combining lean and dmadv to innovate processes

Combining Lean and DMADV to Combining Lean and DMADV to Innovate ProcessesInnovate Processes

Greg RobertsonDirector of Six Sigma

April 30, 2008

April 2008

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Our direction today …

Who is Black & Veatch

Urgency for change

Business Process Management

Innovation through Lean and DMADV

April 2008

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Black & Veatch offers leading engineering, consulting and construction experience in …

April 2008

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Who is Black & Veatch?

22

66 1212

1515 2020

33

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What’s the What’s the Urgency for Urgency for

Our Change?Our Change?

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In the constant battle of “survivalof the fittest”, every business

must constantly re-evaluate itself

What’s driving change?

“Even if you are on the right track, you’ll get run over if you just sit there.” – Will Rogers

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Internal issues driving change in Black & Veatch

How is the work done?

How is the work done?

Where is our work?

Where is our work?

Who does the work?

Who does the work?

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External issues driving change in Black & Veatch

More opportunitiesMore opportunities More risksMore risks

Lean and DMADV used to “create” changeLean and DMADV used to “create” change

Changing markets and competitorsChanging markets and competitors

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Business Business Process Process

ManagementManagement

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Process owners vs. projects

Project Teams Receive and Apply Process Knowledge

Process Owners Develop and Communicate

Process Knowledge

Define Processes

Establish Metrics & Targets

Monitor Process Health

Learn, Understand, and Share

Continuously Improve

Processes

Define Needs

Identify Process Issues

Execute Processes

Adapt to Process Changes

Import Best

Practices

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BPM Maturity Model

Processes recognized but success largely depends on

individual effort and knowledge

Process owners identified but limited process

documentation exists

Process are fully documented and the intent is understood by

process customers

Process metrics established and tracked. Processes are

completely integrated

Process feedback routinely solicited. Process continuously

evaluated and improved

Recognized

Identified

Defined

Managed

Optimized

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How Does How Does B&V Use Six B&V Use Six

SigmaSigma

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We wear many hats

Mentors

Black belts

Facilitators

Researchers

Consultants

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Innovating Innovating through through Lean & Lean & DMADVDMADV

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Valve control stations

Reduced design time by streamlining

the valve station process

April 2008

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Valve Control Stations

RFRP&ID

Received

Insert Isolation Valves

Select Line Code

Information

Generate Pipe

Centerline RoutePipe

Add Bypass Valve

Add Control Valve

Auto Generate

Pull ISO'sAssign

Spool #'s

Add ISO Breaks &

Locate FW

Router, Add Pipe Supports (Sometimes

Pipe Stress Does)

Research Valves, Look Up Dimensions (end to end, operator)

Change to Bottom Routed Pipe & Reduce

Line Pipe Size

Research End to End & Operator Size From Other Projects (keep

sets of old P&ID's)

Verify Flow Direction

Place Spools On Hold For Valve (info if required)

Add Vent Drain

Valves

Insert Reference

Lines for Vent Drain, etc.

Add Caps if Required

Auto Generate

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Flanged Valves

Yes

No

Flanged Valves

Yes

NoFlanged Valves

Yes

No

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Add Bypass

Process cycle time = 40 minutes / valve stationProcess cycle time = 40 minutes / valve station

April 2008

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Valve Control Stations

RFRP&ID

Received

Insert Isolation Valves

Select Line Code

Information

Generate Pipe

Centerline RoutePipe

Add Bypass Valve

Add Control Valve

Auto Generate

Pull ISO'sAssign

Spool #'s

Add ISO Breaks &

Locate FW

Router, Add Pipe Supports (Sometimes

Pipe Stress Does)

Research Valves, Look Up Dimensions (end to end, operator)

Change to Bottom Routed Pipe & Reduce

Line Pipe Size

Research End to End & Operator Size From Other Projects (keep

sets of old P&ID's)

Verify Flow Direction

Place Spools On Hold For Valve (info if required)

Add Vent Drain

Valves

Insert Reference

Lines for Vent Drain, etc.

Add Caps if Required

Auto Generate

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Flanged Valves

Yes

No

Flanged Valves

Yes

NoFlanged Valves

Yes

No

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Delete Home Pipe

Change to Bottom Routed

Auto Generate

PipeAdd Valves

Insert Flange

Add Bypass

Lean innovation eliminated non-value stepsLean innovation eliminated non-value steps

April 2008

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Valve Control Stations

New process cycle time = 2 minutes / valve stationNew process cycle time = 2 minutes / valve station

RFR P&ID Received

Insert PowrTrak

IDs

Add Caps if Required

Select Pipe Supports

Add ISO Breaks &

Locate FW

Verify Flow Direction

Assign Spool #’s

Pull ISO’sSpools on Hold for Valve Info. (If Required)

April 2008

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Chimney foundations

Reduced the installed cost of large chimney foundations

April 2008

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Power plant chimneys

Chimneys over 1,000 feet high …

Equivalent to …

April 2008

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Baseline used cylinder

design

Mat thickness = 1 / 10

diameter

Baseline used cylinder

design

Mat thickness = 1 / 10

diameter

Baseline design practice

April 2008

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New approach uses octagon

shape and hole

Mat thickness is optimized

New approach uses octagon

shape and hole

Mat thickness is optimizedHole Size = ½

Diameter

New design practice

April 2008

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In summary, Lean and DMADV….

Work in an engineering environment

Support process innovation

Help accelerate, sustain and create change