Oil and Gas Well workover Operation Analysis Through an Integrated Approach of Lean Manufacturing, Just-in-Time, and Multi Attribute Failure Mode Analysis
Abstract
Workover operations in oil and gas well are the life line of mature well, but with oil and gas price today, the cost-effective operation is the heart of future operation. Offshore well workover is a sequential activity with high equipment, personnel, transportation, and safety constraints. This study examines an ESP change out program well WSU-3HZ performed with Hydraulic Workover Unit (HWU)-225 based on operational data where experienced an increasing on operational cost up to 101,2% and operating days up to 165%. This study aims to develops an operational improvement by integrating Value Stream Mapping (VSM), Just-In-Time (JIT), Just-In-Case (JIC), and Multi Attribute Failure Mode Analysis (MAFMA). Historical time log and lookahead data shows 335.5 hrs completion time, comprising 137.25 hrs of Value Added (VA), 67.75 hrs of Essential Non-Value Added (ENVA), and 130.5 hrs of Non-Value Added (NVA), yielding a Process Cycle Efficiency (PCE) of 40.91%. The root cause analysis by 7 waste tool and fishbone diagram indicates that the largest systemic issue was an unplanned change in work scope without corresponding with logistic readiness, particularly the introduction of CSG scrapper activities after ESP damage was identified. Survey on 36 workers shows stronger acceptance of JIC (HI 5.68) than JIT (HI 4.34), supporting the differentiated logistics policy rather than full JIT implementation. MAFMA-WRI places the unplanned CSG scrapper, weather related problem, Vessel/transportation waiting, equipment preparation, and Slickline related problems among the principal improvement priorities. The proposed future state retains JIC for critical and long lead resources while applying JIT for selected lower critical item. The modelled configuration reduces Leadtime to 241 hrs, raises PCE to 77.7%, and indicates potential savings of approximately USD 225,260. The study therefore supports Hybrid JIT-JIC policy reinforced by pre-job engineering verification, equipment readiness, logistic synchronization, and contingency planning.
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