Workface Planning

APEGGA Conference

Apr 2007

Jeph Virtue

• 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?

Answer these….

Jeph Virtue Suncor (Chair)

Simon Marshman Flint Maurice D’Aoust Jacobs Catalytic Ltd.Frank DeLuca Bird Construction Ron Embury NOVANiels Frederiksen Jacobs Dan Garon Fluor CanadaDoug Hawkins CLRA Jose Herrero Fluor CanadaGeorge Jergeas UofC Ray Johnson BantrelPreston Noton Hatch Ronald Ramsay BantrelLloyd Rankin UofC Randy Regan SuncorRaymond Rewcastle Bantrel Brian Roy Brand ScaffoldGeoff Ryan Jacobs Gary Semaniuk StantecPat Synnott Jacobs Catalytic Ltd.Celina O’Neill SuncorJohn Vincent Colt Bill Luxton SAIT

Committee Members

Alberta Building Trades CouncilBantrelBantrel ConstructorsBird ConstructionChristian Labour Association of CanadaConstruction Labour Relations – AlbertaShell Canada LimitedSuncor Energy Inc.TransCanada PipelinesCOAA MembersFluor CanadaLedcor Group

Sponsors

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 PrizeSize of the Prize

Tool Time37%

WaitTime15%

Tool Time47%

WaitTime~5%

• 10% more tool time is a 25% improvement in productivity• Safety, morale and predictability improvements

One Bite at a Time

Workface planning will not solve all productivity issues … but it’s a good start

Rework

Workface Planning Bench

marking

Supervisory Skills

Absenteeism

Supervisor Mentoring

Workface Planning Works!

Thesis Extract: Conclusion“There is sufficient evidence to conclude that workface planning, as developed by the COAA steering committee, contributes to higher project performance.”

Same: OwnerEPCMPlant TypeSizeTime period

Project A Project B

Workface Planning from startWorkface Planning added later

~25 to 30% better productionBehind schedule On Plan

Owner Commitment

Dedicated Planner

“Release the Work”

Field Installation Work Package

1 day to 4 weeks of defined scope.

MaterialsToolsEquipmentTrades/SpecialistsDetailed PlanDrawingsVendor Info.Safety RequirementsSupervisor Review

“Plan the Work”

Materials & Equipment Coordinators

Pre

req

uis

ites

Supervisor

“Work the Plan”

Tools

Team

Scope

Ready√

37%

Tool Time Improvement

Workface Planning

47%

A Supervisor’s DayA Supervisor’s Day

On-site Travel

Safety

Paperwork

Initiatives

QA/QC

Supervision 15%

Planning

Meetings

+

+

++ +

+

-

-

Not enough direct supervision. Planning suffers when busy.

always grows

gets squeezed

+

-

Construction Mgr

General Foreman

Superintendent

Foreman

Foreman

Foreman

Foreman

Foreman

Crew

Crew

Crew

Crew

Crew

Workthe Plan

Plan the

Work

Dedicated Planner

Plan The Work

Construction Mgr

General Foreman

Superintendent

Foreman

Foreman

Foreman

Foreman

Foreman

Crew

Crew

Crew

Crew

Crew

Workthe Plan

Performance Improvement

#1: Appoint Dedicated Planners

Workface Planning Rules

?Why do we do this?

Project Size

% Planning

#2: Planner completes Field Installation Work Package (FIWP) and releases when ready

Workface Planning Rules

Field Installation Work Package

MaterialsToolsEquipmentTrades/SpecialistsDetailed PlanDrawingsVendor Info.Safety RequirementsSupervisor Review

#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

Workface Planning Rules

3) Identify Construction Work Packages (CWP) and CWP Release Plan

Considerations• Start-up Sequence• Manhours• Congestion• Access

• Levels• Complexity• Equipment Delivery• Time to complete

#10: Write requirement for Workface Planning into contracts

Workface Planning Rules

#11: Audit to ensure rules are being followed

Workface Planning Rules

Prerequisites - Owner

• Executive declaration: “Use COAA Workface Planning!”

• Appoint Workface Planning Sponsor and Champion

• 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

• 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

DB

ME

DS

EP

C

Construction Management• Commit to Workface Planning

• Make it happen (all phases)

• 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

• 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

DB

ME

DS

EP

C

Construction Contractors

• 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

• 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

DB

ME

DS

EP

C

Prerequisites - Engineer

• Commit to Workface Planning

• Incorporate Workface Planning into Stds, Procedures and Job Instructions

• Establish Work Breakdown Structure

• Develop Path of Engineering – 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

DB

ME

DS

EP

C

• 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

Training

• www.coaa.ab.ca• COAA Conference: May 15 eve, May 16

• Thankyou

More Info