BI-19 Process Improvement

Sea Water Injection Department

Critical To Quality ( CTQ)Critical To Quality ( CTQ) : :• Project cycle time should be 2 Project cycle time should be 2

years or less.years or less.• Actual cost should be within Actual cost should be within

budget ± 10%budget ± 10%

Cost Of Poor QualityCost Of Poor Quality :• Reduced ROI due to long cycle timeReduced ROI due to long cycle time• Budget under or overrunBudget under or overrun• Supplement budget request after the Supplement budget request after the

factfact

Defect Definition :Defect Definition :• Any BI-19 Project which exceeded Any BI-19 Project which exceeded

ER time ER time (2 years)(2 years) or ER budget or ER budget variance by variance by ± 10%± 10%

Goal:Goal:• Defect Rate: Defect Rate: 00• No time extension or Supplement No time extension or Supplement

Budget request after the fact Budget request after the fact

Project Charter

Project Objective :Project Objective :• Complete Complete 100%100% BI-19 Projects BI-19 Projects

within projected time and budget.within projected time and budget.

Problem Statement :Problem Statement :• During 2002-2007 period, 37% During 2002-2007 period, 37%

(12 out of 32) BI-19 projects (12 out of 32) BI-19 projects were not completed within were not completed within estimated time and budget estimated time and budget ± 10%.± 10%.

ER Approval(Start)

Engineering Package Development8 -10 months

Material Procurement10 – 12 Months

Execution Period

6 – 8 Months

MCC / ER Closing3 – 4 Months

(Finish)

High Level Process Map

Total Period = 27 – 34 MonthsTotal Period = 27 – 34 Months

Current Process MapBI-19 Planning (Execution Phase)

Engineering PrepareDetail Design

In House Design ? Initiate PDR 30 % Design

ReviewIs there

comments ?

Yes

Yes

No

60 % DesignReview

Is there comments ?

Yes

90 % DesignReview

NoIs there

comments ?

Yes

EnggPackage

Ops Issue Maintenance

Order

SFC / POProcurement

Award contract

Planner request Material / DC Procurement

Material Received Accepted Material

Staged

Wrong orAdditional

Re-order Material

ReviewMaterial Spec.

Yes

Yes

No

No

No

6-8 months No

Const. Phase

Current Process MapBI-19 Construction (Execution phase)

SFC / PO Procurement

Mobilize Contractor

Approve SFC / SO

Start Construction

Commissioning

Submit Spare Parts

Data Packages

Close AllYes ItemsIn MCC

Submit allRequired As

Built Packages

Submit NMR and OM

MCC Signature

Final Closing

YEAR WBS element WBS Description READ Date ERCLO Date

Duration Org Budgt Cur Budget Rev

Act Total Var: Variance

2005 19-05120-0010 Rep. Obsolete UPS System at SHG Mar-05 Jan-07 1.84 208,000 208,000 0 -208,000 -100.0%2002 19-02120-0035 Extension of control room UWIPS Jul-02 Dec-03 1.42 100,000 100,000 0 -100,000 -100.0%2002 19-02120-0036 Extension of control room UWIPS Jul-02 Dec-03 1.42 100,000 100,000 0 -100,000 -100.0%2002 19-02120-0038 Extension of control room UWIPS Jul-02 Dec-03 1.42 100,000 100,000 0 -100,000 -100.0%2002 19-02120-0037 Extension of control room UWIPS Jul-02 Jul-03 1.00 100,000 100,000 0 -100,000 -100.0%2002 19-02120-0061 Replace A/C units @ Qurayyah Oct-02 Aug-05 2.84 98,000 98,000 0 -98,000 -100.0%2006 19-06120-0052 Purch Stator for Shipper Pump a Jun-06 Jun-08 2.00 890,000 94,000 X0 -94,000 -100.0%2004 19-04120-0037 Replace isolation valve suction May-04 May-06 2.00 495,000 495,000 62,881 -432,119 -87.3%2005 19-05120-0046 Rep of Four 24" x 150 Isolation Apr-05 Jun-07 2.17 358,000 358,000 153,093 -204,907 -57.2%2005 19-05120-0065 Construct battery room at UWIP Oct-05 Dec-07 2.17 470,000 470,000 246,061 -223,939 -47.6%2004 19-04120-0005 UWSS UPS system upgrade Feb-04 Sep-05 1.58 248,000 248,000 157,322 -90,678 -36.6%2002 19-02120-0065 NEW CP SYSTEM Nov-02 Aug-05 2.75 475,000 475,000 304,669 -170,331 -35.9%2004 19-04120-0039 Replace discharge isolation val May-04 May-06 2.00 150,000 150,000 101,643 -48,357 -32.2%2004 19-04120-0035 Replace isolation valve pipelin May-04 May-06 2.00 130,000 130,000 90,797 -39,203 -30.2%2004 19-04120-0034 Replace isolation valve pipelin May-04 May-06 2.00 190,000 190,000 158,297 -31,703 -16.7%2004 19-04120-0055 Auto flash tester Dec-04 Dec-06 2.00 60,000 60,000 50,153 -9,847 -16.4%2004 19-04120-0045 Replace isolation v shipper P G May-04 May-06 2.00 70,000 70,000 60,759 -9,241 -13.2%2003 19-03120-0033 Construction of new storage in May-03 Dec-04 1.59 20,000 20,000 18,133 -1,867 -9.3%2003 19-03120-0052 Replace of 30" x 600 discharge Nov-03 Dec-05 2.08 87,000 87,000 80,963 -6,037 -6.9%2005 19-05120-0040 Retrofit HP Gas Comp. UGOSP-12 Apr-05 Dec-06 1.67 120,000 120,000 118,528 -1,472 -1.2%2003 19-03120-0019 Replace A/C units at power dist Mar-03 Mar-05 2.00 98,000 114,000 X113,353 -647 -0.6%2003 19-03120-0020 Replace of A/C UNITS at switchg Mar-03 Mar-05 2.00 60,000 91,000 X90,503 -497 -0.5%2002 19-02120-0006 Purchase a new hydraulic wrench May-02 Dec-02 0.59 25,000 25,000 25,171 171 0.7%2003 19-03120-0018 Replace A/C units at treatment Apr-03 Mar-05 1.92 89,000 89,000 91,993 2,993 3.4%2003 19-03120-0021 UWIPS-1 remote operation project Apr-03 Nov-04 1.59 358,000 358,000 373,241 15,241 4.3%2004 19-04120-0053 Udh laboratory air compressor Dec-04 Dec-05 1.00 25,000 25,000 26,449 1,449 5.8%2004 19-04120-0051 New confrence room Sep-04 Aug-06 1.92 90,000 90,000 97,401 7,401 8.2%2005 19-05120-0011 Video Surveillance Camera for U Mar-05 Dec-06 1.75 308,000 308,000 335,591 27,591 9.0%2004 19-04120-0008 Replace flow control valves @ Q Mar-04 Dec-05 1.75 520,000 520,000 570,746 50,746 9.8%2002 19-02120-0041 Replace Qurayyah operation bldg Aug-02 Aug-05 3.00 184,000 224,000 X208,775 24,775 11.1%2002 19-02120-0044 Qurayyah bldg. A/C units replac Sep-02 Aug-05 2.92 117,000 175,000 159,102 42,102 24.1%

Completed Projects 2002- 2007

Quality tools

Flow chart Cause & effect diagram Pie diagram