The Reliability of the Power Generators - Six Sigma Process - Management Assignment Help

Assignment Task:

The purpose of this technical paper is to share the plans which were carried out to enhance the reliability of the power generators through using six sigma process. 

If six sigma is not used, this technical paper will be rejected. 

Summary:

We have power generators serving our operating scattered facilities which are the backbone since they are the primary power supply to the gas processing facilities and associated wellheads. Facilities are scattered around within a distance of 200 km the farthest and 70 Km the nearest skid road travelling. 

We have 5 running facilities: A, B1, B2, B3, and B4 with a total number of 10 main generators and 5 Emergency Diesel generators. 

Facility A: 1 Gas generator (Prime), 1 Dual Fuel generator (Standby), and 1 emergency diesel generator 

Facilities B1, B2, B3, and B4: each facility has 2 gas generators (1 prime and 1 standby) plus 1 emergency diesel generator at each. 

Plan we have come up to enhance reliability of the power generators are as follows: 

• Formed power team to ensure reliability of the generators and assigned to them dedicated tasks. 

• Team 

• We have employed generator specialist with 15+ years of experience hands on tools – senior technician 

• Enforcing weekly visual inspection for all ( Monday to visit facility A, Tuesday to visit facility B1 & B3, Wednesday to visit facility B2 & B4) 

• Created facility specific PM procedure to be used during the weekly visual inspection 

• Report to be submitted daily for every visited area 

• Comprehensive checklists (one for electrical system operator, and one for mechanical team) to be submitted every Wednesday end of working hours 

• Hired contract services from same generator vendor – to be called as needed. 

• Built an inventory for all of the emergency and critical spares.

• Built an inventory of all consumables materials which are required for planned maintenance. 

• Purchased all required special tools dedicated to the type of engine. 

• Conducting scheduled preventive maintenance plans for all generators 

• Weekly test run for all emergency diesel generators 

• Bi-weekly test run for all standby generators. 

• Immediate response during power interruption caused by any of the generators. 

• Developed generator trip register to log all alarms/codes which trips the generator. 

• Developed excel sheet for generator lube oil analysis & Preventive Maintenance history to keep track and be accessible for the technical support team to review and direct as needed. 

• Assigned a log book for each generator to be placed inside each generator enclosure to log the daily/weekly activities as well as involved personnel. 

• Established communication with mechanical technical support team to be part of the reviews for the daily reports and weekly updates. 

• Quality assurance audits/ inspection by dedicated technical support team every two months for all of the above points which includes site visits, checklist auditing, and engine healthiness checks. 

• Management to randomly conduct generators check bi-weekly

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