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Workface Planning APEGGA Conference Apr 2007 Jeph Virtue Answer these…. • Who are COAA Workface Planning Members and Sponsors? • What is Workface Planning? • Why do it? • How does it work? (including “the Rules”) • What is your role? • Want more info or training? Committee Members Jeph Virtue Suncor (Chair) Simon Marshman Frank DeLuca Niels Frederiksen Doug Hawkins George Jergeas Preston Noton Lloyd Rankin Raymond Rewcastle Geoff Ryan Pat Synnott John Vincent Flint Maurice D’Aoust Bird Construction Ron Embury Jacobs Dan Garon CLRA Jose Herrero UofC Ray Johnson Hatch Ronald Ramsay UofC Randy Regan Bantrel Brian Roy Jacobs Gary Semaniuk Jacobs Catalytic Ltd.Celina O’Neill Colt Bill Luxton Jacobs Catalytic Ltd. NOVA Fluor Canada Fluor Canada Bantrel Bantrel Suncor Brand Scaffold Stantec Suncor SAIT Sponsors Alberta Building Trades Council Bantrel Bantrel Constructors Bird Construction Christian Labour Association of Canada Construction Labour Relations – Alberta Shell Canada Limited Suncor Energy Inc. TransCanada Pipelines COAA Members Fluor Canada Ledcor Group Workface Planning Definition • Workface Planning is the process of organizing and delivering all the elements necessary, before work is started, to enable craft persons to perform quality work in a safe, effective and efficient manner. Size of the Prize Tool Time 37% Wait Time 15% Tool Time 47% Wait Time ~5% • 10% more tool time is a 25% improvement in productivity • Safety, morale and predictability improvements One Bite at a Time Workface Planning Rework Absenteeism Bench marking Supervisory Skills Supervisor Mentoring Workface planning will not solve all productivity issues … but it’s a good start Workface Planning Works! Project A Same: Owner EPCM Plant Type Size Time period Workface Planning added later Behind schedule Project B Workface Planning from start ~25 to 30% better production On Plan Thesis Extract: Conclusion “There is sufficient evidence to conclude that workface planning, as developed by the COAA steering committee, contributes to higher project performance.” Owner Commitment “Plan the Work” Workface Planning “Release the Work” “Work the Plan” Supervisor Dedicated Planner Prerequisites Materials & Equipment Coordinators Field Installation Work Package Materials Tools Equipment Trades/Specialists Detailed Plan Drawings Vendor Info. Safety Requirements Supervisor Review Scope Ready √ Team Tools 37% 47% 1 day to 4 weeks of defined scope. Tool Time Improvement A Supervisor’s Day Meetings QA/QC Initiatives + + Paperwork Safety Planning + - + + + - Supervision 15% On-site Travel + always grows - gets squeezed Not enough direct supervision. Planning suffers when busy. Construction Mgr Construction Mgr Superintendent General Foreman Work the Plan Plan The Dedicated Work Planner Plan the Work Superintendent General Foreman Foreman Crew Foreman Crew Foreman Crew Foreman Crew Foreman Crew Work the Plan Foreman Crew Foreman Crew Foreman Crew Foreman Crew Foreman Crew Performance Improvement Workface Planning Rules #1: Appoint Dedicated Planners Why do we do this? Workface Planning Rules #2: Planner completes Field Installation Work Package (FIWP) and releases when ready Field Installation Work Package Materials Tools Equipment Trades/Specialists Detailed Plan Drawings Vendor Info. Safety Requirements Supervisor Review Workface Planning Rules #3: Complete FIWP at least 4 weeks prior to construction start on that FIWP Workface Planning Rules #4: Provide Planners with latest versions of documentation Workface Planning Rules #5: Track progress of each FIWP vs targets Workface Planning Rules #6: Develop a backlog of FIWP’s Workface Planning Rules #7: Assign responsibility for integration planning Workface Planning Rules #8: Assign responsibility for Material, Construction Equipment, Scaffold and Specialty Tool Coordination to Dedicated Coordinators Workface Planning Rules #9: Develop Startup sequence, then path of construction, then Construction Work Package Release Plan Workface Planning Rules #9 (Cont.): 1) Develop Startup sequence 2) Path of construction Considerations • Start-up Sequence • Manhours • Congestion • Access • • • • Levels Complexity Equipment Delivery Time to complete 3) Identify Construction Work Packages (CWP) and CWP Release Plan Workface Planning Rules #10: Write requirement for Workface Planning into contracts Workface Planning Rules #11: Audit to ensure rules are being followed DBM Prerequisites - Owner • Executive declaration: “Use COAA Workface Planning!” • Appoint Workface Planning Sponsor and Champion EDS • Develop Workface Planning Execution Strategy for project • Determine systems, tools, organization – Determine how Workface Planning Principles will be implemented – Roles and Responsibilities specific to Workface Planning – Align key stakeholders EPC • Include Workface Planning requirement in Contracts • Define startup sequence of units • Support and audit • Expect Construction Indirects to be higher; but overall Total Installed Cost to be lower DBM Construction Management • Commit to Workface Planning • Make it happen (all phases) EDS • Develop Workface Planning Execution Plan for project • Develop Path of Construction (with Eng and Contractors) – startup sequence – construction logistics and time to complete – by area EPC • Include Workface Planning requirement in contracts • Identify Construction Work Packages (CWP) and release plan • Appoint Integrated Planner • • • • Perform Constructability review (with Eng and Contractors) Coordinate dedicated planners via integrated planner Manage rub points Roll-up overall FIWP progress EDS • Commit to Workface Planning • Develop Path of Construction with Construction Management (CM) • Identify Construction Work Packages (CWP) and develop release plan with CM and Eng • Appoint Dedicated Planners, Equipment Coordinators, Scaffold Coordinators and Workface Planning Leaders EPC DBM Construction Contractors • • • • • • Perform Constructability review (with CM and Eng) Break CWP into Field Installation Work Packages (FIWP) Identify FIWP’s and FIWP release plan Develop FIWP’s Feed 3 week lookahead schedule with FIWP releases Execute FIWP – track progress EDS DBM Prerequisites - Engineer • Commit to Workface Planning • Incorporate Workface Planning into Stds, Procedures and Job Instructions • Establish Work Breakdown Structure • Develop Path of Engineering EPC – based on Construction Work Packages and release plan – allow 2 to 3 months between IFC and construction start – communicate to team consequences if missed (MEET THE PLAN) • Deliver CWP’s per the release plan • Provide document updates to dedicated planners Training • ½ Day Overview ($400) – Executive, Management, Supervision – Owner, EPCM, Construction Contractors • 4 Day Workface Planner Course ($2400) – Workface Area and Integration Planners, Champions, Coordinators (Equipment, Material, Tool, Scaffold) – Owner, Construction Contractor, Construction Manager • Available now More Info • www.coaa.ab.ca • COAA Conference: May 15 eve, May 16 • Thankyou