ML20235D848
| ML20235D848 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 12/03/1987 |
| From: | Russell J TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML082340470 | List:
|
| References | |
| 71100, 71100-V07-R04, 71100-V7-R4, NUDOCS 8902210065 | |
| Download: ML20235D848 (41) | |
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EMPLOYEE 1
CONCERNS SPECIAL PROGRAM VOLUME 7 MANAGEMENT AND PERSONNEL CATEGORY SUBCATEGORY REPORT 71100 MATERIALS UPDATED 6
TVA NUCLEAR POWER
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T7A EMPLOYEE CCNCERNS' REPORT NUMBER:
71100 SPECIAL PROGRAM REPORT TYPE: Management and Personnal Subcategory REVISION NUMBER: 4
'fITLE: Materials PAGE 1 0F 14
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Incorporation of editorial cotments.
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'SRP Secretary's signature denotes SRP concurrences are in files.
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MATERIALS Subcategory Report 71100 Executive Summary This subcategory includes 70 employee concerns which raised 6 issues. These lasues include contentions that materials are wasted through misuse or i
underuse, that materials often are unavailable at the time and place they are needed, and that buying materials from foreign countries was both unpatriotic and resulted in inferior materials that could not be used.
The evaluation found problems with the materials storage and disposition practices of TVA construction groups, especially at the Watts Bar Nuclear (WBN) site. Large amounts of waste and surplus materials are stored in aurillary storage areas without being documented and therefore without accountability. TheJe materials may be used piecemeal, or they may be ignored and eventually solu as scrap or surplus. On the other hand, materials availability wsa not found to be a problem, nor was any evidence found to support the contentions regarding the purchase of foreign materials.
The procedures and policies in use for identification and management of surplus materials and for management and use of auxiliary storage sesas are generally adequate from a materials availability point of tiaw. However, they do not constitute a complete materials management and control system. The D! vision of Nuclear Construction (DNC) uses five different materials secounting or man 4sement systems, none of which is computerized. These manual systems, although adequate to support construction goals thus far, are inharently inefficient.
There are no written, definitive program criteria or guidelines in place to govern inventory control, storage, and disposition of surplus or waste materials. DNC's lack of procedeces for disposition of surplus materials and for use and management of auxiliury storage areau caused unnecessary materials waste.
DNC will revise WBN-SOP 32, " Administrative Control of Material," to incorporate the requirement to return unused and surplus materials to warehouse stock. The newly formed corporate Materials and Procurement Services Staff (part of the ONP Planning and Financial Staff) has been assigned responsibility for direction and oversight of all materials matters, including disposition of excess materials.
39477 Page 1 of 1
f TVA EMPLOYEE CONCERNS REPORT NUMBER: 71100 SPECIAL PROGRAM FRONT KATTER REY: 3 PAGE i 0F vili Preface y
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This subcategory report is one of a series of reports prepared for the Employee Concerns Special Program (ECSP) of the Tennessee Valley Authority (TVA). The ECSP and the organization which carried out the program, the Employee Concerns Task Group (ECTG), were established by TVA's Managor of Nuclear Power to evaluate and report on those Office of Nuclear Power (ONP) employee concerns filed before February 1, 1986. Concerns filed after that l
date are handled by the ongoing ONP Employee Concerns Program (ECP).
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i The ECSP addressed over 5800 employee concerns.
Each of the concerns was a formal, written description of a circumstance or circumstances that an employee thought was unsafe, unjust, inefficient, or inappropriate. The mission of the Employee Concerns Special Program was to thoroughly investigate all issues presented in the concerns and to report the results of those investigations in a form accessible to ONP employees, the NRC, and the general pubile. The results of these investigations are communicated by four levels of ECSP reports: element, subcategory, category, and final.
Element reports, the lowest reporting level, will be published only for those concerns directly affecting the restart of Sequoyah Nuclear Plant's reactor unit 2.
An element consists of one or more closely related issues. An issue is a potential problem identified by ECTG during the l
evaluation process as having been raised in one or more concerns. For i
efficient handling, what appeared to be similar concerns were grouped into elements early in the program, but issue definitions emerged f rom the evaluatien process itself. Consequently, some elements did include only one issue, but often the ECTG evaluation found more than one issue per element.
Subcategory reports summarize the evaluation of a number of elements.
However, the subcategory report does more than collect element level evaluations. The subcategory level overview of element findings leads to an integration of information that cannot take place at the element level.
This integration of information reveals the extent to which problems overlap more than one element and will therefore require corrective action for underlying causes not fully apparent at the element level.
To make the subcategory reports easier to understand, three items have been placed at the front of each report: a preface, a glossary of the terminology unique to ECSP reports, and a list of acronyms.
Additionally, at the end of each subcategory report will be a Subcategory Summary Table that includes the concern numbers; identifies other subcategories that share a concern; designates nuclear safety-related, safety significant, or non-safety related concerns; designates generic applicability; and briefly states each concern.
Either the Subcategory Summary Table or another. attachment or a combination of the two will enable the reader to find the report section or sections in whit;. che inau. celsed by the concern is evaluated.
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TVA EMPLOYEE CONCERNS REPORT NUMBER: 71100 SPECIAL PROGRAM FRONT MATTER REV: 2 PAGE 11 0F vili The subcategories are themasives sununarized in a series of eight category reports. Each category report reviews the major findings and collective i
significance of the subcategory reports in one of the following areas:
management and personnel relations industrial safety construction I
i material control operations l
quality assurance /guality control welding engineering A separate report on employee concerns dealing with specific contentions of intimidation, harassment, and wrongdoing will be released by the TVA Office l
of the Inspector General.
Just as the subcategory reports integrate the information collected at the I
element level, the category reports integrate the information assembled in i
all the subcategory reports within the category, addressing particularly j
the underlying causes of those problems that run across more than one i
subcategory.
A final report will integrate and assess the information collected by all of the lower level reports prepared for the ECSP, including the Inspector 1
General's report.
For more detail on the methods by which ECTG employee concerns were evaluated and reported, consult the Tennessee Valley Authority Employee Concerns Task Group Program Manual. The Manual spells out the program's objectives, scope, organization, and responsibilities. It also specifies the procedures that were followed in the investigation, reporting, and closecut of the issues raised by employee concerns.
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l TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM i
FRONT MATTER REY: 2 PAGE 111 0F vili ECSP GLOSSARY OF REPORT TERMS
- classifiestion of evaluated issues the evaluation of an issue leads to one of the following determinations:
Class A: Issue cannot be verified as factual Class B: Issue is factually accurate, but what is described is not a problem (i.e., not a condition requiring corrective action) l Class C: Issue is factual and identifies a problem, but corrective action I
for the problem was initiated before the evaluation of the issue l
was undertaken l
Class D: Issue is factual and presents a problem for which corrective action has been, or is being, taken as a result of an evaluation Class E: A problem, requiring corrective action, which was not identified by an employee concern, but was revealed during the ECTG evaluation of an issue raised by an employee concern.
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collective significance an analysis which determines the importance and consequences of the findings in a particular ECSP report by putting those findings in the proper perspective.
concern (see " employee concern")
1 corrective action steps taken to fix specific deficiencies or discrepancies revealed by a negative finding and, when necessary, to correct causes in order to prevent recurrence.
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eriterion (plural: criteria) a basis for defining a performance, behavior, or quality which ONP imposes on itself (see also " requirement").
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element or element report an optional level of ECSP report, below the subcategory level, that deals with one or more issues.
employee concern a formal, written description of a circumstance or circumstances that an employee thinks unsafe, unjust, inefficient or inappropriate; usually documented on a K-form or a form equivalent to the K-form.
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TVA EMPLOYEE CONCERNS REPORT NUMBER: 71100
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SPECIAL PROGRAM FRONT MATTER REV:
2 PAGE iv 0F vill evaluator (s) the individual (s) assigned the responsibility to assess a specific grouping of employee concerns, findinas includes both statements of fact and the judgments made about those facts during the evaluation process; negative findings require corrective action.
issue a potential problem, as interpreted by.the ECTG during the evaluation process, raised in one or more concerns.
K-form (see " employee concern")
rea0irement a standard of performance, behavior, or quality on which an evaluation judgment or decision may be based.
root cause the underlying reason for a problem.
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- Terms essential to the program but which require detailed definition have been defined in the ECTG Procedure Manual (e.g., generic, specific, nuclear safety-related, unreviewed safety-significant question).
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TYA RMPLOYEE CONCERNS REPORT NUMBER: 71100 SPECIAL PROGRAM FRONT MATTER REY:
2 PAGE v 0F viii 1
Acronyms j
l AI Administrative Instructic j
AISC American Institute of Steel Construction 1
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ALARA As Low As Reasonably Achievable q
ANS American Nuclear Society i
l ANSI American National Standards Institute p
I ASME American Society of Mechanical Engineers ASTM
&nerican Society for Testing and Materials
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AWS American Welding Society BFN Browns Ferry Nuclear Plant BLN Bellefonte Nuclear Plant CAQ Condition Adverse to Quality i
CAR Corrective Action Report 1
CATD Corrective Action Tracking Document CCTS Corporate Consultment Tracking System CEG-H Category Evaluation Group Head
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CFR Code of Federal Regulations CI Concerned Individual CMTR Certified Material Test Report
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COC Certificate of Conformance/ Compliance DC2 Design Change Request DNC Division of Nuclear Construction (see also NU CON) 5 4
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TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 I
SPECIAL PROGRAM
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FRONT MATTER REY: 2 i
PAGE vi 0F vill DNE Division of Nuclear Engineering DNQA Division of Nuclear Quality Assurance DNT Division of Nuclear Training DOE Department of Energy-DP0 Division Personnel Officer DR Discrepancy Report or Deviation Report ECN Engineering Change Notice ECP Employee Concerns Program ECP-SR Employee Concerns Program-Site Representative ECSP Employee Concerns Special Program ECTG Employee Concerns Task Group EEOC Equal Employment Opportunity Commission EQ Environmental Qualification EMRT Emergency Medical Response Team EN DES Engineering Design ERT Employee Response Team or Emergency Response Team FCR Field Change Request FSAR Final Safety Analysis Report FY Fiscal Yeae GET General Employee Training HCI Hazard Control Instruction tiVAC Heating Ventilating. Air Conditioning II Installation Instruction INPO Institute of Nuclear Power Operations IRN Inspection Rejection Notice
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71100 SPECIAL PROGRAN FRONT MATTER REY: 2 PAGE vil 0F vili L/R Labor Relations Staff c
M&AI Modifications and Additions Instruction MI Maintenance Instruction I
MSPB Merit Systems Protection Board MT Magnetic Particle Testing i
NCR Nonconforming Condition Report NDE Nondestructive Examination NPP Nuclear Performance Plan i
NPS Non-plant Specific or Nuclear Procedures System l
NQAM Nuclear Quality Assurance Manual 1
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NRC Nuclear Regulatory Commission j
f NSB Nuclear Services Branch NSRS Nuclear Safety Review Staff NU CON Division of Nuclear Construction (obsolete abbreviation, see DNC)
NUMARC Nuclear Utility Management and Resources Committee OSHA Occupational Safety and Health Administration (or Act)
ONP Office of Nuclear Power I~
OWCP Office of Workers Compensation Program I
PHR Personal History Record
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4 PT Liould Penetrant Testing l
QA Quality Assurance QAP Quality Assurance. Procedures QC Quality Control QCI Quality Control Instruction f
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I TVA EMPLOYER CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM FRONT MATTER REY: 2 PAGE vili 0F vill
- i QCP Quality Control Procedure QTC Quality Technology Company RIF Reduction in Force RT Radiographic Testing SQN Sequoyah Nuclear Plant SI Surveillance Instruction SOP Standard Operating Procedure SRP Senior Review Panel SWEC Stone and Webster Engineering Corporation f
TAS Technical Assistance Staff 1
T&L Trades and Labor j
TVA Tennessee Valley Authority TVTLC Tennessee Valley Trades and Labor Council UT Ultrasonic Testing VT Visual Testing WBECSP Watts Bar Employee Concern Special Program l
WBN Watts Bar Nuclear Plant
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WR Work Request or Work Rules j
WP Workplans J
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-v TVA EMPLOYEE CONCERNS REPORT NUMBER: 71100 SPECIAL PROGRAM REVISION NUMBER: 4 PAGE 2 0F 14
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1.0 CHARACTERIZATION OF ISSUES This report addresses six issues raised by 70 employee concerns in the Materials Subcategory of the Management and Personnel Category. The issues are grouped into three elements and cover a time span from 19?7 through 1986.
1.1 Materials Waste I
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Issue 71101 - Material Is Misused or Underused This issue was raised by concerns about the weste of materials found I
f onsite but not used for their intended purpose. It also addresses material and equipment which can be used more than once but for various reasons was used only once or not used at all. This issue accounts for 68 percent of the concerns addressed by this report.
1.2 Materials Aval1 ability i
Issue 71102 - Material Is Not Available When Needed This issue was raised by concerns about materials needed for general or specific use on the Watts Bar Nuclear Plant (WBN) Construction project, which, for various reasons, are not onsite when needed or cannot be found.
1.3 Miscellaneous Materials Issues Issue 71103 - Improper To Buy Foreign Materials I
Two Concerned Individuals (CIs) objected to the fact that TVA had an inspection office in Switzerland and bought foreign materials instead of only U.S. products.
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Issue 71104 - Accepting Low Bid Creates Waste l'
The CI contends that accepting the lowest bidder results in poor i
quality material and waste.
Issue 71105 - Purchasing Process Is Inefficient The CI contends that TVA's purchasing process at Watts Bar is not efficient, cost effective, or schedule sensitive.
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71100 SPECIAL PROGRAM
' REVISION NUMBER: 4 PAGE.3 0F 14 Issue 71106 - Stocking and Material Delivery are Inefficient j
Two CIs contend that Power Stores' Auto-stocking System-is not I
reliable due to inadequate stocks and slow delivery.
To locate the issue in which a particular concern is evaluated, consult the following attachments'
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Attachment A. Subcategory Summary Table Attachment B. List of :oncerns by Issue All Management and Personnel Category concerns having a technical component (including all concerns designated Nuclear Safety-related) are shared with the appropriate technical category for investigation and resolution of that technical component. Report (s) sharing a concern with this report are identified'in the entry for that concern on Attachment A.
2.0
SUMMARY
l 2.1 Summary of Issues t
The issues in this subcategory relate primary to perceived waste of materials through misuse or underuse and lack of availability of materials at the time and place they are needed.
2.2 Summary of Evaluation Process The evaluator has reviewed all the information available on the concerns in this subcategory. The information pertinent'to the evaluation of the issues has been considered and incorporated in this report.
TVA and site-specific instructions on the handling of material waste j
were reviewed for adequacy during this evaluation. Several i
subcategory reports produced by the Material Control Category Evaluation Group were also examined.. Numerous. scrap and auxiliary storage areas were visited, and personnel responsible for those areas were interviewed.
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2.3 Summary of Findings No instances of violations or failures to ituplement established Quality Assurance (QA) or non-QA material waste or availability policies and procedures were identified by this evaluation.
I However, such violations were discovered and reported in Material l
Control Task Group's Subcategory Report 4-'3, Installation. That report should be consulted by anyone interested in further l
information.
.i The primary problems identified by this evaluation of the materials waste issue were with the storage and disposition practices of TVA i
construction divisions, especially at the WBN site. Large amounts l
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of waste materials at WBN are stored and disposed of by means j
outside the established policies and procedures that govern the j
accountability and management of the Warehouse Services Unit. These j
problems develop because of the need to use auxilia.ry storage areas (staging) or because of design changes.
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No written policies or procedures establishing adequate guidelines i
for the management of waste materials were identified within TVA.
Such materiale historically are used piecemeal, or they are ignored and eventually sent to scrap areas and surplus property areas for l
sale outside TVA.
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In many cases, such handling of materials for large construction i
I projects at TVA, although undocumented, may be the most efficient
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and cost-effective method of doing business. Nevertheless, without I
established, documented guidelines, such practices have been, and will continue to be, perceived as an unnecessary waste of resources i
by individuals who are not aware of upper management's need to l
balance total project cost against construction schedules and goals.
I The primary problems identified by the evaluation of the materials availability issue were that the Division of Nuclear Construction j
(DNC) uses five different Materials Accounting / Management Systems, j
l none of which is computerized. These manual systems greatly reduce the efficiency of handling materials, particularly for job planning, usage history, reserve stock, establishment of adequate reorder points and quantities, duplication of items, and conununications with potential user / supplier organizations onsite, as well as throughout TVA.
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TVA EMPLOYEE CONCERNS REPORT TJMBER:
71100 SPECIAL PROGRAM RP. VISION NUMBER: 4 PAGE 5 0F 14 Substantial management and engineering attention has been focused on
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procureu nt policies and procedures, but no evidence of management review or evaluation of the adequacy of present materikis management systems could be identified.
2.4 Sjunusary of Collective Significance The procedures and policies in use for identification and management of surplus materials and for management and use of auxiliary storage areas are generally adequate, but they do not constitute a complete
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materials management and control program.
2.5 Sununary of Causes DNC's lack of procedures for governing all phases of surplus materials management and for effective use of auxiliary storage
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areas caused the negative findings of this evaluation.
2.6 Summary of Corrective Action I
DNC will revise WBN-SOP 32. " Administrative Control of Material," to incorporate the requirement that unused and surpfus material be returned to warehouse stock. Additionally, the newly formed Materials and Procurement Service Staff has been assigned direction and oversight responsibility for all materials matters.
3.0 EVALUATION PROCESS 3.1 General Methodology The evaluation of this subcategory was conducted in accordance with the Employee Concerns Task Group (ECTG) Evaluation Plan and the evaluation plan for the Management and Personnel Category. The concern files were reviewed and issues were identified. Source documents were researched and interviews ware conducted to determine the applicable requirements or criteria. The issues were judged against the requirements or criteria. The findings were analyzed for their collective significance. Causes for negative findings were identified, as were the responsible organizations. Corrective action plans were developed and implemented for the negative findings.
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u TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM REVISION NUMBER: 4 PAGE 6 0F 14 l
r 3.2 Specific Methodology I
TVA and specific construction procedures and policies which addressed materials management and control programs were reviewed.
Nine persons were interviewed for this evaluation. These interviews i
included individuals both directly and indirectly involved in
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various phases of materials management and control from warehousing, to engineering, to users. These interviews also included present and former DNC employees not currently onsite at WBN. Numerous r
j materials storage areas were visited. These included the Warehouse Services Unit storage area, the new scrap yard, the primary " bone yard," and various craft "laydown" and staging areas et WBN.
Reports generated by evaluators in the Materials Control Category Evaluation Group of the WBN ECTG were reviewed, as well as surplus property sales reports from WBN covering the period from 1982 through the present. TVA line management responses to individual concerns were reviewed and found to be consistent with the conclusions of this evaluation.
4.0 FINDINGS 4.1 Materials Waste Issue 71101 - Material is Misused or Underused Discussion Substantial amounts of usable (in some cases new and unused) materials were found in scrap yards throughout WBN. DNC, because of prior employee concerns dealing with QA, is in the process of establishing an access-controlled scrap yard and of providing a 3
minimal amount of material sorting, in hopes of using some of these t.
items. However, while this process is a very positive step, the following weaknesses must be addressed:
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A.
There are no written or definitive program criteria, guidelines or controls in place to establish an efficient or cost-effective method of determining when or if an item should be placed in a scrap storage area as opposed to being returned to stock in the Varehouse Services Unit. Further investigation revealed that no organization could be identified within TVA which had a documented program of this nature.
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4 TVA EMPLOYEE CONCERNS REPORT NUMBER:
71300 SPECIAL PROGEAN REVISION NUMBER: 4 PAGE 7 0F 14 B.
There are no manual or automated data processing (ADP) listings of. items and equipment' stored in scrap yards. Such listings would expedite or promote use of these materials and could.
limit the types or quantities of materials kept in scrap yards.
The WBN Construction organization does have a verbal policy which encourages Construction Engineering Section personnel, st'-
their. discretion and when time allows, to visually review these items before procuring new materials.. Again, while this is a very positive step, it is severely limited in scope and effectiveness because of the lack of materials listings and because personnel have to rely solely upon visually spotting one item among several thousands. Further investigation revealed i
that other TVA organizations usually have in effect.the same I
l C.
No written or definitive program criteria, guidelines or controls could be identified establishing a method of determining (1) when materials can no longer be used at WBN,.(2) i when they should therefore be made available to other TVA i
organizations for use, or'(3) when they should be sold to an i
organization outside of TVA. These decisions are usually made l
by representatives from the warehouse. Engineering, and various other DNC personnel, and are typically prompted by lack of space or a site cleanup effort rather'than by actual future needs or the usability of materials. Only in.a very limited number of identified cases have supposed surplus or scrap materials ever had to be replaced for' support of the Construction project after-being transferred to other sites or sold outside'of TVA.
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Substantial amounts of. general and specific'use materials were found l
in auxiliary storage areas throughout WBN. These stored materials are beyond the control of the Warehouse Services Unit in laydown areas, jig rooms, gang boxes, staging areas, and bone yards.
1 There are no written, definitive program criteria, guidelines, or l
controls in place to adequately establish responsibility reporting, j
monetary accounting, inventory control, multiple use of materials, l
or identification of surplus materials.
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i While it is a desirable and cost-effective practice to " stage" i
materials and equipment as close as possible to the work area, the i
I following problems must be addressed
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TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM REVISION NUMBER: 4 I
PAGE 8 0F 14 i~
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Responsibility Reportina--The individual craft foreman, or the r-DNC engineer over the foreman's tasks, is accountable for the l
materials and for the storage areas used by the foreman's crew or system. Upon reassignment or termination of the accountable person, particularly if it is a foreman, the general use items in storage are usually not addressed but rather are ignored, moved in mass to a bone or scrap yard, or are pilferad by other personnel as needed.
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Monetary Accounting--Leftover materials have been charged out to specific jobs or systems and are theoretically consumed completely by that job or system. Currently, it is not considered cost effective in most cases to provide detailed i
account-tracking of the items not used, or those that can be reused.
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Inventerv Control--Little or no effort is currently expended to maintain accurate listings, identifications, or assurances of the integrity of non-QA natorials.
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Multiple or General Use Materials--Since these items are no longer visible by accounting or inventory they are usually kept exclusively for control and use by the foreman and crew that procured them; hence, availability for other jobs and crews is extremely limited.
H.
Identification and Disposition of Surplus Materials--It is within the sole discretion of the " owner" of the item or area to perform a review to determine whether the items identified are to be returned to stock, moved to a larger boneyard, placed in the scrap yard, or ignored. Again, most reviews of this nature are prompted by lack of other work tasks, lack.of space, or general clean-up activities rather than a planned attempt to make use of the leftover. materials.
l Further investigation revealed that similar organizations i
throughout TVA utilize the same practices to some degree and
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experience the same problems. These problems have prompted the Division of Fossil and Hydro Power to initiate the Nonstock Program. With the assistance of the Division of Operations l
Support (Materials), the Division of Fossil and Hydro Power is developing a program to identify, catalog, and account for waste materials through the.use of the Materials Accounting / Management System. However, this system is being developed exclusively around operations and maintenance activities and does not address construction activities or any aspects of continued use of. uncontrolled auxiliary storage areas.
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71100 SPECIAL PROGRAM REVISION NUMBER: 4 PAGE 9 0F 14 The WSN DNC organization procures all raw structural steel multi-purpose products to the highest QA criteria, regardless of the proposed final use. As with any large construction project, a large percentage of temporary and permanent structures and systems do not need to be built entirely from QA controlled materials. The following problems in this area need to be addressed:
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DNC established the all QA policy to ensure that no unqualified materials would be used in the construction of WBN. The all-QA policy ensures quality, but it is an extremely expensive way of doing that.
On the other hand, further investigation revealed that Office of Nuclear Power (ONP) at Browns Ferry, Sequoyah, Bellefonte, and Watts Bar Nuclear Plants all maintain and use inventories of I
non-QA raw structural steel products for use on non-QA application. This'has been very cost effective and efficient for ONP and has resulted in no significant QA problems.
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Although all structural material is purchased to QA i
requirements, it was found that QA records of raw structural i
steel products used for non-QA applications by DNC was not maintained. This is in accordance with the WBN QA Program and therefore follows procedures correctly; however, nontraceable, I
unused quantities of raw structural steel and pipe cannot be returned to the Warehouse Services Unit for potential future use as QA material. This problem accounts for a very large percentage of materials kept in auxiliary storage areas and the scrap yard and therefore is a major contributor to the findings, i
A large percentage of the perceived material waste concerns directly
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cite waste of hanger materials as a major problem. A review of j
procedures for hanger construction and of the individual responses to concerns made by DNC under the old Employee Concerns Program indicate the following items need to be addressed:
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Hanger materials are handled in the same manner and suffer from the same problems as other materials.
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No efforts or programs could be identified that will address how much of the large amount of hanger material still warehoused at the WBN Warehouse Services Unit and stored for WBN at tne q
Hartsville Distribution Center will ever be needed at WBN.
Based on the stage of completion of WBN, there is a high potential for waste of a large amount of surplus and scrap hanger material.
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TVA DEPLOYEE CONCEENS REPORT NUMBER: 71100 REVISION NURSER: ' 4 f
PAGE 10 0F 14 NOTE: Surplus hanger assemblies have been transferred to WBN from Hartsville and Yellow Creek Nuclear Plants at DNC r
insistence. This appears as " waste" because only the needed components of.the hanger assemblies are being used. In reality, use of'these selected hanger components has ultimately saved TVA money because the hanger assemblies at Hartsville and Yellow Creek'could have been sold as scrap material.
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Other than the' individual responses to previous employee j
l concerns, no efforts could be identified to inform employees of the followit.g impediments to the efficient use of hanger materials at WBN*
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l Design changes based on revised nuclear safety requirements l
l or system modifications which raquired modification or replacement of prefabricated hangers.
The storage of and attempt to use surplus materials from cancelled TVA nuclear projects.
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The need to understand that some material waste is an f
inevitable by-product associated with construction activities.
i The lack of a documented program in effect for reelew and use of surplus materials.
Conclusion This issue is factual and identifies a problem for which corrective l
action is being taken as a result of this evaluation.
4.2 Materials Availability Issue 71102 - Material Is Not Available When Needed l
Discussion i
The issue is whether materials needed for general or specific use for WBN's construction are adequately available.
I I-The materials accounting and management system being used by DNC et WBN has been adequate to meet major construction goals, even though most other TVA organizations have moved toward automated e4 e
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A TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM REVISION NUMBER: 4 PAGE 11 0F 14 management systems. However, functions which may be adversely impacted by DNC's manual system are inventory control, communications, materials availability (reorder / reserve quantities),
and surplus / scrap control and disposition. No recent management assessments of the present system's adequacy or inadequacy could be identified.
Conclusion Because a current assessment of the material accounting and l
management system has not been performed this issue can not be verified as factual.
4.3 Miscellaneous Materials Concerns l
l 4.3.1 Issue 71103 - Improper to Buy Foreign Materials 1
Discussion The CIs objected to the fact that TVA had an inspection office in Switzerland and bought foreign material in place of U.S. made material. Several of TVA's steam turbines were l
purchased from Brown Boveri and made in Switzerland.
l TVA does buy from foreign suppliers on occasion but only l
after the foreign supplier's bid is shown to be a significant percentage below qualified domestic bidders and in accord l
with the Buy American Act.
TVA had an office in Switzer1.'nd in past years as a part of the Office of Engineering's Quality Engineering Branch.
l Employees of that office monitored supplier quality performance by witnessing inspections and tests and providing related data to TVA's user organizations. The office was closed a few years ago due to the reduced procurement from European suppliers. The office in Switzerland was involved only in inspection cf materials and equipment and never initiated purchases.
l Conclusion The material was purchased according to TVA and U.S.
Government purchase procedures which call for inspection during the manufacture of the material. Therefore, this issue was not verified as factual.
l L__-_____________-
--a-
l l
TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM REVISION NUMBER: 4 PAGE 12 0F 14 7..
4.3.2 Issue 71104 - Accepting Low Bid Creates Waste Discussion A concern about TVA's policy of accepting the lowest bidder argued that it " creates a lot of waste," because the quality f
1 of the lowest bidder's material is often low.
All TVA procurement are made in accordance with federal p-f procurement regulations. Bids are. requested by Division et j
Purchasing and are evaluated by the requisition organization-1 and Division of Purchasing. Approvals for award are made by i
both those organizations plus the Office of the General Counsel and, for large contracts, by the Board of Directors.
This process is intended to assure TVA has an advantageous contract with a quality supplier, with fairness to all bidders. The bidding process stipuistes minimum acceptable standards of quality.
Conclusion l
1 l
This issue is not factually accurate.
l 4.3.3 Issue 71105 - Purchasing Process is Inefficient Discussion i
l The CI contends that TVA's purchasing process at WBN is not j
efficient, cost effective or schedule sensitive.
l I
Conclusion l
Because of the limited information about particular items, a i
detailed investigation could not be conducted. Therefore, L
this issu. cou1d not be v.eifi.d as factuat.
l 4.3.4 Issue 71106 - Stocking and Material Delivery are Inefficient L
Discussion l
Two concerns related to Power Stores raised an issue about the stocking systems and the material delivery time.
j L.,
f L
P
I O
1 T7A EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM REVISION NUMBER:
4 PAGE 13 0F 14 i
An interview with Power Stores supervision found that the Auto-stocking System reorder point and the reorder quantity is controlled by the unit that uses the material. The Power Stores Unit establishes its stock, reorder point and reorder quantity based on information from the groups ordering the materials. A Power Stores supervisor.also stated that a i
storekeeper, teamster and truck are assigned full-time to the delivery of power stores r.aterials and that deliveries are i
made within two or three nours.
Conclusion The Auto-stocking System is as reliable as the groups using it, and Power Stores delivers within three hours. Therefore, I
the issue is not factually accurate.
l 5.0 COLLECTIVE SIGNIFICANCE The procedures and policies in use by DNC at WBN and other sites for the identification and management of surplus materials and for the management and use of auxiliary storage areas are generally adequate but they do not constitute a complete materials management and control program.
l 6.0 CAUSES
\\
l The overall Materials Management Program in use at WBN has met most production goals. However, DNC's lack of procedures for governing all phases of surplus materials and for effective use of auxiliary storage areas caused the negative findings of this report.
The material management system used by DNC may be inadequate because mort functions are handled manually, rather than by computer.
l 7.0 CORRECTIVE ACTION INITIATED AS A RESULT OF THIS EVALUATION As a result of t hQl g a ag ment has' committed to tne to, lowing corrective actioi P
A.
DNC will rehheVBN
," Admin ra Cont f Materi il," to incorporate :the req lhat d
6e aterial
)e returned to 'the ware ouse s oct, rioreover, a nuvusu.maue t
program does not exist, a number of policy memorandums ao ext it which address the excess material issue.
~
~
u 1
TVA EMPLOYEE CONCERNS REPORT NUMBER:
71100 SPECIAL PROGRAM I
REVISION NUMBER: 4 l
l PAGE 14 0F 14 1
1 e
i l
B.
The newly formed corporate Materials and Procurement Services Staff I
["
(part of the ONP Planning and Financial Staff) is assigned the lead 1
role for providing direction and overview for all materials matters, including disposition or ereens matseials.
bh'aiEI$gd7e[dlo "[da%(45ee jIsh a adequacy f
C.
Power Stores and D s
,e r i Redbethhk'in of existing DNC mat (CATD 711-NPS-02)
I t
~~
8.0 ATTACHMENTS Attachment A. Subcategory Sunnary Table Attachment B. List of Concerns by Issue l
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1 f
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I ATTACHMENT B MATERIALS i
I List of Concerns by Element / Issue l
l This Subcategory Report (71100) addresses six issues raised by 70 l
concerns. The issues are grouped into three elements.
j p.
Materials Waste 1
71101 - Material is Misused or Underused q
l EX-85-031-001 IN-85-720-001 EX-85-075-001 IN-85-725-013 i
EX-85-094-004 IN-85-763-004 i
EX-85-098-002 IN-85-780-002
~
EX-85-101-001 IN-85-800 EX-85-102-001 IN-85-821 09 EX-85-104-001 IN-85-925-001 EX-85-105-001 IN-85-964-001 EX-85-108-001 IN-86-234-003 j
EX-85-110-002 IN-86-287-003 l
EX-85-132-001 MLC-86-001 J
EX-85-138.001 00-85-004-001 EX-85-153-001 PH-85-002-016 l
EX-85-171-002 PH-85-003-017 l
IN-85-049-IO6 SQM-86-004-014 IN-85-382-001 WBP-85-012-004 IN-85-443-003 WBP-86-024-001 IN-85-447-002 WI-85-091-003 IN-85-454-003 WI-85-091-014 IN-85-597-001 XX-85-096-003 IN-85-597-004 XX-85-120-001 IN-85-627-016 XX-b5-121-001 I
IN-85-628-001 XX-85-123-002 l
IN-85-646-002 XX-85-124-001 i
I Materials Availability f
71102 - Material Not Available When Needed EI-85-100-002 IN-85-683-003 EX-85-118-003 IN-85-687-001 IN-85-116-002 IN-85-757-004
]
IN-85-180-002 IN-85-766-002 IN-85-533-008 IN-85-812-001 IN-85-540-002 WI-85-001-001 IN-85-557-001 WI-85-091-019 i
IN-85-683-002 XX-85-120-004 Page 1 of 2 1
4 l
L.
1 J
~
ATTACHMENT B (Continued)
Miscellaneous 71103 - Improper to Buy Foreign Materials IN-85-597-002*
IN-85-821-010 OW-85-005-001 71104 - Accepting Low Bid Creates Waste IN-85-597-002*
71105 - Purchasing Process Is Inefficient IN-86-236-001 71106 - Stocking and Mate, rial Delivery Are Inefficient EX-85-044-001 IN-85-190-002
- Concerns addressed in more than one issue Page 2 of 2 a
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