Colorado Department of Health & Environment OIL & GAS MINOR SOURCE AIR P E R M I TT I N G KA I Z E N E V E N T C h r i s L a p l a n t e K o r b y B r a c k e n , P. E . Air Pollution Control Division Anadarko Petroleum July 17, 2008 Introduction What is Kaizen What are the Benefits What Kaizen Does Not Do Details of the Kaizen Event at
APCD What is Kaizen Japanese philosophy of continual improvement Lean management tool intended to improve the efficiency of any process by eliminating waste What Are the Benefits Improve process flow and reduce lead times
Identifies and focuses work on value added activities Enhance quality of work output Eliminate waste (i.e. reworks, loop-backs, waiting, excessive hand-offs) What Kaizen Does Not Do Affect regulatory stringency Force hasty inadequate work Cut corners Seek to fault staff Work against the agency mission Details of the Kaizen Event at APCD
The APCD hosted a Kaizen Event the week of June 2 June 6, 2008 Focused on improving the process of permitting Oil & Gas Industry minor sources Team Members Sponsor: Paul Tourangeau Consultant: Tom Morin Chris Laplante (Engineer) Scott Patefield (Inspector) Kathy Drulard (Admin) Korby Bracken (Anadarko)
Dawn DeVries (Williams) Ashley Campsie (Encana) Roy Doyle (Inventory) Adam Wozniak (Tech) Matt Burgett (T5 Engineer) Chip Hancock (Engineer) Dana Podell (Inspector) Larry Granato (IT) Jon Torizzo (Modeling) Our Approach
Kaizen Breakthrough Experience Team-based energy and creativity drives immediate process improvement Day 1 Day of Training & Understanding Day 2 Day of Discovery Day 3
Day of Improvement Day 4 Day of Design Implementation & Documentation Day 5 Day of Celebration & Results
At the end of the week, each Kaizen team has achieved dramatic operational improvements 8 2007 Guidon Performance Solutions, LLC. All rights reserved. Guidon Performance Solutions is a licensee of LeanSigma, a service mark of TBM Consulting Group . Key Principles Clear objectives Team process Tight focus on time (one week) Quick and simple, action first Necessary resources available
right away Immediate results (new process functioning by end of week) 9 2007 Guidon Performance Solutions, LLC. All rights reserved. Guidon Performance Solutions is a licensee of LeanSigma, a service mark of TBM Consulting Group. Time-Based Strategies Lead-Time Reduction Identify and eliminate waste
Defects and loop-backs Hand-offs Over-producing Unnecessary processing Decisions in process Excess transportation Waiting 2007 Guidon Performance Solutions, LLC. All rights reserved. Guidon Performance Solutions is a licensee of LeanSigma, a service mark of TBM Consulting Group.
Time-Based Strategies Lead-Time Reduction The Key is to Reduce Your Processes to Core Value Wasted Time and Activity Core Process Value Excessive Backlog Excessive Motion Defects & Loop Backs OPERATIONAL LEAD TIME
Hand-offs Waiting Over processing Unnecessary Processing The key is to reduce your processes to core value 11 2007 Guidon Performance Solutions, LLC. All rights reserved. Guidon Performance Solutions is a licensee of LeanSigma, a service mark of TBM Consulting Group. Scope
From the writing of the application for a permit to the issuance of final approval for minor source permits for oil & gas industry Out of Scope Major source applications & major modifications Regulatory & formal policy changes Permit conditions General permits Feedback Themes Customer feedback length of time to get permits issued Internal feedback eliminate backlog and better
utilize resources Reduce variation and increase consistency Annual Demand nnual applications for Oil & Gas Air Permits = 1,000 to 1,50 or 4 to 6 per work day Objectives Reduce lead time (receipt of complete app date of issuance of initial approval permit) to statutory limits (90 to 135 days) Reduce lead time (receipt of complete selfcertification date of issuance of final approval) to 60 days Measure
Reduce Lead Time (# days) by 50% Reduce Backlog by 50% Current Level Target Gap 160 Days 80 Days 80 Days 541
271 270 Hit targets by August 1, 2009 Goals Eliminate initial approval backlog Eliminate incomplete applications Issue permits within regulatory timeframe Improve communication between industry and Air Division Increase understanding of needs & expectations
Current State Flow Map Voice of the Air Agency Incomplete applications Companies frequently revising applications mid- process Lack of appropriate application forms Unnecessary final approval permitting process Lack of guidance for what represents a complete application No process for rejecting incomplete applications Lack of training on oil and gas processes Too many application hand-offs Voice of the Industry
Permit process too slow Define deadlines to allow for accurate planning Lack of appropriate application materials Non-value added steps are too lengthy Final approval permit not necessary Lack of consistency of permit conditions Inability to determine review engineer and permit tracking Lack of notification that the permit process has begun Confusing invoicing / billing 15 day post start-up notice to provide accurate information Brainstormed Ideas Move application completeness determination to
the beginning of the process & return incomplete applications Create application completeness checklist Develop appropriate application forms (APENs) to assure complete information is provided E-mail engineer assigned to permit & application status to company contact Require Notice of Start-up (NOS) to be filed within 30-days of commencement of operation rather than 30-days prior
Create guidance documents to accompany application forms Brainstormed Ideas (contd.) Submit all Self-Certification paperwork simultaneously Provide specific Self-Certification checklist with permit to guide operator through required steps Standardize O&M plans and include as an attachment to the permit Eliminate need to re-issue permit as Final Approval Require complete facility emissions inventory with permit applications Three New Process Flow Ideas
Improvements Being Made Reduce hand-offs & delays Eliminate re-issuance of a final approval permit while preserving self certification process Incorporate O&M plan into permit Created a permit specific self certification checklist Developed an application completeness checklist Improving application forms Improvements Being Made Improving consistency of permits Enhancing communication between permit engineers
and inspectors Standardized organization of permit applications Expanded billing & permit issuance options Implementing electronic notification of permit application assignments New Process Construction permit phase Compliance certification phase
Key Changes for Stakeholders Applications must be accurate & complete Applications must include Application Completeness Checklist and all required attachments must be included. Air Pollutant Emission Notice(s) (APEN) APEN Filing Fees Company Contact Information Process description and flow diagram Facility wide emissions inventory Emissions calculations are supporting documentation Ambient air impact analysis Operation & Maintenance plan (Synthetic minor & major
sources) Regulatory applicability determinations (Not mandatory) Key Changes for Stakeholders New application forms are being developed and must be used where appropriate Equipment specific APEN forms Facility wide emissions summary Notice of Startup (NOS) Company Contact Information Form Requirement to submit Operating & Maintenance plans with synthetic minor or major permit applications. Based on standard guidelines or site-specific provided by the operator
O&M plan will be incorporated into the permit Key Changes for Stakeholders Standard organization for permit applications (i.e. attachments) APEN filing fees must be submitted with applications New Oil & Gas permitting website under development for one stop shopping for forms,
guidance Notice of Startup will be required 30 days post commencement of operation to ensure accurate information provided (i.e. start-up date and equipment details) Company Contact Information Form will be required to ensure bills are sent to appropriate Key Changes for Stakeholders Permits will be issued with source specific Self Certification Checklist to clearly inform operator what steps must be taken to certify compliance Eliminate the Initial Approval/Final Approval concept Permits will be issued once as a Construction
Permit Self-Certification will still be required and approved via a letter to the operator Permitting lead times will be reduced Summary of Results Measure Before # of Steps Goal After
% Change 114 56 51% # of Handoffs 48 24 50%
# of Decisions 14 10 29% # of Delays 34 9 74%
# of Functions 10 8 20% Lead-time 160 days 50%
TBD Backlog 541 50% TBD Value Adding Steps 8
Construction permit 8 Lessons Learned There is always room for improvement and efficiencies The value of communicating expectations The power of single piece flow once you pick it up, dont put it down until its complete Better appreciation for industry and Division challenges
Lesson Learned (contd.) Encourage how industry and the Division worked together to develop an improved process Realized the benefit of making the process visible using process flow mapping Importance of bringing affected stakeholders (internal and external) together to understand respective challenges Additional Information The anticipated implementation date of the new oil
and gas permitting process is August 2008 APCD will be delivering notifications of the availability of new resources (forms, website, etc.) via the ColoradoAirNews listserve To sign up for listserve notifications, please visit www.cdphe.state.co.us/ap/Listservesubscribe.html Question s?
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