apwa national 2007 · apwa national 2007 sept 10, 2007 peter v. sevcik,p.e. wvsd and billy wright,...
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APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 1
Peter V. Sevcik, P.E.West Valley Sanitation DistrictDirector of Engineering & Operations
APWA National 2007
Billy WrightLA Consulting, Inc
Keeping Your Pipes Clean!Establishing Routine Collection System Cleaning Cycles Using GIS
Clean when it is needed, group and focus on the most important!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 2
►Agenda
� Establishment of Business Process
� Use of Technology – GIS & MMS
� Establishing Routines
� Results and Summary
Keeping Your Pipes Clean!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 3
In In ““Silicon ValleySilicon Valley”” -- Santa Clara CountySanta Clara County
South of San Francisco and adjacent to South of San Francisco and adjacent to
City of San JoseCity of San Jose
Special District (1948) - Campbell, Los Gatos, Saratoga and Monte Sereno
29 Sq Mi w/ 111,418 customers
632 miles of sewer mains and laterals
36,000 connections
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 4
WVSD Approach
1
5
10
16
Typical Approach
Select
Software
Establish/Change
Process to match
Implement
Processes
1
6
6 - 24
Evaluation
of operations
Establish
Mgt. Process
Implement
Processes
Improve
operations Utilize technology to assist, Utilize technology to assist, not direct, operationsnot direct, operations
Select
Software
Implementing a System Approach to Improve
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 5
Reengineered ProcessWest Valley Sanitation District
► Evaluated needs and selected software that matched – Nov 2002
► Implemented system using best business practices – May 2003
► Developed processes to track work and utilize reports to monitor performance
► Documented improvement
► Developed performance based budget
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 6
COSMO was the existing system
CONCRETECONCRETE
MaterialsMaterials
EquipmentEquipment
PeoplePeople
But . . . Accomplishment information such as LF of sewer line cleaned and LBS of
debris removed by segment was tracked
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 7
Several systems were in place with a series of unlinked manual & Excel files used for many
management processes
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 8
WVSD replaced COSMO & Excel with off the shelf system then linked to CCTV & GIS
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 9
Uses a combination of tools to retrieve data in addition to GBA software
reports
Graphics
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 10
Developed Activity Guidelines
••Describe the Work to Describe the Work to
be Performedbe Performed
••List the Required List the Required
ResourcesResources
••List Work Criteria List Work Criteria
and Considerationsand Considerations
••Indicate the Results Indicate the Results
ExpectedExpected
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 11
Updated ProcessWVSD Best Business Practices
► Eliminated 9 work reporting forms
► One timesheet has replaced 4
► Accountability with Activity Guidelines with best work practices – crew sizes and methods
► Developed work goals with reward for employees based on performance
Use both carrot and stick!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 12
Monthly Planned Versus Actual
Work Report
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 13
Days By Activity – Number of days planned to HVC in month of July
Productivity – Number of units per crew day - feet cleaned per day
Cost – Cost to clean line
Unit Cost – Cost per foot
Performance Measurements Are Available
System now has the ability to compare
planned vs. actual accomplishment
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 14
Impact From Reengineering Processes
More than 60% improvement in first year with additional
improvement in following years!Eliminated Balling and increased more efficient practice of
High Velocity Cleaning.
On to the next level…developing routines!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 15
Use of Technology
GBA – Complete maintenance management system (MMS) used for scheduling and tracking work.
CCTV – Linked to MMS. Used for inspecting debris and severity.
GIS – Linked to MMS. Maps are utilized to display condition data, cleaning schedules, and suggested cleaning routines.
Severity Information From CCTV Stored In GBA.
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 16
Lets look at capabilities used by WVSD
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 17
CCTV files linked to GIS on live basis
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 18
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 19
Reports the System and Provides Work Location Analysis and…
Mainline Cleaning
January 06 to June 06
Graphical Evaluations
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 20
Severity Ratings…
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 21
Overdue Segments…
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 22
Strategic Geographical Grouping…
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 23
What? Why? How?
►Expand cleaning cycles to
geographical zones
►Reduce travel time and increase
efficiency and ability of crews to do more with less
►Utilize technology
Let’s look at how the system was used to develop routines.
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 24
Optimized Cleaning Schedule is Currently Being Implemented!
►Schedule based on amount of debris collected and period since previous cleaning
►Debris rating based on amount removed (pounds) and type (grease, roots, etc.)
►Decision logic being integrated into scheduling logic to optimally determine when to clean a line
►Cleaning cycles will be updated/adjusted based on ratings
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 25
<.75
<1
<3
1
Clear
NA
NA
NA
4 *
Severe
Sand/Gravel
Egg Shells
Grease
Debris Types 5 **
Overflow
3
Medium
2
Mild
NA>=1.5>= .75
NA>=2>= 1
NA>=5>=3
Field Rating Using 5-Gallon Buckets
* Amount recovered during stoppage
**Amount removed during overflow
Common Terminology Must Be Developed
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 26
121224243024-29
61218182418-23
36
36
18
12
6
1
Clear
36
30
12
6
3
2
Mild
5
Overflow
4
Severe
3
Medium
Interval Prior to
Cleaning
18243036+
12183030-35
66612-17
3336-11
333<=5
Maintenance Matrix to Define
Cleaning Cycle
Logic Developed to Optimize Cleaning Frequency
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 27
Extracting Data From MMS
�Prior severity and time elapsed before prior cleaning are entered into maintenance matrix to determine cleaning cycle.
�Consultant performed initial routine scheduling manually.
�Programming logic was developed to automate process.
30 years of work accomplishment and
condition data were used!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 28
Other Assumptions
� Conservative cycles – Used greatest frequency when adjacent lines were on different cycles
� One 2-man crew cleans approx. 25,000 LF per week
� 6-inch lines or smaller must not exceed 24-month cycle
� Fixed routines for “problem lines”(Approx. 3% of network)
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 29
Able to use history as a guide...
Reports Developed In Access
Compare current routines against suggested routines…
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 30
Programming logic suggests optimal cleaning cycle based on time elapsed since prior cleaning and severity of
current condition.
Current Routines Proposed Routines
Red – 3 monthsBrown – 6 monthsOrange – 12 monthsGreen – 18 monthsLight Blue – 24 monthsDark Blue – 30 monthsPurple – 36 months
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 31
Cleaning Interval Before…
And After…
System automatically suggests optimized routines, but allows for user to make final decision
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 32
Let’s see an example…
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 33
Utilize Historical Data
23 months - Mild
22 months - Clear
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 34
Select Conservative Cycle According to Maintenance Matrix
Asset ID Months Since Severity Proposed
5336 23 Mild 185337 22 Clear 24
18 Months
Initial routines were set up manually.
Conservative cycles were chosen when assigning
cycles to adjacent segments.
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 35
Geographic Zones
► Currently developing 24 ‘GeoZones’ to reduce travel and crew setup time, thus reducing costs
► Grouped into balanced quantities (approx. 100K LF)
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 36
Work Load Scheduling
►Mixed scheduling methods to clean entire network within 24 months• 1 crew full-time on routines/zones – one
zone per month
• 1 crew spot cleaning overdue and emergency as needed, then assisting with routines/zones
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 37
24 months
Rou
tine/
Zone
clea
ning
Overdue/E
mergency cleaning
Every 24 months, entire network will be cleaned
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 38
-
50
100
150
200
250
Month
1M
onth 2
Month
3M
onth 4
Month
5M
onth 6
Month
7M
onth 8
Month
9M
onth 1
0M
onth 1
1M
onth 1
2M
onth 1
3M
onth 1
4M
onth 1
5M
onth 1
6M
onth 1
7M
onth 1
8M
onth 1
9M
onth 2
0M
onth 2
1M
onth 2
2M
onth 2
3M
onth 2
4L
F C
lea
ne
d
Routine Repeat Special Overdue
Will be caught up after four months!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 39
Preliminary Results - ProductivityProductivity is measured by the average
quantity of work units accomplished in one day. These graphs compare productivity
of crews who worked in the geographical areas versus crews who performed “spot”
cleaning.
Crews on routine are consistently accomplishing more than the “spot”cleaning crews.
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 40
Preliminary Results – Unit Cost
Unit cost is calculated by dividing the total cost of work by the quantity of work
accomplished. The result is the real cost per work unit for an activity.
A crew comparison from the first few
months of implementing the GeoZoneroutines shows significant savings month
after month.
Grouping and scheduling work
improves productivity and saves money!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 41
We are in the process of implementing…
� Reduced travel and crew setup costs
� Optimized routines for efficient cleaning
frequency
� Less stoppages and overflows as a result of systematic scheduling of preventative maintenance
Expected Results
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 42
Summary of Using Technology
• Linked MMS, CCTV, and GIS
• Utilized GIS to develop “GeoZones”
• 30 years of MMS data used to develop routines
• Provides basis for improvement
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 43
Lessons Learned
• No perfect approach to sewer maintenance
• Preventative maintenance planning can decrease overflows
• Improvement is possible!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 44
Success can occur, but it takesSuccess can occur, but it takes……
TimeInvolvementTraining and GuidanceFlexibility
And it never ends!
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 45
What is left to do?
• Training
• Further GIS and GPS integration
• Risk analysis
• Modification of dynamic selection process
APWA National 2007 Sept 10, 2007
Peter v. Sevcik,P.E. WVSD and Billy Wright, LA Consulting, Inc. 46
Billy WrightLA Consulting, Inc.
(310) [email protected]
Peter V. Sevcik, P.E.West Valley Sanitation District
Director of Engineering & Operations(408) [email protected]
Keeping Your Pipes Clean!Establishing Routine Collection System Cleaning Cycles Using GIS