TQM Study in Royal Commission
of Jubail CEM 515
Purpose of the royal commission
Is to develop, construct and maintain the infrastructure of Jubail-2:
Earth Work, Concrete channels & bridges roads Substations 230/34.5 kV & 115/34.5 kV (SEC) Telecom (STC) pipelines: - Seawater cooling (Marafiq) - Water in/out (Marafiq) - Industrial gas Methane/ Ethane (ARAMCO) - Industrial waste (Marafiq)
Sea water cooling pipeline
Problem statement Lack of Coordination between Royal
Commission and Marafiq for the final acceptance of construction works of Jubail-2 Projects
Effects Delay on close-out date of the
project Excessive submittal review work Punch list items not in the scope of
contract Unfamiliarity with construction
problems Rework of finished work Specifications correspondence
between entities Reject of work already paid/accepted
Pareto
Note: Based on feedback from RC staff involved in the project
Pareto Chart
0
5
10
15
20
25
30
35
Delay
Excess ive subm ittals
Unclear scope
Unfam iliar with cons truction
Rework
Specs correspondance
Reject work
As-planned
Award
Initial Acceptance
Close-out
Project Timeline
Final acceptance
App
rova
l of
proj
ect
Area of concern
As-built
Award
Initial Acceptance
Close-out
Project Timeline Commissioning
Delay
Final acceptance
App
rova
l of
proj
ect
RC flow chartStart
Plan the project
Prepare budget
Start design
Marafiq involvement
Start construction
Handle-over to Marafiq IAMarafiq involvement
Close-out
End
YES
NO
Area where problem is noticed
Problem discussion
START
Contractor complete Milestone &ready for Initial Acceptance (I/A)
FCS &his group
determine if milestoneis complete and
contractor requestis ok
Contractor send letter request for I/A
If the above is acceptedFCS prepare I/A inspection package
A
RC Acceptance teamwill designate team for inspection
RC Acceptance teamwill issue I/A Deficiency List
for the complete scopeFCS will review items and
issue letter to Contractor to completeall I/A deficiencies
When I/A Deficiency completedto the satisfaction of FCS,
a request for re-inspection of thecompleted items is sent
The RC acceptance team will issuethe Initial Acceptance Exception List
(Exception for remaining deficiencies)
A
FCS will recommendInitial Acceptance Certificate
with the exceptions to RC
Contractor to complete allexception items during the
warranty periodIf all I/A exception items are
satisfactory completed and the oneyear warranty finish, the FCS/Contract Administrator will
recommend and issueFinal Acceptance Certificate
to RC approvalAll performance bond and release
of financial issues will be done uponissuance of Final Acceptance
Certificate
INITIAL ACCEPTANCE FLOWCHART
END
Yes
No
RC Acceptance team will contactinvolved future Owner Utility Co.
MARAFIQ
SCECO
POWER& TELECOM
ROADS
Process mapping
Marafiq
RC Construction
RC Engineering
RC IA Team
Contractor
Plan
Review
Review
Design
A/E Design
Review
Award
Construct
Supervise Inspect
Inspect
Inspect
Inspect
Review
Accept
Accept
Initial acceptance requirements
AS-BUILT O&M Manuals Spare parts Encroachment Permit
Warranty Performance bond – cant be 3rd party beneficiary
Change orders Claims
Close-out requirements Technical submittals-who should review
them QC documentation Spare parts O&M Manuals As-built drawings Testing and commissioning-wittiness Final quantities Change orders and claims In-House inspection
Force field analysis
• Contractor wants to finish work
• Finance department stress to close-out the project
• Jubail-2 schedule time
• Upper management monthly reviews
• Staff accomplishment records
• Reputation of the Royal commission
• Old procedures JMP-1975
• NO custodian contractual liabilities
• specification correspondence
• Motivation of staff
• Overload on Marafiq
• Mutual scope clarification
• Warranty/Bond expiry
Cause and effect diagram
Lack of coordination between RC and Marafiq
Contractor procedure RC procedure Marafiq procedure
Contractor people RC people Marafiq people
No tracking system
New staff
No technology involved
No mutual procedureUn familiar to RC
No Motivation
OverloadLack of knowledge
Contractual obligation s
When to review submittals
No Mutual procedure
No quality check
No reporting system
New staff
No Motivation
OverloadLack of knowledge
No Motivation
Lack of knowledge
Not familiar with procedures
Solution Review IA procedure and requirements Involve custodian in analysis design and
all construction phases Recruit more people Assign a contractual obligation to
custodian in order to meet demands Establish Mutual procedure Online mutual courses with Mutual
procedure Motivate people