Best Practices for Collaborative Pull Planning of Complex Renovation Work in Manufacturing

Transcription

1 Best Practices for Collaborative Pull Planning of Complex Renovation Work in Manufacturing Samir Emdanat, Ghafari Associates Branden Brickles, General Motors Tim Buckley, Barton Malow Thursday Oct 19 th, :50 2:45 PM C A P T U R E A N D L E V E R A G E T H E L E A N A D V A N T A G E

2 The GM Toledo Plant Expansion Expansion Renovation Switchyard Expansion 2

3 Learning Objectives Learn how to prepare for and communicate the objective and outcomes of pull planning session for complex sequences of work. How to use the results of collaborative pull planning to create well sequenced phase plans. Learn when it is appropriate to use time-based visual representations of the pull plans. How to drive behavior during make ready planning. 3

4 Why GM Applied the Last Planner System? Existing facility runs 7 days a week and cannot be interrupted. Started design in Oct 2016 with a target completion date on Dec 31, 2017 (Power to Plant Milestone) High risk work which involved: Adding new building additions, Renovating existing parts of the plant for retooling, and Replacing/upgrading incoming entire electrical infrastructure. Plant makes transmissions for GMC Trucks Identified LPS as a way to mitigate that risk and improve reliability. 4

5 The Last Planner System (check / act) DID (do) WILL (plan) CAN (plan) SHOULD (plan) SHOULD Commitments Management Weekly Work Planning Make Ready Planning Phase Schedule Master Schedule CAN Complete MO TU WE TH FR WK 1 WK 2 WK 3 WK 4 WK 5 Not Complete SHOULD On Going Alignment of CAN and SHOULD = Reliability

6 Getting Started with LPS Align the stakeholders to identify work in the same way. Identified major phases & major handoffs. Identified areas of similar work, batch size, and sequence Pull planning in each unique batch. October 24,

7 First Design / Construction WWPs Demo work / site work started before design permits were submitted Design Lookahead Plan (ASAP but tied to Pull Dates) Start of Construction WWP (ASAP) 7

8 The Switchyard Team GM Plant GM Facilities GM Engineering October 3, 2016 Baton Malow (GC & self perform for Site/Concrete) Ghafari (A/E) Ruby (S) Orion Superior / Romanoff (E) Magna (Cx) Toledo Edison & First Energy (utility company) 8

9 Switchyard Plan Milestone & Phase Plan Identified long lead items. Identified plant shutdown dates. Identified a mismatch in shutdown work and lead times & adjusted the milestones. Plan is now back on track for the Power to the Plant Milestone. Install New T2 & Remove Old T2 October 10 to 21, 2016 Install Temporary Transformer Install New T1 & Remove Old T1 Power to the Plant Dec 30, 17 9

10 Switchyard Plan Phase Planning Identified interface points with utility company for planned shutdowns to main utility lines Decided to engage the utility company in the plan due to long lead times (30-90 days shutdown notices). Began to detail construction work (make ready work for setting the new Transformers). Began to refine thinking regarding site logistics for moving the transformers to and from site. Detailed planning started to identify possible early completion. Switching of main Power Transformer Foundations Power to the Plant << 12/31/17 10

11 Switchyard Plan Bay shore & Jackman Lines Bay shore Jackman Detailed Planning of Main Power Line Switch over. Must have power to the plant all the time. Must disconnect one main line to install and power new Transformers 11

12 Power to the Plant 12/10/17 Pull Plan (Logic View) Utility Company Pull Plan (Week by Week) 12

13 Switchyard Pull Plan / Electrical vs Other Work Electrical Work Supporting Work Site, Foundations, Structure 13

14 Visual Planning (Pull & Diagrams) Step by Step Visual Diagram of Electrical Work Specific to Electrical Pull Plan of Enabling Work & Electrical Work Timing & Coordinating with other Trades Step 1 14

15 Switchyard Plan Make Ready Planning 15

16 Visual Planning (Pull & Diagrams) 16

17 Visual Planning (Pull & Diagrams) 17

18 Visual Planning (Pull & Diagrams) 18

19 Visual Planning (Pull & Diagrams) Step 30 19

20 Visual Planning (Pull & Diagrams) Power to the Plant Step 32 12/10/17 20

21 Best Practices & Lessons Learned Advantages of the electrical diagrams: Explains step by step sequence to customer and workers. Clearly defined dates for outages with utility company. Advantages of the pull plan: Identifies handoffs from other trades to electrical. Identifies lead times. Identifies constraints Identifies overall sequence and durations. The combined approach allowed the various stakeholders to plan and execute complex work reliably. 21

22 Best Practices & Lessons Learned The Pull Plan & the step-by-step process allowed the team to discuss timing, impact on the plant, and timeline for utilities, and number of shut-downs. Detailed planning resulted in a more realistic plan with an earlier completion date of 12/10/2017 (three weeks early) 22

23 Contact Us Branden Brickles General Motors Samir Emdanat Ghafari Associates Tim Buckley Barton Malow 23

24 In the spirit of continuous improvement, we would like to remind you to complete this session s survey in the Congress app! We look forward to receiving your feedback. Highest rated presenters will be recognized.