20Executive Material ControlPlan.docx

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