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Lean Sigma Project

Reduce Variance Welding Rejection Rate on SLO North Area

Sponsor = NurhasanChampion= Surya AhdiFacilitator= Amran Alidin / Chandra SM Sitorus

Team MemberAgus Fatulilah RW Superintendent Support Mulyadi - RW Project Control Scheduler Alexandra Budiman RW Cost Engineer Masjon RW QA/QC Coordinator Munirruzaman RW QA/QC Inspector Dody - RW QA/QC Inspector

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Project ScopeDefineMeasureAnalyzeImproveControlIn ScopeOut of ScopeWUR under AFE projects on SLO North Area

Welding production within OAFMS project(PT.Vadhana International)

Problem Statement :Based on historical data of WUR under AFE projects within SLO North area in the year 2014, our contractors had fluctuated welding rejection rate about 0 - 23.21%. From this case by Lean Sigma Project will develop and improve become 0% - 5% of welding rejection. Project Objective :Short Term : To decrease fluctuates of welding rejection rate within SLO North area from 0 23.21% become 0% - 5%, to execute the job with safely. Long Term : To standardize welder rejection rate as a main parameter when evaluate welding performance of the contractor, and improve quality control system of welding to reduce welding rejection rate become 0 - 5%

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IPO DiagramImprove to reduce Variance Welding Rejection Rate on SLO North AreaManagementMeasurementProcessInputsOutputsGoalsMethod & SOPManpowerReduce variant of welding rejection rate within SLO North area from 0 - 23.21% become 0% - 5%, DefineMeasureAnalyzeImproveControlWelder Performance and ProductivityWelding & Welder Repair RateWPS/PQR QualifiedQA/QC Plan ProgramNDT Applied (RT) Reduce variant of welding rejection rate within SLO North area from 0 - 23.21% become 0% - 5%, HES Compliance (Achieved 0 ; 0 ; 0) 2010 Chevron 4

Voice of CostumerDefineMeasureAnalyzeImproveControlSLO/FE/CMT NorthTo decrease fluctuates weekly welding rejection rate 0 - 5 %Good welding quality control systemHES CorporateMSW complianceZero TRI, DAFW, MVC 2010 Chevron 5

Base Line Rejection Rate Data Aug - Nov 2014DefineMeasureAnalyzeImproveControl

Limitation Rejection Rate Goal < 5 %Actual Rejection rate = Avg 10.19% 2010 Chevron 56

DefineMeasureAnalyzeImproveControlBase on Company Requirement

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DefineMeasureAnalyzeImproveControlCause and Effect Diagram by RadiographyManpowerMethodeEquipmentInspectionRepair or Cut OffVisual InspectionFit-up Preparation Welding MachineGrinding Machine/brushWelder Qualified Pipe FitterWPS/ PQR Qualified SOP Welding Award and Incentive Defect by RT AppliedIncomplete FusionPorositySlag InclusionCrack PenentrationOthersWeather/Condition 2010 Chevron 78

DefineMeasureAnalyzeImproveControl3 Why MethodWelding Rejection rate within SLO North Area 0 23.21%Additional Cost for Re-Work or Cut OffInitial tracking root cause of RepairRe-Work for Repair or Cut OffAnalyze results:Create and Improvement SOP welding.Provide Award and Incentive for Zero Rejection RatePlanning & Scheduling Project in SLO North Area to be Delay POP and Out of Compliance 2010 Chevron 89

DefineMeasureAnalyzeImproveControlImprovement Plans Manage and assigned welders based on Welding Map (proper qualification for specific weld) Initiation to Develop SOP welding for site strategy Update weekly Welder Repair Rate with objective 5% Reduce cost Re-work and Re-NDT for repaired welds Initiation of monthly Welder Incentive program

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DefineMeasureAnalyzeImproveControl H E S Improvement Maintained good HES performance by closed supervision by either CPI or RW Need fully supports from all concern parties (Facility Owner, CMT North, RW, Business Partner Managements) to safe HES implementations

Achieved O,O,O 2010 Chevron 1011

DefineMeasureAnalyzeImproveControlStandard Operation Procedure Improvement

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DefineMeasureAnalyzeImproveControlStandard Operation Procedure NDT Improvment

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