation as a concern during Reduction Area Readiness
Review meetings.
Recommendations
Develop data collection methods for weekly job hours data (Secondary Metric)
Set up data collection methods for Xs and Ys and analyze
Project controls –Prioritize scope for this process from base line schedule
Contracts – Administrator to expedite FSR related issues.
Field Engineering – Expedite material approval, RFIs, ITPs, Method Statements.
Construction – Coordinate with contractor for site clearance.
Discuss access issues during regular POD meetings.
Contractor – Rigorously respect 3 week look ahead schedule preparation + adherence
A new PIP for Wait time reduction for permanent power availability.

19. Team involved – Thanks
Yellow Belt
Anandhajothi
Murugan
Reduction E&I
supervisor.
Black Belt
Mentor
Narayanan
Doraswamy
Lead six sigma
Engineer
Champion
Charles
(Mark)
Read
Reduction Area
Manager
Process
owner
Jeffrey
Reibel
Reduction Area
Superintendent
Others
Bassem
Semaan
Reduction
Area Planner
Others
Danilo
Molina
Reduction E&I
QC Inspector
Others
Bernard
Fogarty
KENTZ
Reduction E&I
Site Manager
Others
Michael
Fiorill
Reduction Area
E&I supervisor