pmtop day2
DESCRIPTION
PMTOPTRANSCRIPT
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
THE CONSTRUCTION PHASE
SUPPORTING THE FOREMAN
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
THE CONSTRUCTION PHASE
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• Used Drawings• Superceded Drawings
• Used Drawings• Superceded Drawings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
• Used Drawings• Superceded Drawings
6
7
15
16
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
• SCHEDULE • RESOURCES ALLOCATION
SUPERINTENDENT
1
FIELDENGINEERING
ACCOMPLISHMENTREPORT
• 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
THE CONSTRUCTION PHASE
FIELD CHANGE FLOW CHART - CASE 1
PMTOP
CLIENT
FIELD CHANGE • Verbal instruction • Advance S.I. • Advance F.C.N.
FOREMAN
CN / COAPPROVED
ACCOMPLISHMENTREPORT
FIELD CHANGE
• SCHEDULE • RESOURCES ALLOCATION
SUPERVISORFIELD
CHANGECN / CO
CN / COAPPROVED
PCG• SCHEDULE
• RESOURCES ALLOCATION
• SCHEDULE • RESOURCES ALLOCATION
SUPERINTENDENT
1 2
3
4
567
8
9
10
11
12
13
1415
16
17
18
19
FIELDENGINEERING
THE CONSTRUCTION PHASE
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
• Used Drawings• Superceded Drawings
• EQUIPMENT• TOOL PACKS
Work Permits of Completed Work
CLIENT
ERG
1
23
4
5
67
8
1/2
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
TIMELINE for the DELIVERABLES
PMTOP
LOGISTIC • Flow of Materials • Manpower Crew • Construction Equipment • Tool Packs
THE CONSTRUCTION PHASE
SUPPORTING THE FOREMAN
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
TOOLS CONTROL FLOW CHART
PMTOP
• Test Packages • Contents of Test Pack • Contents of the QC Plan
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
Consolidated FIT-UP Reports
Consolidated Production
WELD Reports
Welding SUPV
THE CONSTRUCTION PHASE
FIT-UP and PRODUCTION WELD 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
SUPT
Welding SUPV
Welding FM
Piping FM
FIT-UP
FitterCrew
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
DAILY FIT-UP / WELD REPORTS FLOW CHART
PMTOP
Contents of Test Pack
THE CONSTRUCTION PHASE
TEST PACK
PMTOP
QUALITY CONTROL INSPECTION PLAN
( QCIP )1/24
THE CONSTRUCTION PHASE
QUALITY CONTROL
PMTOP
EVP
QC MANAGERBLDGS & INFRA
QC MANAGERELECTROMECH & IND’L
QC MANAGERSTEELFAB SHOP
QC’s IN-CHARGE PROJECTS
QC’s IN-CHARGE PROJECTS
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
THE CONSTRUCTION PHASE
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 ?
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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.
QUALITY CONTROL INSPECTION PLAN
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
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
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
PMTOP
Critical parts checked partially, progressively, or at activity completion to comply with inspection requirements.
8/24
CONTENTS OF THE QCIP
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
PMTOP
Test methods and or inspection techniques to be applied in order to verify compliance to quality standards.
9/24
CONTENTS OF THE QCIP
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
PMTOP
Extent of test and inspection defined by project specifications, codes, and standards (ie: 100%, 20%, 10%, 5%, Random Sampling).
10/24
CONTENTS OF THE QCIP
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
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
CONTENTS OF THE QCIP
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
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
CONTENTS OF THE QCIP
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
PMTOP
Review of RecordsWitnessing of Tests by Third PartiesAttendance to Hold PointsConduct Specified TestsActivity DocumentationIn-process and Final Inspection
13/24
QC INSPECTION ACTIVITIES
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
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
THE CONSTRUCTION PHASE
QUALITY CONTROL INSPECTION PLAN
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
THE CONSTRUCTION PHASE
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
DUTIES and RESPONSIBILITIES
THE CONSTRUCTION PHASE
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
DUTIES and RESPONSIBILITIES
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
DUTIES and RESPONSIBILITIES
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
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
THE CONSTRUCTION PHASE
QUALITY CONTROL MESSAGE
PMTOP
of Day 2
PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM PMTOP