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Step Change Process Improvements For Projects & Turnarounds Through Mobile Task Management Software
Donald J. Frieden, President & CEO, SAT Corporation
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
What We Will Discuss….
• What are the challenges and compelling automation opportunities in today's Capital Project environment?
• How can Mobile Technology improve project execution through project status updates and asset tracking?
• How can Mobile and Auto-ID Technology reduce the duration of Plant Maintenance Outages?
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
3
Capital Projects Landscape
• NIST estimates that $ 15.8 billion in profits are lost in U.S. capital facilities every year– 6.8 Billion lost in EPC phase– 9.7 Billion lost in MRO phase
• Important because the platform for effective asset lifecycle management during the MRO phase is created during EPC
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
4
Capital Project Landscape
• The Construction and Capital Project industry lags behind manufacturing and transportation for asset management and field-force automation.
• Information delivery and data processing in the field has been traditionally paper-based.
• Tools for automated information authoring, transfer, and collection is rapidly increasing, but adoption of mobile technology and asset identification to enable the front-line workforce is severely lacking.
• In the next decade, successful project execution will be measured by a companies ability to effectively manage it’s stranded assets (people, equipment, and work processes).
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
5
Capital Project Opportunity
• Enterprise Systems for Capital Project Management are being deployed by owner/operators and other project stakeholders (EPC), but are seldom integrated.
ERP (Oracle, JDE, SAP, etc.)PPM (Primavera, MS Project, etc.)CAD/CAM/Document and Engineering Management (Intergraph, CATIA, etc.)Enterprise Knowledge Management Systems-new breed of aggregators designed to provide a backbone for all plant information (SmartPlant, etc.)Specific “Point” Applications (Completion, Safety, QA/QC, etc.)
• Very little field level application of technology to process this information exists today, which limits the effectiveness and productivity of all facets of construction execution.
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
6
Example of a Disconnect
Task updates or material staging
not timely, dependent tasks
left in “wait”mode
Crew waiting because
dependent tasks not updated in
project schedule
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7
Domino Theory
1. Cumulative task cycle time delays
3. Project overruns and demobilization delays
4. First year Operability Effected
2. Critical path of project slips
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
8
Capital Project Improvement Opportunities
Fabrication/Construction
Testing/Acceptance
Operations Decommission/Retrofit
ProjectDesign
ProjectPlanning
ProjectDefinition
Current grassroots/capital projects have the opportunity to take advantage of the availability of this important Information to reduce implementation costs and adoption of mobile technology during EPC Cycle
• Equipment data sheets
• Process flow diagrams
• Vendor/Supplier SOP’s
• Testing Results• Etc.
Results:• Lower Implementation Cost• Capture of early operation
asset data (First Year Operability)• Quicker deployment• Better overall ROI
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9
Reducing EPC Costs and Improving FYO
Fewer Schedule Delaysand Reduction
in Cost Overruns
Fewer Asset Failuresand Reduction in Lifting Costs
Shorter more efficient schedules from a reduction of redundant and duplicated tasks to facilitate faster “look- ahead” views
Reduced maintenance costs earlier in asset’s life from early identification of precursors and consistent delivery of best practices that prevent unplanned downtime
What if you could have?
Asset Lifecycle Management
Engineering, Procurementand
Construction
These results
First Oil/Gas
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
What We Will Discuss….
• What are the challenges and compelling automation opportunities in today's Capital Project environment?
• How can Mobile Technology improve project execution through project status updates and asset tracking?
• How can Mobile and Auto-ID Technology reduce the duration of Plant Maintenance Outages?
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
The Turnaround Challenge
TurnaroundSuccess
Time
Cost
Safety
Quality
Sarbanes-OxleyFlawless Execution
Six-Sigma
Utilization
Balanced-ScorecardLean
OSHA
RBI
RCMBest P
ractices
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
The Turnaround Environment
• For the past 10 years Owner/Operators and service providers have focused on improving performance by deploying improved project management, estimating (time/cost), risk evaluation, and safety methodologies………
• Both labor rates and materials of construction costs are marketplace driven.
• Scope control and work efficiencies are the remaining areas to focus to control duration and costs.
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
Capturing real, verified task execution data including quantitative per cent complete, earned value, asset “as found", test results, field notes, EH&S and other information can:• Enable a safer work environment by insuring task status on
hazardous environment tasks (entry, etc.)• Eliminate redundant and duplicated tasks• Quantitatively verify task completion so dependent tasks can start
earlier• Capture important asset data during construction, testing,
commissioning
Turnaround Opportunities
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
The Process
• Project Steps by Craft• General IntelaTrac Procedures• JSA, Etc.
Job Steps Created in Primavera
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
Mobile User Interface
Tools T ?
Login
K
Test VBase Area
Login ID Admin V
Everyone V
Test
Role
Password
X Change password after logon
Logon
Test VTAR ID •
Base Area – Work Area Sort
•
Task ID – From Primavera
•
Logon ID / Password – From IntelaTrac
•
Role – From IntelaTrac
User logs onto the Mobile IntelaTrac Application
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Primavera Data Categories Added to IntelaTrac
• Status Started• Status Finished• Duration % Completed• Actual Hours• Craft• Activity ID• Activity Description
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Mobile User Interface
1. User selects the equipment type from the dropdown
2. User selects a specific Activity ID for Status Update
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
Mobile User Interface
• Percentage Complete• Status Start• Status Finish• Notes – Available free
text or drop down list data entry for this activity
• Create Work Notification from this screen as required
User Updates Activity Status
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The Process
Special Procedures as needed for:• Blinding• Inspection• LOTO
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Integrated Procedures
• Procedure assignment to Activity using the Primavera P3E interface with embedded browser to Procedure Instances that have been created in IntelaTrac for:– Vessel Entry– Vessel Closure– Mechanical Inspection, Scaffold Inspection, QA/QC– Equipment shut down or start up– Safety Observation, Job Safety Analysis (JSA)– Pre Start Up Safety Review (PSSR)– Scope Change or Request for Additional Work– Crane or Equipment Inspection– Permits– PSV identification and status– Etc.
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The Process
Completed Job Steps Update in Primavera
• Job Step Updates• New Job Steps
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Mechanical Completion/Commissioning
Test Certificate Attached
Seals fitted to operating arm and adjustment cap
Check valve against data sheet
Flanges protected and sealed
Valve tested
Signed By: GM (FAB), IM (HOOKUP)Outstanding Signatures: IC, GE (SUPR)Description xxx
T101
SignOffTransferAdd to Punchlist
Completion Check Safety/Relief Valves
Tag No.
SRVDesc
Details
35768PO No.
Area
System
Sub-system
T101
S-504 Lower
23
001234 5012MC No. Comm. Pack
Verify valve ID (SCAN)
Check gaskets, flanges and final installation
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23
Electronic Mechanical Completion/Commissioning
Test Certificate Attached
Seals fitted to operating arm and adjustment cap
Check valve against data sheet
Flanges protected and sealed
Valve tested
Signed By: GM (FAB), IM (HOOKUP)Outstanding Signatures: IC, GE (SUPR)Description xxx
T101
SignOffTransferAdd to Punchlist
Completion Check Safety/Relief ValvesTag No.
SRVDesc
Details
35768PO No.
Area
System
Sub-system
T101
S-504 Lower
23
001234 5012MC No. Comm. Pack
Verify valve ID (SCAN)
Check gaskets, flanges and final installation
OK Cancel
NESecurity Group
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
What are some of the benefits?
• Planners/Supervisors– Time saved in reduced task status updates– Potential of 15% reduction in time required for
management of tasks per full time equivalent (FTE) per shift
• Ad-hoc work items– More efficient management of added scope tasks– Potential of reduction of management effort for
these tasks of 35-40%• Dependent task reaction/staging
requirements– More efficient execution of dependent tasks, i.e.
insulation, cleaning, etc.
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
What We Will Discuss….
• What are the challenges and compelling automation opportunities in today's Capital Project environment?
• How can Mobile Technology improve project execution through project status updates and asset tracking?
• How can Mobile and Auto-ID Technology reduce the duration of Plant Maintenance Outages?
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
26
Enabling Task Management During Projects
Function Post Project
• Operations routine duty rounds
• Maintenance PM rounds
• I & E inspections
• HSE compliance rounds
• Training field workers
• Offsites tank gauging & lineups
• QA lab sample rounds
During Projects
start-up/commissioning
NDE/inspections
loop tests/calibration
incident investigation
training verification
hydro/vacuum tests
NDE/source inspection
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© 2007 SAT Corporation. All rights reserved. SAT Corporation Proprietary & Confidential
RFID for Supply Chain of Serialized Equipment
Field Name Count ValueEPC-IS 20 255.255.100.11-855004
OEM Data Count Value
manufacture 14 Dresser Rand
model_number 19 DR02-01-3313-CL-414
serial_number 10 PR87073489
manf_date 2 20-Jan-03
Plant Owner Data Count Value
equipment 18 DR234-876-290-5209
functional_location 10 36-EM-10A
PID_number 16 INT99605-231-702
operation_number 12 MP0003-96296
description 40 Overhead Fan Motor
Owner IssuesTagged AssetTo Contractor
OEM InstallsRFID Tag at
Manufacturing
Plant Owner Receives
Tagged Asset
Future Maintenance Routines triggered
By RFID tag
ContractorInstalls Assetand Loop Test
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Thank You
Questions and Answers?