BI-19 Process Improvement Sea Water Injection Department
Project Charter Problem Statement : • During 2002 -2007 period, 37% (12 out of 32) BI-19 projects were not completed within estimated time and budget ± 10%. Project Objective : • Complete 100% BI-19 Projects within projected time and budget. Critical To Quality ( CTQ) : • Project cycle time should be 2 years or less. • Actual cost should be within budget ± 10% Cost Of Poor Quality : • Reduced ROI due to long cycle time • Budget under or overrun • Supplement budget request after the fact Defect Definition : • Any BI-19 Project which exceeded ER time (2 years) or ER budget variance by ± 10% Goal: • Defect Rate: 0 • No time extension or Supplement Budget request after the fact
High Level Process Map ER Approval (Start) Material Procurement 10 – 12 Months Engineering Package Development 8 -10 months MCC / ER Closing 3 – 4 Months (Finish) Execution Period 6 – 8 Months Total Period = 27 – 34 Months
Current Process Map BI-19 Planning (Execution Phase) In House Design ? Engineering Prepare Detail Design 6 -8 months Engg Package No Yes Is there comments ? 30 % Design Review Initiate PDR Yes 90 % Design Review No Is there comments ? No 60 % Design Review Yes Ops Issue Maintenance Order Planner request Material / DC Procurement Material Received Yes Accepted Material Staged No SFC / PO Procurement Award contract Review Material Spec. Yes Wrong or Additional No Re-order Material Const. Phase
Current Process Map BI-19 Construction (Execution phase) SFC / PO Procurement Approve SFC / SO Mobilize Contractor Start Construction Submit Spare Parts Data Packages Final Closing MCC Signature Close All Yes Items In MCC Commissioning Submit all Required As Built Packages Submit NMR and OM
Completed Projects 2002 - 2007
Quality tools l l l Flow chart Cause & effect diagram Pie diagram
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