16th International Conference of the TOC Practitioners Alliance - TOCPA

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April 23, 2015 Johannesburg, South Africa

16th International Conference of the

TOC Practitioners Alliance - TOCPAwww.tocpractice.com

Andy Anderson, for BABCOCK, South Africa23rd April, 2015

Partnering for Ongoing

Improvement

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Strategy

We are remarkably good at

meeting our promises

16th International Conference of the TOC Practitioners Alliance - TOCPA

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No overdue boiler projects

Execution phase shorter than

outage window

We control the bottleneck and

not the bottlenecks us

We induce desired behaviours

Objectives

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Shutdown Problems

Outage prerequisites not in place

Measurement butt welds

Shortage of skilled/experienced Manpower

Repeating same mistakes

Not using available technology

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Deming

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Separate Sheep from Goats

Leverage

Bottleneck

Bubbles

Full Kit

Execution

Planning

Client

Sub-

contractors

Bad Multi

Tasking

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Tactic

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How?

Acquire the required skill and know how.

It needs different behaviours (180 different)

Review construction methods from a flow

perspective

Know our deliverables/products

Relentlessly execute the plan (the plan is the

plan)

16th International Conference of the TOC Practitioners Alliance - TOCPA

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New Rules

Construction must be faster, than available time

Measurement = rate at which sequential tasks

are completed and buffer penetration

We buffer everything; buffers pay for

themselves, many times over

16th International Conference of the TOC Practitioners Alliance - TOCPA

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How it manifests in outage projects:

Moving people between projects on the units- tube

leaks, etc.

Starting tasks that are only scheduled for later by

dividing labour assigned

Moving resources around

Chase for butt welds; resources moved to the next

element prior to completing other work on the

previous element

Reduce Bad Multi Tasking

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Reduce Bad Multi Tasking

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Reduce Bad Multi Tasking

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Planning

Plan around flow it is the number one consideration

Outage plan based on Carab- budget-SOW

Manpower is a direct derivative from the plan

Policy- provide a buffer but never use it

Outage Plan Templates kept and updated

Inputs provided by people doing the work

Planning is useless unless it

significantly helps operations

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Planning: Method Statements

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Planning: Method Statements

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Planning

Opening 1 2 3 4 Totals Total/day

# Butts RH Side Top 500 230 200 700 1630 65

# Butts RH Side Middle 378 174 151 529 1231 49

# Butts RH Side Bottom 114 52 46 160 372 15

Total 992 456 397 1388 3233 129

Butts per day RH Side Top 20 9 8 28 65

Butts per day Top+M+B 40 18 16 56 129

Days to complete 25 25 25 25 25

Right-hand Side Economiser

Bottom

Middle

Top

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Full Kit

From budget-SOW all material procured

a buffer time ahead of the outage

All material as per SOW are available on

the level prior to when required

Buffer of resources available

Scaffolding teams on standby

Other service providers subordinated to

the outage requirements

16th International Conference of the TOC Practitioners Alliance - TOCPA

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Client and Sub Contractors

Client pro-active in dealing with obstacles

Support available on request

Client provides on-going focus to other

contractors

Client open for improvement suggestions

Provided air bags, phased array ultrasonic

testing and many other improvement aids

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Buffer Report

Remaining

Duration

Feeding

Buffer

Penetration

Project

Buffer

Penetration

Buffer

Penetration

Colour

Project

Buffer Trend

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Results

Outage Previous IR Unit 5 IR Variance

People 600 341 -259

Outage Previous GO UNIT 2 GO Variance

People 691 530 -161

Unit Budget Actual Variance

Previous GO R 40m R 80m R 40m

Unit 5 IR R 28m R 25m R 03m

Unit 2 GO R 49m R 39m R 10m

Unit 4 IR R 28m R 22m R 06m

Unit 2 GO Duration Buffer Total

Proj Plan 30 days 15 days 45 days

Actual 39 days 6 days early 39 days

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Client Representative

I have been the Boiler Pressure Part Controller since 2007 and

transformed the pressure part SOW to be completely

computerized. We can track the work performed live anywhere

in the world due to it being web based.

The last three Outages have been my greatest achievements as

regards coming in on time, cost, no major safety incidents and

quality and full SOW complete, this is due to the work I have

done with Carab over many years and the recent introduction of

CCPM by Babcock.

Brain Hancock

Boiler Pressure Part Controller

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The End