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National Nuclear Security Administration Kansas City Plant Transformation. KCRIMS / NSMC Kansas City Responsive Infrastructure Manufacturing & Sourcing National Secure Manufacturing Center. - PowerPoint PPT Presentation
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KCRIMS / NSMCKansas City Responsive Infrastructure Manufacturing & Sourcing
National Secure Manufacturing Center
National Nuclear Security Administration
Kansas City Plant Transformation
“The KCRIMS project, including the NSMC facility, is a cornerstone of the future success of the DOE.” - Steven Chu
Secretary of EnergyRick Lavelock
Sr. Program Manager Honeywell FM&T
KCRIMS / NSMC Program TimelineCalendar Years Shown
SEABReport
RI Roadmap
NNSAJanuaryProcess
D’AgostinoCongressional
Testimony
First KCRIMSTransformation Plans
Joined GSA forFacility Acquisition
KCRIMS DraftBusiness Case
KCRIMS FinalBusiness Case
CD-0
CD-1
NEPA EADecision NEPA
NOI
Site Selection &Press Release
SAIC AlternateSite Study
Draft EA PublicComment Ends
OMBApproval
SolicitDevelopers
CongressionalApproval
FacilityAcquisition
Report
StrategyTeam
FunctionalTeams
MitigatedFONSI
RestartSolicitation
Lease / PIEANegotiations
20053 4
3 42007
1 2 3 4
1 2 3 42006
1 2 3 4
1 2 3 42008
1 2 3 4
1 2 3 4
GSABid
Bust
IPR
ShortList
BidsReceived
DeveloperSelected
NRDCNEPA
Suit Filed
NSMCMOA
BAFO
20091 2 3 4
1 2 3 4
NEPABriefs
Completed
LeaseAgreement
PIEAFinalized
NEPASuit Win
2010
NEPAAppeal
Dismissed
FinancingSecured
Lease SignedConstruction
Start
1 2 3
1 2 3
KCRIMS Transformation Plan Elements
Reduces footprint over 50% and operational costs by 25%Reduces footprint over 50% and operational costs by 25%
RevisedGovernance
MaintenanceOf Cold WarEra Capacity
and RedundantCapabilities
2005KCP
Business Process
Transformation
StrategicSourcing& Sizing
NewFacility
ResponsiveInfrastructure
• 65 years old • 3.1 M ft2
• 2950 employees• High fixed costs• Low utilization• 55% outsourced
• Modern Infrastructure • 1.0 M ft2 (DP Mission)• 2300 employees (given
same workload)• Low fixed costs• Reconfigurable• 70% outsourced
TransformationElements
IntegratedInterdependent
Enterprise
CommercialSupplyBase
CommercialSupplyBase
2014KCP
Enablers TransformationActions
KCRIMS
Current Bannister Federal Complex
NNSA 3.1 M ft2 Controlled2.8 M ft2 In Use
GSA& Tenants 2.0 M ft2 Controlled
National Security Campus Site Plan
For the 20 year lease, the real estate assets will be:
• Owned by: PIEA
• Designed, built, financed and maintained by: CPZ
• Leased by: GSA
• Occupied & operated by: NNSA/Honeywell
Facilities design for flexibility to accommodate all plausible stockpile scenarios.
Site Construction Progress
KCP Transformation Schedule Summary
2006
Integrated Phases for a Comprehensive Transformation
2007 2008 2009 2010 2011 2012 2013 2014 2015
Facility Acquisition &Business Transformation
Phase 1:
Phase 2: Occupancy ProjectIncluding Relocation
Phase 3: Bannister DispositionPlanning & Execution
PrivateConstruction Rolling 19
Month Relocation
Final IT &Security Install
Cost
$138M
$705M(Private Funds)
$291M($264 KCRIMS)
($27 NSMC)
$85M
_______
$1,219M
KCP Operating Requirements
55% Reduction in Operating Requirements
DirectiveBefore
Transformation
After Transformation
(1/30/2007) 1/31/2008 1/31/2009 1/31/2010
DOE Orders 87 30 31 31 41
DOE Regulations 13 5 5 5 5
DOE Requirements 30 11 10 10 11
NFPA 14 12 12 12 2
Standards/Codes 8 8 8 6 6
Other 8 7 7 7 7
Total 160 73 73 71 72
0
50000
100000
150000
200000
250000
300000
FY yr end
Sq
uar
e F
eet
Plan 303210 178000 158000 141000 128000 112300 97800 80800 60000
Actual 196691 178000 157800 140800 127000 111900
2005 2006 2007 2008 2009 2010 2011 2012 2013
0
2000
4000
6000
8000
10000
12000
1 2 3 4 1 2 3 4 1 2 3 4
Actual
Committed
KCRIMS StatusOutsourcing
204/204 Parts = 100% CompleteBuild Aheads
10,352 Pieces Complete = 117% of Plan
Inventory ReductionSpace Requirements Reduced 63%
Business Process TransformationCumulative Labor & Expense Savings = $236M
Hea
dco
unt
Mill
ions
$
FY08 FY09 FY10
0
50
100
150
200
250
300
350
400
06 07 08 09 10 11 12 13 14 15 16
0
500
1000
1500
2000
2500
3000Escalated FTI Cost Targets
FY10 Actual Costs
FTI Headcount Targets
FY10 Q4 Headcount
KCRIMS Strategic Sourcing & Sizing
Strategic Sourcing and Sizing Plan:
NNSA Mission Space From ToManufacturing Space 1.26 M 0.65 MAdministrative Space 1.84 M 0.35 MTotal Usable Space 3.10 M 1.00 M
From ToMake Parts (approx) 3800 (46%) 1000 (35%)Buy Parts (approx) 4400 (54%) 1800 (65%)
Major Sourcing Activities:• Plating
• Cables
• General Machining
• Printed Wiring
Assemblies
• Injection, Compression, & Transfer Molding
• RTV Silicone & RTV Desiccant Molding
• Thermoforming
Major Process Changes:
• Liquid Spray Paint changing to Powder Coating
• Repackaging/Testing Carcinogen encapsulant
Note: Changes in total numbers due to W80 and B61 requirements changes.
FTI Accomplishments to Date
1. Shut down the Flexible Manufacturing System (FMS)
2. Eliminated the on-site Fire Department
3. Eliminated the Emergency Operations Center
4. Closed down and outsourced the Plating Department
5. Implemented additional outsourcing of products
6. Implemented new IT tools for Finance and Program Management
7. Consolidated store rooms/reduced inventory
8. Implemented Honeywell Operating System (HOS)
9. Implemented Fact-Based Quality (FBQ)
10. Executed co-sourcing plan for IT services
11. Transitioned HR & Staffing to HON Corporate model
12. Consolidated over 90 software applications
13. Implemented Engineering Support Specialist
14. Consolidated IT servers
15. Outsourced staffing administrative support
16. Implemented a facilities pause plan
17. Outsourced Medical Services and Carpenter Shop
18. Consolidated Waste Management Functions
19. EDSV Data Center shut down
Transition Governance Structure
Chris Gentile / Bill RossTransition Leads
New FacilityDan Fritts
RelocationDale Lock
Transition Program Management
KCRIMS - Rick LavelockFTI – Steve Halter
NSMC – Steve HalterNSMC Growth – Dave Lowe
Integrated Project Planning – Diana Blackburn*Communications – Sharon Robinson
Production Linda Wright HSE
DonFitzpatrick
PMRobertRepine
SecurityMike Ginder
Steve Zvacek
QualityRick
Vanhoose
ISCCurtisMearsBiz Ops
KevinBaughn
ITJohn Engel
PhilipClark
HRGina
Angello Lobaugh
SendingTeam Receiving
Team
BridgeFunctions
Transition Approval Committee(TAC)
Chris Gentile
Robin StubenhoferBill Ross
David Feather
Sourcing Linda Wright
Jim Jeffries
BradHughes
FacilitiesMike GinderBart Stuckey
NSMCProduction
Dan Grote
* *
*
*
***
Red denotes NSMC leader or co-leader
* denotes NSMC POC added to team
Production Linda Wright HSE
Curt Valle
PMRobertRepine
QualityRick
Vanhoose
ISCRick
VanhooseBiz OpsKevin
Baughn
ITJohn Engel
PhilipClark
HRGina
Angello LobaughKurtLorenzen
FacilitiesDenny Fulmer
Bart Stuckey
NSMCProduction
Lee Hoover
* *
**
**
Gloria ZarrellaBrian Fischer
Jeff Fuller
SecurityRussel BruchSteve Zvacek
Transition ProcessExpert
NNSA KCSO
NNSA HQ
HoneywellCorporate Oversight
Transition ProcessExpert
NNSA KCSO
NNSA HQ
HoneywellCorporate Oversight
Delivers reductions in infrastructure
costs while fulfilling NNSA mission requirements
Delivers reductions in infrastructure
costs while fulfilling NNSA mission requirements
Function Current(sq. ft.)
Future(sq. ft.)
Plating Facility 22,252 -
Refurbishment & Dismantlement 20,589 12,000
Rubber & Plastics Manufacturing 96,646 38,400
Paint & Heat Treat 24,533 10,000
Machining & Gas Transfer Systems 206,293 102,500
Assembly & Electrical Fabrication 227,583 162,450
Trailers 34,642 -
Special Material Production 25,256 22,300
Purchased & Other Inspection 44,125 34,500
Labs & Engineering Labs 160,898 73,300
Test Equipment, Gage Support & Metrology 66,240 29,700
Packaging & Shipping 27,604 20,800
Storage Areas 303,210 60,000
Sub - Total 1,259,871 565,950
Allocated White Space (Included Above) 21,050
Unallocated White Space 62,800
Total Manufacturing Space 628,750
KCRIMS Strategic Sizing Summary
Relocation PlanningMacro Plan Update Results
– Update to overall & phase durations – Move Phases: 105: KCRIMS – 100; NSMC - 5
– Changes/Additions to the Macro Plan (i.e. equipment quantities)
– Confirmation of departmental sequencing
– Factors in resource constraints
• Move Duration – Start dates following Security Transitions (Two months after bldg completion for KCRIMS, Four months for NSMC)
• KCRIMS: January 23, 2013 – August 7, 2014 (391 working days) ~18.5 Months• NSMC: September 10, 2013 – January 23, 2014 (93 working days) ~ 4.5 Months
KCRIMS/NSMC Project Summary
Reduces KCP operational cost by $100M annually (FY06 dollars)
Reduces KCP total footprint by over 50%, weapons funded space by 2/3rds
Project has positive cash flow (savings > costs) for entire duration
Reduces energy consumption by over 50%, LEED Gold sustainability
Flexible to accommodate any all anticipated stockpile scenarios
Lease allows easy adaptation of future NNSA business model
Comprehensively planned to assure schedule deliveries
Full and robust risk management program
Provides 1500 construction jobs and generates $1.2B of near term stimulus
Project Demonstrates Responsible GovernmentProject Demonstrates Responsible Government
KCP National Security Campus
Questions?