Lean nuclear power plant? A project example

Paluel nuclear power plant

Is it possible to streamline processes according to Lean principles even in industries with the highest safety standards?

Project example: Paluel nuclear power plant in Normandy, France.

Nuclear energy is the predominant energy source in France. It accounts for around 75 percent of the total energy mix. In the next ten years, the share is expected to drop to 50 percent due to the expansion of renewables, but even then nuclear energy will remain the main source of energy for the French. Today, France has around 60 reactors in commercial use. However, the majority of these reactors have been in operation for over 30 years and will require technical overhaul in the next few years.

The upcoming maintenance and reconstruction of the reactors are cost-intensive and extremely complex. The increased safety risk posed by a nuclear power plant increases the complexity of the maintenance, as does the strict schedule to be adhered to, which provides for a fixed date for subsequent operation. Added to this is the complex coordination of the subcontractors commissioned.

Against this backdrop, Lean Maritime was commissioned with the aim of sustainably increasing the productivity of maintenance and conversion work at the Paluel nuclear power plant. During the six-week project period, a structured planning concept with daily performance monitoring was developed and implemented. The innovative methods made it possible to use the available resources more efficiently and thus significantly increase productivity.

Numerous aspects had to be considered and hurdles overcome for the implementation and sustainable use of the innovative planning concept. The fact that the 30 m high steam generators inside the reactor were being replaced for the first time had to be taken into account in the planning process, as did the legally regulated upper limit of radiation exposure for the workers. In addition, an overcapacity of material and personnel had built up in the safety-conscious environment over the past years, which had a negative impact on productivity in the past.

The innovative planning concept, which guarantees efficient completion of the activities under the given conditions (safety and adherence to deadlines), was developed together with the employees on site and with the involvement of Lean principles. In the following weeks, the employees were accompanied and supported in the use of the new methodology in order to ensure sustainable success.