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Packer testing & knowledge capture
Nicolas Garnier
Six Sigma Black Belt
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Define
Define
DMAIC
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Problem statement
The demand for NPD and RR Packer projects has been increasing and the task force knowledge not always captured . It is important to keep and share knowledge of what works and what doesn't in an accessible, searchable form.
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Project Objectives
1. Reduce number of tests per qualified product by 15% by end of 2004
2. Capture knowledge within the Packers group. Between sizes, product lines, materials…(for 10K packers)
3. Implement metrics, to measure group’s baseline and measure improvement.
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Benefits
Decrease the number of test iterations Decrease testing time & cost Decrease packer development cycle
time and cost Finding all necessary information in the
same place
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Project Metrics
Number of tests per qualified packer Number of tests captured in Database
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Defect definition
1. Database not operational by end of MayAlpha version by 05/05/04
2. Number of tests per qualified packer > Baseline-15%
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Project Team
Sponsor: – Dan Torbett
Process Owners: – Diana Orzechowski– J.D. Hendrickson– Karen Grosser
Process Personnel– Reggie Francis– Tom Christensen
(EQ)
Black Belt:– Nicolas Garnier
IT:– Tom Stevenson (c)– John Howard (i)
Finance:– Fernan Carpio
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Action Items
1. Measure number of tests per qualified product for 2003 to establish a Baseline
2. Creation of a database to1. Capture knowledge (design and testing
parameters)2. Facilitate test iterations and reports3. Generate Metrics on Packers testing
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Measure
Measure
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Baseline data
2003 Number of tests per qualified product: 16.0399 tests for 25 qualified packersSource: EQ, Process owners
Goal: tests/qualified Packer < 13.6
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Baseline graph
35
262
32
513
45
7
0
50
100
150
200
250
300
# Tests
MRP
QL
QMax
QMP
QX
XHP
XMP
2003 Averages per product line
DMAIC
5
10
2
1 1
4
2
0
5
10
Qualified Packers
7
26.2
16
5
13
11.25
3.5
0
5
10
15
20
25
30
Tests/Packer
Goal
’03 mean
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Process Maps (1/2)ElementDesignStudy
Manufacturing
ElementTest 1
V3
ElementTest 2
V3 repeat if needed (low confidence*) V0 if required
Element ready forPacker Testing
PackerTesting
Cost
Vendor
Requirements
Existing Design
Design Guidelines
FEA
GeMS #
Drawing
Material Spec
Yes
No
MatureProduct?
Test Valid?Yes
* Low confidence
Failure*Analysis
No
Test Valid?Test Valid? Yes
Yes
No
Due to Element
NOT due to Element
Order
Yes** High confidence
4/21/2004Schlumberger N. Garnier
Element Design rev AB
Test2 =V0* Low confidence
Test2 = V3
1
1
Notes:* Low confidence:- high # of iterations (xx)- new design
** High confidence:- low # of iterations (xx)- no leak (xx %)
Element Scan:All elements except wiremesh
IterationTest
Or
Documentation
Personal TestIterations File
GeMS RecordsET Reports
Iteration Test
X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.
Y: Personal Data File
+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1
Y: Personal Data File
+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1 1
X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.
X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.
Y: Personal Data File
+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis
ElementTest 3
V0 Repeat
IterationTest
Start
DMAIC
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Process Maps (2/2)PackerDesignStudy
Packer designed inrespect of element
geometry
Manufacturing
Assembly
ISOTest 1
V3 (new design)V0 (existing design)
per cutomer req.
ISOTest 2
V0 after V3or
Test1 repeat (NPD)
PackerISO Qualified
Cost
Vendor
Requirements
Existing Design
Design Guidelines
FEA
GeMS #
Drawing
Material Spec
Failure*Analysis
Test Valid?
Test Valid?
Yes
Yes
No No
NOT due to Packer
Order
Parts
Assembly Drawing
Due toElement
SQ Event
Due to Packer
Elementready forPackerTesting
Manuf. Process Parts
BOM
Assembly ProcedureTemplate
Assembly ProcedureDraft
AssembledPacker
Test1 = V3
Test1 = V0
4/21/2004Schlumberger N. Garnier
Packer Design rev AB
Requirement
NoIteration Test
RR
Or
Additionnal Testingper Customer Request
1. Run in hole test 2. Shoks & vibrations test 3. Mill up test 4. Torque test 5. Integration test
X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.
Y: Personal Data File
+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1
1
X+ Test Plan+ Test Fixtures+ Element+ Element Scan+ Pre-Test Insp.
Y: Personal Data File
+ Test Observations+ Pictures+ Post-Test Inspection+ Failure Analysis 1
Iteration Test
Documentation
Operating Manual
Assy ProcedureComplete
ET Reports
Personal TestIterations File
GeMS Records
ET Reports
Start
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Analyze
Analyze
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Root Causes1. Documentation
Iterations info personally stocked Documentation completed for each test after series With current Process, Database will be used after the
facts.
2. Test Results Binary Test Result: Pass/Fail: no intermediate measure Test results are not sufficient to establish a mathematical
model
3. Criteria establishment Design step: element testing to packer testing, based on
exp. Criteria: High/Low “confidence”
4. Cycle Time No cycle time measurement (development time for an
element?) BDM impose development time w/o documented Baseline
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Improve
Improve
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Proposed Solutions
Database MUST be used during the testing phase.
Standardize test results: – Tests classification (Element, Packer, Additional)– Need figures to differentiate 2 failed tests
• Checklists! Number of successful reversals passed
• If leak: %, #of bubbles…• Failure cause captured: leak, design, equipment,
manipulation error… Establish standard criteria Easy Search Results Available Metrics
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Requirements document
Initial Data Entry Packer GeMS Number, rev Test Iteration Number Element Stack GeMS Number, rev Test type: [Element; Packer], Test Date ET number , Test Report GeMS number: Person Responsible for test:
Packer Parameters: Packer Type: [QL; QMax; XHP; QMP; XMP;
MRP] Casing Size, ID, Weight Range: Max. Mandrel OD, Max. Gauge Ring OD QCP Number Element Type: [garter spring backup;
fold back ring backup; expandable ring backup; other]
DMAIC
Test Parameters: Test Fixture GeMS Number, rev,
Serial # Test Fixture Mandrel type Test Type: [V4; V3; V0;
experimental] Test Medium Test Temp, Pressure Setting Force, Method of Setting Max. force delivered to Element Test Results: Test Result & Observations Element Failure mode
{Help available w/ pictures} Passed ISO? Comments Attachments
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Implement Solutions DMAIC
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Control DMAIC
Control
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New Process
Test info to be entered after each test Search to be done before each new design Process Owners (Managers) to control the
process. Monthly Check between EQ (Tom
Christensen) and Database Administrator (Karen Grosser)
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ROI (1)-Cost Avoidance DMAIC20
03H1-2004
Est. 2004
# Tests 399
68 ?
# Packer Qualified
25 7 20
#Tests per Qualified Packer
16.0
9.7 9.7
Test Plan (10% of tests)– Engineering time (2h)
Test Avoidance (1% of tests, 3d/test )– Engineering time ($2,520/test)– EQ time ($7,200/test)– Material ($4,000/test)
Tests Efficiency (10% impact from database)– [10%]*[$Test avoidance] *[#tests not
done(6.3*20)]
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ROI (2) - Costs
Database Programing ($12k) Uploading data ($5k)
– 2months-Intern Project Support (BB) ($0)
– Free in 2004 Engineering Team time (meeting)
– 5 meetings of 2h * 10p
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ROI (3) – Total savings
H1-2004: $ 104kEst.2004: $ 215k
2003
H1-2004
Est. 2004
# Tests 399
68 ?
# Packer Qualified
25 7 20
#Tests per Qualified Packer
16.0
9.7 9.7
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Conclusion Database = base of knowledge Link to TEAMS? Characterizing design parameters
– Project Objective: Identify the influential parameters of the 7IN HNBR Element Fold Back package / Q4-2004– Design Guidelines– Best Practices
– Benefits– Reduce number of tests– Reduce costs– Establish model / guidelines– Base for future design / FEA
– Design Of Experiments Expand methodology to other packers (material / sizes)
DMAIC