saner tanju atis_ material management system industrial
DESCRIPTION
TRANSCRIPT
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INDUSTRIAL PROJECTS......
STRATEGIC APPROACHES TO MATERIAL MANAGEMENT SYSTEM AT SITE
CONFIDENTIAL – Saner Tanju ATIS
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1 -What is the Strategic Material Management
System at Site? 2 -Why is it important? 3 -Strategic MMS analysis at Site 4 -Principles of Warehouse design 5 -Essentials Symbols for handling and storage 6 -Receipt and Incoming Stages Inspection Flow
Inspection of Incoming Process- IIP What constitute a material deviation ?
7 -Objectives of the MTC – Material Test Certificates
8 -Storage – a Pillar of Category Process 9 -In-Warehouse Preservation – Improving the
work Methods 10-Proven Issue methods – LBID Cycle 11-Question /ClosingCONFIDENTIAL – Saner Tanju ATIS
AGENDA
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What is the Strategic Material Management System at Site?
Scientific technique, Concerned with planing, Organizing & Control of flow of ..
... Good Overview, Comprehensive view of Inventory ...A well- organized design on effective stores layout ...Enhance performance to support operations...... ...To consolidate and efficiently handling
process... ...Safety, Knowledge and Data transfer... ...Quality control is integral to the continuing
of operation..
Ability to anticipate needs, forecast conditions, set
goals and standarts, plan and schedule work and measure results.
CONFIDENTIAL – Saner Tanju ATIS
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Why is MMS important at site?
Support us organisation’s strategic and complimantary planing at site
Increase ability of workforce to utilize operations bases
Creates and enable a learning , sharing and focus an practical application
Quality and technical skills improvement.
Improved internal teamwork and communication
Streamlined our work for better time and business process
Focuses on making changes to simplify and become more efficiency
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STRATEGIC MMS ANALYSIS at Site
Transportation
- Review
- Needs
-Time Period
- Knowledge Transfers
Observed Shipment Data
Selection Criteria
- Detect lists
- Classify
- Internal & Exter.
Communications
Observed Packing
Analysis
Handling Plan
- Indivudual materials group
- Storage objective
- Storage strategies
Planning
Management Plan
- Procedures
- Instructions
- Training
Planning
Organ.Chart
- People/ Positions
- Seperate disciplines
- Workforce Planing
Observed Data Analysis
Action Plan
- Analysis Prioritize
- Review plan
- Execution planPlaning
Strategic Action View
Strategic Look-ahead View
SUCCESS
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Principles Of Warehouse design
Scope of Work ; Storage instructions based on materials specifications
and manufacturers instruction .......Take over facilities for warehouse and site
store ......... Type, condition,number of facilities
Temporary site facilities arrangement ..... location of quarantine store, clear separation
Technical specification for warehousing .... .Materials handling details,organizing
principals ........Organize storage areas in compliance with
storage instructions ...........Designation of storage areas by
categories(open air, covered,with air-conditioning, etc) Install computer hardware and software
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The factors elements
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- Type Of Storage (TOS)=A + B + C + D- A=The Scope of items Supplied- Piping, Electrical, Equipments, Steel Structures- B=Material Specifications- Instructions Specified by Manufacturers- C=Order Volume- Project Material Orders (Acc.. BOQ)- D=Safety Measures- Detrimental Conditions (by moisture,rain,
snow,sandstorm,insects),dirt(by bird droppings,dust,tar), static and dynamics load.
- Closed Area TOS
Open Area
With Fence,Without Fence,
Roofed
CONFIDENTIAL – Saner Tanju ATIS
Lockable, Air condioned,
Dry
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1.3 Features of Database System
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1.4 Subgroup of Database• 1-Define Storage Location.... Store / storage place
• 2-Material Receipt .... Against part shipment no, PO no, by item.
• 2.1- Material Arrival ..... Delivery Editor for pt. Shp.no, PO, material.
• 2.2- Material Receiving Report .... Ordered qty,arrived qty,Order status per parts no.
• 3-Material Planning
• 3.1- Filter Setting...... Tracebility and range of data
• 3.2- Piping Material Reservation.... Scheduling- reserve
• 3.3- Reservation Cancellation.... Cancellation existing reserve
• 4- Material Issue....
• 4.1- MIF Filter Setting .... Piping, E+I, Eqp...
• 4.2- Piping Material Issue.... Issue list Editor, Individual form
• 4.3- Non-piping Material Issue...E+I and EQP issues Editor
• 5- Material Take Back....Store transaction,Takeback
• 6- Material Ordering .....Ordering Editor,Type of Pack
• 6.1- Ordering Additional Material ....New PO
• 6.2- Ordering Missing BoM Material ..Bulk order editor,QTY missing part
• 7- Additional Store Transactions .... Storege list editor
• a- Stock Adjustment
• b- Stock Movement
• c- Block and unblock material
• 8- Certificate Management ..... Store / Material certificate, HEAT no
1.5 Material Handling Process
ISTANBUL
Data Feedback
BUL=Order and delivery recordMIF=Material Issue Form
BuL & MTO via e-mail
SITE
1.1 Logistic Organization Delivery System
Material Tracking • Goods to be ordered...........• - equipment (pumps, vessels,..)• - piping (valves,pipe,elbows,..)• - electrical (motors,cabinets,..)• - instrumentation (transmitter,cables,..)
Ordering System
Packing & Transport Agent
Supplier/ Manufacturer
Record of Orders (RO)
LOADS
Goods Received
Material Management
System
Material PurchaseOrder data supplier
adresses
Arrival of goods on Site
AT SITE
Types,Quantities,etc.
Loose parts package information
part shipment information
Goods (loose Part)
Loose Parts Package
part shipment
Labels
Part Shipment
Computerized System
Info, When and What kind of material is expected at site and feedback RO
1
2
2
3
4
5*
5,8
5
6
7
P.O 2
Loose Part: Smallest individually labelled item
2* *=data transfer via filetransfer
1.2 DATA Flow and Sources of Information
Quantities received /reserved / issued Material
Receving system (Loose
Part Level)
SMS Material Management• Materials inventory control(ord./rec./iss./arrived)• Parts list management(scheduled/current requirement)• Piping prefab./construction plann.
Delivery dataQuantities supplied
Construction Cost Estimation.
Construction costs/Scope
Work Progress Controller
PO dataQuantities Ordered
3.3 Implementation of Material Work Flow at Qatar
WAREHOUSE
Document
E- System
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Essentials Symbols for handling and storage
The Symbols for handling storage marked on the packages and equipment items in accordance with EN ISO 780 should be observed. Symbols for the handling of equipment
• 1 = This is up• 2 = Fragile, handle with care• 3 = Keep dry • 4 = Keep away from heat 1 2 3 4
5• 5 = Use no hooks• 6 = Centre of gravity• 7 = Sling here • 8 = No hand truck here • 9 = Clamp here 6 7 8 9
10• 10 = Do not use fork lift truck here • 11 = Roofed storage
• 12 =Storage in closed rooms
• 13 =Storage at ambient temperature of >0
• 14 =Storage in air condition 11 12 13 14
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Lifting and Slinging gear
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Receipt and Incoming Stages•
Tasks Content Result Inspect incoming materials,
check for damage, completeness and compliance with delivery documents and speciation’s as well as data transferred
Mark any damaged materials, transfer to quarantine store
Prompt and coordinate corrective action, e.g. inspections by transport insurance company, repair work
Implement storage instructions correctly
Prompt any additional preservation or special measures and document in accordance with regulations (e.g. continuous inerting, turning of shafts, etc.)
Any damage, incomplete delivery, variance from delivery specification
Type of damage, planned measures if any
Detailed description of damage, detailed description of planned repair work, etc.
Specification of storage location and characteristics, measures in case of emergency (failure of HVAC)
What measures when and how often – times, duration, tests
Notification of receipt of material, damage report, NCR, certificate filing
Quarantine store status
Inspection log, repair procedure, repeat order
Database stroge list, special instructions
Preservation and special measures log
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Port
Transport Agent
Loaded On Truck
LOT
Receipt Of
PackageUnpacked Reports
Checking the packing for damage during the Ship Checking the outside packing for damage during transport to site
Checking the packing lists against the number of packages received, Checking the outside packing for damage, Checking the inside packing (e.g. welded plastic sheets) for damage, Checking damaged packages for completeness and damage to the contents, Checking any protective inert-gas fillings.
Essential Reports
(MRR,etc..)
Checking the contents for completeness,
Checking the outer condition of the
indivudual components.
(e.g. corrosion protection, preservation),
Checking the technical details
Project site
Inspection Flow
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Inspection of Incoming Process IIP – Specific Projects Materials
• checking for damage in transit, • checking the accessories (gaskets, bolts, etc.) supplied for completeness and correctness
• checking for damage in transit, • checking the accessories (gaskets, bolts, etc.) supplied for completeness and correctness
• checking the material for completeness, • checking the material for being undamaged (damage in transit), • visual inspection for compliance with the technical specification (e.g. sealing faces, supporting surfaces of bolts, welding edges, etc.), • checking for correct stamping, coding, batch number and compliance with certificate, • checking the marking of valves, • dimensional checking (mating dimensions, wall thickness, weld edge preparation, thickness of flanges, bolt holes, roundness),
• checking the material for completeness, • checking the material for being undamaged (damage in transit), • visual inspection for compliance with the technical specification (e.g. sealing faces, supporting surfaces of bolts, welding edges, etc.), • checking for correct stamping, coding, batch number and compliance with certificate, • checking the marking of valves, • dimensional checking (mating dimensions, wall thickness, weld edge preparation, thickness of flanges, bolt holes, roundness),
• checking the name plate data for compliance with the purchase order specification, • comparing the characteristic data of the material supplied with the data sheets, • checking the material for being undamaged (damage in transit), • checking for completeness, especially the accessories.
• checking the name plate data for compliance with the purchase order specification, • comparing the characteristic data of the material supplied with the data sheets, • checking the material for being undamaged (damage in transit), • checking for completeness, especially the accessories.
• Sensitive Materials• checking the package properly • Sensitive Materials• checking the package properly
Equipment & Steel
Structures
Piping Materials
Electrical & Instrumentat
ion
Fragile, Others
IIP
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What Constitutes a material Deviation ?
Deviations
Overage Damage Hold Rejection
Shortage
Deficiency Report Dimensional Technical Specification Elimination of Defects Faulty Assembly CONFIDENTIAL – Saner Tanju ATIS
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Objectives of the Material Test Certificates
Tasks Content Result Create filing system for
certificate management
Check incoming certificates for correctness and completeness and completeness, and enter in Database
Initiate and expedite corrective measures
Put material with no or incorrect / incomplete certificates in quarantine store
Classification, structure
Checklist based on check criteria
Type of corrective action, critical deadlines
Reason why certificates are not O.K., name of material
Certificate management in Database
Updates incoming materials log
Correspondence
Quarantine store status
Correspondence
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A control necessary to meet the control objectives is available or... Identified material and Match with Test Certificates to ensure.. Material Safety Data Sheet (MSDS),Chemical and Hazardous Materials
.... Work place safety
.... Physical and chemical datas
..... Storage and handling informations
Item Code (Part No)
ASTM Standart
DimensionHeat Number
90 Degree Elbow CONFIDENTIAL – Saner Tanju ATIS
Face the Fact
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Storage – a Pillar of Category Process
...............Technical SpecificationThe individual groups of components must be characterized by boards, marked with
part number, dimensionand material.Technical International Standarts.Stored in accordance with the technical specification...................Implement Instruction (Vendor)In accordance with the manufacturer’s instructions either outdoors,indoors, in cooled or
in dry rooms.Material Data Sheet instruction to be followed.......................Safety and Security RegulationsSafety regulations for chemicals and dangerous materials should be applied.The products which would be damaged through exposure from sunlight should be
protected by adequate covers or stored indoors.Adequately protected and guarded against theft, pilferage,fire.........................Segregation (Storage Profiles and Layouts)External and internal storage areas (aisles,bin,section,yard plots etc.) should be clearly
defined and identified with appropriatestorage location sign as per material storage plan.Designated Area in the basis of Unit Process.............................TraceabilityIdentify Locations data transfer to material Tracking system.Completeness of the information for every step in a process.Refers to the capability to gain materials in the timely manner.Monitor and issued “first come-first go” basis..
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Storage – Creating a Plan to achieve your goals !
Anticipation to deliveries schedule for priority plan
Make a adequate reserve place of estimated capacity for materials
Knowledge sharing with team,information, Skills, or expertise
Build and Organize , motive your team to get to do deliveries and storage conditions
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Open area (Laydown)
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Piping components
Pipes, spools, fittings, elbows, flanges and valves.
stored outdoors on timber baulks of approx. 150 mm thickness or on timber pallets.
Flange faces shall not be damaged.
Pipes may be stacked to a height of approx. 1.5 m if properly secured.
In the case of pipes . DN 500, only two pipes should be stacked one upon the other.
Equipment & Vessels, Steel Structures
dcsSteel structures, vessels, machinery, and the like should be stored outdoors on timber baulks of approx. 150 mm
thickness. Placing the equipment on unprotected, bare, or machined surfaces as well as on flanges is not
permitted. Care shall be taken not to damage nozzles, shaft ends, or other protruding parts.
Electrical & Instrumentation
Transformers for outdoor service, cable supports, cable drums and sectional steel for fixtures may be stored outdoors.
Other electrical, measuring and control equipment should be stored in dry and well ventilated rooms on timber pallets or on shelves.
Instruments shall be stored on shelves. The original packing shall only be removed at the place of installation.
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Storage – Individual Stock
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.
Rubber-lined equipment and plastic equipment shall be stored with special care.The temperature within rubber-lined equipment should
not drop below -10oC if the hardness of the
rubber lining is > 75 Shore D and not below -20oC if the hardness of the rubber lining is < 75 Shore D
Coating materials shall be stored at temperatures between 5 C and 30 C in dry and well ventilated rooms.
Bricks (for refractory linings),
Polyester resins
Solvents, fuels, lubricants, and corrosive chemicals
Oils and insulating fluids
CONFIDENTIAL – Saner Tanju ATIS
Storage – Individual Stock
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Matrix for Storing Facilities and Locations
SN ItemInside the warehouse
Out Side the warehouseAir Condition No Air Condition
1 Steel Plates, Shapes, Fittings, etc < 4” Fitting > 4”
2 Materials with Machined Parts <4” Remaining
3 Valves <4” >5”4 Gaskets, O-rings, bolts and nuts
5 Welding Wires and Electrodes
6 Paints and adhesives As per MSDS NA
7 Insulation and Refractory
8 Machinery and Equipments
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Civil Materials sands, Mortars, Cement Aggregating As per MSDS
10 Architectural Material
11 Anchor Bolts
12 Electrical and InstrumentationAs per instruction Measuring Equipment,Switch
Board,Distrubution board,Contol Panel,Instrument Tubes
Transformer, cable,Supports,Cable Drum and steel structure
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In-Warehouse Preservation – Improving the work Methods
Create a preservation communication and
application plan Make an Assessment, Classified group of
materials, safety regulations Establish priorities, Designated Storage
areas,Preservation team for tasks.. Identified needed resources, vendor specific
documents,Manufacturers Instructions Identify short and long term activities, storage and
maintenance duration Develop a strategy to increase preservation,
enhance performance result of implementation Application of preservation agents instructions ( e.g.
Table.1..),recommendations Tracibility of Preservation Matrix, Requirements,
Interval, Referance documents,Storage areas Execution at site, Labeling – Job Card and
RecordingCONFIDENTIAL – Saner Tanju ATIS
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In-Warehouse Preservation – Preservation Recommendation
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In-Warehouse Preservation – Regular Checking Period
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After BeforeCONFIDENTIAL – Saner Tanju ATIS
KEEPME
CLEAN
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Proven issue Methods
Issue starts and an ongoing with
engaged the project time schedule
Compliance of essential circumstances to issue
Indivudal groups materials
Return, Take back to Store
LBID Cycle – Journey to Movement........ From our initial engagement with all
movements to the end of Material journey to adhere to the stipulated time for Individual Projects.
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Proven issue Methods - LBID CYCLE
Delivery + Order
Piping – Prefabrication
Piping - Erection
Isometric -Reservation
Pipes, Fittings....
Isometric -Reservation
Valves, Bolts,Gaskets...
MTC- MSDS
Availablity
Inspection
AUTHENTICATED
REALIZE
ASSURE
Equipment
Electrical
Equipment, Others
E + I
E + I
Equipment, Others
Breakthrough
Incremental
Lean
Decisive
Piping - Erection
Commissioning
Recycling
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% 55 Piping > % 20 Eqp. + % 15 Elec.
% 55 Eqp > % 30 Piping + % 20 E+I
% 65 E+I > % 25 Eqp. + % 15 Piping
1
23
% 58 E+I > Eqp
% 40 Eqp > Piping
% 75 E+I > Piping
Proven issue Methods – Variable Rates
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55
30
50
25 20 15
65
%
.
.
.
.
. .
.
.
Zone 1
3 2
.
End Line Initial Line
Eqp. P
E+I
Proven issue Methods - Progress Zone Coordinates
Z1
Z2
Z1 > Z2
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Required Ordered Delivered Issued
Piping 2800000 2950000 1416707 1042755
Equipment 15000000 15500000 10500000 6570000
E+I 10500000 7560000 5470000 3260000
Others 1500000 1650000 1100000 950000
Kg
Sample - Cycle of Project Materials
Kg
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MIF- Material Issue Form
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MMS – Closing
......Facilitate having good inventory improve the efficiency organization
.........Organizational goal settings
.............Additional strategic planning initiatives
.................Evaluation of correct performance indicators
Development of additional internal and external performance measures for the Organization
Building an integrated Warehousing system It is an integrated process that demands integrated
processes and databases to become truly effective. The need for sharing processes and databases
throughout the entire organization Additional education and employee empowerment
lead to increased job satisfaction and personal performance
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MMS – Closing
Open Discussion
Questions
Saner Tanju
ATIS
CONFIDENTIAL – Saner Tanju ATIS