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Fabrication Presentation Slide by Fahmi

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Fabrication Presentation
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  • Present By;Mohd Fahmi Adli

    Bin Salahuddin

    M 0001Management Trainee

    Dynac Sdn Bhd

  • Contents Of Presentation

    1. Syllabus

    2. DYNAC Group Organization

    3. HVAC Fabrication & Production Process Flow

    4. Fabrication Department Element Chart

    5. Research & Development

    6. Area of Improvements

    7. Activities Involved

    8. Q&A

    9. Conclusion

    10. Acknowledgement

    11. End

  • Dynac Sdn BhdManagement Trainee Program

    Fabrication DepartmentWeek 1

    To know overall HVACfabrication process flow

    I. Introduction toAHU fabricationprocess flow

    II. Introduction toACCU fabricationprocess flow

    III. Introduction toDucting Damperfabricationprocess flow

    IV. Introduction toPiping activityprocess flow

    Week 2

    To understand how tofabricate AHU/ACCU

    I. Trainee requiredto review CNCcutting plandrawing forAHU/ACCU

    II. Trainee will begiven a task tosketch cuttingplan forAHU/ACCU

    III. Trainee requiredto review theinstallation of theblower fan,cooling coil, filterand etc for AHUequipment

    IV. Trainee will becommunicatingwith supervisorsif he/she havedoubt

    Week 3

    To understand how tofabricate ACCU and Pipingactivity

    I. Trainee requiredto review theinstallation ofACCU accessoriessuch ascompressor, oilseparator, suctionaccumulator, filterdriver and etc forACCU equipment

    II. Trainee will begiven a task toprepare/draw thepipe routing forrefrigerant

    III. Trainee will becommunicatingwith supervisorsif he/she havedoubt

    Week 4

    To know the fabrication of thedampers, sound attenuators &filter coalesce. To be able toexplain & understand thefabrication of all product. Togive suggestion for productsimprovement

    I. Trainee required toreview the installationof damper, soundattenuator and filtercoalesce

    II. Trainee will explain allproducts fabricationprocess flow/piperouting to theengineer/supervisorand give at least onesuggestion for productsimprovement

    Contents

  • DYNAC Group Organization

  • DYNAC GROUP

    DYNAC SDN BHD

    Engineering Dept.

    QA/QC Dept.

    Project/Fabrication Dept.

    Purchasing Dept.

    HR/Admin Dept.

    PIE/PIEZZOE

    Sale Dept

    Production Dept

    QA/QC Dept

    DYNAC ENGINEERING SDN

    BHD

    QA/QC Dept

    Engineering Dept

    Project Dept

    Production Dept

    Purchasing Dept

    HR/Admin Dept

    CSS

    CABLE SUPPORT SYSTEM

    Fabrication Dept

    Sales Dept

    QA/QC Dept

    Contents

  • DYNAC SDN BHD: Fabrication Department-Quality Objectives

    Project/Fabrication Department Quality Objective :

    To ensure clients issued Non Conformance or official complaints arenot more than two (2) NOS (number of subject) per project.

    Chart

  • HVAC Fabrication &

    Production Process Flow

  • HVAC Fabrication & Production Process Flow

    Project Department

    Fabrication Department

    Design Cutting Plan Drawings

    CNC Process

    Ducting & Dampers

    AHU ACCU GI Ducting

    Contents

    Work Order & Detail Drawing

    Work Order & Cutting Plan

    Work Order

  • HVAC Fabrication & Production Process Flow; Work Order & Detail Drawing

    Work order received from EDD Dept. to Fabrication Dept.

  • HVAC Fabrication & Production Process Flow; Work Order & Detail Drawing-cont

    Detail drawing received from EDD

    Dept. to Fabrication Dept.

    Production

  • HVAC Fabrication & Production Process Flow; Work Order & Cutting Plan

    Work order received from Production Engineer/Head

    of Fabrication Dept. to supervisor that related

    with the project

  • HVAC Fabrication & Production Process Flow; Work Order & Cutting Plan-cont

    Cutting plan created by drafter or supervisor

    Production

  • Fabrication Department

    Element Chart

  • Element Chart For Fabrication Department

    Fabrication

    AHU CNC ACCU Skid Ducting & Dampers

    Piping GI

    Ducting

    Name Plate

    Contents

  • Process Flow-Ducting & Dampers

    Plates Bending/Rolling

    Fabricates & Welding

    Fitting & Installation

    Cleaning & VCI

    FAT/Inspection

    Clear Punch List/Rework

    Packing & Delivery

    END FabricationDept.

  • Process Flow-AHU (Air Handling Unit)

    Bending Process

    Fabricates & Welding

    Insulation & Jacketing

    Fan & Coil Installation

    Piping & Instrumentation

    Cleaning & VCI

    FAT/Inspection

    Clear Punch List/Rework

    Packing & Delivery

    END FabricationDept.

  • Process Flow-ACCU (Air Cooled Condensing Unit)Bending Process

    Fabricates & Welding

    Condensing Coil & Impeller Motor Installation

    Compressor & Refrigerant Components Installation

    Piping & Instrumentation

    Run Copper Pipe Leak Test

    Cleaning & VCI

    FAT/Inspection

    Clear Punch list/Rework

    Packing & Delivery

    ENDFabrication

    Dept.

  • Process Flow-GI Ducting

    Marking Process

    Fabricates & Fitting

    Insulation & Welding

    Internal Pre-Inspection

    FAT/Inspection

    Clear Punch List/Rework

    Wrapping & Delivery

    END FabricationDept.

  • Process Flow-Name Plate

    Coating Process

    UV Expose Process

    Develop Process

    Touch Up Process

    Deboss Process

    END FabricationDept.

  • Process Flow-CNC (Computer Numerical Control)

    Design or create cutting plan drawings

    CNC process

    Grinding sharp edges and burrs

    Bending process

    END FabricationDept.

  • Process Flow-Skid Received Drawing

    Order material

    Material inspection

    Fabrication process (cutting/grinding/fitting)

    Fit-Up inspection

    Continue for fabrication process

    Inspection (visual inspection/MPI/etc)

    Rectification

    Blasting & painting process

    Thickness inspection for painting on skid

    Skid send to fabrication department

    ENDFabrication

    Dept.

  • Process Flow-Piping Received issued drawings from Engineering dept. or

    Production supervisor

    Parts selection

    Routing pipes c/w fitting accessories and brackets

    Brazing activities begin

    Minor cleaning

    Install instrument and supports

    Tubing activities begin

    Run leak test

    Visual inspection

    VCI the pipes (Job completed)Fabrication

    Dept.

  • Research & Development

  • Punch List Analysis On FLNG 1101 (Duty)

    Based On AHU Production Process

    Flows

  • Contents

    5.1 Method of Analysis

    5.2 Definition of Punch List

    5.3 Task Definition

    5.4 Origin of Punch List

    5.5 Category of Punch List

    5.6 Data

    5.7 Analysis

    5.8 Discussion

    5.9 Improvement

    5.10 Control

    Contents

  • 5.1 Method of Analysis: Process of Analysis

    Define

    Measure

    Analysis

    Improvement

    Control

  • 5.1 Method of Analysis-cont

    Definition of Punch List

    1. Describe the meaning of punch list.

    Definition of Task

    1. A concise description of the issues that need to beaddressed by a problem solving team and should bepresented to them (or created by them) before they try tosolve the problem.

    2. It will consist of objective and the benefits of the analysiswith to the company.

  • 5.1 Method of Analysis-cont Punch List category analysis focus

    Category of Punch List Symbol Remark

    Rectify R The equipment wasinstalled but need to rectifydue to functionless, did notfollow the specification orbroken

    Out Standing O/S The equipment did notcomplete the installationprocess

    Additional/Wish List A Additional requirementrequested by client

  • 5.1 Method of Analysis-cont

    Analysis

    1. To find the origin of the punch list based on the punch listcategory.

    2. To find the percentage for every punch list category based onthe FLNG LAB 1101 (Duty).

    3. To analysis the process flows of AHU based on the numberof manpower used and duration of day required tocomplete the FLNG LAB 1101 (Duty) before the FactoryAcceptance Test (FAT).

    Discussion

    1. To find the causes that contribute to punch list based on theAHU production process flows.

  • 5.1 Method of Analysis-cont

    Improvement

    1. To find the improvement that can be made based on theanalysis and discussion.

    Control

    1. To find the suitable process or method to maintain theimprovement.

    R & D

  • 5.2 Definition of Punch List

    Definition of Punch List

    A punch list is a list of tasks that need to complete to satisfythe terms of a construction contract.

    R & D

  • 5.3 Definition of Task

    Problem Statement

    Number of punch list for FLNG LAB 1101 (Duty) is 12.

    Objective of Task

    To find the root caused of punch list that occurred in FLNGLAB 1101 (Duty) project.

    To find any improvement that can be implemented regardingto the AHU production process flows.

    Business Benefits

    To achieve customer satisfaction on the product and company.

    To reduce the cost for rework process.

    R & D

  • 5.4 Origin of Punch List

    Origin of Punch List

    Engineering Department

    Project/Fabrication Dept

    Purchasing&Procument Dept

    Electrical Dept

    Quality Dept

    R & D

  • 5.5 Category of Punch List

    Category of Punch List

    Out Standing

    Progress

    Instrument

    Workmanship

    Additional/Wish List

    Functionality

    Durability

    Rectify

    Specification

    Non Uniform Standard

    Deviation

    Drawing

    Material

    Cosmetics (Appearance)

    Finishing

    Supplier R & D

  • 5.6 Data Origin of Punch List Based on Punch List Data for FLNG LAB 1101

    (Duty).TAG NO

    FAT DATE

    ORIGIN OF PUNCH LIST

    NO PUCH LIST DESCRIPTION / PUNCHLIST CATEGORY Out Standing Rectify AdditionalTOTAL PUNCH LIST BY ORIGIN

    FLNG (LAB)

    1101 DUTY

    23-09-

    2013

    FABRICATION

    1 To install name plate & tag nos /

    7

    2To install cable tray for differential pressure transmitter (PDT)

    /

    3 To install silicon inside AHU joints /

    4To cover/protect pipe flange surface prior to packing

    /

    5 To remove sharp edges manufacturer /

    6VCI coating to apply at SS316L AHU casing prior to packing

    /

    7 Fan shaft shall be SS316lL /

    ELECTRICAL

    1To remove spiral earthing cable to straight earthing cable

    /

    5

    2To install stuffing glands and gland plate for power and instrument cables to motor and instrument (air flow switch), lighting

    /

    3 To install lighting switch at AHU duty /

    4To install cable tag at cable supplied by Dynac inside and outside AHU (including stuffing glands)

    /

    5 To rearrange grounding system /

    TOTAL PUNCH LIST BY CATEGORY 8 3 1

    R & D

  • 5.7 Analysis of Data

    Punch List Graphical Summary on FLNG LAB 1101 (Duty).

    58.3%

    41.7%

    0.0%

    10.0%

    20.0%

    30.0%

    40.0%

    50.0%

    60.0%

    70.0%

    0

    1

    2

    3

    4

    5

    6

    7

    8

    Fabr (AHU Team) Electrical % o

    f P

    un

    ch

    Lis

    t (b

    y D

    ep

    art

    me

    nt)

    to

    th

    e t

    ota

    l o

    f P

    un

    ch

    Lis

    t

    Nu

    mb

    er

    of

    Pu

    nc

    h L

    ist

    Department

    Punch List of AHU System for FLNG LAB 1101 (Duty)

    Total %

  • 5.7 Analysis of Data -cont

    Punch List Analysis Summary Based on the FLNG LAB 1101 (Duty).

    DEPARTMENTTOTAL

    O/STOTAL

    RECTIFYTOTAL

    ADDITIONALOVERALL %OVERALL

    FABRICATION 5 1 1 7 58.33%

    ELECTRICAL 3 2 0 5 41.67%

    TOTAL 8 3 1 13

  • 5.7 Analysis of Data -cont Punch List Graphical Analysis Summary Based on the FLNG LAB 1101

    (Duty).

    0

    0.5

    1

    1.5

    2

    2.5

    3

    3.5

    4

    4.5

    5

    OUT STANDING RECTIFY ADDITIONAL

    5

    1 1

    3

    2

    0

    NU

    MB

    ER O

    F P

    UN

    CH

    LIST

    CATEGORY OF PUNCHLIST

    Number of Punch List For Department Involved Based On Punch List Category

    FABRICATION ELECTRICAL

  • 5.7 Analysis of AHU Process Flow

    Process flow for FLNG 1101 (Duty). The data in the process flow based on the these condition;

    1.Worker involved due to the project are skilled.

    2.Size of the equipment is 3000mm (L) x 1450mm (W) x 1050mm (H).

    3.The equipment were build include;

    Average over time are 3 hours everyday.

    Overtime for Sunday are 8 hours- 2 times a month.

    FLNG 1101 (Duty)

  • 5.7 Analysis of AHU Process Flow- cont Process flow of progress for FLNG 1101 (Duty)-Process Flow Chart;

    [1]

    Received drawing from EDD

    [2]

    AHU design & create cutting plan drawings

    Duration:7 Day

    Manpower:1 person (supervisor)

    [3]

    CNC plan for cutting plan

    Duration:1 Day

    Manpower:1 person (cnc supervisor)

    [4]

    CNC cutting process

    Duration:3 Day

    Manpower:2 person (cnc operator & helper)

    [5]

    Grinding sharp edges & burrs

    Duration:2 Day

    Manpower:1 person (helper)

    [6]

    Bending process

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [7]

    Fabricate bottom frame

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [8]

    Install bottom jacket & cladding (inner&outer)

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [9]

    Fabricate top frame

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [10]

    Install top panels, insulation & jacket or cladding

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [11]

    Fabricate & install structure or pentapost

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [12]

    Install galvanized skid

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [13]

    Install side panels & do insulation

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [14]

    Install side jacket or cladding

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [15]

    Install cooling coil, filter frame & filter housing

    Duration:3 Day

    Manpower:2 person (fitter & welder)

    [16]

    Fabricate & install fan supports

    Duration:1 Day

    Manpower:2 person (fitter & welder)

    [17]

    Install fan & flexible connector

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [18]

    Install copper pipe c/w brazing

    Duration:3 Day

    Manpower:3 person (fitter, welder & brazer)

    [19]

    Install instrument c/w tubbing & fitting

    Duration:2 Day

    Manpower:1 person (fitter)

    [20]

    Fabricate & install removable panel

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [21]

    Full weld the equipment

    Duration:1 Day

    Manpower:1 person (welder)

    [22]

    Fabricate & install access doors

    Duration:2 Day

    Manpower:2 person (fitter & welder)

    [23]

    Fabricate & install instrument bracket &

    accessories

    Duration:1 Day

    Manpower:1 person (fitter)

    [24]

    Finish up overall enclosure c/w VCI

    Duration:2 Day

    Manpower:2 person (fitter & helper)

    [25]

    Run copper pipes leak test

    [26]

    Factory Acceptance Test (FAT)

    [27]

    Clear punch list (Repair & touch-up)

    Duration:2 Day

    Manpower:2 person (fitter & helper)

    [28]

    Unit measurement, wrapping & packing

    [29]

    Product delivery

    [30]

    END

  • 5.7 Analysis of AHU Process Flow- cont Process flow of progress for FLNG 1101 (Duty)-Process Flow

    Description;

    No Process Flow Number Process Description

    1. [1] Drawing received

    2. [2] AHU Cutting Plan Design

    3. [3]-[4] CNC Process

    4. [5]-[17][20]-[24]

    AHU Fabrication Process

    5. [18]-[19] Piping & Tubing Process

    6. [25]-[26] Testing Process

    7. [27] Rectification Process

    8. [28]-[29] Packaging & Delivering Process

  • 5.7 Analysis of AHU Process Flow- cont

    Summary for process flow of progress-FLNG 1101 (Duty);

    1. Analysis of manpower to complete the equipment;

    No Type Of Manpower Number of Manpower

    1. AHU Supervisor 1

    2. CNC Supervisor 1

    3. CNC Operator 1

    4. Fitter 1

    5. Welder 1

    6. Brazer 1

    7. Helper 1

    Total Number Of Manpower 7

  • 5.7 Analysis of AHU Process Flow- cont

    Summary for process flow of progress-FLNG 1101 (Duty);

    2. Analysis for duration of day required to complete the equipment before Factory Acceptance Test (FAT);

    No Process Flow Number

    Process Description Duration Of Day Required

    1. [2] AHU Cutting Plan Design 7

    2. [3]-[4] CNC Process 4

    3. [5]-[17][20]-[24]

    AHU Fabrication Process 29

    4. [18]-[19] Piping & Tubing Process 5

    Total Duration Day Required 45

  • 5.7 Analysis of AHU Process Flow- cont Punch list data based on category for FLNG 1101 (Duty) ;

    No/Category of Punch List

    Out Standing Rectify Additional

    1 To install name plate & tag nos

    To remove sharp edges manufacturer

    Fan shaft shall be SS316lL

    2 To install cable tray for differential pressure

    transmitter (PDT)

    3 To install silicon inside AHU joints

    4 To cover/protect pipe flange surface prior to packing

    5VCI coating to apply at SS316L AHU casing prior to packing

    TOTAL5 1 1

  • 5.7 Analysis of AHU Process Flow- cont The caused of punch list based on Process Flow Number and Process

    Description;

    Punch List Category

    No Punch List Description Process Flow NumberProcess

    Description

    OUT STANDING

    1 To install name plate & tag nos [24]AHU Fabrication

    Process

    2 To install cable tray for differential pressure transmitter (PDT) [23]AHU Fabrication

    Process

    3 To install silicon inside AHU joints [24]AHU Fabrication

    Process

    4 To cover/protect pipe flange surface prior to packing [24]AHU Fabrication

    Process

    5 VCI coating to apply at SS316L AHU casing prior to packing [24]AHU Fabrication

    Process

    RECTIFY 1 Fan shaft shall be SS316lL [16]AHU Fabrication

    Process

    ADDITIONAL 1 To remove sharp edges manufacturer [24]AHU Fabrication

    Process

    R & D

  • 5.8 Discussion of AHU Process Flow

    From the analysis of punch list data based on category of punch list forFLNG 1101 (Duty) it show that;

    1. The highest number of punch list based on category is Out Standingwhich are 5 items. Followed by Rectify and Additional which is 1 item.

    From the analysis for caused of punch list based on Process Flow Numberand Process Description it show that;

    1. Process flow of [24] which is Finish up overall enclosure c/w VCI underAHU Fabrication Process showed the highest value among other whichare 5 items.

    2. Followed by process flow of [23] which is Fabricate & install instrumentbracket & accessories AND process flow of [16] which is Fabricate &install fan supports. Both of process flow are under AHU FabricationProcess. Both of process flow contributes 1 item.

    R & D

  • 5.9 Improvement Based on the analysis and discussion, the discussion continued with

    the analysis on the possible caused of punch list;

    Fabrication

    Out Standing

    Insufficient duration of working progress

    Insufficient duration of time for working progress

    to complete the equipment before FAT

    date based on the punch list description

    Insufficient / inadequate of

    resources

    Man power

    Equipment

    RectificationQuality done by

    worker are inadequate

    AdditionalAdditional request

    from client

    Department

    Punch list category

    Root of Caused Description of Caused

    R & D

  • 5.9 Improvement: Out Standing

    Suggestion

    9.0 Improvement

    Out Standing

    Insufficient duration of working progress

    Insufficient duration of time for working progress to complete the

    equipment before FAT date based on the punch list

    description

    Increase the duration of time for working progress before

    FAT

    Maintain the duration of time for working progress before

    FAT date BUT reduce the suitable process flow to

    accommodate the duration.

    Centralization of current fabrication progress

    information with all of department

    Insufficient / inadequate of resources

    Man powerUtilization number of man

    power based on the current number of project

    Equipment

    Maintenance of equipment should be done periodically

    The number of equipment should be sufficient based on

    the number of man power regarding to the type of

    manpower

    Punch list category

    Root of Caused Description of Caused

    Suggestion

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)

    Based on the previous analysis and discussion, the duration ofprocess flow need to increase on;

    1. Process flow number [24] and the suggestion of increasing ofduration is 2 days.

    2. Process flow number [16] & [23] and the suggestion of increasing ofduration is 1/2 day for each process flow number.

    3. The total additional duration for fabrication process are 3 days.

    9.0 Improvement: Out Standing

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)-cont

    Based on the AHU process flow, the possible process flow numberthat can be reduced are;

    1. Process flow number [2] which is AHU design & create cutting plandrawings AND process flow number [15];

    i. The process flow can be reduced by improve the drawing layoutbefore hand over for fabrication process.

    ii. The possible duration process can be reduced based of processflow number [2] is 2 days. Whereas, the possible duration processcan be reduced for process flow number [15] is 1 day.

    iii. As an example, refer the next slide of presentation.

    2. The total decreasing of fabrication process are 3 days.

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)-cont

    1. Process flow number [2]-cont;

    Wheatstone layout drawing FLNG 1101 layout drawing

    The difference between both of drawing is the detail of layout drawing. Wheatstonelayout drawing has details on the support size and bending process method for equipment. Whereas, the FLNG 1101 layout drawing did not have the details as

    Wheatstone layout drawing. 9.0 Improvement: Out

    Standing

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)-cont

    To ensure the equipment progress is ready before the FAT date, theinformation about the current progress of equipment should beknown by each of department. As a suggestion;

    1. Create a document in the server.

    i. The document should contain the current progress for eachdepartment especially for fabrication department.

    ii. As an example, refer the next slide of presentation.

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)-cont

    AHU PROGRESS REPORT (FLNG1101-DUTY)

    NO PRODUCTION FLOW PROCESS FAT DATE

    FABRICATION DEPARTMENT QUALITY DEPARTMENT

    PROGRESS REMARK TOTAL PROGRESS (%)PLAN ACTUALSTATUS

    PLAN ACTUALSTATUS

    START FINISH START FINISH START FINISH START FINISH

    1 Received drawing from EDD 1

    68.96551724

    2 Design or create cutting plan drawings 0

    3 CNC process 1

    4 Grinding sharp edges & burss 0

    5 Bending process 0

    6 Fabricate bottom frame 0

    7 Install bottom jacket or cladding 0

    8 Fabricate top frame 1

    9 Install top panels, insulation & jacket or cladding 0

    10 Fabricate & install structure or pentapost 1

    11 Install galvanized skid 1

    12 Install side panels & do insulation 0

    13 Install side jacket or cladding 1

    14 Install cooling coil & filter housing 0

    15 Install fan supports 1

    16 Install fan & flexible connector 1

    17 Install side jacket or cladding 1

    18 Installcopper pipe c/w brazing 1

    19 Install instrument c/w tubbing & fitting 1

    20 Fabricate & install removable panel 1

    21 Full weld the equipment 1

    22 Fabricate & install access doors 1

    23 Fabricate & install flexible connector 1

    24 Install instrument bracket & accessories 1

    25 Finish up overall enclosure c/w VCI 1

    26 Run copper pipes leak test 1

    27 Clear punch list (Repair & Touch-Up) 1

    28 Unit Measurement, wrapping & packing 1

    29 Product delivery 0

    iii. As an example, refer the next slide of presentation.-cont

    9.0 Improvement: Out Standing

  • 5.9 Improvement: Out Standing (Root of Caused: Suggestion)-cont

    Based the previous analysis, the total number of man power requiredto complete equipment for FLNG 1101 (Duty) are 7 person. Samplecalculation for man power required based on these condition;1. Not include for AHU supervisor, CNC supervisor, & CNC operator.

    2. Assuming the current number of equipment of AHU need to be completed is4.

    3. The situation and number of man power based on FLNG 1101 (Duty).

    9.0 Improvement: Out Standing

    No Type of Manpower Number of man power Total Number of man power required (Number

    of man power x 4)

    1 Fitter 1 4

    2 Welder 1 4

    3 Brazer 1 4

    4 Helper 1 4

    TOTAL NUMBER OF MAN POWER REQUIRED 16

  • 5.9 Improvement: Rectification

    RectificationQuality done by

    worker are inadequate

    Qualification AND understanding about quality

    every of man power

    Mentor-mentee between senior worker and junior worker

    Punch list categoryRoot of Caused

    Suggestion

    9.0 Improvement

  • 5.9 Improvement: Rectification (Root of Caused: Suggestion)

    Based on the analysis, the suggestion of improvement can beimplemented for qualification of man power and understandingabout quality such as;

    1. Welder need to be tested every 6 month to ensure the quality ofwelding maintained.

    2. Each of man power should be exposed on the quality requirementduring the process to complete an equipment.

    3. Every equipment should be specified the responsible of worker inorder to evaluate the quality of work.

    9.0 Improvement: Rectification

  • 5.9 Improvement: Rectification (Root of Caused: Suggestion)

    Since our product, HVAC system for oil and gas platform which isdifferent between another production company it require aconsistent and improvement for quality of ways of working. Thus, itwill need continuous learning. Mentor-mantee is one of a methodthat suitable to use;

    1. New worker will be attached with senior worker.

    2. Senior worker will evaluate the performance of new worker.

    3. Any suggestion or comment will be submitted to the managementfor improvement of worker or the training program.

    9.0 Improvement: Rectification

  • 5.9 Improvement: Additional

    Additional Additional

    request from client

    Refer client specification

    Refer on ITP & PQP

    Refer International specification

    Punch list category

    Root of Caused

    Suggestion

    R & D

  • 5.10 Control 1. Centralization for information of project progress in

    fabrication department and inter-department in Dynac SdnBhd.

    2. Analysis and improvement in term of resources in order toensure the fabrication process and progress going smoothly.

    3. Continuous assessment on quality and viability of workersand an award may be gifted to the chosen worker based ontheir performance.

    4. Do analysis (e.g SWOT) for every project before and after ofcompletion.

    5. Implementation of Key Performance Index (KPI) to enhancethe productivity and performance of resources.

    R & D

  • Area of Improvements

  • Area of Improvements

    For AHU (Air Handling Unit) ;

    1. Inspection request for QA/QC inspector for the equipmentduring and after complete the process ;

    To increase awareness about quality of work among the worker.

    2. Implementation of mentor-mantee program ;

    To increase the understanding of process flow of AHU system.

    To ensure the worker are able to work without high observationby supervisor.

  • Area of Improvements-cont

    For ACCU (Air Condensing Cooling Unit) ;

    1. Inspection request for QA/QC inspector for the equipmentduring and after complete the process ;

    To increase awareness about quality of work among theworker.

    2. Implementation of mentor-mantee program ;

    To increase the understanding of process flow of ACCUsystem.

    To ensure the worker are able to work without highobservation by supervisor.

  • Area of Improvements-cont

    For CNC (Computer Numerical Control) machine ;

    1. Do the monthly maintenance for CNC machine ;

    To ensure that any potential for machine brake down canbe prevented.

    Ducting & Damper ;

    1. Implementation for work order instruction ;

    To ensure the amount of ducting delivered to yard basedon the order/drawing

    To ensure that every product is inspected from qualitydepartment representative.

    Contents

  • Activities Involved

  • Safety briefing about working at high place on 18/10/2013

    Safety Briefing: Working At High Place

  • Daily Exercise

    Daily exercise on 22/10/2013(Everyday)

  • Punch list meeting for Wheatstone ACCU on 23/10/13

    Punch List : Wheatstone ACCU

  • Welding qualification test on 29/10/2013

    Welding Qualification Test

  • Red Line Marking : Wheatstone AHU

    Red line marking of AHU Wheatstone on 7/11/2013

  • Punch List : Wheatstone AHU

    Punch list meeting for Wheatstone AHU on 9/11/2013

  • Equipment & Machine

    Update equipment & machine inventory on 18/11/2013

  • Welding Machine

    Update welding machine inventory on 20/11/2013

  • Inspection & Calibration Welding Machine

    Inspection and calibration process of welding machine done by AMCOWELD representative on

    27/11/2013

  • OHSAS Meeting

    Attend for OHSAS meeting on 25/11/2013

  • Toolbox Meeting

    Participated for toolbox meeting conducted by HSE Dept. on 29/11/2013

  • Housekeeping

    Contents

    Housekeeping session on 30/11/2013

  • Contents

  • Conclusion

  • Conclusion

    Good Quality & Productivity

    Management

    Resources R & D

    Contents

  • Acknowledgement Tuan Hj Allam Tawfiq Said

    Technical Director

    Mr Tawfiq Allam Said

    Production Coordinator

    Mr Ahmad Noorzen Bin Diran

    CNC Team Leader

    Mr Kamaluddin Bin Talib

    Ducting (GI) / Skid Team Leader

    Mr Sim Boon Teek

    Damper & Ducting Team Leader

    Mohd Nor Bin Ambia

    Piping & Refrigerant Team Leader

    Mr Zaidi Bin Jumaat

    AHU & ACCU Team Leader

    Mr Sahid Bin Mokhtar

    AHU Supervisor

    Mr Samsol Bin Md Buang

    ACCU Assistant Supervisor

    Contents

  • End


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