SANER TANJU ATIS_MMS

1,279 views

Published on

Strategic Approaches to Material Management Sytem at site

0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
1,279
On SlideShare
0
From Embeds
0
Number of Embeds
17
Actions
Shares
0
Downloads
17
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

SANER TANJU ATIS_MMS

  1. 1. STRATEGIC APPROACHES TO MATERIAL MANAGEMENT SYSTEM AT SITE <br />INDUSTRIAL PROJECTS......<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  2. 2. AGENDA<br /> <br />1 -What is the Strategic Material Management System at Site?<br /> 2 -Why is it important?<br /> 3 -Strategic MMS analysis at Site<br />4 -Principles of Warehouse design<br />5 -Essentials Symbols for handling and storage<br />6 -Receipt and Incoming Stages<br />Inspection Flow<br />Inspection of Incoming Process- IIP<br /> What constitute a material deviation ?<br />7 -Objectives of the MTC – Material Test Certificates<br />8 -Storage – a Pillar of Category Process<br />9 -In-Warehouse Preservation – Improving the work Methods<br />10-Proven Issue methods – LBID Cycle <br /> 11-Question /Closing<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  3. 3. What is the Strategic Material Management System at Site?<br /><ul><li>Scientific technique, Concerned with planing, Organizing & Control of flow of .. </li></ul> ... Good Overview, Comprehensive view of Inventory<br /> ...A well- organized design on effective stores layout <br /> ...Enhance performance to support operations......<br /> ...To consolidate and efficiently handling process...<br /> ...Safety, Knowledge and Data transfer...<br /> ...Quality control is integral to the continuing of operation..<br /><ul><li> Ability to anticipate needs, forecast conditions, set goals and standarts, plan and schedule work and measure results.</li></ul> <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  4. 4. Why is MMS important at site?<br /><ul><li>Support us organisation’s strategic and complimantary planing at site
  5. 5. Increase ability of workforce to utilize operations bases
  6. 6. Creates and enable a learning , sharing and focus an practical application
  7. 7. Quality and technical skills improvement.
  8. 8. Improved internal teamwork and communication
  9. 9. Streamlined our work for better time and business process
  10. 10. Focuses on making changes to simplify and become more efficiency</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  11. 11. STRATEGIC MMS ANALYSIS at Site<br />Strategic Action View<br />Strategic Look-ahead View<br />Transportation<br />- Review<br />- Needs<br />-Time Period<br />- Knowledge <br /> Transfers<br />Observed <br />Shipment Data<br />Selection Criteria <br /> - Detect lists<br /> - Classify<br /> - Internal & Exter. <br /> Communications <br />Observed <br /> Packing Analysis<br />Handling Plan<br /> - Indivudual <br /> materials<br /> group<br /> - Storage <br /> objective <br /> - Storage <br /> strategies <br />Planning<br />Management <br />Plan<br />- Procedures<br />- Instructions<br />- Training<br />Planning<br />Organ.Chart<br />- People/<br /> Positions<br />- Seperate<br /> disciplines<br />- Workforce <br /> Planing<br />Observed <br />Data Analysis<br />Action Plan<br />- Analysis <br /> Prioritize<br />- Review plan<br />- Execution<br /> plan<br />Planing<br />SUCCESS<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  12. 12. Principles Of Warehouse design<br />Scope of Work ;<br /><ul><li>Storage instructions based on materials specifications and manufacturers instruction</li></ul> .......Take over facilities for warehouse and site store<br /> ......... Type, condition,number of facilities<br /><ul><li>Temporary site facilities arrangement </li></ul> ..... location of quarantine store, clear separation<br /><ul><li>Technical specification for warehousing</li></ul> .... .Materials handling details,organizing principals<br /> ........Organize storage areas in compliance with storage instructions<br /> ...........Designation of storage areas by categories(open air, covered,with air-conditioning, etc)<br /><ul><li> Install computer hardware and software</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  13. 13. The factors elements<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  14. 14. <ul><li>Type Of Storage (TOS)=A + B + C + D
  15. 15. A=The Scope of items Supplied
  16. 16. Piping, Electrical, Equipments, Steel Structures
  17. 17. B=Material Specifications
  18. 18. Instructions Specified by Manufacturers
  19. 19. C=Order Volume
  20. 20. Project Material Orders (Acc.. BOQ)
  21. 21. D=Safety Measures
  22. 22. Detrimental Conditions (by moisture,rain, snow,sandstorm,insects),dirt(by bird droppings,dust,tar), static and dynamics load.
  23. 23. Closed Area TOS</li></ul> Open Area <br />Lockable, <br />Air condioned,<br />Dry<br />With Fence,<br />Without Fence,<br />Roofed<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  24. 24. Features of Database System for Material Handling<br /><ul><li>Material cataloque and part list of ısometrics
  25. 25. Filter functions
  26. 26. Import record of order data
  27. 27. Scheduling in advance
  28. 28. Storage areas and material Certificate
  29. 29. Material receving on site
  30. 30. Storage list
  31. 31. Material reservation (Piping) and material issuing</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  32. 32. Material handling process<br />HEAD OFFICE<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  33. 33. Material Work Flow<br />WAREHOUSE<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  34. 34. Essentials Symbols for handling and storage <br />The Symbols for handling storage marked on the packages and equipment items in accordance with EN ISO 780 should be observed. Symbols for the handling of equipment<br /><ul><li> 1 = This is up
  35. 35. 2 = Fragile, handle with care
  36. 36. 3 = Keep dry
  37. 37. 4 = Keep away from heat1 2 3 4 5
  38. 38. 5 = Use no hooks
  39. 39. 6 = Centre of gravity
  40. 40. 7 = Sling here
  41. 41. 8 = No hand truck here
  42. 42. 9 = Clamp here6 7 8 9 10
  43. 43. 10 = Do not use fork lift truck here
  44. 44. 11= Roofed storage
  45. 45. 12=Storage in closed rooms
  46. 46. 13=Storage at ambient temperature of >0
  47. 47. 14=Storage in air condition 11 12 13 14 </li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  48. 48. Lifting and Slinging gear<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  49. 49. Receipt and Incoming Stages<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  50. 50. Inspection Flow<br />Project site<br />Port<br />Transport Agent<br />Loaded On Truck<br /> LOT<br />Receipt Of Package<br />Unpacked<br />Reports<br />Checking the packing <br />for damage during the Ship Checking the outside packing <br /> for damage during transport to site<br />Checking the packing lists against the number of packages received,<br />Checking the outside packing for damage,<br />Checking the inside packing (e.g. welded plastic sheets) for damage,<br />Checking damaged packages for completeness and damage to the contents,<br /> Checking any protective inert-gas fillings. Essential Reports <br /> (MRR,etc..) <br />Checking the contents for completeness,<br /> Checking the outer condition of the <br /> indivudual components.<br /> (e.g. corrosion protection, preservation),<br />Checking the technical details<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  51. 51. Inspection of Incoming Process IIP – Specific Projects Materials<br />• checking for damage in transit, <br />• checking the accessories (gaskets, bolts, etc.) supplied for completeness and correctness <br />Equipment & Steel Structures<br />• checking the material for completeness, <br />• checking the material for being undamaged (damage in transit), <br />• visual inspection for compliance with the technical specification (e.g. sealing faces, supporting surfaces of bolts, welding edges, etc.), <br />• checking for correct stamping, coding, batch number and compliance with certificate, <br />• checking the marking of valves, <br />• dimensional checking (mating dimensions, wall thickness, weld edge preparation, thickness of flanges, bolt holes, roundness), <br />Piping Materials<br />IIP<br />• checking the name plate data for compliance with the purchase order specification, <br />• comparing the characteristic data of the material supplied with the data sheets, <br />• checking the material for being undamaged (damage in transit), <br />• checking for completeness, especially the accessories. <br />Electrical & Instrumentation<br />• Sensitive Materials<br />• checking the package properly<br />Fragile, Others <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  52. 52. What Constitutes a material Deviation ?<br />Deviations<br />Overage Damage Hold Rejection <br /> Shortage <br />Deficiency Report<br /> Dimensional <br /> Technical Specification<br /> Elimination of Defects <br /> Faulty Assembly <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  53. 53. Objectives of the Material Test Certificates <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  54. 54. Face the Fact<br /><ul><li> A control necessary to meet the control objectives is available or...
  55. 55. Identified material and Match with Test Certificates to ensure..
  56. 56. Material Safety Data Sheet (MSDS),Chemical and Hazardous Materials</li></ul> .... Work place safety<br /> .... Physical and chemical datas<br /> ..... Storage and handling informations<br />Item Code (Part No)<br />ASTM Standart<br />Heat Number<br />Dimension<br />90 Degree Elbow <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  57. 57. CONFIDENTIAL – Saner Tanju ATIS<br />
  58. 58. Storage – a Pillar of Category Process<br />...............Technical Specification<br />The individual groups of components must be characterized by boards, marked with part number, dimension<br />and material.<br />Technical International Standarts.<br />Stored in accordance with the technical specification<br />...................Implement Instruction (Vendor)<br />In accordance with the manufacturer’s instructions either outdoors,indoors, in cooled or in dry rooms.<br />Material Data Sheet instruction to be followed.<br />......................Safety and Security Regulations<br />Safety regulations for chemicals and dangerous materials should be applied.<br />The products which would be damaged through exposure from sunlight should be protected by adequate covers or stored indoors.<br />Adequately protected and guarded against theft, pilferage,fire.<br />........................Segregation (Storage Profiles and Layouts)<br />External and internal storage areas (aisles,bin,section,yard plots etc.) should be clearly defined and identified with appropriate<br />storage location sign as per material storage plan.<br />Designated Area in the basis of Unit Process.<br />............................Traceability<br />Identify Locations data transfer to material Tracking system.<br />Completeness of the information for every step in a process.<br />Refers to the capability to gain materials in the timely manner.<br />Monitor and issued “first come-first go” basis..<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  59. 59. Storage – Creating a Plan to achieve your goals !<br /><ul><li>Anticipation to deliveries schedule for priority plan
  60. 60. Make a adequate reserve place of estimated capacity for materials
  61. 61. Knowledge sharing with team,information, Skills, or expertise
  62. 62. Build and Organize , motive your team to get to do deliveries and storage conditions</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  63. 63. Open area (Laydown)<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  64. 64. Piping components<br />Pipes, spools, fittings, elbows, flanges and valves.<br />stored outdoors on timber baulks of approx. 150 mmthickness or on timber pallets.<br />Flange faces shall not be damaged.<br />Pipes may be stacked to a height of approx. 1.5 m if properly secured.<br />In the case of pipes . DN 500, only twopipes should be stacked one upon the other.<br />Storage – Individual Stock <br />Equipment & Vessels, Steel Structures<br />dcsSteel structures, vessels, machinery, and the like should be stored outdoors on timber baulks of approx. 150 mm<br />thickness. Placing the equipment on unprotected, bare, or machined surfaces as well as on flanges is not<br />permitted. Care shall be taken not to damage nozzles, shaft ends, or other protruding parts.<br />Electrical & Instrumentation<br />Transformers for outdoor service, cable supports, cable drums and sectional steel for fixtures may be storedoutdoors.<br />Other electrical, measuring and control equipment should be stored in dry and well ventilated rooms on timberpallets or on shelves.<br />Instruments shall be stored on shelves. The original packing shall only be removed at the place of installation.<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  65. 65. .<br />Rubber-lined equipment and plastic equipment shall be stored with special care.The temperature within rubber-lined equipment should not drop below -10oC if the hardness of the<br />rubber lining is > 75 Shore D and not below -20oC if the hardness of the rubber lining is < 75 Shore D<br /> Storage – Individual Stock <br />Coating materials shall be stored at temperatures between 5C and 30C in dry and well ventilated rooms. <br />Bricks (for refractory linings), <br />Polyester resins<br />Solvents, fuels, lubricants, and corrosive chemicals<br />Oils and insulating fluids <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  66. 66. Matrix for Storing Facilities and Locations<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  67. 67. In-Warehouse Preservation – Improving the work Methods<br /><ul><li>Create a preservation communication and application plan
  68. 68. Make an Assessment, Classifiedgroup of materials, safety regulations
  69. 69. Establish priorities, DesignatedStorage areas,Preservation team for tasks..
  70. 70. Identified needed resources, vendor specific documents,Manufacturers Instructions
  71. 71. Identify short and long term activities, storage and maintenance duration
  72. 72. Develop a strategy to increase preservation, enhance performance result of implementation
  73. 73. Application of preservation agents instructions ( e.g. Table.1..),recommendations
  74. 74. Tracibility of Preservation Matrix, Requirements, Interval, Referance documents,Storage areas
  75. 75. Execution at site, Labeling – Job Card and Recording</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  76. 76. CONFIDENTIAL – Saner Tanju ATIS<br />In-Warehouse Preservation – Preservation Recommendation<br />
  77. 77. CONFIDENTIAL – Saner Tanju ATIS<br />In-Warehouse Preservation – Regular Checking Period<br />
  78. 78. KEEP<br />ME<br />CLEAN<br />After<br />Before<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  79. 79. Proven issue Methods<br /><ul><li> Issue starts and an ongoing with engaged the project time schedule
  80. 80. Compliance of essential circumstances to issue
  81. 81. Indivudal groups materials
  82. 82. Return, Take back to Store
  83. 83. LBID Cycle – Journey to Movement</li></ul>........ From our initial engagement with all movements to the end of Material journey to adhere to the stipulated time for Individual Projects. <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  84. 84. Proven issue Methods - LBID CYCLE<br />Lean<br /> Breakthrough<br />ASSURE<br />Delivery + Order <br />Piping – Prefabrication <br />Inspection<br />Isometric -Reservation <br />AUTHENTICATED<br />Pipes, Fittings.... <br />MTC- MSDS <br />Equipment<br />REALIZE<br />Electrical<br />Availablity<br />Piping - Erection<br />Isometric -Reservation <br />Commissioning<br />Valves, Bolts,Gaskets... <br />Piping - Erection<br />Equipment, Others<br />Equipment, Others<br />E + I<br />E + I<br />Recycling<br />Incremental<br /> Decisive<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  85. 85. Proven issue Methods – Variable Rates <br />1<br />% 55 Piping > % 20 Eqp. + % 15 Elec.<br />2<br />3<br />% 55 Eqp > % 30 Piping + % 20 E+I <br />% 58<br /> E+I > Eqp<br />% 75<br /> E+I > Piping <br />% 40 <br />Eqp > Piping<br />% 65 E+I > % 25 Eqp. + % 15 Piping <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  86. 86. Proven issue Methods - Progress Zone Coordinates <br />%<br />Eqp. <br />P<br /> E+I<br />Z2 <br />End Line <br />Initial Line <br />.<br />65 <br />.<br />.<br />55 <br />Z1<br />50 <br />.<br />30 <br /> Z1 >Z2<br />.<br />25 <br />.<br />.<br />.<br />.<br />20 <br />15 <br />Zone<br /> 1 <br />3 <br />2 <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  87. 87. Sample - Cycle of Project Materials<br />Kg <br />Kg <br />CONFIDENTIAL – Saner Tanju ATIS<br />
  88. 88. MIF- Material Issue Form<br />CONFIDENTIAL – Saner Tanju ATIS<br />
  89. 89. MMS – Closing<br />......Facilitate having good inventory improvethe efficiency organization<br />.........Organizationalgoalsettings <br />.............Additionalstrategic planning initiatives<br />.................Evaluation of correct performance indicators <br /><ul><li>Development of additional internal and external performance measuresfor the Organization
  90. 90. Buildingan integrated Warehousing system
  91. 91. It is an integrated process thatdemands integrated processes and databases to become truly effective.
  92. 92. The need for sharing processes and databases throughout the entire organization
  93. 93. Additionaleducation and employee empowerment lead to increased job satisfaction and personal performance</li></ul>CONFIDENTIAL – Saner Tanju ATIS<br />
  94. 94. MMS – Closing<br />Open Discussion<br />Questions<br />Saner Tanju ATIS<br />saneratis@yahoo.com<br />CONFIDENTIAL – Saner Tanju ATIS<br />

×