1. Structural Weld Overlay
KAIZEN
Time Compression
through
Application of Lean Thinking
"Value Stream Mapping &Tools of
Quality"

2. 2RF10 Refueling Outage Structural Weld Overlay
130 People involved in 25 Small and Large Group KAIZEN activities
Process Pressurizer Structural Weld Overlay
Nuclear/Lean
Principles and
Practices
Applied
VALUE,, FLOW, PULL, VALUE STREAM, Level Loading, Constraint Management
Value Stream Mapping, FMEA, C/E Matrix, Poka Yoke, Operating Experience,
Lessons Learned, Eng. Technical Reviews, Risk Assessments, Safety evaluations
Product A Performance Demonstrated Initiative inspectable Structural Weld Overlay with NO
rejectable indications / defects
Customers Plant Operations, NRC
Process Value
Add
Welding the Correct amount of weld overlay material no more / no less than required
to create a weld overlay with zero defects
Results: 5.5 Day reduction
Breaker’s Open to Acceptable FINAL PDI Inspection = 15 Days
ZERO Safety Incidents + ZERO Indications/Defects
Safe and Reliable 27% Cycle Time Improvement

3. Event 1: Strawman of VSM, Define Process, Define VA, ID Customers,

4. Event 2 Communication and Alignment
Kick Off: End to End VSM Evaluation – End to End Walkdown

5. Final Product
WIP
Visual Management
During implementation

6. Measurements of Process Performance
Continuous Metrics
Delivery: (Schedule Adherence) Ahead, On , Behind Schedule
RESULT: 12 hours ahead of planned schedule.
Quality: Zero Indications during all welding steps
RESULT: Zero Indications /Defects
Binary Metrics
Quality: Zero Indications at Final NDE testing
RESULT: Zero Indications / Zero Rework / Defect Free final Non Destructive Examination
Safety:
RESULT: Zero OSHA Recordables / 1 First Aid
World Record in Nuclear
We owe all success
to these people