Just in Time Inventory Management
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1 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 1
2 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 2
3 Project Work Scope Overview Replace pressure tubes Replace feeder tubes Project Work Scope Overview Replace 8 steam generators 3
4 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 4
5 RP Consumable Project Strategy 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. Project Work Scope Overview RP Consumable Project Strategy Vendor Selection Consumable Programs and Results Questions Just in Time Inventory Management 5
6 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. 6
7 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. Rapid new item approval process for unexpected material needs (no purchasing required). 7
8 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 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 Fun Fact Duct Tape Used 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 Washed 4 m iles of 8 ducting so it could be reused w/o th e need for PPE. 8
9 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, UniTech purchases and delivers to requestor. 4. Requestor signs I got it 5. UniTech assembles all supporting documentation to support billing, includes with monthly billing Rapid Approvals used over the project duration. 0 to $100 8% $100 to $1K 36% $1K to $5K 37% $5K to $10K 8% $10K to $100 8% $100 to $500K 3% Top 11% exclusively PAPR s 9
10 Consumable Programs and Results 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. 10
11 Consumable Programs and Results 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 11
12 Consumable Programs and Results 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 Summary Just in Time Inventory Management Project staff stayed focused on project Costs were controlled and savings realized Radioactive waste was minimized No project delays due to consumable shortages 12
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