Download ppt - Schlumberger Private Packer testing & knowledge capture Nicolas Garnier Six Sigma Black Belt

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Packer testing & knowledge capture

Nicolas Garnier

Six Sigma Black Belt

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Define

Define

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Problem statement

The demand for NPD and RR Packer projects has been increasing and the task force knowledge not always captured . It is important to keep and share knowledge of what works and what doesn't in an accessible, searchable form.

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Project Objectives

1. Reduce number of tests per qualified product by 15% by end of 2004

2. Capture knowledge within the Packers group. Between sizes, product lines, materials…(for 10K packers)

3. Implement metrics, to measure group’s baseline and measure improvement.

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Benefits

Decrease the number of test iterations Decrease testing time & cost Decrease packer development cycle

time and cost Finding all necessary information in the

same place

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Project Metrics

Number of tests per qualified packer Number of tests captured in Database

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Defect definition

1. Database not operational by end of MayAlpha version by 05/05/04

2. Number of tests per qualified packer > Baseline-15%

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Project Team

Sponsor: – Dan Torbett

Process Owners: – Diana Orzechowski– J.D. Hendrickson– Karen Grosser

Process Personnel– Reggie Francis– Tom Christensen

(EQ)

Black Belt:– Nicolas Garnier

IT:– Tom Stevenson (c)– John Howard (i)

Finance:– Fernan Carpio

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Action Items

1. Measure number of tests per qualified product for 2003 to establish a Baseline

2. Creation of a database to1. Capture knowledge (design and testing

parameters)2. Facilitate test iterations and reports3. Generate Metrics on Packers testing

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Measure

Measure

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Baseline data

2003 Number of tests per qualified product: 16.0399 tests for 25 qualified packersSource: EQ, Process owners

Goal: tests/qualified Packer < 13.6

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Baseline graph

35

262

32

513

45

7

0

50

100

150

200

250

300

# Tests

MRP

QL

QMax

QMP

QX

XHP

XMP

2003 Averages per product line

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5

10

2

1 1

4

2

0

5

10

Qualified Packers

7

26.2

16

5

13

11.25

3.5

0

5

10

15

20

25

30

Tests/Packer

Goal

’03 mean

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Process Maps (1/2)ElementDesignStudy

Manufacturing

ElementTest 1

V3

ElementTest 2

V3 repeat if needed (low confidence*) V0 if required

Element ready forPacker Testing

PackerTesting

Cost

Vendor

Requirements

Existing Design

Design Guidelines

FEA

GeMS #

Drawing

Material Spec

Yes

No

MatureProduct?

Test Valid?Yes

* Low confidence

Failure*Analysis

No

Test Valid?Test Valid? Yes

Yes

No

Due to Element

NOT due to Element

Order

Yes** High confidence

4/21/2004Schlumberger N. Garnier

Element Design rev AB

Test2 =V0* Low confidence

Test2 = V3

1

1

Notes:* Low confidence:- high # of iterations (xx)- new design

** High confidence:- low # of iterations (xx)- no leak (xx %)

Element Scan:All elements except wiremesh

IterationTest

Or

Documentation

Personal TestIterations File

GeMS RecordsET Reports

Iteration Test

X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.

Y: Personal Data File

+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1


+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1 1




+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis

ElementTest 3

V0 Repeat

IterationTest

Start

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Process Maps (2/2)PackerDesignStudy

Packer designed inrespect of element

geometry

Manufacturing

Assembly

ISOTest 1

V3 (new design)V0 (existing design)

per cutomer req.

ISOTest 2

V0 after V3or

Test1 repeat (NPD)

PackerISO Qualified

Cost

Vendor

Requirements

Existing Design

Design Guidelines

FEA

GeMS #

Drawing

Material Spec

Failure*Analysis

Test Valid?

Test Valid?

Yes

Yes

No No

NOT due to Packer

Order

Parts

Assembly Drawing

Due toElement

SQ Event

Due to Packer

Elementready forPackerTesting

Manuf. Process Parts

BOM

Assembly ProcedureTemplate

Assembly ProcedureDraft

AssembledPacker

Test1 = V3

Test1 = V0

4/21/2004Schlumberger N. Garnier

Packer Design rev AB

Requirement

NoIteration Test

RR

Or

Additionnal Testingper Customer Request

1. Run in hole test 2. Shoks & vibrations test 3. Mill up test 4. Torque test 5. Integration test




1




Iteration Test

Documentation

Operating Manual

Assy ProcedureComplete

ET Reports

Personal TestIterations File

GeMS Records

ET Reports

Start

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Analyze

Analyze

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Root Causes1. Documentation

Iterations info personally stocked Documentation completed for each test after series With current Process, Database will be used after the

facts.

2. Test Results Binary Test Result: Pass/Fail: no intermediate measure Test results are not sufficient to establish a mathematical

model

3. Criteria establishment Design step: element testing to packer testing, based on

exp. Criteria: High/Low “confidence”

4. Cycle Time No cycle time measurement (development time for an

element?) BDM impose development time w/o documented Baseline

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Improve

Improve

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Proposed Solutions

Database MUST be used during the testing phase.

Standardize test results: – Tests classification (Element, Packer, Additional)– Need figures to differentiate 2 failed tests

• Checklists! Number of successful reversals passed

• If leak: %, #of bubbles…• Failure cause captured: leak, design, equipment,

manipulation error… Establish standard criteria Easy Search Results Available Metrics

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Requirements document

Initial Data Entry Packer GeMS Number, rev Test Iteration Number Element Stack GeMS Number, rev Test type: [Element; Packer], Test Date ET number , Test Report GeMS number: Person Responsible for test:

Packer Parameters: Packer Type: [QL; QMax; XHP; QMP; XMP;

MRP] Casing Size, ID, Weight Range: Max. Mandrel OD, Max. Gauge Ring OD QCP Number Element Type: [garter spring backup;

fold back ring backup; expandable ring backup; other]

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Test Parameters: Test Fixture GeMS Number, rev,

Serial # Test Fixture Mandrel type Test Type: [V4; V3; V0;

experimental] Test Medium Test Temp, Pressure Setting Force, Method of Setting Max. force delivered to Element Test Results: Test Result & Observations Element Failure mode

{Help available w/ pictures} Passed ISO? Comments Attachments

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Implement Solutions DMAIC

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Control DMAIC

Control

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New Process

Test info to be entered after each test Search to be done before each new design Process Owners (Managers) to control the

process. Monthly Check between EQ (Tom

Christensen) and Database Administrator (Karen Grosser)

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ROI (1)-Cost Avoidance DMAIC20

03H1-2004

Est. 2004

# Tests 399

68 ?

# Packer Qualified

25 7 20

#Tests per Qualified Packer

16.0

9.7 9.7

Test Plan (10% of tests)– Engineering time (2h)

Test Avoidance (1% of tests, 3d/test )– Engineering time ($2,520/test)– EQ time ($7,200/test)– Material ($4,000/test)

Tests Efficiency (10% impact from database)– [10%]*[$Test avoidance] *[#tests not

done(6.3*20)]

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ROI (2) - Costs

Database Programing ($12k) Uploading data ($5k)

– 2months-Intern Project Support (BB) ($0)

– Free in 2004 Engineering Team time (meeting)

– 5 meetings of 2h * 10p

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ROI (3) – Total savings

H1-2004: $ 104kEst.2004: $ 215k

2003

H1-2004

Est. 2004

# Tests 399

68 ?

# Packer Qualified

25 7 20

#Tests per Qualified Packer

16.0

9.7 9.7

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Conclusion Database = base of knowledge Link to TEAMS? Characterizing design parameters

– Project Objective: Identify the influential parameters of the 7IN HNBR Element Fold Back package / Q4-2004– Design Guidelines– Best Practices

– Benefits– Reduce number of tests– Reduce costs– Establish model / guidelines– Base for future design / FEA

– Design Of Experiments Expand methodology to other packers (material / sizes)

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