Rapid Frac Material Handling

Beth NowackiSCMP Intern Final Presentation

B.U.M: Thomas SweeneyPGL: Kaci CookAugust 4, 2011

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About Me- Elizabeth (Beth) Nowacki

B.S. Industrial Engineering, Minor in

Mathematics

LSU- GEAUX TIGERS!!

Dallas Native

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Tables of Contents

HSE project

Rapid Frac Material Handling

Lessons Learned

Thank you!

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HSE: Recommendations to improve Ergonomics in the Send Out Crating Area

Ergonomic Issues:

Back StrainKnee Problems

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JSA/ RISK ASSESSMENT FORM

• Kneepads• Lifting Table

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Rapid Frac

Enables continuous pumping of multi-zone treatments

Helps reduce completion cycle time and improve production

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-Field estimates 1200 assemblies per month

- Takt rate of 72 assemblies per day.

Project Statement: Improve the overall logistics of

handling rapid frac material.

Rapid Frac

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Introduction to Halliburton Introduction to Rapid Frac

Data Collection Basic Analysis

Weeks 1-6

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor

- In house production only

- In house production, with external finishing's

- External production

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Saws

Crating

Staging

QM Lot

External Vendor

Staging

Send Out

Organize

Staging

Receiving Dock

1

2

45

78

9

6

WarehouseRF

1110

3

Areas of Improvement Crating (1.5 hours) Receiving (10 days)

Re-palletize (15 mins) Saw Area

Initial State

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Saws

Crating

Staging

External Vendor

Staging

Send Out

Organize

Staging

Receiving Dock

2

WarehouseRF

3

5

Long Bar Send Out

Pallet Pull System

1

4

6

Ideal Future State

QM Lot

Crating: Before: 1.5 hours After: NONE

Receiving Before: 10 days After: 3 days

Re-palletize Before: 15 mins After: NONE

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ROI- Receiving Current State (150-300 Assemblies)

Average Number of Pallets Received per day– 5.6 pallets

Time spent Re-palletizing per day (15 min/pallet)– 84 min or 1.4 hours per day– 285 hours per year

Indirect Labor Cost (Labor Burn Rate $56/hour)– $78.40/day– $15,993.80/year

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ROI- Receiving Future State with Current Pallet System

Average Number of Pallets Received per day– 22.4 pallets

Time spent Re-palletizing per day– 336 min or 5.6 hours per day– 1,442 hours per year

Indirect Labor Cost (Labor Burn Rate $56/hour)– $313/day– $63,974 /year

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Implementing a standardize pallet will be the most efficient way to improve overall logistics of Rapid Frac.

• Reduce the number of Touches• Reduce time in Receiving

• Reduce time in Crating• Integrate into the Pull Systems• Ergonomically and Cost Effect

Introduction to Halliburton

Introduction to Rapid Frac

Data Collection Basic Analysis

Research Solutions

Ergonomic Assessment

Container Comparisons Action Plan

Weeks 1-6 Weeks 7-12

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Requirements For Standardize PalletGood

Ergonomics: Lifting

Good Ergonomics: Transportation

Under $350 each

Reduce Time in Receiving

Reduce Time in Crating

Forklift Accessible

Weight Capacity of 2000 lbs

Ability to stack at least 3 high

Pallets

Wire Basket

Steel Corrugated

Bin

Metal Pallet with

Removable Doors

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Metal Pallet (Wooden Replica)

Good Ergonomics: both Transporting and Lifting

$276 2000 lbs static load Stackable (3) Forklift Accessible 2 Removable Doors Lined with cardboard or

corrugated plastic

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Sustainability

Management of Change

Standard Work

10 metal pallets on order– 3 week lead time

Jason Besly- EPIC Project Manager - Rapid Frac

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Initial State Future State

# of Touches (Specifically in the Send out Process) 11 touches 6 touches

Reducing time in Crating 1.5 hours None

Waiting time in Receiving 10 days15 min

3 daysNone

Integrate into Pull System 0 2

By Implementing a the metal pallet with two removable doors:

$63,974 ROI

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Lessons Learned

Ask Questions!

Don’t wait for something to happen, make it happen yourself!!

Network!!!!

Good communication is essential!

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Thank You! Ryan Arrington Jason Besly Mark Bregenzer Kaci Cook David Dockweiler Gary Freet Joe Haddad Bryan Hensley Dean Wynia Jimilee McCleskey Susan Price Lynsey Ritchie

Cheri Rogers Shannon Sixkiller Tom Sweeney Dan Swofford Donna Willis Chad Woodward Carrollton Interns

– Austin Baltes– Kimberly Caleon– Haley Helweg– Lee Smiley– Javier Penaflor– Aditya Mittal

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Questions?

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Action Plan People

– Overall Manager: Jason– To finish ergonomic testing of metal samples: (Epic: Jason or Dean)– Updating Vendors on how to properly load parts (Jim Gilmore with Standard

Work from Beth)– Inform Receiving and Crating on new pallets (Mark Bregenzer)– Pallet included in PO (Joy)

6 star documents (SOP) standard work– Instructions put parts in bin/pallet– MOC– ROI(completed)

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor

11 touches

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor Long Bar

Send Out

Bin Pull

6 touches

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor

23 touches

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor

22 touches

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Saws

Crating

Receiving

Warehouse

QM Lot

TRT

Inspection

Manufacturing

Assembly

RF

RF

RF

External Vendor

16 touches

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Manufacturing Process