20Executive Material ControlPlan.docx
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20ExecutiveMaterialControlPlan
2.0ExecutiveMaterialControlPlan
CONTENTS
1.General
2.ApplicableSpecification
3.Organization&Duties
4.Pre-FabricationShopReceivingMaterialManagementProcedures
5.MaterialFurnishedByContractor
6.MaterialWarehousingAndStorage
7.ErectionMaterialAndEquipmentManagementProcedures
8.ReturnOfMaterialsToWarehouse
9.SpecialToolsAndSpareParts
Attachments:
Attachment1:
MaterialControlOrganizationChart
Attachment2:
Pre-fabricationMaterialManagementFlowDiagram
Attachment3:
FieldErectionMaterialManagementFlowDiagram
Attachment4:
PipingMaterialHandling/Storage/PreservationProcedure
1.GENERAL
ThisplancoverstheTCC’smaterialhandlingandcontrolprogrammeintendedtobeconductedatthesiteforSubcontractWorksofAbovegroundPiping,Painting&MechanicalWorksofDungQuatRefinery(DQR)Project.Thisistodefinetheentirematerialcontrolfunctionfrompreparationformaterialreceivingbothatpre-fabricationshopandatsite,unloadingwork,handling,unpacking,receivinginspection,materialstorageincludingpreservation,andmaterialissuance,toreuseorscrapofmaterial.
2.APPLIABLEDOCUMENTS
ØContractor’sPS&KPDocuments
ØTCC’sQualityAssuranceManualandProceduralDocuments
3.ORGANIZATION&DUTIES
3.1Organization
ThefieldorganizationfortheMaterialControlisshowninAttachment-1herewith.
3.2Responsibility
AllMaterialControllersandwarehousingkeepersareonfull-timeassignmenttositeorganization.Theirrespectivefunctionandresponsibilityareasfollow:
3.2.1MaterialControlManager
(1)General
TheMaterialControlManagerhastheresponsibilitytoplanandexecuteallfunctionsandactivitiesintheMaterialControlGroup(MCP)toleadthefieldworksuccessful.MaterialControlManagerwillsetandissueinstructiontohissubordinatingstaff,communicatewithotherrelatedgroups,subcontractors(ifany),thirdparty,etc.,andreporttotheProjectManger.
Hisdutyalsoincludesactivitiesrelatedtomaterialsinconstructionphaseandcertainareainengineeringandprocurementphase(asandwhenrequired)andtomaintaincloseco-ordinationwithContractorFieldMaterialControlGroupandTCChomeofficetogainconsistentcontrol.
(2)ProcedureandOperationSystem
HewillbeinvolvedinthecoordinationandimplementationofthefollowingproceduresandMaterialControlSystem.
-MaterialControlSystem
-FieldMaterialPreservationProcedure
-FieldPurchasingProcedure
(3)InformationonMaterialStatus
HeisresponsibleforcollectingthefollowinginformationrelatedtomaterialstatustoproceedwithMaterialControlGroup’sworksattheSitesmoothly.
-BillofMaterial(B/M),itslatestrevisions,andFieldchangesheetstoknowthefinallynecessaryquantitiesofmaterials.
-EquipmentList
-PurchaseOrders(P/O)
-MaterialStatusReport(MSP)
-PackingListprovidedbyContractorforitssuppliedmaterialsandequipment.
-Catalogue(Equipment,toolsandmaterials)
-HeavyCargosandDangerousCargoesList
-StorageInstructionandPreservationInstructionfromVendor.
Heisalsoresponsibletomaintainandarrangeallmaterial-controlrelateddocuments.Essentialdocument,suchasthoseunder-mentioned,shouldbesystematicallyfiledforimmediateandaccuratereferenceatalltime.
-Cargos/MaterialArrivalNotice(withPackagingList)
-DailyReceivingReport
-Cargos/MaterialReceivingInspectionReport
-TruckfromInlandTransportation
-LocalMaterialPurchaseOrder(L-P/O)
-MaterialExceptionReport(MER)
-ClaimRegistrationforMarineDamagesandInsuranceifsuppliedbyTCC
-MaterialIssuanceRecordtoworkingcrewsand/orsubcontractors.
(4)OverallPlanning
Assistedbyhissubordinatingstaff,andsupportedbyContractor’sCoordinator,heisresponsibleforsettingoverallplanformaterialsoff-loading,receiving,storageandissuing.
(5)MobilizationPlanforWorkForce
HeisresponsibleforplanningaworkforcemobilizationfortheMaterialsControlGroupwhichincludeswarehousekeeping,cargodischarging&in-sitetransportation,materialtransaction(receiving&issuing)etc.
(6)MonitoringofCriticalMaterial
Heisresponsibleformonitoringmaterialstatusandissuinganalarmtothefieldmanagementwhenmaterialshortageisexpectedormaterialdeliveryscheduleisnotconsistentwithfieldwork.
(7)Safety
Hehasthefullresponsibilityforthesafetyofhismaterialcontrolgroupinroutinematerialhandlingactivitiesmonitoringthroughhismaterialcontrollers.
(8)Security
HewillcoordinatewiththeContractor’ssecuritydepartmentsandensurethatmaximum-securitymeasuresareprovidedtosafeguardallmaterialsandpropertiesundercustodyoftheMaterialControlGroup.Hewillalsomonitorthroughhissubordinatestafftheproperenforcementofsuchsystem.
3.2.2MaterialController
(1)General
TherespectiveMaterialControllersareresponsibleforthecontrolofallmaterialsandequipmenteitherreceivedfromContractorordirectlysuppliedbyTCC,undereachassignedcategory,fromwhichtheyaredeliveredtoastorageareatilltheissuancetoworkingcrewsforfabricationorfieldinstallation.
TheMaterialControllerisresponsibletoexecutereceivingactivities,andhandoverthereceivedcargoestoeachcategoryworkingcrewinaccordancewiththisprocedureanddetailprocedure.
(2)MonitoringofShippingForecast
HeshallcloselymonitorthearrivalofeachscheduledshipmentasperNotificationofArrivalfromContractor,forpreparationofunloadingandstorageplanpriortoactualarrivalatsite.
(3)ArrangementofUnloadingArea
Heshalldecidewhetherthearrivingcargoistobeunloadedaton-sitewarehouse,off-sitestoragearea(PipingFabricationShop)ordirectlytotheconstructionsiteundercoordinationwithContractor’sMaterialController.Ifsomematerialswhosestorageareaisnotsamearearrivedinthesameboxorsametruck,unloadingworkshallbedoneatonestorageareatemporarily.ThereafterheshallimmediatelytransferthematerialtocorrectstorageareaundercoordinationwithContractor’sMaterialcontrollers.
(4)DailyReceivingReportandOS&DReport
HeshallprepareanddistributeDailyReceivingReporteverydayforallthecargoreceivingonthedayandOS&DReportafterreceivingvisualinspectionachieved.
(5)WorkForceMobilizationPlan
Heshallsetthescheduleformobilizationoflabors,constructionequipment,tools,gearsandothernecessitiesformaterialhandlingactivities,andsubmittotheMaterialControlManagerforapproval.
(6)MaterialHandlingOperation
Heisresponsibletosuperviseallwarehouseactivities,whichismaterialreceiving,storageincludingpreservation,andissuing.Heshallcautiouslypaycloseattentiontothehandlingofdangerousitemsrequiredproperprotectionfromhigh/lowtemperature,vibration,moisture,dust,variousformofcorrosion,aswellasmaterialssubjecttotraceabilityHeshallpreparedailymaterialscontrolreportforsubmissiontoMaterialControlManager.AnydamagedmaterialsreceivedaftervisualchecksshallbequarantinedandreportingtoMaterialControlManagerandContractorMaterialController.
(7)PeriodicInventoryCheck/InventoryStatusReport
Heshallphysicallyconductperiodicstocktakingonallcategoriesofmaterialheldatwarehouses/yardsandupdatetheirinventoryrecordsaccordingly.TheInventoryStatusReportsshallbepreparedandsubmittedtoContractorperiodically.
“RandomSpot-check”onselectivematerialquantitycanbedonedaily,butInventoryAuditingshallbeatleastonaQuarterlybasis.Eachcategorymaybeonrotationmanner(forexample,checkallElbowsonthefirstday,allReducersonthe2ndday,andsoon)duringthequarterlyauditing.
(8)Safety
HeisresponsibletokeepallequipmentutilizedIntheMaterialControlGroupingoodcondition.HealsoshallmonitoronthesafetyoftheMaterialControlGroupandreporttotheMaterialControlManageraccordingly.Heshalltakeimmediateactiontowarnthoseconcernedpersonswheneverheencountersadangerousact;Monitoritcontinuouslyuntilcorrectiveactioniscompletelytakenandthesituationreturnsbacktonormal.
(9)Security
HeshallcoordinatewithContractor’ssecuritydepartmentandensurethatallsecuritymeasuresarefullyenforced.HeshallalsoforwardhisrecommendationtotheMaterialControlManagerifadditionalstepsaretobetakentoimprovethesecuritysystem.TheMaterialControlManagerwillliaisewiththeHSEManagerorContractorHSEManagerasrequired.ThedetailedsecurityplanshallrefertotheBidForm15SubcontractorHealth,SafetyandEnvironmentPlan.
3.2.3WarehouseKeeper
TheWarehouseKeeperisresponsibleforallmaterialreceiving,storageandissuingactivitiesintherespectivewarehouseofassignmentundercooperationwithandinstructionbyhisMaterialController.
Hisfunctionbasicallyincludesthefollowing:
-Inspectandmaintainwarehousingequipmentandtools.
-Supervisehislaborsandpatrolstorageareas
-Regularlyandproperlyarrangematerialsinthestorageareaandthewarehousesoastofacilitatereceivingofnewmaterialsandissuing.
-Regularlycheckthequantitiesandqualityofmaterialswhenreceivingandissuingthem,tracingthematerialutilizationforinventoryrecords.
-CarryoutmaterialidentificationandassistQCinspectorandMaterialControllerinalloyverificationtestforpipingmaterial.
-Preparedailyincomingmaterialsregister,andothernecessaryreportsonmaterialshortagesordamagesandifanyfound,heshallreporttohisrespectiveMaterialController.
-Conductappropriatehousekeepinginwarehousesandsu