PMTOP day2

PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM

DAY 1

PMTOPDAY 2

THE CONSTRUCTION PHASE

SUPPORTING THE FOREMAN

PMTOP

DATE TIME RESOURCE PERSON

• Generating AFC Drawings

• Securing the Work Permits

• Field Change (CO / CN) • Deliverables and Time Log • Crewing the Foreman • Flow of Materials to the Foreman

12:00-1:00

• Supplying the Construction Equipment

• Supplying the Tool Packs • Test Packages • Contents of Test Pack• Contents of the QC Plan

DAY 2

THE EXECUTION / CONSTRUCTION PHASESupporting the Foreman

TOPICS

2:00-5:30 EE CRISTI

LUNCH BREAK

1:00-2:00 EY CHUA

10:00-12:00 EY CHUA

8:30-10:00 FJ CHAN

PMT ORIENTATION PROGRAM

PROGRAM SCHEDULE - DAY 2

PMTOP

• Generating AFC Drawings • Securing the Work Permits • Field Change (CO / CN) • Deliverables and Time Log



PMTOP

Construction Work Package • AFC Drawings • L5 3-Weeks Schedule • Manpower • Materials • Materials • Consumables • Equipment • Tool Packs • Material Allocation List • Work Permits / PTP

CM

SUPT’S

PLANNING

PM

FIELD STAFF

DTRs and EDTRsReports

Consolidated ReportsDTRs and EDTRs

Field Foreman

Field Supervisor

AFC DrawingsL5 Schedule

Quantities to InstallManhours Allocations

Bill of Materials and Consumables Procurement ScheduleSubcontract Packages

Equipment and Tools ScheduleManpower Requirement

MethodologiesQCIP / Test Procedures

Test PackWork Permits / Pre-Task Plan

Risk Management

PROJECT MANAGEMENT TEAM

PROJECT EXECUTION

PROJECT LIFE CYCLE


PMTOP

ISO DrawingsSpool DrawingsWeld MappingPS Drawings

ISO DrawingsSpool DrawingsWeld MappingPS Drawings

Records and Issue • Drawing List • Piping Drawings - FI / FR Drawings - AFC Drawings • Test Pack List

• AFC Drawings - ISO Drawings - Spool Drawings - Weld Mapping - PS Drawings

• Drawing List• Piping Drawings - FI / FR Drawings - AFC Drawings• Test Pack List

• Used Drawings• Superceded Drawings


FOREMAN

SUPERVISOR

SUPERINTENDENT

FIELD ENGINEERING

EEI DOCUMENTCONTROL SECTION

CLIENT

1

2

3

4

5

8

9

10

11

1213

14

CMS

• Drawing Status• ISO Drawings• Bill of Materials

• Piping Drawings - FI / FR Drawings • Test Pack List


6

7

15

16


AFC PIPING DRAWINS FLOW CHART

PMTOP

OK to Apply WorkPermit with

attached PTP

SUPERVISOR

CLIENTWork Permit Forms Hot Work Cold Work Excavation Work Confined Space Work Road Block Vehicle Entry

Work Permit Pre-Task PlanWith attachedL5 Schedule

SAFETY ENGINEER

Approved Work Permitwith attached PTP

Approved Work Permitwith attached PTP

FOREMAN

Work Permit Activity Completed

Work Permit ActivityCompleted

1

2

3

8

9

10

11

12

13

Apply Work Permitwith attached PTP

4

5

6

7

1415

16


WORK PERMIT FLOW CHART

PMTOP

CLIENTFIELD CHANGE • Site Instructions • Field Change Notice (FCN)

FOREMAN

CN / COAPPROVED

ACCOMPLISHMENTREPORT

• SCHEDULE • RESOURCES ALLOCATION

SUPERVISORCN / CO

CN / COAPPROVED

PCG• SCHEDULE

• RESOURCES ALLOCATION


SUPERINTENDENT

1

FIELDENGINEERING


• Labor Distribution - Manhours per activity - Labor cost• Productivity

ABC • Progress • Quantity Installed • Manhours per activity • Productivity

P6

23

4

5

6

7

8 910

11

12

13

14

15

16

17

18


FIELD CHANGE FLOW CHART - CASE 1

PMTOP

CLIENT

FIELD CHANGE • Verbal instruction • Advance S.I. • Advance F.C.N.

FOREMAN

CN / COAPPROVED


FIELD CHANGE


SUPERVISORFIELD

CHANGECN / CO

CN / COAPPROVED

PCG• SCHEDULE

• RESOURCES ALLOCATION


SUPERINTENDENT

1 2

3

4

567

8

9

10

11

12

13

1415

16

17

18

19

FIELDENGINEERING


FIELD CHANGE FLOW CHART - CASE 2

PMTOP

SUPERINTENDENT

� CONSTRUCTION WORK PACKAGE • AFC Drawings (ISO dwgs, SPOOL dwgs, WELD mapping, PS dwgs.) • 3-Weeks Schedule, L5 • Materials and Consumables Allocation • Equipment Allocation • Manpower Allocation • Tool Packs Allocation

Document Control Section

SUPERVISOR CONSTRUCTION WORK PACKAGE� • AFC Drawings (ISO dwgs, SPOOL dwgs, WELD mapping, PS dwgs.) • 3-Weeks Schedule, L5 • DTRs ( Temporary and Official ) • Work Permits / PTP Materials and Consumables from � 3-Weeks Schedule, L5 MP Crew from 3-Weeks Schedule, L5� Equipment from 3-Weeks Schedule, L5� Tool Packs from 3-Weeks Schedule, L5�

FOREMAN

• DTRs (Official) – Accomplishment Reports• EDTRs – A / S (Acknowledged and Signed)• MP Crew of Completed Works• Equipment of Completed Works• Tool Packs of Completed Works• Work Permits of Completed Works• Used Drawings• Superceded Drawings

• DTRs (Official)• EDTRs – A / S PCG

EDTRs – A / SDTRs (Official)SITE ACCOUNTING

EDTRs

• Used Drawings• Superceded Drawings• MP Crew of Completed Works


• EQUIPMENT• TOOL PACKS

Work Permits of Completed Work

CLIENT

ERG

1

23

4

5

67

8

1/2


DELIVERABLES - SUPT / SUPV / FOREMAN

PMTOP

2/2

SOFTWARE HARDWARE CONSTRUCTION WORK PACKAGE AFC Drawings ( ISO Drawings, Spool Drawings, Weld Mapping, PS Drawings Every Saturday at 9:00 AM and 3 - Weeks Schedule, L5 immediate when changes occurs. Materials and Consumables Allocation Manpower Allocation Equipment Allocation Tool Packs Allocation

MP Crew of completed works Immediate Re-assignment of MP Crew ( for re-assignment or Demob) Demob MP Crew if not needed

CONSTRUCTION WORK PACKAGE AFC Drawings ( ISO Drawings, Spool Every Saturday at 10:00 AM and Drawings, Weld Mapping, PS Drawings immediate when changes occurs. 3 - Weeks Schedule, L5 DTRs ( Temporary and Official ) Temporary DTRs for 1 week and

daily for official DTRs EDTRs ( from ERG ) Daily Work Permits / PTP Daily when required

Materials and Consumables Deliver to site 2 or 3 days before the need date from schedule. Materials are good for 3 days work when pssible.

MP Crew Deliver to site 1 hr before the need date Equipment from schedule. Tool Packs

DTRs ( Official ) - Accomplishment Reports Submit daily at 9:00 AM EDTRs - A / S ( Acknowledge and Signed ) Submit daily at 9:00 AM Work Permits of completed works Submit to CLIENT daily Used Drawings Return to Superintendent immediately Superceded Drawings Return to Superintendent immediately

MP Crew of completed works Advised Superintendent and ERG Equipment of completed works 3-days before the completion of the Tool Packs of completed works works.

DTRs ( Official ) - Accomplishment Reports Submit the following day at 9:00 AM EDTRs - A / S ( Acknowledge and Signed ) Submit the following day at 9:00 AM Work Permits of completed works Submit daily Used Drawings Return to Supervisor immediately Superceded Drawings Return to Supervisor immediately

MP Crew of completed works Advised Supervisor 3-days before Equipment of completed works the completion of the works. Tool Packs of completed works

D E L I V E R A B L E S TIMELINEACTION PARTY

SUPERINTENDENT

FOREMAN

SUPERVISOR


TIMELINE for the DELIVERABLES

PMTOP

LOGISTIC • Flow of Materials • Manpower Crew • Construction Equipment • Tool Packs



PMTOP

• PMRR • GATE PASS

• JMIF

FOREMAN

SUPERVISORRDS from L5 Scheduleand Material

Allocation List

Materials from

L5 Schedule

DTRs( QTY. Installed )

Consolidated DTRs

(QTY. Installed)

PCG

MCE INSPECTION POINT

2

3

4

7

8

9

10

SITEWAREHOUSE

IMS

• INVENTORY• WITHDRAWAL

• COST OF INVENTORY• COST OF MATERIAL

WITHDRAWN PER ACTIVITY

ABC

P6

RDS from L5 Schedule

• Progress • Quantity Installed

• Manhours per activity

• Productivity

1

11

12

13

14

15

A

B

C

D

E

6

Deliver Materials from

L4 Schedule

Delivery From Procurement Plan


MATERIAL CONTROL FLOW CHART

PMTOP

DELIVERY TOSHOP FOREMAN

PIPE SHOPSUPERVISOR

ERECT FOREMAN

FIELD-ROUTED & INSTALLING

MATERIALSFABRICATION

SHOP

SPOOLS and PIPE SUPPORTS

SPOOL YARD

ISO SPOOLS and

PIPE SUPPORTS

• INSTALLING MATL’S• SPOOLS

• PIPE SUPPORTS

FIELD SUPERVISOR

MCE CONTROL POINT

IMS

INVENTORY

WAREHOUSE

RAW MATERIALS FOR ISO’S and

PIPE SUPPORTS


PIPING MATERIALS FLOW CHART

PMTOP

DTR ACCOUNTING

MP Crew forRe-assignment

or Demob

SITE HR• Billeting• EEI Orientation• Client Orientation

SUPERINTENDENT

MP Crew assignment from L5 Schedule

SUPERVISOR

FOREMAN

MP Crew reduce or MP CrewFor Re-assignment after

Works completed

MP Crew Assignment

MP Crew

SUPV. INSPECTION POINT

3

4

5

6

7

8

9

10

11

12

PERSIS

1

2

• MP Mob documents• LH MP Contracts

• MP Re-assignment• Demob MP Crew

ABC• Labor Cost

• Payroll

MP Crew forRe-assignment

or Demob 13

14

A

B

C

E

D

F

MP CREW From

MOB PLAN


MANPOWER CONTROL FLOW CHART

PMTOP

• DR• Gate Pass• EDTRs

FOREMAN

SUPERVISOREQUIPMENTrequest from L5 Schedule

EQUIPMENT

EDTRsAcknowledged /

Approved

Return Equipment

PCG

LOGISTICSERG

Return Equipment After Work Completion

EDTRs

SUPV. INSPECTION POINT

• Equipment Hour per activity• Fuel Consumption

EQUIPMENT

12

34

5

6

713

8

9

12

10

11

EDTRs Approved

EMS

• Inventory• Equipment Utilization

14

16

17

ABC

15

Mobilization from Equipment Plan


EQUIPMENT CONTROL FLOW CHART

PMTOP

INVENTORYand Cost

FOREMAN TOOL PACKS

TOOL PACKSfrom L5 Schedule

• PMRR • GATE PASS• BTS• TOOL PACKS RETURN

BTS FORTOOL PACKS

from L5 Schedule

TOOL PACKS RETURN

TOOL PACKSReturn After

Works Completed

SUPERVISOR12

3

4

5

6

7

8

910

CTRIS

SITELOGISTICS

TOOL ROOMDelivery From E & T Plan


TOOLS CONTROL FLOW CHART

PMTOP

• Test Packages • Contents of Test Pack • Contents of the QC Plan


THE TEST PACKS and QUALITY CONTROL

PMTOP

RESTORATIONSUPV

QUALITY CONTROL

TEST PACKS

SYSTEMS TEST PACK SCHEDULE

TEST PACK

TEST PACKLINE COMPLETION TP HYDROTEST TP RESTORATION

TP LINECOMPLETION

OK

TP HYDROTEST

OK

TP RESTORATION

OK

TEST PACKTEST PACK

PIPINGSUPERINTENDENT

FOREMAN FOREMAN FOREMAN

HYDROTESTSUPV

ERECTIONSUPV

FIELD ENGINEERING INSPECTION POINT

WENDS


TEST PACK FLOW CHART

PMTOP

Welder

Piping SUPV

INSPECTION POINT

TEST PACK

FIT-UP Reports

FIT-UP

Daily FIT-UP Reports

Consolidated FIT-UP Reports

Daily Schedule

PIPING Schedule, L5

3-Weeks Schedule, L5

PRODUCTION WELD

Consolidated Production

WELD Reports

Daily Production

WELD Reports

PIPING SUPT

Welding FM

Piping FM

FIT-UP

FitterCrew

Welding SUPT



WELD Reports

Welding SUPV


FIT-UP and PRODUCTION WELD FLOW CHART

PMTOP

Welder

Piping SUPV

INSPECTION POINT

TEST PACK

FIT-UP Reports

FIT-UP

Daily FIT-UP Reports


Daily Schedule

PIPING Schedule, L5

3-Weeks Schedule, L5

PRODUCTION WELD


WELD Reports

Daily Production

WELD Reports

SUPT

Welding SUPV

Welding FM

Piping FM

FIT-UP

FitterCrew


PRODUCTION WELD FLOW CHART

PMTOP

CONSOLIDATEDFIT-UP REPORTS

( Inspected / Approved ) PIPING

SUPERINTENDENT

ConsolidatedFIT-UP Reports

FIELDENGINEERING

WENDS

WELDING SUPERINTENDENTConsolidated

FIT-UP Reports

WELDINGSUPERVISOR

FIT-UPREPORTS

WELDINGFOREMAN

WELDREPORTS

ConsolidatedPRODUCTION WELD ReportsQC

NDT REPORTS

JOINT STATUS • Fit-up • Weld • NDT

12

3

4

6 7

8

9

10

11

12

165

13

15

18 17

14

PIPINGSUPERVISOR

JOINT STATUS • Fit-up • Weld • NDT

20

19


DAILY FIT-UP / WELD REPORTS FLOW CHART

PMTOP

Contents of Test Pack


TEST PACK

PMTOP

QUALITY CONTROL INSPECTION PLAN

( QCIP )1/24


QUALITY CONTROL

PMTOP

EVP

QC MANAGERBLDGS & INFRA

QC MANAGERELECTROMECH & IND’L

QC MANAGERSTEELFAB SHOP

QC’s IN-CHARGE PROJECTS



SVP

HOMEBASEPROJECT/JOB SITE

NOTE:Quality Control team OF THE SITE PMT FUNCTIONALLY REPORTS TO THE HOMEBASE QC MANAGER AND ADMINISTRATIVELY under THE JOBSITE PROJECT MANAGER.

QC GROUPMANAGER

2/24


QUALITY CONTROL ORGANIZATION

PMTOP

Quality means satisfying our customers every time we deal with them.

HOW ?By doing things right at the first time and all the time and by doing them better and better.

3/24

WHAT IS QUALITY ?


INTRODUCTION TO QUALITY

PMTOP

Higher productivity

Less rework

Less waste

Lower overall cost

Greater customer satisfaction

Higher project team morale

Credible & competitive company image.4/24

BENEFITS OF GOOD QUALITY


INTRODUCTION TO QUALITY

PMTOP

Materials Receiving & Inspection Storage

In-process Fabrication, Erection &Construction

Turn-OverInspection & Final Test

&Documentations

Project Owner

Materials identification through all stages of fabrication/construction where appropriate traceability to specified requirements.

5/24

QUALITY CONTROL PROCESS MAP


QUALITY CONTROL PROCESS MAP

PMTOP

6/24

The QCIP is essentially a schedule of HOLD POINTS on work activities that require inspection or specified test procedures, before succeeding activities are allowed to continue.




PMTOP

Sequential activities based on L5 WBS identifying work items or critical parts that will be subject to inspection or tests.

7/24

CONTENTS OF THE QCIP



PMTOP

Critical parts checked partially, progressively, or at activity completion to comply with inspection requirements.

8/24




PMTOP

Test methods and or inspection techniques to be applied in order to verify compliance to quality standards.

9/24




PMTOP

Extent of test and inspection defined by project specifications, codes, and standards (ie: 100%, 20%, 10%, 5%, Random Sampling).

10/24




PMTOP

References for work acceptance where information on tests and inspection are applied, like project specifications, codes, manufacturing manuals, or AFC drawings (This includes tolerances in measurements).

11/24




PMTOP

Organization of the Project Inspection Team composed of the FOG Foremen/ Supervisor, QC Inspector, Client’s inspectors or at times, third-party inspectors.

12/24




PMTOP

Review of RecordsWitnessing of Tests by Third PartiesAttendance to Hold PointsConduct Specified TestsActivity DocumentationIn-process and Final Inspection

13/24

QC INSPECTION ACTIVITIES



PMTOP

14/24

are effective tools in preventing escalation of non-conformances, as next activity cannot start unless the preceding work is cleared and accepted.

HOLD POINTS



PMTOP

CONSTRUCTION TEAMForemen, Supervisor and Superintendent

Perform its quality line function by ensuring compliance of the work to Client specifications, plans, drawings, applicable codes, and workmanship standards (Do it right the first time and everytime and doing it better and better).

15/24

DUTIES and RESPONSIBILITIES


ROLE OF THE FOG in QC ACTIVITIES

PMTOP

CONSTRUCTION TEAMForemen, Supervisor and Superintendent

Plan and schedule work inspection aligned to their work activity schedule to avoid delays, prepare and submit request for inspection (RFI) to QC at least 12 hours before requested time of inspection.

16/24



ROLE OF THE FOG in QC ACTIVITIES

PMTOP

QC INSPECTOR

Prepare, orient the FOG, and implement the approved QCIP to ensure that the quality requirements of the project are achieved per plan.

17/24



ROLE OF THE QC ENGINEER

PMTOP

Project assigned QC In-charge consolidate and issue the monthly OPQR to the homebase unit for the QC Head and Officers’ information and must be concurred by the Project Manager or Project In-Charge. The PM or PIC Shall respond positively and do action if the target benchmark of 95% rating is not achieved.

22/24

RESPONSIBILITY


ROLE OF THE QC ENGINEER

PMTOP

CLIENT INSPECTOR

Approve the QCIP and monitor compliance of the Construction Activities and QC Inspection performed as per the plan. Attend to the inspection if required.

18/24



ROLE OF THE CLIENT in QC ACTIVITIES

PMTOP

Any work deviation from the

reference specification, codes,

standards, sound engineering

practice and approved material.

19/24

NON-CONFORMANCE


NON CONFORMANCE

PMTOP

QC Inspection Report (QCIR)

A report on any ACCEPTANCE or Non-conformances (usually minor findings)

Non-Conformance Report (NCR)

A report on any NON-CONFORMANCE or deviation. (usually major findings that may have greater impact to project quality)

20/24

NON-CONFORMANCE


NON CONFORMANCE

PMTOP

Projects’ Quality Status are monitored / reported monthly by the quality control as a management tool to give indicator for actions of the PMT to avoid or minimize the lost of profit due to poor quality of works and excessive repairs.

21/24

OPERATION PROJECT QUALITY RATING


QUALITY CONTROL RATING

PMTOP

Increased quality is likely to be associated with project whose team members display pride, commitment and an interest in workmanship.

23/24

A FINAL WORD ON QUALITY WORK


QUALITY CONTROL MESSAGE

PMTOP

Remember this…….““The cost of repair and / or The cost of repair and / or rejection comes directly out rejection comes directly out of profit”. of profit”.

24/24


QUALITY CONTROL MESSAGE

PMTOP

of Day 2

PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM PMTOP

Date post:	18-Jul-2016
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