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BI-19 Process Improvement

BI-19 Process Improvement. Project Charter. Problem Statement : During 2002-2007 period, 37% (12 out of 32) BI-19 projects were not completed within estimated time and budget ± 10%. Cost Of Poor Quality : Reduced ROI due to long cycle time Budget under or overrun

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BI-19 Process Improvement

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  1. BI-19 Process Improvement

  2. Project Charter • Problem Statement : • During 2002-2007 period, 37% (12 out of 32) BI-19 projects were not completed within estimated time and budget ± 10%. • Cost Of Poor Quality : • Reduced ROI due to long cycle time • Budget under or overrun • Supplement budget request after the fact • Project Objective : • Complete 100% BI-19 Projects within projected time and budget. • Defect Definition : • Any BI-19 Project which exceeded ER time (2 years) or ER budget variance by ± 10% • Critical To Quality ( CTQ) : • Project cycle time should be 2 years or less. • Actual cost should be within budget ± 10% • Goal: • Defect Rate: 0 • No time extension or Supplement Budget request after the fact

  3. High Level Process Map MCC / ER Closing 3 – 4 Months (Finish) Material Procurement 10 – 12 Months Engineering Package Development 8 -10 months Execution Period 6 – 8 Months ER Approval (Start) Total Period = 27 – 34 Months

  4. Current Process Map BI-19 Planning (Execution Phase) Yes Is there comments ? In House Design ? No Engineering Prepare Detail Design Initiate PDR 30 % Design Review Yes 6-8 months Yes No Is there comments ? Is there comments ? No Engg Package No 90 % Design Review 60 % Design Review Yes Accepted Yes Ops Issue Maintenance Order Planner request Material / DC Procurement Material Received Material Staged No SFC / PO Procurement Wrong or Additional Review Material Spec. Yes Const. Phase No Award contract Re-order Material

  5. Current Process Map BI-19 Construction (Execution phase) SFC / PO Procurement Approve SFC / SO Mobilize Contractor Start Construction Submit Spare Parts Data Packages Close All Yes Items In MCC Final Closing MCC Signature Commissioning Submit all Required As Built Packages Submit NMR and OM

  6. Completed Projects 2002- 2007 Cancelled Under budget Over budget

  7. Quality tools • Flow chart • Cause & effect diagram • Pie diagram

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