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Procedure For LEAN Management & Waste Elimination Example

This document outlines Shell Refining Company's plans for implementing lean management and eliminating waste during their 2021 major turnaround. It discusses promoting lean working culture through workshops, identifying examples of current waste, and proposing lean initiatives. Specific proposals include optimizing work schedules through planning sessions, staging work in packaged groups to incentivize early completion, and rearranging site facilities to reduce unnecessary worker movement and wait times. Visual management tools like management diagrams and gemba walks are also recommended.

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Allif Tukiran
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58 views

Procedure For LEAN Management & Waste Elimination Example

This document outlines Shell Refining Company's plans for implementing lean management and eliminating waste during their 2021 major turnaround. It discusses promoting lean working culture through workshops, identifying examples of current waste, and proposing lean initiatives. Specific proposals include optimizing work schedules through planning sessions, staging work in packaged groups to incentivize early completion, and rearranging site facilities to reduce unnecessary worker movement and wait times. Visual management tools like management diagrams and gemba walks are also recommended.

Uploaded by

Allif Tukiran
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 11

OWNER DOC. NO.

Shell Refining Company (F.O.M.) Berhad EPCM DOC. NO. Rev 0


SANKYU DOC. NO. ECSO/SRCMTA/WP/11/09
DATE 24 JAN 2011
SRC 2011 MAJOR TURNAROUND EPCM Contractor :
CHIYODA ( S ) PTE. LTD.
FOR

PACKAGE 1A & 1C
Contractor :
SANKYU ( M ) SDN BHD
LOT 4, JALAN 215, 46050 PETALING JAYA
SELANGOR, MALAYSIA.

LEAN MANAGEMENT
AND
WASTE ELIMINATION
PREPARED BY REVIEW BY APPROVED BY
SIGNITURE

NAME

TITLE
COMPANY SANKYU ( M ) SDN BHD CHIYODA ( S ) PTE. LTD. / SHELL REFINING CO.
SANKYU ( M ) SDN BHD ( F.O.M. ) BHD
LEAN MANAGEMENT PROGRAM

PROMOTE LEAN WORKING PROGRAM

ORGANIZE WORKSHOP FOR MANAGEMENT


AND SUPERVISORY STAFFS TO EXPLAIN AND
PROMOTE LEAN WORKING CULTURE

ORGANIZE WORKSHOP OR ACTIVITIES TO IDENTIFY


WASTE AND WASTE ELIMINATION IDEAS

Page 01
MANAGEMENT SYSTEMS

WHAT
What is the management responsibilities?
- Work transparently with Customer (Shell)
- Work proactively
- Provide ideas/improvements/experience

What are the major activities during pre-TA phase?


- Establish /review work package
- Establish detail schedule and Critical path
- Establish and prepare all Work Method Statements, JHA, etc
- Plan/Establish resources planning for TA-Execution

What are the KEY MILESTONE AND TARGETS?


- Establish milestones with Customer (Shell)
- Establish KPI’s

Page 02
MANAGEMENT SYSTEMS

WHEN
Establish reviews to be held with Customer (Shell) at pre-TA
Establish reviews that require SUBCONTRACTOR participation?
Establish frequency of these reviews at pre-TA

HOW - Alignment
Establish communication channel within organization & with
SHELL
Establish linkage and coordination within site organization
Establish coordination linkage with others (Subcontractors)

Page 03
WASTE IDENTIFICATION

EXAMPLE OF WASTE
● Lack of clear understanding of responsibilities
● Multiple meetings to address the same issues
● Lack of advance planning on known requirements
● Unnecessary meetings
● Major activities cramped into short time frame
● Haphazard communication processes
● Involvement in meetings which were of limited value
● Unsystematic housekeeping
● Lost time due to taking tea breaks and lunch
● Lost time due to site being too far from canteen
● Waiting time for Permit and gas test

Page 04
LEAN MANAGEMENT

● Initial Study & Planning


- Let site supervisor & foreman involve in initial
stage of planning work – to ensure the accuracy
of planning for execution.
- Carry out the initial study & planning together
with Owner to maximize the usage of existing
facilities for cost saving

Page 05
LEAN MANAGEMENT

● Schedule Development
- Conduct Schedule Optimization Session with all
Level & Department.
- To optimize the schedule to be realistic & benefit
to all parties.

● Resources Mobilization
- Mobilize resources according optimized plan &
schedule – minimize contingency.

Page 06
LEAN MANAGEMENT

● Working Hours
- Minimize workers to break at 10am by paying
incentive – to maintain work momentum &
productivity.
- To staggered the break time for confine space.
- To organize flexible lunch break for critical work
to meet the time schedule of each stage.

Page 07
LEAN MANAGEMENT

● Management of Manpower
- Organize works in packages – offer each groups
of manpower as lump sum contract for each
package of work
- Worker will expedite the work since
early completion of work package (Less man-hrs)
will be more profitable
- Better control of manpower since every group has
own leader to control.

Page 08
LEAN MANAGEMENT

● SITE ARRANGEMENT TO ELIMINATE WASTE


- Establish worker waiting shelter closer to work
site – minimize workers walking time
- Locate sanitary facilities (Toilets) at strategic area,
example on top of R & R

- Locate drinking station near to work area


- Locate tool boxes close to work area and storage
containers nearer to site
- Kitting and practice 5S for tools, material and
consumable storage at site
Page 09
LEAN & WASTE ELIMINATION PROPOSALS

LEAN MANAGEMENT

● MANAGEMENT DIAGRAMMING – VISUALS CONTROL


● GEMBA WALK
● AUDIT CHECKLISTS
● AUDIT ASSESSMENT CALIBRATION
● AWARENESS TRAINING – BOOT CAMPS
● KAIZEN WORKSHOP FOR PTW, JIM
● WHAT IF ANALYSIS
● ASSIGN IMPROVEMENT LEADER/AGENT

Page 10

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