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SANER TANJU ATIS_MMS

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Strategic Approaches to Material Management Sytem at site

Strategic Approaches to Material Management Sytem at site


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