Oil & Gas – Pressure Equipment Integrity (PEI) Inspection Work Process Improvement Program

 In Engineering, Inspection, Operations, Time-on-Tools, Work Management

Optimizing the Inspection Work Flow

Pacesetting companies continue to invest in opportunities that create a more safe and productive work environment for their employees and contractors.  This blog post summarizes a recent program designed to help better align company and contractor work flow expectations, improve inspection scoping efforts and work package quality, provide systems integration support (SAP) to improve the planning & scheduling capabilities as well as improve inspection (NDE) resource utilization and barrier removal.  The program objectives and approach are summarized below.

Program Objectives

  • Conduct a PEI Inspection “As Is” Assessment – Including Work Process and Time-on-Tool observations
  • Improve Organizational Alignment – Develop a small Alignment Team of client & contractor inspection personnel to vet, refine, align, and document the Inspection work process for managing the Inspection work flow with the specified contractors
  • Develop functional Roles & Responsibilities – The Alignment team will define roles, responsibilities, and interfaces for the Inspection team in the scoping, prioritization, planning & scheduling, execution, close out and barrier elimination of inspection work
  • Conduct Inspection work process training & behavioral field coaching
  • Develop and implement the Inspection Barrier Management Process
  • Conduct ongoing informal field Time-on-Tool observations to validate implementation changes

Initial findings

  • Roles and Responsibilities were not clearly defined – Little evidence of work process documentation – work flow, concepts, tools, methods, etc.
  • Too much variability in hand-off from Inspectors to Contractor resources
  • No evidence of prioritization criteria/methodology (Break-in vs P/S work)
  • No planned hour estimates available for resource loading (i.e., demand)
  • Lacking a demand-based resource loaded schedule, i.e., man-loads undefined, cost too high compared to industry benchmarks
  • NDE Tech Time-on-tools (ToT) baseline performance below industry best practices
  • Execution barriers and KPI’s not driving improvements

Program Elements – Alignment, Train and Implement the To Be Work Process

  • Engineering, Inspection and Maintenance Champions helped launch/champion process roll-out across site
  • Multi-disciplined Alignment team working with consultant to develop the Inspection work process and best practices:
    • Vetted, refined and defined Roles and Responsibilities to drive accountability
    • Provided role group training for all users, including managers
    • Development of Daily Schedule to track and eliminate barriers to work execution
    • Development of a Risk Based Decision Model to determine work priority (P1- Emergency, P2- Urgent, P3- Routine)
    • Identified critical process metrics to drive performance improvements

Results

  • Developed the To Be Work Flow Process Map
  • Developed Concepts & Tools for training and implementation
  • Defined clear performer roles & responsibilities (RACI)
  • Facilitated White Paper Fair Communication/Awareness prior to training roll-out
  • Conducted work process training & behavioral field coaching
  • Implemented short interval scheduling (Daily Assignments)
  • Implemented the Barrier Management Process – Root cause analysis & problem-solving skills
  • Facilitated Employee involvement
  • Completed ongoing informal ToT observations to validate implementation effectiveness
  • Improved NDE Tech Time-on-Tool performance by 35%
  • Barrier analysis and KPI’s driving improvements

Please contact us to explore how we may be able to help address your needs and assist with your improvement initiatives.  The following link summarizes our service offerings.  We can also be reached by phone at 612-868-3000.

 

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