Sellafield Process Improvement by Howard Cooper

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The new

Sellafield Ltd

Management System (SLMS)

Facilitating a safer, more effective means of conducting business through collaborative teamwork

Howard Cooper

Head of Quality, Sellafield Ltd

Karine Rackham

Management System Manager, Sellafield Ltd

Dan Plung

Programme Manager, URS

The challenge

• Replace a management system that had become difficult to use, contained ineffective arrangements, and had limited credibility among the user base

• Establish a system that would facilitate and support the new management team’s commitment to “effective working”

“ making changes to our systems and processes and, by removing some of the barriers to effective working, making it easier to get work done and also to stop work that doesn't add value”

• Establish reasoned consistency across Sellafield Ltd

• Support paced and sustained change

• Align programme structure to business strategies

• Ensure compliance with ISO-9001 and ISO-14001

• Provide for improved interaction with regulators

The approach: return to fundamental principles

• Reorient system to focus on users

• Collectively engage users and process owners

– in enhancing processes to improve safety and efficiency

– in assessing and addressing implementation strategies

• Align ownership, accountability and responsibility for arrangements, compliance and site licence conditions

• Create an enhanced document architecture and delivery platform

• Promote development of user-orientated arrangements

• Design structure to provide long-term system sustainability

• Provide traceability to obligations

Phase 1: Build an infrastructure to enhance safety and effectiveness through improved quality, use and access to arrangements

Essential components of the new management system

A single integrated

Compliance demonstrated at an appropriate level

An engaged community of owners, users and subject matter experts

An intuitive configuration configuration based on business based on business processes (topic areas)

“Topic” Manuals and a collection of enduser oriented “How Do I?”

“Topic” Manuals and a collection of enduser oriented “How Do I?”

• Designed for usability

• Exclusive focus on task/activity

A simplified hierarchy

• Simple and clear relationships among

A document types simplified hierarchy

• Simple and clear relationships among document types

• Discrete document purposes

Develop high quality and proportionality of arrangements through collaborative process

• Single point of accountability for processes (topic areas)

• Disciplined process of appointments (Process Owners/Reviewers)

• Implementation strategy agreed during development of arrangements

• Enhanced visibility of interactions among processes

• Engaged personnel reflecting corporate perspective / Management commitment:

– Process Owners: have exclusive accountability for their topic

– Designated Reviewers: represent the Directorate perspectives (users)

– Subject Matter Experts: assist with development and implementation

– Heads of Manufacturing: provide enhanced user (OU) perspective

– Process Sponsors: establish expectations, resolve outstanding issues

Establish a document structure that clearly communicates (and delineates among) the

‘how’, ‘what’, and ‘why’

Policies

& Charters

Manuals and Plans

Sellafield Ltd

Practices

(“How Do I?”s) (SLPs)

Sellafield Ltd

Supporting Practices

Local Working Documents

Policies state executive level expectations.

Charters provide executive endorsement for execution of a plan, task, or activity (e.g. Terms of

Reference for a governance committee).

Manuals/Plans describe and state the rules and strategy for a planned process or programme of work.

SLPs inform individuals how to:

•request delivery of a service

•complete a specific task or activity.

SL Supporting Practices give detailed instruction or guidance on a process, programme, task or activity.

Local Working Documents (e.g. Operating

Instructions, Maintenance Instructions,).

Provide user-oriented arrangements: the new Sellafield Ltd Practices (SLPs)

• “How Do I?” oriented

• Prescribe how to complete a single, discrete activity

• Provide only the detail needed to successfully complete the task

(majority <10 pages)

• Facilitate more effective, less timeconsuming reviews (including emphasising focus on process)

• Contributes to reduced publication cycle time (4-6 weeks from draft to publication)

Provide a basic organisational logic based on contract scope of work

Project execution and managing, operating and maintaining

Operating Units

Key support functions

General Sellafield

Ltd infrastructure

*

Programmes that ensures accountability, fairness and transparency

…that provides ready access and navigation to all arrangements and supporting information

Left hand zone:

• Information and user guidance

(including

“ Frequently Asked

Questions

”)

• Compliance information

• Transition index

Access to Local

Link Maps , with all local documents (e.g.

OIs, MIs).

Users can provide feedback or get help on SLMS

Topics (i.e. process areas) organised in 4 broad categories

“New & Info” and

“Recent Changes”

. . . and ensures users find and have what they need

Document hierarchy

Policies

& Charters

Manuals and Plans

Sellafield Ltd

Practices (SLPs)

(“How Do I’s”)

Sellafield Ltd Supporting

Practices

Users can set up alerts to receive automatic notification of changes to topics of interest.

All active transitional procedural arrangements (and associated documents e.g. templates) mapped to the topic

Phase 2: Manage the Transition

Supporting timely issuance of arrangements

Sellafield Ltd Management System - Content delivery

600 • Process Owners set schedules

• Priorities aligned with the

ICP, Nuclear Safety programme and Strategic

Business Imperatives

500

400

300

• Reduced requirement for lower-tier implementing documents

200

• Business Change

Managers engaged

• Legacy arrangements withdrawn when safe/appropriate

100

76% of documents published to schedule

(app. 60% of total forecast)

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Cumulative scheduled Cumulative published

Actively engaging and supporting users to ensure an effective transition...

• Process Owners and Designated

Reviewers

• Key stakeholders (Executive,

Regulators, NDA)

• Intranet / Energize

• Demo facility

• Team 4 action

• Human Performance

• Face to face briefings

• Animated demo tool

• Left hand zone and FAQs

• Supportive feedback

• >90% queries answered within

2 working days

• Awareness and navigation briefings for over 2200 key users

Implementing arrangements collaboratively and proportionally

• Implementation is agreed during development of arrangements

• Implementation effectiveness is a collaborative activity

OUs implement

• Process Owners provide needed support / oversight

• Proportional implementation strategy

Isolations

– formal training

• DSEAR Process – testing

• Administrative SLPs – notices/ communications

…and identifying metrics to validate effective

SLMS performance and identify improvements

• Metrics identified to provide a clear measure of SLMS performance and sufficient trending information to allow timely adjustments, as warranted

• Metrics derived through careful consideration of a number of factors:

– principles embedded in ISO-9001, Quality Management System

Requirements and GS-R-3, The Management System for Facilities and

Activities ;

– principles that served as the foundation for the system’s development;

– and the risks explored in the Management of Change (MoC) assessment completed in the months before the system went live

• Metrics have evolved over the first year of the system’s operation

• Metrics are reported to Process Owners and Process Sponsors

(Executive) monthly, further amplified by an annual self assessment report

Phase 3: Realising the potential

The Sellafield Ltd Management System continues to mature

SLMS endorsed

(Oct 2009)

System design developed

Key personnel appointed

Topics defined

Documentation plans and schedules developed

Obligation (inc.

NSLC) detail developed

Demo system made available

System arrangements/ infrastructure developed

(Jan 2010)

SLMS platform goes live

(April 2010)

Compliance matrix goes live

(Oct 2010)

Independent assessments by

Assurance &

LRQA

(Oct-Nov 2010)

MoC closed

Existing arrangements mapped into new system

SLMS monitoring

(metrics) and reporting initiated

Since Nov 2010

Continued effective engagement

Ownership growing

Arrangements being issued to schedule

Enhanced focus on implementation

System arrangements enhanced

What we have gained: a system capable of delivering on the commitments of the management team

• Stronger executive and senior management engagement / support

• Clearer accountability and ownership for SLMS arrangements

• Enhanced collaboration between Process Owners and users

• Better integration of processes - clearer picture of interdependencies

• More opportunity to identify and address gaps and opportunities

• Enhanced visibility of our obligations and how we meet them

• Enhanced responsiveness to regulator and key stakeholder expectations

• Stronger interface with our key stakeholders (e.g. NII, EA, Dft)

• Enhanced confidence in our Management System as “the springboard for continuous improvement across the full scope of

[Sellafield Ltd’s] core and support process.” (LRQA)

More effective focus on our work and increasing ownership by key communities

Category New Arrangements Existing* Benefit

(*includes anticipated withdrawals from SSPs/ SPSWs,

Engineering IMS, Capenhurst and Windscale

Management Systems)

1. Project and

Operations

42 23 54 455

1 3 9 93

574

106

1395

386

2. Operational

Support

3. Managing the

Business

16 12 23 218

5 1 7 41

269

54

721

157

Heightened emphasis on project-based work . Decommissioning and Termination and

Project Execution added

—capturing key work improvement initiatives.

Enhanced operational support . Reflects comprehensive rethinking (e.g., Maintenance and Asset Care); more effectively integrated processes (e.g., Environmental Management)

More effective governance . Clearer representation of decision making and predicates of running Sellafield Ltd.

4. Business and

Administrative

Services

20 7 15 103 145 131 System more reflective of Sellafield Ltd scope of work. Scope expanded (e.g. IT,

Occupational Health and HR) included; arrangements improved / controlled

Enhanced compliance

• Content owned by Process

Owners

• Ready access provided to detail regarding obligations & documents providing compliance

• Clear traceability of compliance with obligations, license conditions, lessons learnt, ISO standards, commitments

• Approach effectively supporting programmes where delivery is distributed

(e.g., environmental, leak protection)

More robust administration of arrangements

• Greater alignment with key initiatives (e,g, Nuclear Safety)

• Guidance / communications issued promoting enhanced quality of arrangements

• Performance closely monitored / widely reported

• Improved ownership / accountability

• Streamlined publication processes

Free release of forms and templates

No signatures required

Process Owners authorised to approve / issue arrangements

• Single, controlled document system

1.1

Need for temporary variation identified

Process Owner / OU / Facility / Function

1.2

Temporary variation and justification evaluated

Process Owner

No

1.3

Direction for continued use of established method communicated

Process Owner

Variation appropriate and justified?

Yes

1.4

Agreement for temporary variation documented

Process Owner / Implementing Organisation

1.5

SLF 4.05.08 completed

Process Owner

1.6

Applicability statement and notation inserted in SLP

Site Document Control

1.7

Watermark added to approved variation document

Site Document Control

1.8

Arrangements posted

Site Document Control

1.9

Compliance Matrix updated

Sellafield Ltd Compliance Manager

... and improved system performance

• >50% reduction in the quantity of documents/quantity of pages

• 86% of SLPs ≤10 pages in length

• 83% reduction in cycle time (from draft to publication)

• >90% feedback/queries resolved within 2 days

• Focus of feedback increasingly on content

• > 8.5 million hits to date on the SLMS home page

• >2,200 users have received face-to-face briefings on SLMS

Phase 4: Staying the Course

As two LRQA and two independent Assurance

Department reviews suggest, we are well on our way to achieving the results we envisioned in Oct 2009

Sellafield Ltd: Working together to promote and deliver safer, more efficient means of conducting business

SLMS endorsed

(Oct 2009)

SLMS platform launched

(April 2010)

Compliance matrix launched

(Oct 2010)

Independent assessments by Assurance

& LRQA

Develop system design

Redesign

(Promoting Awareness)

Implementation

(Creating Change)

Develop system arrangements and inf rastructure

Close

MoC

Map existing arrangements to new system

Metrics and reporting initiated

Align f ocus to business imperatives

Realisation

(Bringing full expertise to bear)

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