Nuclear Power Station

Parts acquisition for replacement parts of a nuclear reactor complex was too slow. Safety and reliability dictated that great care needed to be taken to ensure that replacement parts met the exact specifications of the originals. However, the cumbersome process was increasing the risk of an unplanned shutdown of the reactor at a revenue loss of $1 million every two days.

Over a nine day period the Ben Graham-certified consultant created a detailed map of the parts acquisition process. This map detailed the entire process from the point when an equipment deficiency was noted on the plant floor, and proceeded through engineering, sourcing, vendor quality assurance, ordering, and ultimately receiving. An analysis team made up of a maintenance assessor, shift supervisor, engineering assistant, engineer, VQA specialist, supply planner, and purchasing agent then met for four days around the process maps and developed recommendations for change. Immediately after analysis 21 of 23 recommendations were approved by the Station Manager and his management team.

These recommendations were implemented over a period of several months and the problem was resolved.