Project: 13” Double BOP Masking Process Cycle Time

Improvement

ETS Project Number:Brian Jordan

Thomas Rd.

April 2014

TARGET

Team Members

Aftermarket Drilling Systems – Pressure Control

Houston – Thomas Road

Cycle TimeCost ReductionCustomer ExperienceHSE

Black Belt: Sindhura Bikki

Green Belt: Brian Jordan

Master Black Belt: Srikanth Sarathy

Champion: Myron Brooks

Process Owner: Brian Jordan

Finance Manager: Veronica Oliveira

Team Members: Brian Jordan, Mickerin Gresham

DEFINE MEASURE ANALYZE IMPROVE CONTROL3

Problem From past twelve months, the average cycle time for masking a 13-5/8 U BOP was 2 hours costing $200/job. A gap of $100 from our Business Objective target of less than $100/job exists. This represents an opportunity of $100 savings per masking job. This project will focus to reduce the masking process cost by 50% from the BSL.

Goal Masking cost reduction

Scope 13-5/8 U BOP masking process

Problem, Goal and Scope

Voice of the Customer

DEFINE MEASURE ANALYZE IMPROVE CONTROL

Paint/Sandblast Employees:

Masking a BOP most of the time takes longer to complete than blasting.

Strategic Alignment

DEFINE MEASURE ANALYZE IMPROVE CONTROL

TRIR

OTD

REWORK

COGS

OTD – On time delivery: The reduction in cycle time will help improve the

chances of on time delivery.

COGS – Cost of goods sold: the reduction in man hours directly effect the

cost of goods sold.

Cycle Time

Cost

Reduction

Customer

Experience

HSE

3 C Alignment

Cycle time: is the goal = cost reduction = customer experience

D – the factors that are the root cause of the undesired cycle time

M – The current cycle time by way of time study

A – Data before and after standardizing process

I – (IMPROVE – brief explanation)

C – (CONTROL – brief explanation)

Current Process Map

PART ARRIVES AT PAINT AREA

Collect masking tools5 min

Cover lock screw w/ 3 layers nonstick

tape 5 min

Cover ring grooves 3 layers of sticky tape

25 min

Roll nonstick tape to create plug for

bonnet lift holes8 min

Roll nonstick tape to create plug for

bonnet weeping holes2 min

PART MOVED TO BLASTING TABLE

YES

THOMAS RD PAINT MASKING PROCESS MAPCover lock screw w/

3 layers of sticky tape

10 min

Use razor blade to remove excess from

ring groove 2 min

Cover studs w/3layers non sticky

tape35 min

Cover studs w/ 3 layers sticky tape

25 min

DEFINEMEASUR

EANALYZ

EIMPROV

ECONTRO

L

THOMAS RD PAINT MASKING PROCESS

The previous process contained waste in the

following X of 8 wastes:

Defects Sometimes tape is blast through striking

protected surfaces.

Overproduction

Waiting • Takes longer to mask than to blast (Bottle

Necks Process at Times) also unmasking

Non-standard or

Over processing

• Every paint shop employee has his own way

and level of quality of the masking process

Transportation

Injuries • Excessive use of blades increase the chance

for injury

Motion • Lots of repetitive motion when masking and

unmasking

Excess

Inventory

• Tape must be ordered by the case load

8

PICK Chart

Po

sit

ive

Im

pa

ct

On

Go

al

Difficulty To Implement

High

Low

HardEasy

I-Implement C-Challenge

K-KillP-Plan

Plugs

Drying booth

Mechanical

Masking

(write here)

Ring groove

sized stickers

For quick

masking,

Stud caps

DEFINE MEASURE ANALYZE IMPROVE CONTROL

Masking Tools

Time Study Post Improvements

Total Time 00:35:25

00:03:35 Wipe areas to be

taped with thinner

00:08:26 Apply stud strips

00:03:17 Shrink wrap locking screws

00:01:19 Plug holes

00:08:53 Cover ring groove

00:02:16 Add stud covers

00:07:10 Tape locking screw and tags

14

Project.

CURRENT WEEK REVIEW

END-GAME WATCH

UPCOMING SCHEDULE (1-2 WEEKS)

• Accomplished this week: data collection and analyses

• .

• Outcomes from weekly meeting need process broken down in to sectors, must insert raw

data, correct liars with time study and standardized S.A.P. data.

• .

PROJECT OVERVIEW

Champion meeting DONE

Kick off meeting DONE

Baseline DONE

DONE

• Review more new sap data

• Control set up

•