Project Support

A piping design flaw threatened vibration related failure and subsequent potential loss of primary containment at thousands of sites throughout a large facility. A project team had been in place for over 3 years but was only able to rectify 1.25 sites/week (4.6/week at peak). Forecast completion was 5 years out, 4 years beyond the business target completion date.
We started by spending time with the team to understand their process. We then established a Value Stream Map to capture and identify the Process Time for each step. By applying Takt Time, we adjusted the workforce and removed significant roadblocks. We also challenged the methods used to identify the areas at risk.
By applying a field-based vibration assessment approach instead of the desktop method used to date, project scope was reduced by 70%. The implementation of Takt Time increased the execution rate from 1.25 to 10 sites/week. The project was completed 9 months later, 3 months before the business target completion date.