“Just in Time Inventory Management”
Bruce Power Unit 1 & 2 Rebuild
April 2006 to Oct 2012
•
Project Work Scope Overview
•RP Consumable Project Strategy
•Vendor Selection
•Consumable Programs and Results
•Questions
Just in Time Inventory
Management
Project Work Scope Overview
Replace 480 pressure tubes per unit
Replace 8 steam generators per unit Replace 960 feeders per unit
Replace 480 calandria tubes per unit
Project Work Scope Overview
Separate Unit 1 & 2 from Unit 3 & 4 to form a construction island
Project Work Scope Overview
Replace pressure tubes Replace feeder tubes
Project Work Scope Overview
Project Work Scope Overview
Project Clothing Statistics
Category Item Name Qty. Process Daily Wear Coveralls FR/non-FR 764,342
White Bath Towel 833,119 Tritium Plastic Suit - Mark 3B 167,131 Protection Oversuits ProTech & FR 159,104 Black Booties 1,512,387 Comfo Respirator 66,998 Anti-C's ProTech/FR Anti-C's 698,409 Rubber Glove 3,072,016 ProTech & FR Booties 2,122,576 Cotton Liners 1,845,250 Laundry Bags 443,606 Rubber Overshoes 120,704 Project Statistics Total Items 11,865,963 Full Lease and Launder $29,543,611 Project Duration 6.5 Years
•Project Work Scope Overview
•
RP Consumable Project Strategy
•Vendor Selection
•Consumable Programs and Results
•Questions
Just in Time Inventory
Management
•
Keep RP staff focused on the
project not on managing
consumable needs.
•
Establish a program where
needed materials were available
and managed.
•
Establish a program to easily and
quickly manage unexpected and
emergency consumable needs
(Purchasing not needed)
•
Reduce cost and radwaste to the
maximum extent possible.
RP Consumable Project Strategy
•Project Work Scope Overview
•RP Consumable Project Strategy
•
Vendor Selection
•Consumable Programs and Results
•Questions
Just in Time Inventory
Management
Vendor Selection
•
UniTech was managing:
•
PPE Full lease and
decontamination
•
Border Management
•
Transportation
•
On-site Coordinator
•
Materials delivered
directly into the plant
almost every day.
Also Managed….
• Respirator Lease and Processing
• Tool and Metal Decon with specialty monitoring
• HEPA service
• Arc Flash Clothing/Glove Recertification
• Personal Cooling Systems
Vendor Selection
With the PPE Structure in place, UniTech offered the following unique features:
• With the security plan, UniTech
could deliver consumables directly into the plant.
• UniTech could disposition all
secondary consumable item packaging. The cardboard left with the laundry truck.
• With the onsite coordinator all
material needs could be rapidly processed.
• Project Work Scope Overview
• RP Consumable Project Strategy
• Vendor Selection
•
Consumable Programs and Results
• Questions
Just in Time Inventory
Management
Consumable Programs and Results
Three specific programs for consumable item management were developed:
• On-site Min/Max Mgt. for
common items.
• Warehouse support from
the laundry facility for less common items.
•Mitchell Tritium Cartridges •P100 Cartridges •Catch Containments •Radiological Sampling •Tape •Batteries
•Rubber Area Supplies
•Dosimetry Supplies •Decon Supplies •Instrument Supplies •Cleaning Supplies •Respiratory Protection Supplies •Ventilation Supplies
Consumable Programs and Results
On-site Min/Max management with 2 Mobile Safety Stores for common items.
• 80 items min/max managed • Restocked from laundry truck • All secondary packaging
dispositioned
• 150,000 units of stock managed
• $3.4M over 6.5 years
Fun Fact D uct Tape U sed 1,000,000 rolls -34,000 m iles
Consumable Programs and Results
Warehouse support from the laundry facility for the less common items:
• Detailed items lists were assembled in the project planning stage.
• Specific branded
products were stocked at the laundry facility. • Orders received with 3
hours notice prior to shipment - made the laundry truck.
• $4.9M in product was
delivered directly into the plant.
HEPA Ventilation Units HEPA Vacuums
Elephant trunk and accessories
Tyvek Hoods Striped Waste Bags Shielding
Radiation signage/stanchions Arc Flash PPE
Air Hoses
Passive Sampler (H3) RAMS Air Horns Drums
Fun Fact
W ashed 4 m iles of 8” ducting so it could be reused w /o the need for PPE.
Consumable Programs and Results
Rapid new item approval process for unexpected or emergency material needs.
• Contract line item: “Cost + 15%
“ supported w/actual invoice and shipping documentation.
• Purchasing NOT involved (not
a 12 month process)
• From $5 to $500,000 per
transaction.
• $10M in product was delivered directly into the plant.
• PAPR Units and Supplies
• Glove testing/certification • Velcro • Vacuum Bags • Hand tools • Diffuser caps • Cotton swabs
• H3 Hot work and grinding hoods
• Lens cleaning stations
• Tyvek balaclavas
• Hard hat liners
• Safety vests – high visibility
• Funnel
• Pliers
• Nalgene Bottles
• Equipment repair parts
Fun Fact
Forensic audit on the entire consumable scope, $16.5M. No
findings!
Consumable Programs and Results
• Rapid Approval Program
included a standard format:
1. Requestor fills out form for “I want” and brief “why” – gives to UniTech Coordinator.
2. UniTech shops the item – gets price – shows requestor. Requestor signs “I still want it” 3. UniTech takes form to designated
management, they approve, or contact requestor. If approved,
• 1144 Rapid Approvals used over the project duration.
Developed launderable PAPR cover.
• Single use cover from MSA $21/use with
Radwaste
• Launderable $4 per use to process and $1/use for
cover purchase $5/use all in.
With 150,000 uses, this product saved $2.4M in direct
cost.
Consumable Programs and Results
Design and manufactured microfiber Swab Head
Cover for Calandria inspections.
Designed to fit the different tool heads, post
manufacture processed and tested is a Clean Room, certified lint free.
Started with “make me a cover fast” ended with an 8
page technical spec.
Design and manufactured Calandria glove bag.
Supplied 2000 units. From design to approval in 4
days to support emergency inspections on critical path. All units delivered within 4 weeks.
Consumable Programs and Results
Managed Class I and II Electrical Glove Program
• Recertification every 90 days
• Replacement as needed
18 New Launderable Items introduced to
replace single use Tyvek.
• Avoided generating 5,600 M3 of RadWaste valued at $11.6M
Launderables saved $5,156,257 compared to
just purchasing the single use clothing
PCE’s were significantly less than the 6
operating units combined annually over each year from 2006 through 2011 .
Consumable Programs and Results
Summary
•Project staff stayed focused on project
•Costs were controlled and savings realized
•Radioactive waste was minimized
•No project delays due to consumable shortages
Just in Time Inventory
Management