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Rapid Frac Material Handling

Rapid Frac Material Handling. Beth Nowacki SCMP Intern Final Presentation B.U.M: Thomas Sweeney PGL: Kaci Cook August 4, 2011. About Me- Elizabeth (Beth) Nowacki. Tables of Contents. HSE project Rapid Frac Material Handling Lessons Learned Thank you!.

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Rapid Frac Material Handling

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  1. Rapid Frac Material Handling Beth Nowacki SCMP Intern Final Presentation B.U.M: Thomas Sweeney PGL: Kaci Cook August 4, 2011

  2. About Me- Elizabeth (Beth) Nowacki

  3. Tables of Contents • HSE project • Rapid Frac Material Handling • Lessons Learned • Thank you!

  4. HSE: Recommendations to improve Ergonomics in the Send Out Crating Area

  5. Rapid Frac • Enables continuous pumping of multi-zone treatments • Helps reduce completion cycle time and improve production

  6. Rapid Frac

  7. Weeks 1-6

  8. External Vendor Receiving • In house production only • In house production, with external finishing's • External production Crating QM Lot RF Saws Warehouse RF RF TRT Inspection Manufacturing Assembly

  9. Receiving Dock 8 External Vendor 7 Initial State Staging 6 Crating Send Out QM Lot 4 5 9 Staging 3 1 Saws Areas of Improvement • Crating (1.5 hours) • Receiving (10 days) • Re-palletize (15 mins) • Saw Area Organize RF Warehouse Staging 2 10 11

  10. 1 Long Bar Send Out 3 Receiving Dock External Vendor Staging Ideal Future State 2 • Receiving • Before: 10 days • After: 3 days • Re-palletize • Before: 15 mins • After: NONE Pallet Pull System Crating QM Lot Send Out 4 Staging • Crating: • Before: 1.5 hours • After: NONE Saws Organize RF Warehouse Staging 5 6

  11. ROI- Receiving Current State (150-300 Assemblies) • Average Number of Pallets Received per day • 5.6 pallets • Time spent Re-palletizing per day (15 min/pallet) • 84 min or 1.4 hours per day • 285 hours per year • Indirect Labor Cost (Labor Burn Rate $56/hour) • $78.40/day • $15,993.80/year

  12. ROI- Receiving Future State with Current Pallet System • Average Number of Pallets Received per day • 22.4 pallets • Time spent Re-palletizing per day • 336 min or 5.6 hours per day • 1,442 hours per year • Indirect Labor Cost (Labor Burn Rate $56/hour) • $313/day • $63,974 /year

  13. Weeks 1-6 Weeks 7-12 Implementing a standardize pallet will be the most efficient way to improve overall logistics of Rapid Frac. • Reduce the number of Touches • Reduce time in Receiving • Reduce time in Crating • Integrate into the Pull Systems • Ergonomically and Cost Effect

  14. Requirements For Standardize Pallet

  15. Metal Pallet (Wooden Replica) • Good Ergonomics: both Transporting and Lifting • $276 • 2000 lbs static load • Stackable (3) • Forklift Accessible • 2 Removable Doors • Lined with cardboard or corrugated plastic

  16. Sustainability • Management of Change • Standard Work • 10 metal pallets on order • 3 week lead time • Jason Besly- EPIC Project Manager - Rapid Frac

  17. By Implementing a the metal pallet with two removable doors: $63,974 ROI

  18. Lessons Learned

  19. Thank You! • Ryan Arrington • Jason Besly • Mark Bregenzer • Kaci Cook • David Dockweiler • Gary Freet • Joe Haddad • Bryan Hensley • Dean Wynia • Jimilee McCleskey • Susan Price • Lynsey Ritchie • Cheri Rogers • Shannon Sixkiller • Tom Sweeney • Dan Swofford • Donna Willis • Chad Woodward • Carrollton Interns • Austin Baltes • Kimberly Caleon • Haley Helweg • Lee Smiley • Javier Penaflor • Aditya Mittal

  20. Questions?

  21. Action Plan • People • Overall Manager: Jason • To finish ergonomic testing of metal samples: (Epic: Jason or Dean) • Updating Vendors on how to properly load parts (Jim Gilmore with Standard Work from Beth) • Inform Receiving and Crating on new pallets (Mark Bregenzer) • Pallet included in PO (Joy) • 6 star documents (SOP) standard work • Instructions put parts in bin/pallet • MOC • ROI(completed)

  22. External Vendor Receiving Crating QM Lot RF Saws Warehouse RF RF 11 touches TRT Inspection Manufacturing Assembly

  23. External Vendor Long Bar Send Out Receiving Bin Pull Crating QM Lot RF Saws Warehouse RF RF 6 touches TRT Inspection Manufacturing Assembly

  24. External Vendor Receiving Crating QM Lot RF Saws Warehouse RF RF 23 touches TRT Inspection Manufacturing Assembly

  25. External Vendor Receiving Crating QM Lot RF Saws Warehouse RF RF 22 touches TRT Inspection Manufacturing Assembly

  26. External Vendor Receiving Crating QM Lot RF Saws Warehouse RF RF 16 touches TRT Inspection Manufacturing Assembly

  27. Manufacturing Process

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