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Improving Engineering Effectiveness at the Savannah River Site

Improving Engineering Effectiveness at the Savannah River Site. Fred Beranek Site Chief Engineer. Issues. Loss of Experience/Numbers Cost/Schedule vs. Quality Fragmented Engineering Organization Support vs. Ownership Computers vs. Understanding. Modify Behaviors. Clarify Expectations

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Improving Engineering Effectiveness at the Savannah River Site

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  1. Improving Engineering Effectivenessat the Savannah River Site Fred Beranek Site Chief Engineer

  2. Issues • Loss of Experience/Numbers • Cost/Schedule vs. Quality • Fragmented Engineering Organization • Support vs. Ownership • Computers vs. Understanding

  3. Modify Behaviors • Clarify Expectations • Quality first, then schedule, then cost • Communicate Expectations • All managers meeting • Reinforced in engineering roundtables • Support the Expectations • Centralized engineering • Performance judged on quality

  4. Process Improvements • Human Performance Improvement Training • Mandatory for all engineers/managers • Selected 5 HP tools • Pre-job Brief • Verify Assumptions • Questioning Attitude • Self-Check • Peer Verification • Trained all engineers/managers in 9 months • Developed engineering aids • USQ Screening Tool – Defense Programs Engineering • Engineering Pre-job Briefing Checklist – Liquid Waste Engineering

  5. Process Improvements (Cont’d) • Initiated Senior Technical Review Group in H Canyon • Retirement of technical experts • Compensatory measure until quality expectations are achieved • Has caught several errors prior to implementation • Expanded use of Safety Input Review Committee • Used in Liquid Waste Operation for several years • Reviews DSA inputs, assumptions and outputs • Includes DOE as a member • Resolves issues in beginning of process

  6. Process Improvements (Cont’d) • Establishing Engineering Assistant Positions • Engineers performing non-engineering tasks • Need engineers to focus • Goal of 30 over next year • Initiated Scenario Review Committee • Compensatory measure • Assure consistency and reasonableness of accident scenarios • Will disband when SIRC is trained

  7. Process Improvements (Cont’d) • AB Development Process • Paralleling project management process • Emphasis on inputs and assumptions • Removes compensatory measures that had been added over the years • Minimize rework

  8. Technology Improvements • Implementing Smart Plant Foundation across site • Complete in Defense Programs • Currently rolling out across site • Provided Crane 410 Software to all engineers • Electronic Consolidated Hazards Assessment Process (ECHAP) • Provides standard format • Assures consistency across site • Prompts while completing analysis • Reports • Assures accurate translation to DSA

  9. Technology Improvements (Cont’d) • PlantWeb (Emerson product) • Implemented at Modular Caustic Side Solvent Extraction Unit (MCU) and Actinide Removal Process (ARP) • Partially implemented at Saltstone • Provides automated diagnostics on many components • Reduces troubleshooting needs • Successfully identified component problems and reduced downtime

  10. Technology Improvements (Cont’d) • Teorija rezhenija izobretatelskih zadach (TRIZ) • Innovative, simple solutions to complex problems • Piloted at SRS for about 2 years • Several Successful applications • Trained 15 practicioners • Washington Group International championing process across DOE sites

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