Safety in a Lean Environment Efficient Pressure Management techniques

Transcription

1 Safety in a Lean Environment Efficient Pressure Management techniques By Jay Smith CFO and Energy Segment GM September 17, 2015 Oseco Safety in a Lean Environment Sept

2 Safety in a Lean Environment Efficient Pressure Management techniques YOU WILL NEED YOUR CELL PHONE or TEXTING CAPABLE DEVICE FOR THIS SESSION PLEASE TEXT oseco to or NOTE: All texts are anonymous, the phone numbers are not visible to the presenter or audience, no data can be collected other than vote tabulation Oseco Safety in a Lean Environment Sept

3 Who is Oseco? 34+ years of pressure management experience Chemical process Oil and gas Manufacturing Fire protection... and others Owned by Halma U.K. based holding company 2.8Bn Mar Cap Global footprint All products manufactured Broken Arrow, Oklahoma Operational excellence focus Oseco Safety in a Lean Environment Sept

4 What is an lean manufacturer? Lean at Oseco Leadership Driven Lean Culture All employees Lean 101 Kaizen Leaders 2 Lean Coaches 16 Facilitators all functional areas Kaizen Selection Monthly Steering Committee Meeting Value Driven Activities Kaizen Events 2 a month 2 to 3 days Daily 5S office and manufacturing Kanban Poka-Yoke One Piece Flow Visual Controls Kata lean is a management philosophy to systematically eliminate everything that does not add value to the customer. Oseco Safety in a Lean Environment Sept

5 5s in the Office!!!! Sales Copier Area Daily Checks 1. Paper left at the end day will be shredded 2. Tray x 11 Plain 3. Tray x 11 Plain 4. Tray x 14 Legal Plain 5. Tray 4 11 x 14 Plain Weekly Checks 1. Shredded basket emptied 2. All surfaces are wiped clean 3. All Trays are replenished Oseco Safety in a Lean Environment Sept

6 Making Pizza, so where s the waste? Oseco Safety in a Lean Environment Sept

7 Oseco Safety in a Lean Environment Sept

8 Making Pizza, 80% is Waiting and Transportation Order Placed Move to Queue Wait for Action Dough Shaped Spread in Pan Shape Pie Curst Sauce Added Cheese Added Toppings Added Wait for Baking Place in Oven Baked Remove From Oven Cut in Slices Place in Box Place on Hot Rack Check Quality Wait for Delivery Place in Hot Bag Deliver to Customer Summary' Type'of'Activity Occurances Total'Time Green Operations 9 10 Yellow Transportation 7 22 Blue Inspections 1 2 Red Wait 3 26 White Storage 0 0 Total Oseco Safety in a Lean Environment Sept

9 5 Principles of Lean Lean Learning Center, Troy MI 4 Oseco Safety in a Lean Environment Sept

10 Today s Kaizen Event Efficient Pressure Management techniques on the well site using lean principles Small Project High-Level Overview Event Cross Functional Group Oseco Safety in a Lean Environment Sept

11 Principle #1 Directly observe the activities, connections and flows including the measurements for each Product / Process Maps Cross Functional Activity Maps Value Stream Maps 3-Flow Maps Activity Maps & Spaghetti Diagrams Oseco Safety in a Lean Environment Sept

12 Current Technology used today Pressure Safety Devices Locations Emergency Relief valves 2 Pop Offs Spring Loaded Full Bore unloading Valve 3 N2 valve Gas operated Oseco Safety in a Lean Environment Sept

13 Technology Comparison Spring Loaded Gas Operated Safety Plug Setting Factory or Site Factory or Site Factory only Weight 75 to 80lbs 200lbs 20lbs Maintenance Yes Off site Every 20 stages Yes Off site Every 20 stages None One time use Every Completion Site Test Pops Yes Every Stage Job Start Yes Every Stage Job Start None required Factory certification Equipment for setting Calibrated Gauge Calibrated Gauge Nitrogen Gas Supply None Oseco Safety in a Lean Environment Sept

14 Supply Chain Map Pressure Safety Devices Map the Current State Material People Information Nitrogen Gas Management Non Field Location E&P Asset Location Transportation PRD Management Site Activities Test Pops (30 to 40 minutes) Calibrated Gauges Timing Dependent Every stage 1 per completion change of crew Local Site Maintenance (N minutes) Storage (N minutes) Rigging Up (N minutes) Field Location Oseco Safety in a Lean Environment Sept

15 Principle #2 Systemically Reduce Waste What are the types of Waste? Oseco Safety in a Lean Environment Sept

16 Supply Chain Map Flow 1 Flow 1 Material People Information Nitrogen Gas Management Non Field Location E&P Asset Location Transportation Field Location Oseco Safety in a Lean Environment Sept

17 Supply Chain Map Flow 1 Text what you believe would be the greatest waste From the 4 areas above Oseco Safety in a Lean Environment Sept

18 Oseco Safety in a Lean Environment Sept

19 Supply Chain Map Flow 2 Flow 2 Material People Information Non Field Location E&P Asset Location Transportation PRD Management Field Location Oseco Safety in a Lean Environment Sept

20 Supply Chain Map Flow 2 Text what you believe would be the greatest waste From the 4 areas above Oseco Safety in a Lean Environment Sept

21 Oseco Safety in a Lean Environment Sept

22 Supply Chain Map Flow 3 Flow 3 Non Field Location E&P Asset Location Transportation Site Activities Test Pops (30 to 40 minutes) Calibrated Gauges Timing Dependent Every stage 1 per completion change of crew Local Site Maintenance (N minutes) Storage (N minutes) Rigging Up (N minutes) Field Location Oseco Safety in a Lean Environment Sept

23 Supply Chain Map Flow 3 Text what you believe would be the greatest waste From the 4 areas above Oseco Safety in a Lean Environment Sept

24 Oseco Safety in a Lean Environment Sept

25 Principle #3 Systematic Problem Solving - 5 Basic Steps Identify the Problem Contain the Problem Understand the Root Cause Experiment Using Lean Rules Verify Structure every activity Connect every customer supplier Simply every flow path Improve through experimentation Oseco Safety in a Lean Environment Sept

26 Key Pressure Safety Devices Locations Oseco Safety in a Lean Environment Sept

27 Supply Chain Map Pressure Safety Devices Future State Material People Information Nitrogen Gas Management Non Field Location E&P Asset Location Transportation PRD Management Site Activities Test Pops (30 to 40 minutes) Calibrated Gauges Timing Dependent Every stage 1 per completion change of crew Local Site Maintenance (N minutes) Storage (N minutes) Rigging Up (N minutes) Field Location Oseco Safety in a Lean Environment Sept

28 Principle #4 Establish High Agreement of What and How Standard work instructions Five S s Error-proofing Visual controls Oseco Safety in a Lean Environment Sept

29 Principle #5 Create a learning organization - Reflection - Repeat #1 through #4 Oseco Safety in a Lean Environment Sept

30 Key Take Away Observe the current state Focus on easily identifiable waste Using problem solving techniques to find new technologies to reduce the waste Standardize the process on the what and how Verify the results - Reflection Continuous Improvement - Repeat Oseco Safety in a Lean Environment Sept

31 Questions? By Jay Smith CFO and Energy Segment GM September 17, 2015 Oseco Safety in a Lean Environment Sept