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Site Material Management

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A brief overview of some of the important considerations when implementing a material control system. Some examples of systems in the field and the functionality they can provide. …

A brief overview of some of the important considerations when implementing a material control system. Some examples of systems in the field and the functionality they can provide.

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  • Project management systems that integrate and make use of information from every part of the supply chain are becoming more sophisticated.
  • Successful projects reap the benefits of a disciplined approach to supply chain management. Site material management being at the end of the chain, relies heavily on careful documentation and sharing of information from engineering, procurement and logistics functions. From CAD design systems we now extract with relative ease, full material take offs and bills of materials for all areas of the plant design. Often this work is carried out many months before there is any construction activity at site so can easily be overlooked. By linking engineering and design data to site material management you will many hours of work with a better system for controlling and issuing materials. Material Requests Some SMM systems can now call up material requirements based on installation drawings used at site. A material engineer simply loads the drawing numbers and a build analysis is carried out to verify there is enough materials to complete the current activity. If there is insufficient materials work may be rescheduled until the material arrives at site.
  • Missing information from any part of the supply chain can result in poor management of resources, including warehousing, site laydowns, equipment and human resources for unloading, inspecting materials and general handling. Accurate expediting reports allow site material managers and site planners to adjust the schedule if needed based on scheduled deliveries.
  • A key to successful site material management is implementing best practice methodologies, procedures and control systems to link all parts of the supply chain. During a project assignment to Pend Lai, China, Michael was tasked with implementing a material control system for the module yard. A total of 350 containers were in transit and all due to hit the wharf within six weeks. Having accurate information of container contents was imperitive for the planning of warehousing, laydown yard use and people and equipment resources
  • A key to successful site material management is implementing best practice methodologies, procedures and control systems to link all parts of the supply chain.
  • Michael Downing worked closely with PJOE fabrication company. During startup of the module yard Michael oversaw the implementation of integrated management systems for the control of site materials. The Chinese had fairly simple control systems but instead chose to adopt the integrated system as it provided advance build analysis of each module and accurately tracked materials in multiple warehouses, lay down areas and materials in transit.
  • Cutting edge technology, such as the satellite GPS tracking system used at the Boyne Smelter can see huge gains in productivity. Receiving materials is faster and the time to locate, tag and retrieve materials is significantly reduced. The material tracking system project was managed by Michael Downing. The system successfully tracked over 14,000 steel components and recorded exact placement in each lay down yard. The use of the system was later expanded to assist with receiving and tracking 3.7 million refractory bricks, with storage locations in both Gladstone and at site.
  • Cutting edge technology, such as the satellite GPS tracking system used at the Boyne Smelter can see huge gains in productivity. Receiving materials is faster and the time to locate, tag and retrieve materials is significantly reduced. The material tracking system project was managed by Michael Downing. The system successfully tracked over 14,000 steel components and recorded exact placement in each lay down yard. The use of the system was expanded to assist with receiving and tracking 3.7 million refractory bricks, with storage locations in both Gladstone and at site.
  • The ground is littered with the remains of the 1000’s of firecrackers. Michael Downing (6 th from right) was assigned to the fabrication yard during the initial weeks of the project to ensure material control methodology and systems were correctly implemented by the fabricator.
  • Transcript

    • 1. Site Material Management: Presented by Michael Downing Project Controls Manager and Project Management Specialist Perth, Western Australia 2011 Best practice in control systems
    • 2.
      • Presentation Contents
      • SMM Definition
      • Information Sources and Integration
      • Systems Options
      • Case Study 1 – Module Fabrication
      • Case Study 2 - EPCM
      Site Material Management
    • 3. Site Material Management (SMM) is the Management, Planning, Monitoring and Control of all materials (bulk and equipment) for the project . Site Material Management
    • 4. Receiving Shipping Expediting & QS Purchasing Engineering Procurement Construction Supply Chain Material List Site Material Management Logistics Quality Surveillance Expediting Purchase Order Site Material Management Procurement Package
    • 5.
      • Information Sources - Engineering
      • Equipment Lists
      • Material Take Offs (MTO)
      • Bill of Materials (BOM)
      • Procurement Items
      Site Material Management
    • 6.
      • Information Sources - Procurement
      • Purchase Orders
      • Expediting Reports
      • Logistics
      Site Material Management
    • 7.
      • Information Sources - Logistics
      • Shipping manifests
      • Container reports
      • Packing Lists
      • Pre-Alerts
      Photo: Fabrication Yard, Peng Lai, China 2009 Having accurate information allows for better planning of people and equipment resources for unloading Site Material Management
    • 8. Information Sources - Integration Engineering Procurement Logistics Material Controller Site Material Management
    • 9. Systems Options Site Material Management Fully Integrated EPCM System Fully Integrated EPCM System Multi Company Disjointed Applications Fully Integrated EPCM System OR
    • 10. Case Study 1 Sino Iron Desalination Plant Module Yard Management Peng Lai, China 2009 Site Material Management Photo: Loading module at PJOE wharf for transportation to Cape Preston, Western Australia
    • 11. Case Study 2 Rio Tinto Alcan – Boyne Smelter Anode Furnace Construction Boyne Island, Queensland 2010 Site Material Management Photo: Michael Downing using the satellite GPS material tracking system in one of the smelter lay down areas.
    • 12. Site Material Management Photo: Material locations are plotted on google maps allowing for fast location and retrieval of components.
    • 13. Site Material Management Photo Album Cutting Ceremony - Michael Downing (4 th from left) touring the Chinese workshops as fabrication of the first module commences.
    • 14. Site Material Management Photo Album The setting off of 1000’s of firecrackers brings good luck and marks the commencement of each new module.
    • 15. Site Material Management Photo Album The setting off of 1000’s of firecrackers brings good luck and marks the commencement of each new module.
    • 16. Site Material Management Photo Album Unloading steel components at Rio Tinto Alcan’s Boyne Smelter
    • 17. Site Material Management Photo Album Unloading steel components at Rio Tinto Alcan’s Boyne Smelter
    • 18. Site Material Management Photo Album Office based staff can search for material and place material requests. Site staff using hand held GPS and 3G communications devices can locate material quickly in the field.