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Combining Lean and DMADV to Combining Lean and DMADV to Innovate ProcessesInnovate Processes
Greg RobertsonDirector of Six Sigma
April 30, 2008
April 2008
GWR - 2
Our direction today …
Who is Black & Veatch
Urgency for change
Business Process Management
Innovation through Lean and DMADV
April 2008
GWR - 3
Black & Veatch offers leading engineering, consulting and construction experience in …
April 2008
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Who is Black & Veatch?
22
66 1212
1515 2020
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What’s the What’s the Urgency for Urgency for
Our Change?Our Change?
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In the constant battle of “survivalof the fittest”, every business
must constantly re-evaluate itself
What’s driving change?
“Even if you are on the right track, you’ll get run over if you just sit there.” – Will Rogers
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Internal issues driving change in Black & Veatch
How is the work done?
How is the work done?
Where is our work?
Where is our work?
Who does the work?
Who does the work?
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External issues driving change in Black & Veatch
More opportunitiesMore opportunities More risksMore risks
Lean and DMADV used to “create” changeLean and DMADV used to “create” change
Changing markets and competitorsChanging markets and competitors
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Business Business Process Process
ManagementManagement
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Process owners vs. projects
Project Teams Receive and Apply Process Knowledge
Process Owners Develop and Communicate
Process Knowledge
Define Processes
Establish Metrics & Targets
Monitor Process Health
Learn, Understand, and Share
Continuously Improve
Processes
Define Needs
Identify Process Issues
Execute Processes
Adapt to Process Changes
Import Best
Practices
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BPM Maturity Model
Processes recognized but success largely depends on
individual effort and knowledge
Process owners identified but limited process
documentation exists
Process are fully documented and the intent is understood by
process customers
Process metrics established and tracked. Processes are
completely integrated
Process feedback routinely solicited. Process continuously
evaluated and improved
Recognized
Identified
Defined
Managed
Optimized
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How Does How Does B&V Use Six B&V Use Six
SigmaSigma
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We wear many hats
Mentors
Black belts
Facilitators
Researchers
Consultants
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Innovating Innovating through through Lean & Lean & DMADVDMADV
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Valve control stations
Reduced design time by streamlining
the valve station process
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Valve Control Stations
RFRP&ID
Received
Insert Isolation Valves
Select Line Code
Information
Generate Pipe
Centerline RoutePipe
Add Bypass Valve
Add Control Valve
Auto Generate
Pull ISO'sAssign
Spool #'s
Add ISO Breaks &
Locate FW
Router, Add Pipe Supports (Sometimes
Pipe Stress Does)
Research Valves, Look Up Dimensions (end to end, operator)
Change to Bottom Routed Pipe & Reduce
Line Pipe Size
Research End to End & Operator Size From Other Projects (keep
sets of old P&ID's)
Verify Flow Direction
Place Spools On Hold For Valve (info if required)
Add Vent Drain
Valves
Insert Reference
Lines for Vent Drain, etc.
Add Caps if Required
Auto Generate
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Flanged Valves
Yes
No
Flanged Valves
Yes
NoFlanged Valves
Yes
No
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Add Bypass
Process cycle time = 40 minutes / valve stationProcess cycle time = 40 minutes / valve station
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Valve Control Stations
RFRP&ID
Received
Insert Isolation Valves
Select Line Code
Information
Generate Pipe
Centerline RoutePipe
Add Bypass Valve
Add Control Valve
Auto Generate
Pull ISO'sAssign
Spool #'s
Add ISO Breaks &
Locate FW
Router, Add Pipe Supports (Sometimes
Pipe Stress Does)
Research Valves, Look Up Dimensions (end to end, operator)
Change to Bottom Routed Pipe & Reduce
Line Pipe Size
Research End to End & Operator Size From Other Projects (keep
sets of old P&ID's)
Verify Flow Direction
Place Spools On Hold For Valve (info if required)
Add Vent Drain
Valves
Insert Reference
Lines for Vent Drain, etc.
Add Caps if Required
Auto Generate
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Flanged Valves
Yes
No
Flanged Valves
Yes
NoFlanged Valves
Yes
No
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Delete Home Pipe
Change to Bottom Routed
Auto Generate
PipeAdd Valves
Insert Flange
Add Bypass
Lean innovation eliminated non-value stepsLean innovation eliminated non-value steps
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Valve Control Stations
New process cycle time = 2 minutes / valve stationNew process cycle time = 2 minutes / valve station
RFR P&ID Received
Insert PowrTrak
IDs
Add Caps if Required
Select Pipe Supports
Add ISO Breaks &
Locate FW
Verify Flow Direction
Assign Spool #’s
Pull ISO’sSpools on Hold for Valve Info. (If Required)
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Chimney foundations
Reduced the installed cost of large chimney foundations
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Power plant chimneys
Chimneys over 1,000 feet high …
Equivalent to …
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Baseline used cylinder
design
Mat thickness = 1 / 10
diameter
Baseline used cylinder
design
Mat thickness = 1 / 10
diameter
Baseline design practice
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New approach uses octagon
shape and hole
Mat thickness is optimized
New approach uses octagon
shape and hole
Mat thickness is optimizedHole Size = ½
Diameter
New design practice
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In summary, Lean and DMADV….
Work in an engineering environment
Support process innovation
Help accelerate, sustain and create change
