Manufacturing Quality Surveillance as part of Procurement Control …€¦ · ·...

1 / 21 IAEA TM – Industrial Involvement and Localization for New NPP Construction – Qingdao Aug. 2014

Manufacturing Quality Surveillance as part of Procurement Control Process. EDF experience feedback

J.P. FeyteEDF China Holding


Summary

1. Current nuclear context and Basic Nuclear regulatory background

2. Analysis of Lessons learned

3. Procurement Control: A major challenge for EDF

4. Qualification of Equipment –preservation is a challenge for operator

5. Conclusion


Current nuclear context is characterized by Numerous nuclear New Builds, involving new partners and intelligent customers More complex new build projects framed by increasing level of safety (new international more demanding context after Fukushima)Difficulties encountered with respect to milestones and costsIncreasing requirements for operating fleet meant for better capacity, availability, and extension of operating life span

EDF is convinced thatThe long term competiveness of Nuclear relies on the success of New Build and Life span extension projects against increasing safety requirementsA key factor for the success depends on the "Procurement Control Process" ability to secure Safety, Quality, Lead time and Cost of nuclear projects



The owner/operator, facing increasing demands for quality:

Endorses the ultimate responsibility for the safety (French Nuclear transparency law 2006.06.13) and the first responsibility in case of nuclear accident (Nuclear operator civil liability in Environment Code)

Ensures that following provisions are addressed in it's management system (Nuclear installations French order 2012.02.07):

Identification of the elements and activities important for protection and attached defined requirements (Protection = safety of persons, public health and sanitation, protection of nature and environment), Compliance with the defined requirements and provisions related to technical inspections and verifications (audits); Identification and handling of deviations and significant events; Collection and handling of the operating experience feedback; Definition of the appropriate effectiveness and indicators.



Meanwhile, Technical regulation requires:Legal design and manufacturing conformity assessment of Nuclear pressure equipment (ESPN Order 2005.12.12 for France)

Level 1 directly performed by French Safety Authority (as per technical guide n°8)Level 2 and 3 performed by an authorized nuclear notified body or inspectorate (as per technical guide n°8)

Designers to demonstrate the compliance of the code they use to the essential legal safety and radioprotection requirements for design as well as fabrication (Appendix 1, 2 3 & 4 to ESPN Order 2005.12.12 addressed in RCC-M Appendix ZT, ZU & ZY)



Better evaluation of supplier chain prior to the contract awarding

Ability to manufacture productAbility to apply nuclear codes and standardsAbility to manage NCR (Engineering capabilities)Ability to select and oversee sub-suppliers

New suppliersAttention needed at the early stage of the contract to verify the good understanding and management of code and standards in manufacturing procedures

Historic supplierPreservation of competence to be verified

2. Analysis of Lessons learned from recent new built / Selection of suppliers


RCC-M versus ASME, a different approachRCC-M

State of the art code, continuously introducing the feedback from designers, manufacturers and customers.Few open options

ASMEMore general contentsOwners (designers and/or manufacturers) have to waive options and to add experience-based requirements

2. Analysis of Lessons learned from recent new built / Purchase specifications


Nuclear codes and standards / Contractual technical specifications

Owner needs well trained and qualified personnel toDraft the specifications of the ownerReview the key documents of the contractor and its suppliers

Contractor needs well trained and qualified personnel toUnderstand, challenge and manage the specifications of the ownerWrite the equipment specification and proceduresManage the non-conformities

2. Analysis of Lessons learned from recent new built/ Purchase specifications


Owner’s Inspection processHas to be continuously rebalanced, taking into account events, circumstances and level of confidence in the supplier’s chain

Element and activities important for the preservation of safety

Suppliers find difficult to identify the activities that may have an influence on safety performance of the productOwner must endorse the final definition

Identification of critical manufacturing process help to select documents to be reviewed

Criticality criteria based on safety, quality, schedule and cost impactsAdditional criteria

New specification/New supplier - New manufacturing process - Negative feedback of manufacturing process

2. Analysis of Lessons learned from recent new built / Surveillance & inspection


Partnership is necessary abroadTo be developed abroad through specific associations such as PFCE or PFME French entitiesTo encourage suppliers, giving them visibility, to participate to some project, or to build facilities To share the qualification technical risk

Transparency is a key factor Controls have to be reinforced after a tong period without new built

2. Analysis of Lessons learned from recent new built / Partnership & transparency


3. Procurement Control: A major challenge for EDF"Procurement control project" was set up within EDF in 2010, aiming at:

Fixing a comprehensive approach of the Procurement control equallyinvolving the upstream and the downstream of the project,Better defining and explaining our requirements to the suppliers,Being more cautious and proactive in the selection of the sub-suppliers,Adapting more rapidly our inspection resources depending on the performance of the sub-suppliers,Reporting more efficiently to the project director,Making sure that from the bidding to the release of the product :

Every player is aware of the respective key-roles of the othersInterfaces management is focusing on: Transparency / Simplified communication / More frequent dialogues.


3. Details of Procurement Control upgraded process

It does not cope with:The Regulatory assessment of pressure equipmentThe Surveillance of design activitiesThe qualification of active components under accidental conditions The purchasing strategy

It includesFabrication, pre-assembly and on site erection activities of :

Mechanical & Electromechanical componentsElectrical componentsInstrumentation & Control, SoftwareCivil works activitiesNuclear Fuel

* Including the manufacturing oversight of active components qualified to accident conditions (reference file review & in-shop inspections).


3. Details of Procurement Control upgraded process

11 sub-process are addressed

Surveillance oversight (when subcontracted)

Schedule and lead time oversight

MQSI Management and reporting

NCR Treatment

In-shop & OnsiteOversight & Inspection

Manufacturing Document

Surveillance

SurveillanceMandate

Technical specification

& other contractual

provisions

Evaluationof offers

Evaluation / Qualification of Suppliers1

End of manufacturing and shipping

11

9

8

7

6

5

432 10

Manufacturing Control Process includes

MQS and surveillance of Surveillance


Evaluation / Qualification of Suppliers

Technical specification

& other contractual

provisions

11

1

3 4

5

6

7

9

10

8

2Evaluationof offers

SurveillanceMandate

In-shop & OnsiteOversight & Inspection

End of manufacturing and shipping

DocumentSurveillance

NCR Treatment

Management and reporting

Schedule and lead time oversight

Surveillance oversight (when subcontracted)

Comprehensive approach of existing practices: Evaluation &

validation of industrial organization scheme proposed by bidders prior

to the contract signature Empowerment of a preferred actor for management of NCR

treatment from detection to implementation of the

corrective actions

• A clearly documented interface between "customer-inspection-

contractor-supplier“• An anticipated & well detailed

mandate for surveillance

• Analysis of the possible contractual levers• Identification of their practical implementation• Integration of experience feedback in the technical specifications

CEIDRE defines principles and rules of surveillance

based on experience feedback of all actors

•Supplier and inspector plan Quality control

• Alert in case of delays

A new area for improvement

3. Details of Procurement Control upgraded process / Identified improvements


Non-conformitymanagement

Non-conformitysurveillance(design point of view)

Contract management

Surveillancemandate

Designdocumentationsurveillance

TechnicalSpecifications

Contractualrequirements

Evaluation of the BID

Supplier selection& qualification

Surveillanceoffer

(based onvalidated principle)

Manufacturingdocumentationsurveillance

On-field Inspection(shop & site)

Evaluation of suppliers

Evaluationof industrial

scheme

• Reporting• Non-conformitysurveillance(manuf. Pointof view)• Surveillance feedback

Access into the factory, clear industrial scheme, sub-orders review, schedule,

oversight of sub-contractors, NCR treatment process…

Specific entry point for each project

Adapted offer to the Client expectation,

modularity, expediting, reporting

3. Details of Procurement Control upgraded process / interfaces


3. Details of Procurement Control upgraded process / integration

Non-conformitymanagement

Non-conformitysurveillance(design point of view)

Contract management

Surveillancemandate

Designdocumentationsurveillance

TechnicalSpecifications

Contractualrequirements

Evaluation of the BID

Supplier selection& qualification

Surveillanceoffer

(based onvalidated principles)

Manufacturingdocumentationsurveillance

On-field Inspection(shop & site)

Evaluation of suppliers

Evaluationof industrial

scheme

• Reporting• Non-conformitysurveillance(manuf. Pointof view)• Surveillance feedback

COST (Committee of EDF reference doctrine) Technical OFE,

codes

Industrial sectorknowledge capitalization

EMIB (EDF Manufacturing Inspection Body), Clear mandate

EMIB, rigorous management, OFE implementation

EMIB, tutorial training, competencies, inspectors'

posture, on-field supervision.


4. Qualification of equipment – preservation is a challenge for operator

Qualification of the Equipment

Qualification of the Supplier

Preservation of the qualification

Supplier is able to make mass production of the qualified equipment, can provide qualified spare parts and deals with obsolescence

Equipment satisfies its qualification requirement

Qualification needs to be maintained during manufacturing, erection, andmaintenance for the whole qualified lifetime

Design Input

Safety requirement



DURING MANUFACTURE

Selection of a product-supplier pairing,

Analyses of the impact of changes on qualification , with surveillance of the Reference Files updated by the manufacturers.

ERECTION ON SITE

The Qualification Preservation Sheet indicates the key points for preserving EQ during installation or erection on site. This is particularly important for components assembled on site as electrical connectors. Installation procedures, based on manufacturer specifications, are part of the Reference File.


DURING OPERATION

Application of the Equipment Qualification Preservation File based on Qualification Preservation Sheets,Analysis of operating feed-back from the sites.Extensions potentially needed during the lifetime of qualified equipment

Initial qualification may take into account an assumption about length of life (qualified life) which is lower than the actual planned life of the equipment. Then, an extension of qualification must be achieved, before the lifetime exceeds the qualified life.

On-going qualification may use different methods.



5. Conclusion

Procurement control process is a long term key factor to manage both Safety and Performance of Nuclear Power station

Some events can appear 20 or 30 years after start up

It is necessary to establish long term partnership with key suppliers

New Built project must be based on a sharing of issues and on transparency

=> Procurement control is a pre-requisite to ensure the success of Nuclear industry in the long term


谢谢！Thanks for your attention

Manufacturing Quality Surveillance as part of Procurement Control …€¦ · ·...

Documents

Transcript of Manufacturing Quality Surveillance as part of Procurement Control …€¦ · ·...