1. Schlumberger Private Packer testing & knowledge capture Nicolas Garnier Six Sigma Black Belt

2. Schlumberger Private Pg 1 NG Define DMAI C

3. Schlumberger Private Pg 2 NG Problem statement The demand for NPD and RR Packer projects has been increasing and the task force knowledge not always captured. It is important to keep and share knowledge of what works and what doesn't in an accessible, searchable form. DMAI C

4. Schlumberger Private Pg 3 NG Project Objectives  Reduce number of tests per qualified product by 15% by end of 2004  Capture knowledge within the Packers group. Between sizes, product lines, materials…(for 10K packers)  Implement metrics, to measure group’s baseline and measure improvement. DMAI C

5. Schlumberger Private Pg 4 NG Benefits Decrease the number of test iterations Decrease testing time & cost Decrease packer development cycle time and cost Finding all necessary information in the same place DMAI C

6. Schlumberger Private Pg 5 NG Project Metrics Number of tests per qualified packer Number of tests captured in Database DMAI C

7. Schlumberger Private Pg 6 NG Defect definition 1. Database not operational by end of May Alpha version by 05/05/04 2. Number of tests per qualified packer > Baseline- 15% DMAI C

8. Schlumberger Private Pg 7 NG Project Team Sponsor : –Dan Torbett Process Owners: –Diana Orzechowski –J.D. Hendrickson –Karen Grosser Process Personnel –Reggie Francis –Tom Christensen (EQ) Black Belt: –Nicolas Garnier IT: –Tom Stevenson (c) –John Howard (i) Finance: –Fernan Carpio DMAI C

9. Schlumberger Private Pg 8 NG Action Items  Measure number of tests per qualified product for 2003 to establish a Baseline  Creation of a database to  Capture knowledge (design and testing parameters)  Facilitate test iterations and reports  Generate Metrics on Packers testing DMAI C

10. Schlumberger Private Pg 9 NG Measure DMAI C

11. Schlumberger Private Pg 10 NG Baseline data 2003 Number of tests per qualified product: 16.0 399 tests for 25 qualified packers Source: EQ, Process owners Goal: tests/qualified Packer < 13.6 DMAI C

12. Schlumberger Private Pg 11 NG Baseline graph 2003 Averages per product line DMAI C Goa l ’03 mean

13. Schlumberger Private Pg 12 NG Process Maps (1/2) DMAI C

14. Schlumberger Private Pg 13 NG Process Maps (2/2) DMAI C

15. Schlumberger Private Pg 14 NG Analyze DMAI C

16. Schlumberger Private Pg 15 NG Root Causes  Documentation Iterations info personally stocked Documentation completed for each test after series With current Process, Database will be used after the facts.  Test Results Binary Test Result: Pass/Fail: no intermediate measure Test results are not sufficient to establish a mathematical model  Criteria establishment Design step: element testing to packer testing, based on exp. Criteria: High/Low “confidence”  Cycle Time No cycle time measurement (development time for an element?) BDM impose development time w/o documented Baseline DMAI C

17. Schlumberger Private Pg 16 NG Improve DMAI C

18. Schlumberger Private Pg 17 NG Proposed Solutions Database MUST be used during the testing phase. Standardize test results: –Tests classification (Element, Packer, Additional) –Need figures to differentiate 2 failed tests Checklists!  Number of successful reversals passed If leak: %, #of bubbles… Failure cause captured: leak, design, equipment, manipulation error… Establish standard criteria Easy Search Results Available Metrics DMAI C

19. Schlumberger Private Pg 18 NG Requirements document Initial Data Entry Packer GeMS Number, rev Test Iteration Number Element Stack GeMS Number, rev Test type: [Element; Packer], Test Date ET number, Test Report GeMS number: Person Responsible for test: Packer Parameters: Packer Type: [QL; QMax; XHP; QMP; XMP; MRP] Casing Size, ID, Weight Range: Max. Mandrel OD, Max. Gauge Ring OD QCP Number Element Type: [garter spring backup; fold back ring backup; expandable ring backup; other] DMAI C Test Parameters: Test Fixture GeMS Number, rev, Serial # Test Fixture Mandrel type Test Type: [V4; V3; V0; experimental] Test Medium Test Temp, Pressure Setting Force, Method of Setting Max. force delivered to Element Test Results: Test Result & Observations Element Failure mode {Help available w/ pictures} Passed ISO? Comments Attachments

20. Schlumberger Private Pg 19 NG Implement Solutions DMAI C

21. Schlumberger Private Pg 20 NG Control DMAI C Control

22. Schlumberger Private Pg 21 NG New Process Test info to be entered after each test Search to be done before each new design Process Owners (Managers) to control the process. Monthly Check between EQ (Tom Christensen) and Database Administrator (Karen Grosser) DMAI C

23. Schlumberger Private Pg 22 NG ROI (1)-Cost Avoidance DMAI C 200 3 H1- 2004 Est. 2004 # Tests39968? # Packer Qualified 25720 #Tests per Qualified Packer 16. 0 9.7 Test Plan (10% of tests) –Engineering time (2h) Test Avoidance (1% of tests, 3d/test ) –Engineering time ($2,520/test) –EQ time ($7,200/test) –Material ($4,000/test) Tests Efficiency (10% impact from database) –[10%]*[$Test avoidance] *[#tests not done(6.3*20)]

24. Schlumberger Private Pg 23 NG ROI (2) - Costs Database Programing ($12k) Uploading data ($5k) –2months-Intern Project Support (BB) ($0) –Free in 2004 Engineering Team time (meeting) –5 meetings of 2h * 10p DMAI C

25. Schlumberger Private Pg 24 NG ROI (3) – Total savings H1-2004: $ 104k Est.2004: $ 215k 200 3 H1- 2004 Est. 2004 # Tests39968? # Packer Qualified 25720 #Tests per Qualified Packer 16. 0 9.7 DMAI C

26. Schlumberger Private Pg 25 NG Conclusion Database = base of knowledge Link to TEAMS? Characterizing design parameters –Project Objective: Identify the influential parameters of the 7IN HNBR Element Fold Back package / Q4-2004 –Design Guidelines –Best Practices –Benefits –Reduce number of tests –Reduce costs –Establish model / guidelines –Base for future design / FEA –Design Of Experiments Expand methodology to other packers (material / sizes) DMAI C