Learning From Others - AOG...Lean Production Systems in Mining, Defence, O&G Leading Lean...

1

Highly Productive Maintenance Execution

Trends in Mining & Defence

How automotive manufacturing best practices have been

successfully applied in non-manufacturing industries

Learning From Others

2

AGENDA

Introduction

Standard Work

The Oil & Gas Industry Challenge

Case Studies – Mining and Defence

Enabling Technology

The Way Forward / Next Steps

3

INTRODUCTION

General Manager, Partner

John Grout

Former VP Operations Tier 1 Suppliers -

>16years in the European Automotive Industry

Specialist in Developing and Implementing

Lean Production Systems in Mining, Defence,

O&G

Leading Lean Implementation, Supply Chain

Optimisation and Technology Management for

over 10 years’ in Australia & the APAC

Region

Director, Partner

Mark Haverty

Mobile technology specialist

Over 10 years’ delivering technology solutions

to the Oil & Gas industry

Leading Codealign’s technology partnership

with SECORA

Delivery of disruptive technology solutions to

Nissan, E.ON, Tesco, G4S and Walmart

4

Strategic direction of

the majority of major

mining companies

Basic Competencies

for the Mining Sector

EVOLUTION OF EXECUTION OPTIMISATION

2010 – 2016 2013 – 2015 2012 – 2016

Pro

du

ctivity an

d S

ustain

ab

ility

Felt Leadership

Frontlline

Supervision

Tool Time Focus

Quick Change Over

(QCO)

BREAKTHROUGH

Standard Work

Technology Apps

2016 Onwards

5

Our deployment approach starts with personal engagement to educate and nurture the waste elimination philosophy.

During implementation we coach and support the right behaviours displayed by work crews when dealing with variance to standards and abnormalities.

We use state of the art technology to provide tailored solutions for sustainable improvements. Our approach covers systems, processes, technology, hearts and minds

KEYS TO SUSTAINABLE IMPROVEMENT

Our deployment approach starts with

personal engagement to educate and

nurture the waste elimination philosophy

We use state of the

art technology to

provide tailored

solutions for

sustainable

improvements.

Our approach

covers systems,

processes,

technology as well

as people (hearts

and minds)

During implementation we coach and

support the right behaviours displayed by

work crews when dealing with variance to

standards and abnormalties

6

WHAT IS STANDARD WORK?

Step

#

Work Steps NVA Auto

Time Elements

1

VA ENVA Walk

ASSEMBLE CLUTCH PIPE 4 2

2 TEMP FIT CLUTCH PIPE ASSY TO BODY

2 6

3 PICK UP AIR TOOL

2 1

4 SECURE CLUTCH PIPE ASSY TO BODY

2 2

5 RETURN AIR TOOL AND PICK UP WASHER PIPE 3 1

6 TEMP FIT WASHER PIPE TO BODY 9 1

7 PICK UP ROOF RAIL 2 5

8 TEMP FIT ROOF RAIL TO BODY

2 4

9 PICK UP AIR TOOL & 3 NUTS

2 2

10 SECURE ROOF RAIL

2 7

21 !! Total Walk Time

FL

OW

RA

CK

Too

l

7

4

2

1

3

6

8

9

5

10

AUTOMOTIVE EXAMPLE OPTIMISING THE WORK CELL

7

STANDARD WORK, WES, YAMAZUMI

3. YAMAZUMI

Work Element Sheet Care Points Knack Quality Safety Environment Critical

Secure ash tray to J-gate Trim & Final

WL4/02/077 SL402003A casting Assembly

Line Four

S-Type

Standard

Working Position

1. Safety Shoes 5. Hard Hat 9. Ear Plugs

2. Safety Glasses 6. Cap 10. Wrist Cover

3. Mask/Visor 7. Gloves 11. Arm Cover

8 Apron

1 # Obtain two ash tray fixing screws. # From toolbox. # To secure ash tray.

2 # Secure ash tray. # Position two screws through ash tray into J-gate casting. # To hold down ash tray in place.

3 # Obtain battery gun and secure. # Pick-up battery gun from toolbox. Place screw on bit of gun, # To secure ash tray.

and secure and torque off both fixings.

WES No. SWC No. NVA

6

GSPAS No. / EOS Numbers: FTC00670

0.31.5No2 Phillips Bit

ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON

Sup'r/PLOp's/Assoc'sGL/TLOriginator Engineer Sup'nt/PAM

Major Step (WHAT) Reason (WHY)

L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1

VAElement Description

R4

VARRTGTool

Battery Gun

E C

2. Work Element Sheets 1. Standard Work

Note: The Supervisor plays a critical role in this system as the custodian of

Standard Work and driver of CI. Leadership Development will be a key

component of successful implementation

8

STANDARD WORK

Standard Work

Standard Work: Configured like

a playlist in iTunes with songs

from the iTunes library




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C

Work Element Sheet Library

Work Element Sheet Library: Populated with ‘best practice’

standard work elements. to be configured as required for the

Standard Work Sheets/Programs




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C

9

Mining – Haul Truck Servicing (500hr)

> 60% Reduction

Case Study

10

SCOPING & PLANNING 500HR SERVICE

d

An Industrial Engineering

approach was then taken

to logistically analyse the

location of activities

around the truck and the

logical numbers of

Standard Work, Work

Element Sheets and

Elements

11

RESULTING STD. WORK FOR TRUCK SERVICE

Task Order Map

Inspect condition of side walls3

Date:

Supervisor Sign Off:

Initial Reading

Revision No: 1.1 Revision Date: Oct 2016

Standardised Work Sheet


Inspect condition of tyre bead3


1.5Inspect condition of tyres.2

6 Inspect RH Rear Suspension Joint


1.5Inspect condition of tyres.3

Inspect valve hardware1

Measure tyre tread depths

Inspect Rear Magnetic Plug & Hub Oil Level4

Inspect valve hardware1

Measure tyre tread depths3

5 Inspect RH Front Suspension Joint

Inspect wheel studs, flanges for loose or missing nuts or bolts.1

35

25

27

26

37

36

40

38 2 Measure tyre tread depths

33

28 3

32 1 Inspect the condition of wheel rims.

31 1 Inspect wheel studs, flanges for loose or missing nuts or bolts.

29

39 6 Inpsect LH Rear Suspension Joints

0.3

0.8

Process Name: 793F 500hr service

Product Name: 500hr Fitter 1 Name:

0.75

No Wes No Work Element DescriptionVA NVA Time

Start at Tyre P1 - LH Front 0.25

3 1 Inspect valve hardware



Inspect condition of tyre bead6 3

0.75

1.5

4 2 Inspect Front Magnetic Plug & Hub Oil Level

5 3 Inspect condition of tyres.

7 3 Inspect condition of side walls

8 3 Measure tyre tread depths

0.25

0.75


9 5 Inspect LH Front Suspension Joint

10 Walk to Tyre P2 - RH Front


Inspect condition of tyres.15 3

0.75

1.5

13 1 Inspect valve hardware

14 2 Inspect Front Magnetic Plug & Hub Oil Level

16

17

0.8

Walk to Tyre P4 - RH Rear 0.321

18

20

19


23

24

30

Inspect Rear Magnetic Plug & Hub Oil Level34 4 0.8


0.8

Walk to Tyre P3 - LH Rear

1

10

11

20

21

30

31

12

IMPLEMENTED SYSTEM

Work Sequence Board Standard Work Sheets Performance Board

13

RESULTS

Original Setup Time

Step 1: Detail Steps &

Separate (internal /

external)

Step 2: Change the

internal to external steps

Step3: Rationalise the

internal steps

Step 4 (TBD): Design for

maintenance

T4 T3 T0 T1 T2

Time

External Internal

297 min

196 min

165 min

120 min

60 min

(estimate)

14

Defence – Helicopter Maintenance Downtime

50% Reduction

Case Study – Royal Australian Navy

15

RAN – SEAHAWK HELICOPTER SERVICE

An Industrial Engineering

approach was then taken to

logistically analyse the location

of activities around the

helicopter and the logical

numbers of Standard Work,

Work Element Sheets and

Elements

16

24

25

21

22

23

Sign Off

TL SV QA

2

Standardised Work Sheet Product Name: Seahawk FLC LAMY 1&2 Key Point Symbols

No Wes No Work Element DescriptionVA NVA Time

Revision No: 1.1 Revision Date: Feb 2011 Process Name: Daily Flightline Check

3 3 Hydraulic Systems Y 2

Short Vibration Analysis

Y 4.8

Y 25

Flightline Check (Daily - Overnight)

1 1 Environmental Control System

2

1.5

3.8

5

5

5 5 Engine Drive Shaft and Air Inlet Assembly Y

Main Transmission and Cargo Hook Support Y6 6

4 4 Flight Controls Y

8 8 Service part return (Bag & tag) Y

9

7 7 Visual inspection - Sensors Y

Y 6.25

Engine Drive Shaft and Air Inlet Assembly

1

Y 8.7510 1

12 3 Tail Rotor Drive Shafts Y

11 2 Transmission Systems 1

13

2.5

2.5

5

13 4 Tail Rotor Drive Shafts Y

Transmission Systems 2 Y14 5

16 7 Flight controls - Tail Rotor Cables 1 Y

17 8 Flight controls - Tail Rotor Cables 2 Y

15 6 Main and Tail Shock Struts Y

Service part return (Bag & tag) Y

3.5

3.5

118 9

20

19

43

Sheet No 1 of 1

44

Total Time (hours) 48.1

D

( 1

3

3 4

4

7

2

1

6

78

2

9 5

81

( 2

5

6

STORE

RAN – SEAHAWK HELICOPTER SERVICE

17

RELEVANT EXPERIENCE - DEFENCE

Submarine Capability Improvement Program (Collins Class)

Design & implement Lean-based CI program

Cross-functional training, implementation, change management

~$0.5Bn saving over the remaining asset life

Minor War Vessels Logistics CI Program

Establish & implement framework across 1st & 2nd line logistics

Standardise processes & procedures across all the FLSE

ROI ~8.0x . Critical asset availability increase by 30%

HUMVEE – MRAP Joint Program (Afghanistan)

Fielding capacity increased from 30-90 vehicles per week using Standard Work

Design and implementation

200% increase in throughput for critical equipment manufacture

18

INOVATIVE APPLICATION - CONSTRUCTION

Lendlease CLT Factory, Toyota Production System

Lean Construction, Lean Manufacturing, Lean Life Cycle Cost Optimisation

Standard Work developed and implemented for entire delivery process (from factory to site)

APQP methodology manufacturing process (factory layout, logistics, training requirements and

internal capabilities) in parallel with the factory design

Automotive style manufacturing facility taken to the construction industry

Just in Sequence Supply Chain Setup

19

Enabling Technology

20

ENABLING MOBILE READY STD. WORKS

Work Element Sheets Standard Work Sheets




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C




Line Four

S-Type

Standard

Working Position




8 Apron





WES No. SWC No. NVA

6



ENVA

28/01/2004

Date

Attachment

Dept

Area

Key Point (HOW)

Model

Spec

Protection

4. High Vis Vest

NOM

ICON



L3S1

1 3

C4

L4

R1 R2 R3

C1 C2 C3

L1 L2

1


R4

VARRTGTool

Battery Gun

E C

21

STANDARD WORKS APP

Supports the process of implementing

Standard Work processes

Simple user interface to streamline the

user experience

Apply and monitor safety regulations

Capture data associated to Standard

Works through, barcode, QR code,

photo, video, text and user forms

Instant updates to Standard Works

Standard Works App – Login Page

22

Standard

Work module

Fault

Reporting

module

Works Order

module

Tools for

Diagnostics

module

GPS Tracking

& Maps

module

???

EXAPANDABLE INNOVATION

Lean

Manufacturin

g

Facility

Inspection

23

Thank you

Questions?

24 24

WHERE PRODUCTIVITY MEETS SUSTAINABILITY

Company Information SECORA Australasia Pty Ltd

ABN: 38 123 554 085

WWW.SECORA.COM.AU

COMMERCIAL IN CONFIDENCE

SECORA AUSTRALASIA PTY LTD

SECORA Perth

Level 24 Allendale Square,

77 St Georges Terrace,

Perth, WA 6000

+61 8 6141 3298

[email protected]

SECORA Sydney

Level 6,

60 Carrington Street

Sydney, NSW 2000

+61 2 9299 4582

[email protected]

SECORA Singapore

20 Maxwell Road

#02-01 Maxwell House

Singapore 069113

+65 9359 6305

[email protected]

SECORA Berlin

Steinweg 53, D-14532

Kleinmachnow,

Germany

+49 33 203 222712

[email protected]

SECORA Tampa

8478 Dunham Station Drive,

Tampa, FL 33647, United

States

+1 813 409 5663

[email protected]

Learning From Others - AOG...Lean Production Systems in Mining, Defence, O&G Leading Lean...

Documents

Transcript of Learning From Others - AOG...Lean Production Systems in Mining, Defence, O&G Leading Lean...