Structural Weld OverlayKAIZEN

Time Compressionthrough

Application of Lean Thinking 

"Value Stream Mapping &Tools of Quality"

2RF10 Refueling Outage Structural Weld Overlay

130 People involved in 25 Small and Large Group KAIZEN activities

Process Pressurizer Structural Weld Overlay

Nuclear/Lean Principles and

Practices Applied

VALUE,, FLOW, PULL, VALUE STREAM, Level Loading, Constraint Management Value Stream Mapping, FMEA, C/E Matrix, Poka Yoke, Operating Experience, Lessons Learned, Eng. Technical Reviews, Risk Assessments, Safety evaluations

Product A Performance Demonstrated Initiative inspectable Structural Weld Overlay with NO rejectable indications / defects

Customers Plant Operations, NRC

Process Value Add

Welding the Correct amount of weld overlay material no more / no less than required to create a weld overlay with zero defects

Results: 5.5 Day reduction Breaker’s Open to Acceptable FINAL PDI Inspection = 15 Days  ZERO Safety Incidents + ZERO Indications/Defects Safe and Reliable 27% Cycle Time Improvement

Event 1: Strawman of VSM, Define Process, Define VA, ID Customers,

Event 2 Communication and AlignmentKick Off: End to End VSM Evaluation – End to End Walkdown

Final Product

WIP

Visual Management During implementation

Measurements of Process Performance Continuous MetricsDelivery: (Schedule Adherence) Ahead, On , Behind Schedule           RESULT: 12 hours ahead of planned schedule. Quality: Zero Indications during all welding steps    RESULT: Zero Indications /Defects Binary Metrics Quality: Zero Indications at Final NDE testing     RESULT: Zero Indications / Zero Rework / Defect Free final Non Destructive Examination

Safety:      RESULT: Zero OSHA Recordables / 1 First Aid

World Record in Nuclear 

We owe all successto these people