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Configuration Management Benchmarking Group Seattle, June 2014. Configuration Backlog Reduction – There and Back Again Susan Atkin, Wolf Creek N.O.C. Configuration Backlog Reduction. In May 2013, there were 1521 packages open. 319 in Development phase

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Configuration Management Benchmarking Group Seattle, June 2014

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Configuration Management Benchmarking GroupSeattle, June 2014

Configuration Backlog Reduction –

There and Back Again

Susan Atkin, Wolf Creek N.O.C.


Configuration Backlog Reduction

  • In May 2013, there were 1521 packages open.

    • 319 in Development phase

    • 506 with Fieldwork, in phases of Planning, Implementation, and Program Updates

    • 528 Document Change Only, released from Engineering and waiting for Closeout to begin

    • 151 in Engineering Closeout phase

    • 9 held at Document Services due to problems

    • 8 “ongoing” packages


Configuration Backlog Reduction

  • Of 1521 packages, 1202 packages had drawings, manuals, and calculations that potentially did not match the plant configuration (packages released from Engineering)

  • If we estimate approximately 10 documents affected per package on average, then…

  • 1202 packages = 12,020 documents with fidelity uncertainty


Configuration Backlog Reduction

  • Essential Control Room Drawings are revised within 24 Normal Working Hours

  • Significant Drawings (Clearance Orders/ Personnel Safety) are revised within 15 days

  • Document Backlog DID NOT include these.

  • Document Backlog DID include

    • Calculations, Vendor Manuals, Design Drawings, Specifications


Configuration Backlog Reduction

  • Culture in which Design Engineering wasn’t allowed to say “no” created:

    • No appetite suppression

    • 319 packages in Development phase (May 2013)

    • 30 Design Engineers

    • Approximately 300 packages developed per year

    • Each engineer had over a year’s worth of work waiting for him/her (packages, CR evaluations, training, level of effort work)

    • No time for “low priority” work like Closeouts


Configuration Backlog Reduction

  • Money allocated for Closeouts was re-directed to special projects yearly

  • Design Change Process excludes Engineering from post-implementation turnover to Operations (engineer didn’t know when modification was implemented)

  • Maintenance had heavy workload implementing 300 packages/ year on top of PMs and broke/fix work

  • Engineering and Maintenance Supervisors didn’t schedule time for Closeouts


Configuration Backlog Reduction

  • How did we get there?

    Culture


Configuration Backlog ReductionHow do we get back again?


Configuration Backlog ReductionHow do we get back again?


Configuration Backlog Reduction

  • Remedial

    • Close packages at all stages, end goal of 100 open

    • Create Closeout Team

    • Make Closeout process easier

  • Preventive

    • Create a front-end filter to say “No”

    • 20/40 List

    • Revise Development process

    • Stakeholders process

    • Communicate and Hold Accountable


Configuration Backlog Reduction

  • Remedial, Close packages at all stages

    • Design Engineering provided list of packages from Development through Planning to System Engineering

    • System Engineering force ranked packages by system

    • Maintenance, Operations, Design, and Systems culled the list of packages (Managers)

    • Packages cancelled or approved

    • Packages approved for development prioritized

      • Need to work now vs. Nice to have eventually

      • dropped 304 to 161


Configuration Backlog Reduction

  • Remedial, Close packages at all stages

    • Packages in Planning, Implementation stages

      • Scheduled Work

    • Packages in Program Updates stage (Implementation Complete)

      • Maintenance Closeout Team (3 coordinators)

    • Packages in Engineering Closeout

      • Engineering Closeout Team (3 coordinators, 6 drafters, 2 checkers, 3 engineers, 1 project manager, 1 supervisor)

      • Configuration Management Drafters working Closeout exclusively 1 week/month each


Configuration Backlog Reduction

  • Remedial, Make Closeout process easier

    • Procedure changes

      • Allow up to 5 DDCNs per document

      • Allow up to 5 Final CCNs per calculation

      • Created Closeout Procedure

      • Engineers trained on new procedure

    • Closeout Coordinators helping with forms


Configuration Backlog Reduction

  • Preventive, Front End Filter

    • Managers as front-end filter

      • Packages must have manager approval before being initiated

    • PHC as front-end filter

      • Non-Emergent Fieldwork Packages must have PHC approval before being initiated

      • Funding must be committed before Engineering work is initiated

      • Modification Impact Summary created to help PHC make informed decisions


Configuration Backlog Reduction

  • Preventive, 20/40 List

  • 20 Outage / 40 Online Fieldwork Packages

  • Current 20/40 List has 161 Packages

  • Strategy: Attrition and Front-end Filter


Configuration Backlog ReductionPreventive, Revise Development Process* 36 Procedures changing, mid-July roll out *Changes include moving activities from end of Design Change Process to Development stage

  • PM development

  • Procedure change identification

  • Fieldwork

  • Spare parts levels

  • Simulator changes

  • RWO reviews

  • Identification of problems or concerns

  • Post Mod Testing

  • Training

  • ERDS data points


Configuration Backlog Reduction

  • Preventive, Stakeholders Process

    • Design Change Packages

      • Function, failure mode, bounding parameters

      • 10%, 30%, 50%, 90% meetings

      • Impacts form required for mandatory stakeholders for meetings


Configuration Backlog Reduction

  • Preventive,

    Communicate & Hold Accountable

  • Email notices twice monthly to engineers

    • Packages in Closeout

    • Packages ready for Closeout – NFW

    • Packages with Implementation Complete, currently in Program Updates stage – FW

  • Escalate as needed, CRs after 90 days at AP7


Configuration Backlog Reduction

So how are we doing so far?


Configuration Backlog Reduction


Configuration Backlog Reduction


Configuration Backlog Reduction

  • Questions?

  • Comments?

  • Thank you.


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