Abstract
This paper presents an innovative solution to mitigate the risk of unintended lifting clamp selection in Electrical Submersible Pump (ESP) installations by implementing the Poka-Yoke methodology. The potential for accidents in oilfield operations can be grave, so proactive measures must be taken. Through a thorough case study investigating a dropped ESP seal, an integrated approach to safety and quality risk analysis led to the implementation of Poka-Yoke for continuous improvement to minimize risks and improve process reliability. The implementation of a Standard Operating Procedure (SOP) infused with the ingenious Poka-Yoke tool from Lean Manufacturing Methodology was initiated to curtail potential hazards in ESP installations. The following steps were taken: (1) Creation of a Multidisciplinary Team, including those who work directly in the process; (2) Route Cause Analysis and Hazard Assessment; (3) Brainstorming Sessions to fortify ideas and procedures for the detection and eradication of threats using the Poka-Yoke concept; (4) Implementation of a Pilot-Scale Solution; (5) follow-up meetings for Process Revision, (6) Improvement process lead by process revision, and (7) dissemination of knowledge to the entire company through workshops and pre-job meetings. The Poka-Yoke system employs a color code system that matches the lifting clamps with their corresponding ESP equipment. Furthermore, a custom colored-scale caliper was implemented to check the diameters of the equipment and their respective lifting clamps, ensuring that they are correctly matched. The use of visual signals instead of texts in this system greatly simplifies the information conveyed, making it more accessible and understandable to all stakeholders involved in the operation. The article introduces a Lean Manufacturing Methodology concept adapted for service delivery, emphasizing the reduction of operational risks. By utilizing the Poka-Yoke tool to detect and prevent errors, it is possible to enhance the reliability of a process. This is achieved by reducing the probability of errors resulting from human error or other factors, which in turn can minimize the occurrence of defects, rework, and other quality-related concerns that could compromise the process's reliability.
