View
166
Download
4
Category
Preview:
Citation preview
Structural Weld OverlayKAIZEN
Time Compressionthrough
Application of Lean Thinking
"Value Stream Mapping &Tools of Quality"
2RF10 Refueling Outage Structural Weld Overlay
130 People involved in 25 Small and Large Group KAIZEN activities
Process Pressurizer Structural Weld Overlay
Nuclear/Lean Principles and
Practices Applied
VALUE,, FLOW, PULL, VALUE STREAM, Level Loading, Constraint Management Value Stream Mapping, FMEA, C/E Matrix, Poka Yoke, Operating Experience, Lessons Learned, Eng. Technical Reviews, Risk Assessments, Safety evaluations
Product A Performance Demonstrated Initiative inspectable Structural Weld Overlay with NO rejectable indications / defects
Customers Plant Operations, NRC
Process Value Add
Welding the Correct amount of weld overlay material no more / no less than required to create a weld overlay with zero defects
Results: 5.5 Day reduction Breaker’s Open to Acceptable FINAL PDI Inspection = 15 Days ZERO Safety Incidents + ZERO Indications/Defects Safe and Reliable 27% Cycle Time Improvement
Event 1: Strawman of VSM, Define Process, Define VA, ID Customers,
Event 2 Communication and AlignmentKick Off: End to End VSM Evaluation – End to End Walkdown
Final Product
WIP
Visual Management During implementation
Measurements of Process Performance Continuous MetricsDelivery: (Schedule Adherence) Ahead, On , Behind Schedule RESULT: 12 hours ahead of planned schedule. Quality: Zero Indications during all welding steps RESULT: Zero Indications /Defects Binary Metrics Quality: Zero Indications at Final NDE testing RESULT: Zero Indications / Zero Rework / Defect Free final Non Destructive Examination
Safety: RESULT: Zero OSHA Recordables / 1 First Aid
World Record in Nuclear
We owe all successto these people
Recommended