SEPTEMBER 4 - 6, 2019
Teaming Up On Steel Pole Quality,And Why It Matters To You.
Greg Ade, PMP, CQAQuality Manager, Corporate OversightR. John Falkenrath, PE, SETransmission Civil & Structural EngineerLeo Padron, ASNT Level III, ISO – RAB/QSACorporate Vice President of Quality Assurance & Continuous Improvement
SEPTEMBER 4 - 6, 2019
TopicsSituation:• Owner Business NeedBackground:• Scope of Work• Team ContributionsActions:• Supplier Qualification / Re-Qualification• Supplier Performance Management• Continuous Improvement / InnovationResults:• Relationship Lessons Learned• Alliance Development Summary• …And Why It Matter$ To You• Closing / Questions
SEPTEMBER 4 - 6, 2019
Owner Business Need• 2012 Transmission Capital Investment Rapid Growth Forecast
• Estimated Annual Steel Poles Expenditures @ $60M +/-
• Striving to Better Manage Risks Throughout Project Lifecycle
• Need For Most Efficient Designs to Meet Criteria
• Previous Non-Alliance Supplier Posed Quality and Schedule Risks
• Solution: Develop Alliance Steel Pole Supplier Relationship
Quality Manages Risks Over Project Lifecycle
Operations
SEPTEMBER 4 - 6, 2019
Scope of Work• Develop Supplier Alliance to Continuously Improve Quality
• Reduce Rework / Installation Issues / Risk of Schedule Delays
• Support Portfolio of 345kV / 138kV Capital Investment Projects
• Provide Codes / Standards Mandated Quality Assurance
• Adhere to Quality Management Industry Best Practices
• Foster Collaboration on Continuous Improvement / Innovation
Scope Of Work
Quality
Sche
dule
Safe
ty
Cos
t
SEPTEMBER 4 - 6, 2019
Team ContributionsSupplier Quality Management• Quality Program Development / Implementation / Maintenance
• Product / Materials / Sub-Supplier Quality / Records Management
• Product Non-Conformance Quality Evaluations / Repairs
• Product / Inspection Innovation / Continuous Improvement
• ASNT / AWS Quality / Weld Inspection Personnel
OQMSE
OE
TEAM
SQM
SEPTEMBER 4 - 6, 2019
SQM
Team ContributionsOwner Quality Management• Critical Supplier Qualification / Periodic Re-Qualification Process
• Product Nonconformance Tracking / Review / Trending Process
• Innovation / Continuous Improvement Recommendations
• ASQ Quality Management Personnel
SE
OE
TEAM OQM
SEPTEMBER 4 - 6, 2019
OQM
Team ContributionsSupplier Engineering• Design Compliance With Codes / Standards / Owner Criteria
• Design Documentation / Records Management
• Product Nonconformance Engineering Evaluations / Repair Designs
• Design Standards / Innovation / Continuous Improvement
• Registered Professional Engineering Personnel
SQM
OE
TEAMSE
SEPTEMBER 4 - 6, 2019
OQM
Team ContributionsOwner Engineering• Owner Criteria / Specifications Development / Maintenance
• Supplier Qualification For Codes / Standards / Owner Criteria
• Product Nonconformance Engineering Evaluations / Repair Reviews
• Standards / Innovation / Continuous Improvement Recommendations
• Registered Professional Engineering Personnel
SQM
SE TEAM
OE
SEPTEMBER 4 - 6, 2019
Supplier Qualification / Re-Qualification• Quality Management Reviews
• Quality Policy / Program / Processes / Standard Operating Procedures
• Records Management
• Products / Materials Traceability / Sub-Suppliers Quality Records
• Calibrations / Certifications / Training Records
• Production Operations for Demonstration of Quality Program
SEPTEMBER 4 - 6, 2019
Supplier Qualification / Re-Qualification• Engineering Reviews
• Design Methodologies / Details / Software / Checking• Criteria / Specifications / Codes / Standards Compliance• Fabrication Tolerances / Welding Specifications / Practices
SEPTEMBER 4 - 6, 2019
Supplier Qualification / Re-Qualification• Re-Qualification Frequency Depends on Quality Status• Quality Audit Visits Rotate Between Production Facilities• Fabrication / In-House Galvanizing / Storage / Shipping Operations• Improvement Example:
• Months For 2013 Alvarado Plant Qualification• Days For 2018 Bossier City Plant Qualification
SEPTEMBER 4 - 6, 2019
Supplier Performance Management• Quality Management Reviews of Non-Conformances
• Quality Evaluations / In-Process and Field Repairs / Documentation• Root Cause / Corrective Actions / Extent of Conditions Analyses• Uses Supplier In-Process / Owner Non-Conformance Tracking• Address Cost and Schedule Impacts
SEPTEMBER 4 - 6, 2019
Supplier Performance Management• Engineering Dispositions of Non-Conformances
• Supplier Addresses Safety / Serviceability / Performance / Warranty• Owner Addresses Safety / Serviceability / Performance / Acceptance• Sometimes Require Surveys / Tests / Inspections / Calculations
SEPTEMBER 4 - 6, 2019
Supplier Performance Management• Regularly Scheduled Quality Action Items / Metrics Calls
• Improvement Example: Began as Weekly / Now Held Monthly• Over 300 Open Action Log Items Since 2014 / Typically 20 +/- Active
• Monthly Pole Order Schedule Projections Coordination Call
• Periodic Contractor / Shipping / Handling / Assembly Training• Periodic Installed Product Inspections
SEPTEMBER 4 - 6, 2019
Continuous Improvement / Innovation • Supplier Quality Continuous Improvement and Innovation Initiatives
• Inspections / Materials / Process Improvements• Automation / Research / Development Efforts
• Owner Quality Continuous Improvement Recommendations• Engineering Design Innovation Collaboration• Collaboration Improvement Example:
• Use Lessons Learned in Specifications / Standards • Vetting / Adopting Supplier Standard Practices
SEPTEMBER 4 - 6, 2019
Relationship Lessons Learned• Maintain a Core Quality Management / Engineering Team• Team Maturity Cycles: Storming / Norming / Performing Stages• Many Internal / External Stakeholders / Contributors to Manage• Team Success Requires Open / Timely Communication• Alliance Management of Quality Improves Results
• Reduced Frequency of Monitoring • Improved Product Quality Metrics Over Time • Reduced Non-Conformance Rates• Reduced Rework / Schedule Impacts• Improved Cost Control / Product Confidence
SEPTEMBER 4 - 6, 2019
Alliance Development Summary
SEPTEMBER 4 - 6, 2019
…And Why It Matter$ To You• Increased Product Confidence / Reliability
• Lower Product Non-Conformance Rates / Severity• Negligible Component Failure Rates
• Reduced Risks to Scope / Schedule / Cost / Safety / Quality• Improved Stakeholder Relations / The Right Product at The Right Time
• Reduced Owner Risk of Installation Delays / Costs
• Reduced Supplier Rework / Costs
SEPTEMBER 4 - 6, 2019
ClosingSituation:• Owner Business NeedBackground:• Scope of Work• Team ContributionsActions:• Supplier Qualification / Re-Qualification• Supplier Performance Management• Continuous Improvement / InnovationResults:• Relationship Lessons Learned• Alliance Development Summary• …And Why It Matter$ To You• Closing / Questions
SEPTEMBER 4 - 6, 2019
QUESTIONS?
Teaming Up On Steel Pole Quality, And Why It Matters To You.
Greg Ade, PMP, CQAQuality Manager, Corporate Oversight314.206.1817, [email protected]
R. John Falkenrath, PE, SETransmission Civil & Structural Engineer314.554.4285, [email protected]
Leo Padron, ASNT Level III, ISO – RAB/QSACorporate Vice President of Quality Assurance & Continuous Improvement817.706.0223, [email protected]