1. BI-19 Process Improvement
Sea Water Injection Department

2. Project Charter Problem Statement : Cost Of Poor Quality :
During period, 37% (12 out of 32) BI-19 projects were not completed within estimated time and budget ± 10%.
Cost Of Poor Quality :
Reduced ROI due to long cycle time
Budget under or overrun
Supplement budget request after the fact
Project Objective :
Complete 100% BI-19 Projects within projected time and budget.
Defect Definition :
Any BI-19 Project which exceeded ER time (2 years) or ER budget variance by ± 10%
Critical To Quality ( CTQ) :
Project cycle time should be 2 years or less.
Actual cost should be within budget ± 10%
Goal:
Defect Rate: 0
No time extension or Supplement Budget request after the fact

3. Engineering Package Development
High Level Process Map
MCC / ER Closing
3 – 4 Months
(Finish)
ER Approval
(Start)
Material Procurement
10 – 12 Months
My first point is to give background and history of the Spare Parts Stocking Guidelines:
In 1992, a study team was formed to evaluate solutions to control spare parts growth.
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As a result, the Spare Parts Stocking Guidelines were implemented in 1993.
In 1999 the Equipment Templates that provide the initial stocking levels were enhanced based on consumption history to further control spare parts growth.
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In 2005 further enhancements were implemented on equipment templates.
The intention of these updates was to optimize spares while retaining Service levels to customer organizations.
In 2007, we started our initiative to conduct a comprehensive review on the SP Stocking Guidelines.
Engineering Package Development
8 -10 months
Execution
Period
6 – 8 Months
Total Period = 27 – 34 Months 3

4. Current Process Map BI-19 Planning (Execution Phase) Yes Is there
comments ?
In House
Design ? No
Engineering Prepare
Detail Design
Initiate PDR
30 % Design
Review
Yes
6-8 months
Yes No
Is there
comments ?
Is there
comments ? No
Engg
Package No
90 % Design
Review
60 % Design
Review
Yes
Accepted
Yes
Ops Issue Maintenance Order
Planner request
Material / DC Procurement
Material
Received
Material
Staged No
SFC / PO
Procurement
Wrong or
Additional
Review
Material Spec.
Yes
Const.
Phase No
Award
contract
Re-order
Material

5. Current Process Map Start Construction Final Closing
BI-19 Construction (Execution phase)
SFC / PO
Procurement
Approve
SFC / SO
Mobilize
Contractor
Start
Construction
Submit
Spare Parts
Data Packages
Close All
Yes Items
In MCC
Final
Closing
MCC
Signature
Commissioning
Submit all
Required As
Built Packages
Submit
NMR and OM

6. Cancelled Under budget Over budget
Completed Projects
Cancelled
Under budget
Over budget

7. Quality tools
Flow chart
Cause & effect diagram
Pie diagram