Saner Tanju Atis_ Material Management System Industrial

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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.


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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


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

23CONFIDENTIAL – Saner Tanju ATIS

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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.


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


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


In-Warehouse Preservation – Preservation Recommendation


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



% 55 Piping > % 20 Eqp. + % 15 Elec.

% 55 Eqp > % 30 Piping + % 20 E+I

% 65 E+I > % 25 Eqp. + % 15 Piping

1

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% 58 E+I > Eqp

% 40 Eqp > Piping

% 75 E+I > Piping

Proven issue Methods – Variable Rates


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


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


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

[email protected]


Saner Tanju Atis_ Material Management System Industrial

Business

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