SPURRING INNOVATIVE IDEAS IN WIDE OPEN...
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Annual Educational Conference
Welcome
FORT WORTH, TEXAS MAY 7-‐10, 2017
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Annual Educational Conference
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
RANDY ROBERTS ELECTRIC SUPPLIER QUALITY MANAGER
PACIFIC GAS & ELECTRIC
MAY 9, 2017
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACESAnnual Educational Conference
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Power Plants Electric Grid Customers
Hydro Power Plants
Nuclear Power Plant (Diablo)
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
Solar Farms / Power Plants
Wind Farms
Plug-in Electric Vehicles
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
! California U;lity serving 5.1 million electric customers ! Electric, Gas, Hydro-‐Genera;on, Solar, Nuclear ! $6 billion of yearly spend on services/procured products ! 20,000 employees (7,000 contractors)
! Use 16,000 ea, 1ø pole mounted transformers/year
! Use 2,500 ea, 3ø pole mounted transformers/year
think we
We are the most supplier quality conscious u;lity in the U.S.!
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Quality = Safety And….
Quality = Long Term Cost Savings (Supplier/U?lity)
And for U?lity Suppliers…
Quality = Differen?a?on from low cost suppliers
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Annual Educational Conference
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
San Bruno Fire Ball Rancho Cordova
Why I was hired
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
PG&E’s Wake-‐Up Calls: ! 12/2008: Gas explosion (defec;ve pipe (1 death)) ! 9/2010: Gas explosion (defec;ve pipe (8 deaths)). Not strictly a purchased part
problem…but could have been ! 11/2012: Electrical Fire: Bushing failed, dropping a neutral line. House burned
PG&E’s Reality: ! San Bruno: Penal;es and Criminal convic;on…Cost $2.5 Billion
" We have a “proba;on officer” with 5 years of oversight
! California CPUC is very aggressive in it’s oversight of PG&E " Product defect caused injuries and near-‐hits receive in-‐depth aeen;on by CPUC
! Other states’ u;lity commissions increasingly model California
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
One phase horizontal transformer: Exploded…Note the steel street cover was thrown in the air
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
Pad Mount Transformer: Rus[ng and removed a]er 3 years
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
Leaking Transformer: Oversize cut-‐out: Gasket won’t seal to prevent leaks
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
Bleeding Poles: Pending law suits related to exposure of children to the treatment chemicals
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
Hydro Power Plants
Natural Gas Generators Transmission Lines
Distribu;on Substa;ons
Auto Splice: Quality / Design Issue: No drain holes, carbon steel and aluminum, dissimilar metals …..millions of them
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Annual Educational Conference
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Annual Educational Conference
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Maybe not…..Aerospace industry is similar to ours (really!) and has gone through a similar transi;on
! Product failures can result in deaths
! Both products have to survive harsh elements
! Both must last for many decades without a much maintenance
! Failures result in huge liability risk to the manufacturers
! The Aerospace sector (25 years ago) had a lax regard for quality as the u;lity sector does today-‐ not anymore…DPPM in 100’s
! Suppliers that embraced quality took market share and thrived
We think we are seeing the same Paradigm shii today in the U;lity Sector.
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACES
1990 ! McDonnell ! General Dynamics ! GE ! Raytheon ! GM ! Lockheed ! UTC ! Mar[n Marieda ! Boeing ! Grumman ! GTE ! Rockwell
4 of 12 are s[ll top suppliers (6 are no longer in this business)
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Annual Educational Conference
SPURRING INNOVATIVE IDEAS SPURRING INNOVATIVE IDEAS IN WIDE OPEN SPACESIN WIDE OPEN SPACESAnnual Educational Conference
Our Vision for this Industry
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! Partner with key suppliers to ins[ll a vision for zero material defects
! Cer[fy to ISO9001 (PG&E cer[fied in 3/2016) ! Train and Cer[fy quality staff: ASQ Quality Engineers, Auditors, & Inspectors ! Qualify & audit key suppliers (can they build repeatable product?) ! Share Quality Programs via U[lity Benchmarking Events
! Create a U[lity industry forum to support material suppliers
PG&E is ACTIVELY conduc;ng benchmarking with the largest U;li;es and sharing our procedures and approach…we want to CHANGE the industry
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! Inspect 100% high value/safety related products (with inspec;on plans) ! Collect/analyze field failure data to rate suppliers’ products & tune inspec;on ! Source only suppliers with top rate quality – Work with the others… if they will
commit to gepng beeer
" Measure quality for all suppliers using DPPM " Require suppliers to conduct RCA for each defect found
" Qualify all new suppliers/audit all key suppliers
" De-‐source suppliers for poor quality – only when nothing else works
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Process begins with Standards Engineering….they define the cri;cal/high risk ranking manufacturers and create enforceable standards (roadmap for SQ)
PG&E’s basic Quality Roles:
SQ Audit Team QMS review SCAR (QMS process) QSL database
SQ Inspec;on Team Receiving Inspec;on Source (site) Inspec;on
SQ Engineers PPQP MPR/SCAR (part defect) DPPM & Scorecard eSCR
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To eliminate confusion and assure roles & responsibili[es are known, these documents must be clear & standardized
Web Based
• 68 procedures@ PG&E
– Manuals
– Policies – Inspec[on Procedures – Job Aids – Check lists
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5,252
2,131 1,373 1,146 950
9,735
5,013
2,059
1,066 850
0
3,000
6,000
9,000
2012 2013 2014 2015 2016 2017
DPPM Actual & 2017 Objec;ve
Gas Electric
• Supplier defects reduced by 95% achieving 99.9% defect free
• Combined with PG&E Inspec[on quality is nearing five sigma
19,507
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Denial Phase: “Our products are highest quality!!!!” Reality Phase: When problems start to show:
! SCARS (photos of problems and returned material) ! Cadence mee;ngs (2x/month) ! Plant visits and feedback ! Possible Loss of business / quo;ng other suppliers (if ac;ons not taken)
Recovery Phase: ! Add Inspec;on plans (end of line) ! Hire professional quality team ! Add process enhancements / make capital expenditures ! Add in-‐process controls ! Expect high inspec;on and rework costs ! Containment plans installed to protect the customer
Nirvana: ! DPPM down ! Decreased rework $$$ ! Efficiency and decreased manufacturing costs ! Solid customer rela;onships / Supplier of the year award
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! An independent Director or VP of Quality (trained and empowered)
! An ability & willingness to derive Root Cause for defects every ;me ! An ability to stop the line with support of Sr. Exec’s ! A culture of “;ger teams” with resources to improve process
! Regular cadence mee;ngs with customers with ac;on registers
! Con;nuous improvement philosophy throughout company
! In depth training programs
! A capital budget to address process and equipment enhancements
! A good internal metrics collec;on system
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! New HALT tested paint systems…longer las;ng ! New SST pad-‐mount boeom sec;ons (resist rust) ! New Leak check technologies ! New weld technologies / weld wire / robots /procedures ! New crimp technology, tools and products ! New torque tools and methods ! Bar code tracking systems ! New tes;ng equipment and procedures ! New gasket designs ! New oil fill methods
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! Honest and frank feedback ! Clear product requirements ! Clear metrics goals ! Fair advocacy during disputes ! Clear feedback (accurate and ;mely)
" Material Problem Reports (MPRs) " Supplier Correc;ve Ac;on Request (SCAR) as needed
! SQ Engineering support to help with supplier process enhancements
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! Strong metrics performance numbers…………………. A great manufacturing process ! Long lived, low maintenance and easy to install products
! Controlled Change process (EscR) " Change to any major sub-‐;er supplier " Change of manufacturing loca;on " Break in produc;on of that product for more than 2 years " Change of key manufacturing equipment
! Controlled “Escape Process” in Factory " Warning and “containment” if there is a material problem " Correc;ve ac;on (SCAR) that iden;fies and corrects discrete and systemic problems
! Qualified Products " Products are safe to use (over the long term) " Products have been subjected to rigorous accelerated age tested (HALT) " Products that will not nega;vely affect the environment
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Annual Educational Conference
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! Listen to your customer’s needs (LoB) What is important about your products?
! Products can’t be “good enough” any longer ! Sell your team members that change is here…Explain the risks/opportuni;es
! Ensure your team maintains an edge
Andy Grove: “Only the paranoid survive”
! Hire the right people with a forward view and free them to improve things
! Invest in Quality and training, beeer processes and beeer design
Don’t get caught during this major market paradigm shii …stay ahead of the change
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