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
www.tocpractice.com
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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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Deming
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
www.tocpractice.com
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
www.tocpractice.com
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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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Planning: Method Statements
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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Buffer Report
Remaining
Duration
Feeding
Buffer
Penetration
Project
Buffer
Penetration
Buffer
Penetration
Colour
Project
Buffer Trend
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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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
16th International Conference of the TOC Practitioners Alliance - TOCPA
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The End
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