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The Vendor Connection Engineering Human Performance

The Vendor Connection Engineering Human Performance. Raymond Pace Entergy – Pilgrim Station. June 29, 2009. Our Expectations Of Our Vendor. Establish an appropriate and effective communication process (Entergy will perform pre-job brief, post-job review).

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The Vendor Connection Engineering Human Performance

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  1. The Vendor ConnectionEngineering Human Performance Raymond Pace Entergy – Pilgrim Station June 29, 2009

  2. Our Expectations Of Our Vendor • Establish an appropriate and effective communication process (Entergy will perform pre-job brief, post-job review). • Commit to an achievable schedule (product quality must be maintained, consider HU traps and tools). • Establish design inputs (per the design specification & PO). • Identify the critical steps (i.e., steps that are not reversible). • Monitor the process (heightened communication, peer check, Entergy site review, third party review) • Determine appropriate product acceptance methodology (QC, factory acceptance test, receipt inspection). • Commitment to teamwork to insure that the product will be right the first time, on time.

  3. HUMAN PERFORMANCE Error Traps 1. Time pressure 2. Distractions 3. Multiple tasks 4. Overconfidence 5. Vague guidance 6. Peer pressure 7. Change 8. Physical environment 9. Mental stress 10. First shift/ Late shift

  4. HUMAN PERFORMANCE Error Prevention Tools • Self checking (STAR) • Questioning Attitude • Peer checking/ Devil’s Advocate • Effective Communication

  5. ASSUME HUMAN PERFORMANCE CHALLENGE ALL ASSUMPTIONS

  6. Vendor Human Performance Training • Design Engineer provides HU fundamentals training to vendors at their facility. • Improves product quality through identification of traps and use of tools. • Encourages the vendor becomes part of the team. • Eliminates rework of correcting flawed products after the fact.

  7. Vendor Human Performance Training VENDOR QUESTIONS (Most Asked): • Q: So if I tell you your schedule is unreasonable what will happen? • Q: So if I tell you I’ll be a day or two late because the verification is incomplete what will happen? • Q: So if I tell you we’ve run up against an unanticipated problem that will impact the product what will happen?

  8. Drywell Cooler Fans • A vendor supplied four electric motors with incorrectly sized horsepower (HP) ratings. • Specified 10 HP motors supplied were apparently 15 HP. • The vendor misunderstood the product line from the sub-supplier. • Two horsepower ratings (15 HP & 10 HP) stamped on the nameplate: 15 HP derated to 10 HP. • Initial in-rush current of a 15 HP motor • Modifications to the circuit breakers required which supply power/ overload protection for the drywell electrical penetrations. • Resulted in expedited motor replacements and two fan deferrals.

  9. Drywell Cooler Fans • Significant communication with the vendor on quality/ schedule. • Initial trip to the vendors to review assembly components. • Motors were not yet at the vendor's facility. • Obtained photograph of the motor nameplate. • Unusual motor nameplate rated at 15 HP and 10 HP • Vendor immediately recommended we discuss this issue with the motor supplier. • Motor supplier confirmed - in-rush current upon starting was based on 15 HP. • Vendor confirmed steady-state operation at less than 10 braking HP. • Modification to the breaker supplying the drywell fan assembly motor required. • Issue with circuit protection to the drywell electrical penetration.

  10. Drywell Cooler Fans Consequences: • The motor sub-supplier could not supply the 10 HP motors in the timeframe required. • PNPS shipped two refurbished 10 HP motors from the warehouse. Causes: • Motor supplier did not request a peer check from the appropriate product line engineers. • Recovery discussions confirmed 10 HP windings & 10 HP in-rush current. • Sub-supplier representative for the motor manufacturer provided inaccurate information.

  11. Drywell Cooler Fans Corrective Actions: • Pilgrim shipped the vendor two older style 10 HP motors that were in our warehouse for installation in two units. These were refurbished and installed during the recent refueling outage. • Installation of the remaining two units needed to be deferred to a subsequent outage. Lessons Learned for the Industry: Communication with vendors and their sub-suppliers during the entire manufacturing process is an essential aspect of obtaining quality equipment on schedule.

  12. Summary • Promote teamwork with your vendors through briefings & scheduled communications. • Communicate with all levels of the vendor/ supplier organization. • Remember your vendor is an important member of your team. HU fundamentals promote team resolution to issues.

  13. Questions?

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