teaming up on steel pole quality, and why it matters to...

SEPTEMBER 4 - 6, 2019

Teaming Up On Steel Pole Quality,And Why It Matters To You.

Greg Ade, PMP, CQAQuality Manager, Corporate OversightR. John Falkenrath, PE, SETransmission Civil & Structural EngineerLeo Padron, ASNT Level III, ISO – RAB/QSACorporate Vice President of Quality Assurance & Continuous Improvement

SEPTEMBER 4 - 6, 2019

TopicsSituation:• Owner Business NeedBackground:• Scope of Work• Team ContributionsActions:• Supplier Qualification / Re-Qualification• Supplier Performance Management• Continuous Improvement / InnovationResults:• Relationship Lessons Learned• Alliance Development Summary• …And Why It Matter$ To You• Closing / Questions

SEPTEMBER 4 - 6, 2019

Owner Business Need• 2012 Transmission Capital Investment Rapid Growth Forecast

• Estimated Annual Steel Poles Expenditures @ $60M +/-

• Striving to Better Manage Risks Throughout Project Lifecycle

• Need For Most Efficient Designs to Meet Criteria

• Previous Non-Alliance Supplier Posed Quality and Schedule Risks

• Solution: Develop Alliance Steel Pole Supplier Relationship

Quality Manages Risks Over Project Lifecycle

Operations

SEPTEMBER 4 - 6, 2019

Scope of Work• Develop Supplier Alliance to Continuously Improve Quality

• Reduce Rework / Installation Issues / Risk of Schedule Delays

• Support Portfolio of 345kV / 138kV Capital Investment Projects

• Provide Codes / Standards Mandated Quality Assurance

• Adhere to Quality Management Industry Best Practices

• Foster Collaboration on Continuous Improvement / Innovation

Scope Of Work

Quality

Sche

dule

Safe

ty

Cos

t

SEPTEMBER 4 - 6, 2019

Team ContributionsSupplier Quality Management• Quality Program Development / Implementation / Maintenance

• Product / Materials / Sub-Supplier Quality / Records Management

• Product Non-Conformance Quality Evaluations / Repairs

• Product / Inspection Innovation / Continuous Improvement

• ASNT / AWS Quality / Weld Inspection Personnel

OQMSE

OE

TEAM

SQM

SEPTEMBER 4 - 6, 2019

SQM

Team ContributionsOwner Quality Management• Critical Supplier Qualification / Periodic Re-Qualification Process

• Product Nonconformance Tracking / Review / Trending Process

• Innovation / Continuous Improvement Recommendations

• ASQ Quality Management Personnel

SE

OE

TEAM OQM

SEPTEMBER 4 - 6, 2019

OQM

Team ContributionsSupplier Engineering• Design Compliance With Codes / Standards / Owner Criteria

• Design Documentation / Records Management

• Product Nonconformance Engineering Evaluations / Repair Designs

• Design Standards / Innovation / Continuous Improvement

• Registered Professional Engineering Personnel

SQM

OE

TEAMSE

SEPTEMBER 4 - 6, 2019

OQM

Team ContributionsOwner Engineering• Owner Criteria / Specifications Development / Maintenance

• Supplier Qualification For Codes / Standards / Owner Criteria

• Product Nonconformance Engineering Evaluations / Repair Reviews

• Standards / Innovation / Continuous Improvement Recommendations

• Registered Professional Engineering Personnel

SQM

SE TEAM

OE

SEPTEMBER 4 - 6, 2019

Supplier Qualification / Re-Qualification• Quality Management Reviews

• Quality Policy / Program / Processes / Standard Operating Procedures

• Records Management

• Products / Materials Traceability / Sub-Suppliers Quality Records

• Calibrations / Certifications / Training Records

• Production Operations for Demonstration of Quality Program

SEPTEMBER 4 - 6, 2019

Supplier Qualification / Re-Qualification• Engineering Reviews

• Design Methodologies / Details / Software / Checking• Criteria / Specifications / Codes / Standards Compliance• Fabrication Tolerances / Welding Specifications / Practices

SEPTEMBER 4 - 6, 2019

Supplier Qualification / Re-Qualification• Re-Qualification Frequency Depends on Quality Status• Quality Audit Visits Rotate Between Production Facilities• Fabrication / In-House Galvanizing / Storage / Shipping Operations• Improvement Example:

• Months For 2013 Alvarado Plant Qualification• Days For 2018 Bossier City Plant Qualification

SEPTEMBER 4 - 6, 2019

Supplier Performance Management• Quality Management Reviews of Non-Conformances

• Quality Evaluations / In-Process and Field Repairs / Documentation• Root Cause / Corrective Actions / Extent of Conditions Analyses• Uses Supplier In-Process / Owner Non-Conformance Tracking• Address Cost and Schedule Impacts

SEPTEMBER 4 - 6, 2019

Supplier Performance Management• Engineering Dispositions of Non-Conformances

• Supplier Addresses Safety / Serviceability / Performance / Warranty• Owner Addresses Safety / Serviceability / Performance / Acceptance• Sometimes Require Surveys / Tests / Inspections / Calculations

SEPTEMBER 4 - 6, 2019

Supplier Performance Management• Regularly Scheduled Quality Action Items / Metrics Calls

• Improvement Example: Began as Weekly / Now Held Monthly• Over 300 Open Action Log Items Since 2014 / Typically 20 +/- Active

• Monthly Pole Order Schedule Projections Coordination Call

• Periodic Contractor / Shipping / Handling / Assembly Training• Periodic Installed Product Inspections

SEPTEMBER 4 - 6, 2019

Continuous Improvement / Innovation • Supplier Quality Continuous Improvement and Innovation Initiatives

• Inspections / Materials / Process Improvements• Automation / Research / Development Efforts

• Owner Quality Continuous Improvement Recommendations• Engineering Design Innovation Collaboration• Collaboration Improvement Example:

• Use Lessons Learned in Specifications / Standards • Vetting / Adopting Supplier Standard Practices

SEPTEMBER 4 - 6, 2019

Relationship Lessons Learned• Maintain a Core Quality Management / Engineering Team• Team Maturity Cycles: Storming / Norming / Performing Stages• Many Internal / External Stakeholders / Contributors to Manage• Team Success Requires Open / Timely Communication• Alliance Management of Quality Improves Results

• Reduced Frequency of Monitoring • Improved Product Quality Metrics Over Time • Reduced Non-Conformance Rates• Reduced Rework / Schedule Impacts• Improved Cost Control / Product Confidence

SEPTEMBER 4 - 6, 2019

Alliance Development Summary

SEPTEMBER 4 - 6, 2019

…And Why It Matter$ To You• Increased Product Confidence / Reliability

• Lower Product Non-Conformance Rates / Severity• Negligible Component Failure Rates

• Reduced Risks to Scope / Schedule / Cost / Safety / Quality• Improved Stakeholder Relations / The Right Product at The Right Time

• Reduced Owner Risk of Installation Delays / Costs

• Reduced Supplier Rework / Costs

SEPTEMBER 4 - 6, 2019

ClosingSituation:• Owner Business NeedBackground:• Scope of Work• Team ContributionsActions:• Supplier Qualification / Re-Qualification• Supplier Performance Management• Continuous Improvement / InnovationResults:• Relationship Lessons Learned• Alliance Development Summary• …And Why It Matter$ To You• Closing / Questions

SEPTEMBER 4 - 6, 2019

QUESTIONS?

Teaming Up On Steel Pole Quality, And Why It Matters To You.

Greg Ade, PMP, CQAQuality Manager, Corporate Oversight314.206.1817, gade@ameren.com

R. John Falkenrath, PE, SETransmission Civil & Structural Engineer314.554.4285, rfalkenrath@ameren.com

Leo Padron, ASNT Level III, ISO – RAB/QSACorporate Vice President of Quality Assurance & Continuous Improvement817.706.0223, padronl@fwtllc.com