PMTOP Day2

PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM
DAY 1
P
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THE CONSTRUCTION PHASE

SUPPORTING THE FOREMAN
PMTOP
DAY 2
P
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PMT ORIENTATION PROGRAM

PROGRAM SCHEDULE - DAY 2
DATE
TOPICS
THE EXECUTION / CONSTRUCTION PHASE

Supporting the Foreman
Generating AFC Drawings
Securing the Work Permits
Field Change (CO / CN)
Deliverables and Time Log
Crewing the Foreman
Flow of Materials to the Foreman
TIME
RESOURCE PERSON
8:30-10:00
FJ CHAN
10:00-12:00
EY CHUA
DAY 2
LUNCH BREAK
Supplying the Construction Equipment

Supplying the Tool Packs
Test Packages
Contents of Test Pack
Contents of the QC Plan
12:00-1:00
1:00-2:00
EY CHUA
2:00-5:30
EE CRISTI
P
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Generating AFC Drawings

Securing the Work Permits
Field Change (CO / CN)
Deliverables and Time Log
P
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PROJECT LIFE CYCLE

PROJECT EXECUTION
PROJECT MANAGEMENT TEAM
PM
FIELD
STAFF
Consolidated Reports
DTRs and EDTRs
PLANNING
CM
SUPTS
AFC Drawings
L5 Schedule
Quantities to Install
Manhours Allocations
Bill of Materials and Consumables
Procurement Schedule
Subcontract Packages
Equipment and Tools Schedule
Manpower Requirement
Methodologies
QCIP / Test Procedures
Test Pack
Work Permits / Pre-Task Plan
Risk Management
Field Supervisor
Construction Work Package

AFC Drawings
L5 3-Weeks Schedule
Manpower
Materials
Materials
Consumables
Equipment
Tool Packs
Material Allocation List
Work Permits / PTP
Field Foreman
DTRs and EDTRs

Reports
P
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AFC PIPING DRAWINS FLOW CHART
Piping Drawings
- FI / FR Drawings
Test Pack List
FIELD ENGINEERING
CLIENT
5
1
Drawing List
Piping Drawings
- FI / FR Drawings
- AFC Drawings
Test Pack List
Records and Issue

Drawing List
Piping Drawings
- FI / FR Drawings
- AFC Drawings
Test Pack List
AFC Drawings
- ISO Drawings
- Spool Drawings
- Weld Mapping
- PS Drawings
SUPERINTENDENT
2
14
CMS
Drawing Status
ISO Drawings
Bill of Materials
ISO Drawings
Spool Drawings
Weld Mapping
PS Drawings
EEI DOCUMENT
CONTROL SECTION
Used Drawings
Superceded
Drawings
16
Used Drawings
Superceded
Drawings
Used Drawings
Superceded
Drawings
SUPERVISOR
13
12
11
9
15
ISO Drawings
Spool Drawings
Weld Mapping
PS Drawings
FOREMAN
10
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WORK PERMIT FLOW CHART
CLIENT
16
9
Approved Work Permit

11 with attached PTP
Work Permit Forms

Hot Work
Cold Work
Excavation Work
Confined Space Work
Road Block
Vehicle Entry
12
FOREMAN
Approved Work Permit

with attached PTP
13
Work Permit Activity

Completed
SUPERVISOR
10
6
15
Apply Work Permit

with attached PTP
3
7
SAFETY ENGINEER
Work Permit
Pre-Task Plan
With attached
L5 Schedule
14
Work Permit Activity

Completed
OK to Apply Work
Permit with
attached PTP
5
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FIELD CHANGE FLOW CHART - CASE 1
SCHEDULE
RESOURCES
ALLOCATION
FIELD CHANGE
Site Instructions
Field Change Notice (FCN)
CLIENT
1
FOREMAN
14
4
13
15
CN / CO
3
CN / CO
APPROVED
6
ACCOMPLISHMENT
REPORT
SUPERVISOR
16
FIELD
ENGINEERING
12
17
CN / CO
APPROVED
SCHEDULE
RESOURCES
ALLOCATION
ACCOMPLISHMENT
REPORT
11
18
PCG
8
Labor Distribution
- Manhours per
activity
- Labor cost
Productivity
ABC
P6
SCHEDULE
RESOURCES
ALLOCATION
SUPERINTENDENT
10
Progress
Quantity Installed
Manhours per activity
Productivity
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FIELD CHANGE FLOW CHART - CASE 2
FIELD CHANGE
19
Verbal instruction
Advance S.I.
Advance F.C.N.
CLIENT
1
8
ACCOMPLISHMENT
REPORT
FOREMAN
2
18
3
CN / CO
APPROVED
FIELD
CHANGE
SCHEDULE
RESOURCES
ALLOCATION
17
10
CN / CO
7
FIELD
ENGINEERING
FIELD
CHANGE
6
SUPERVISOR
5
16
11
CN / CO
APPROVED
SUPERINTENDENT
15
14
12
PCG
13
SCHEDULE
RESOURCES
ALLOCATION
SCHEDULE
RESOURCES
ALLOCATION
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Document Control
Section

DELIVERABLES - SUPT / SUPV / FOREMAN
DTRs (Official)
SITE ACCOUNTING
EDTRs A / S
ERG
5
Used Drawings
Superceded Drawings
DTRs (Official)
EDTRs A / S
EQUIPMENT
TOOL PACKS
PCG
Used Drawings
Superceded Drawings
MP Crew of Completed
Works
SUPERVISOR
3
2
8
SUPERINTENDENT
Work Permits of
Completed Work
EDTRs
CONSTRUCTION WORK PACKAGE

AFC Drawings (ISO dwgs, SPOOL
dwgs, WELD mapping, PS dwgs.)
3-Weeks Schedule, L5
DTRs ( Temporary and Official )
Work Permits / PTP
Materials and Consumables from
MP Crew from 3-Weeks Schedule, L5
Equipment from 3-Weeks Schedule, L5
Tool Packs from 3-Weeks Schedule, L5
CLIENT
AFC Drawings (ISO dwgs, SPOOL dwgs,
WELD mapping, PS dwgs.)
Materials and Consumables Allocation
Equipment Allocation
Manpower Allocation
Tool Packs Allocation
DTRs (Official) Accomplishment Reports

EDTRs A / S (Acknowledged and Signed)
MP Crew of Completed Works
Equipment of Completed Works
Tool Packs of Completed Works
Work Permits of Completed Works
Used Drawings
Superceded Drawings
FOREMAN
7
1/2
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TIMELINE for the DELIVERABLES
DELIVERABLES
ACTION PARTY
SOFTWARE
SUPERINTENDENT

AFC Drawings ( ISO Drawings, Spool
Drawings, Weld Mapping, PS Drawings
3 - Weeks Schedule, L5
Materials and Consumables Allocation
Manpower Allocation
Equipment Allocation
Tool Packs Allocation
Every Saturday at 9:00 AM and

immediate when changes occurs.
MP Crew of completed works

( for re-assignment or Demob)
AFC Drawings ( ISO Drawings, Spool
Drawings, Weld Mapping, PS Drawings
3 - Weeks Schedule, L5
DTRs ( Temporary and Official )
Immediate Re-assignment of MP Crew

Demob MP Crew if not needed
Every Saturday at 10:00 AM and
immediate when changes occurs.
EDTRs ( from ERG )

Work Permits / PTP
Materials and Consumables
SUPERVISOR
MP Crew
Equipment
Tool Packs
DTRs ( Official ) - Accomplishment Reports
EDTRs - A / S ( Acknowledge and Signed )
Work Permits of completed works
Used Drawings
Superceded Drawings
Equipment of completed works
Tool Packs of completed works
FOREMAN
TIMELINE
HARDWARE
DTRs ( Official ) - Accomplishment Reports

EDTRs - A / S ( Acknowledge and Signed )
Work Permits of completed works
Used Drawings
Superceded Drawings
Equipment of completed works
Tool Packs of completed works
Temporary DTRs for 1 week and

daily for official DTRs
Daily
Daily when required
Deliver to site 2 or 3 days before the
need date from schedule. Materials are
good for 3 days work when pssible.
Deliver to site 1 hr before the need date
from schedule.
Submit daily at 9:00 AM
Submit daily at 9:00 AM
Submit to CLIENT daily
Return to Superintendent immediately
Return to Superintendent immediately
Advised Superintendent and ERG
3-days before the completion of the
works.
Submit the following day at 9:00 AM
Submit the following day at 9:00 AM
Submit daily
Return to Supervisor immediately
Return to Supervisor immediately
Advised Supervisor 3-days before
the completion of the works.
2/2
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LOGISTIC
Flow of Materials
Manpower Crew
Construction Equipment
Tool Packs
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MATERIAL CONTROL FLOW CHART
Deliver Materials
from
L4 Schedule
6
Delivery From
Procurement Plan
SITE
WAREHOUSE
4
RDS from
L5 Schedule
and Material
Allocation List
SUPERVISOR
10
7
3
A
Consolidated
DTRs
(QTY. Installed)
PMRR
GATE PASS
JMIF
IMS
B
C
ABC
D
COST OF INVENTORY
COST OF MATERIAL
WITHDRAWN PER ACTIVITY
RDS from L5
Schedule
PCG
13
Progress
Quantity Installed
Manhours per
activity
Productivity
FOREMAN
2
14
11
12
INVENTORY
WITHDRAWAL
Materials
from
L5 Schedule
15
P6
DTRs
( QTY. Installed )
MCE INSPECTION POINT
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PIPING MATERIALS FLOW CHART
RAW MATERIALS
FOR ISOS and
PIPE SUPPORTS
WAREHOUSE
FIELD-ROUTED
& INSTALLING
MATERIALS
IMS
FIELD
SUPERVISOR
PIPE SHOP
SUPERVISOR
DELIVERY TO
SHOP FOREMAN
ISO SPOOLS
and
PIPE SUPPORTS
FABRICATION
SHOP
SPOOLS and
PIPE SUPPORTS
INVENTORY
INSTALLING MATLS
SPOOLS
PIPE SUPPORTS
SPOOL YARD
ERECT
FOREMAN
MCE CONTROL POINT
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MANPOWER CONTROL FLOW CHART
MP CREW
From
MOB PLAN
MP Crew for
Re-assignment
or Demob
Billeting
EEI Orientation
Client Orientation
SITE HR
2
14
MP Crew for
Re-assignment
or Demob
MP Crew
SUPERVISOR
10
MP Crew
Assignment
13
SUPERINTENDENT
MP Mob documents
LH MP Contracts
MP Re-assignment
Demob MP Crew
11
12
FOREMAN
PERSIS
B
C
DTR
ACCOUNTING
D
Labor Cost
Payroll
ABC
F
MP Crew assignment
from L5 Schedule
MP Crew reduce or MP Crew

For Re-assignment after
Works completed
SUPV. INSPECTION POINT
P
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EQUIPMENT CONTROL FLOW CHART
EQUIPMENT
3
4
Mobilization from
Equipment Plan
LOGISTICS
ERG
EQUIPMENT
request from
L5 Schedule
SUPERVISOR
1
8
5
10
17
DR
Gate Pass
EDTRs
Return
Equipment
EDTRs
Approved
EQUIPMENT
9
EDTRs
16
11
FOREMAN
PCG
14
EMS
15
Inventory
Equipment
Utilization
ABC
12
EDTRs
Acknowledged /
Approved
13
7
Equipment Hour
per activity
Fuel Consumption
Return Equipment After

Work Completion
SUPV. INSPECTION POINT
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TOOLS CONTROL FLOW CHART
SITE
LOGISTICS
Delivery From
E & T Plan
TOOL ROOM
10
TOOL PACKS
from L5 Schedule
BTS FOR
TOOL PACKS
from L5 Schedule
SUPERVISOR
1
TOOL PACKS
RETURN
PMRR
GATE PASS
BTS
TOOL PACKS RETURN
TOOL PACKS
FOREMAN
6
INVENTORY
and Cost
CTRIS
TOOL PACKS
Return After
Works Completed
P
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THE TEST PACKS and QUALITY CONTROL
Test Packages
Contents of the QC Plan
P
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FIELD
ENGINEERING

TEST PACK FLOW CHART
TEST PACKS
WENDS
INSPECTION POINT
QUALITY CONTROL
PIPING
SUPERINTENDENT
TP LINE
COMPLETION
OK
TP
HYDROTEST
OK
TP
RESTORATION
OK
SYSTEMS TEST PACK SCHEDULE
ERECTION
SUPV
HYDROTEST
SUPV
RESTORATION
SUPV
TEST PACK
TEST PACK
TEST PACK
FOREMAN
FOREMAN
FOREMAN
TEST PACK
LINE COMPLETION
TP HYDROTEST
TP RESTORATION
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PIPING SUPT

FIT-UP and PRODUCTION WELD FLOW CHART
PIPING
Schedule, L5
Piping SUPV
Consolidated
FIT-UP Reports
Consolidated
Production
WELD Reports
Piping FM
FIT-UP
PRODUCTION WELD
Daily
Schedule
Welding SUPV
FIT-UP Reports
Consolidated
Production
WELD Reports
Welder
Daily FIT-UP
Reports
Consolidated
FIT-UP Reports
TEST PACK
Welding SUPT
3-Weeks
Schedule, L5
Welding FM
Daily
Production
WELD Reports
Fitter
Crew
FIT-UP
INSPECTION POINT
P
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SUPT

PRODUCTION WELD FLOW CHART
PIPING
Schedule, L5
Piping SUPV
Consolidated
FIT-UP Reports
TEST PACK
Consolidated
Production
WELD Reports
Daily FIT-UP
Reports
Piping FM
Daily
Schedule
Welding SUPV
FIT-UP Reports
Welder
3-Weeks
Schedule, L5
FIT-UP
PRODUCTION WELD
Welding FM
Daily
Production
WELD Reports
Fitter
Crew
FIT-UP
INSPECTION POINT
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DAILY FIT-UP / WELD REPORTS FLOW CHART
JOINT STATUS
Fit-up
Weld
NDT
PIPING
SUPERINTENDENT
CONSOLIDATED
FIT-UP REPORTS
( Inspected / Approved )
PIPING
SUPERVISOR
WENDS
3
FIELD
ENGINEERING
16
Consolidated
FIT-UP
Reports
20
QC
18
19
14
15
Consolidated
PRODUCTION
WELD Reports
NDT
REPORTS
WELDING SUPERINTENDENT
Consolidated
FIT-UP
Reports
WELDING
SUPERVISOR
13
12
17
9
JOINT STATUS
Fit-up
Weld
NDT
WELDING
FOREMAN
FIT-UP
REPORTS
10
WELD
REPORTS
11
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TEST PACK
P
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QUALITY CONTROL
QUALITY CONTROL
INSPECTION PLAN
( QCIP )
1/24
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QUALITY CONTROL ORGANIZATION
EVP
SVP
QC GROUPMANAGER
QC MANAGER
QC MANAGER
QC MANAGER
BLDGS & INFRA
ELECTROMECH & INDL
STEELFAB SHOP
QCs IN-CHARGE
QCs IN-CHARGE
QCs IN-CHARGE
PROJECTS
PROJECTS
PROJECTS
HOMEBASE
PROJECT/JOB SITE
NOTE:
Quality Control team OF THE SITE PMT FUNCTIONALLY REPORTS TO
THE HOMEBASE QC MANAGER AND ADMINISTRATIVELY under THE
JOBSITE PROJECT MANAGER.
2/24
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INTRODUCTION TO QUALITY
WHAT IS QUALITY ?
Quality means satisfying our
customers every time we deal with
them.
HOW ?
By doing things right at the first
time and all the time and by doing
them better and better.
3/24
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INTRODUCTION TO QUALITY
BENEFITS OF GOOD QUALITY

Higher productivity
Less rework
Less waste
Lower overall cost
Greater customer satisfaction
Higher project team morale

Credible & competitive company image.
4/24
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QUALITY CONTROL PROCESS MAP
QUALITY CONTROL PROCESS MAP

Materials Receiving
& Inspection
Project Owner
Storage
Turn-Over
In-process Fabrication,
Erection &Construction
Inspection & Final Test

&
Documentations
Materials identification through all stages of

fabrication/construction where appropriate
traceability to specified requirements.
5/24
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QUALITY CONTROL INSPECTION PLAN

The QCIP is essentially a schedule of
HOLD POINTS on work
activities that require
inspection or specified
test procedures, before
succeeding activities are
allowed to continue.
6/24
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CONTENTS OF THE QCIP
Sequential activities based on

L5 WBS identifying work items
or critical parts that will be
subject to inspection or tests.
7/24
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Critical parts checked partially,
progressively,
or
at
activity
completion to comply with inspection
requirements.
8/24
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Test methods and or inspection
techniques to be applied in order to
verify
compliance
to
quality
standards.
9/24
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Extent of test and inspection defined
by project specifications, codes, and
standards (ie: 100%, 20%, 10%, 5%,
Random Sampling).
10/24
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References for work acceptance where
information on tests and inspection are
applied,
like project specifications,
codes, manufacturing manuals, or AFC
drawings (This includes tolerances in
measurements).
11/24
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Organization of the Project Inspection
Team
composed of
the FOG
Foremen/ Supervisor, QC Inspector,
Clients inspectors or at times, thirdparty inspectors.
12/24
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QC INSPECTION ACTIVITIES
Review of Records
Witnessing of Tests by Third Parties
Attendance to Hold Points
Conduct Specified Tests
Activity Documentation
In-process and Final Inspection
13/24
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HOLD POINTS are effective tools
in preventing escalation of nonconformances,

as next activity
cannot start
unless the
preceding work is cleared and
accepted.
14/24
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ROLE OF THE FOG in QC ACTIVITIES
DUTIES and RESPONSIBILITIES

CONSTRUCTION TEAM
Foremen, Supervisor and Superintendent
Perform its quality line function by ensuring
compliance
of the work to Client
specifications, plans, drawings, applicable
codes, and workmanship standards (Do it
right the first time and everytime and doing
it better and better).
15/24
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ROLE OF THE FOG in QC ACTIVITIES

CONSTRUCTION TEAM
Foremen, Supervisor and Superintendent
Plan and schedule work inspection aligned
to their work activity schedule to avoid
delays, prepare and submit request for
inspection (RFI) to QC at least 12 hours
before requested time of inspection.
16/24
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ROLE OF THE QC ENGINEER

QC INSPECTOR
Prepare, orient the FOG, and implement
the approved QCIP to ensure that the
quality requirements of the project are
achieved per plan.
17/24
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ROLE OF THE QC ENGINEER
RESPONSIBILITY
Project assigned QC In-charge consolidate and issue
the monthly OPQR to the homebase unit for the QC

Head and Officers information and must be concurred
by the Project Manager or Project In-Charge. The PM or
PIC Shall respond positively and do action if the target

benchmark of 95% rating is not achieved.
22/24
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ROLE OF THE CLIENT in QC ACTIVITIES
CLIENT INSPECTOR
Approve
the
QCIP
and
monitor
compliance of the Construction Activities
and QC Inspection performed as per the
plan. Attend to the inspection if required.
18/24
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NON CONFORMANCE
NON-CONFORMANCE
Any work deviation from the

reference specification, codes,
standards, sound engineering
practice and approved material.
19/24
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NON CONFORMANCE
NON-CONFORMANCE
QC Inspection Report (QCIR)
A report on any ACCEPTANCE or Nonconformances (usually minor findings)
Non-Conformance Report (NCR)
A report on any NON-CONFORMANCE or

deviation. (usually major findings that may
have greater impact to project quality)
20/24
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QUALITY CONTROL RATING
OPERATION PROJECT QUALITY RATING

Projects Quality Status are monitored /
reported monthly by the quality control
as a management tool to give indicator
for actions of the PMT to avoid or
minimize the lost of profit due to poor
quality of works and excessive repairs.
21/24
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QUALITY CONTROL MESSAGE
A FINAL WORD ON QUALITY WORK
Increased quality is likely to be

associated with
project whose
team members
display pride,
commitment and an interest in
workmanship.
23/24
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QUALITY CONTROL MESSAGE
Remember this.
The cost of repair and / or
rejection comes directly out
of profit.
24/24
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PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM
of Day 2

PMTOP Day2

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PROJECT MANAGEMENT TEAM ORIENTATION PROGRAM

THE CONSTRUCTION PHASE

PMT ORIENTATION PROGRAM

THE EXECUTION / CONSTRUCTION PHASE

Supplying the Construction Equipment

THE CONSTRUCTION PHASE

Generating AFC Drawings

PROJECT LIFE CYCLE

Construction Work Package

DTRs and EDTRs

THE CONSTRUCTION PHASE

Records and Issue

THE CONSTRUCTION PHASE

Approved Work Permit

Work Permit Forms

Approved Work Permit

Work Permit Activity

Apply Work Permit

Work Permit Activity

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

CONSTRUCTION WORK PACKAGE

DTRs (Official) Accomplishment Reports

THE CONSTRUCTION PHASE

CONSTRUCTION WORK PACKAGE

Every Saturday at 9:00 AM and

MP Crew of completed works

Immediate Re-assignment of MP Crew

EDTRs ( from ERG )

DTRs ( Official ) - Accomplishment Reports

Temporary DTRs for 1 week and

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

MCE INSPECTION POINT

THE CONSTRUCTION PHASE

MCE CONTROL POINT

THE CONSTRUCTION PHASE

MP Crew reduce or MP Crew

SUPV. INSPECTION POINT

THE CONSTRUCTION PHASE

Return Equipment After

SUPV. INSPECTION POINT

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

SYSTEMS TEST PACK SCHEDULE

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

Contents of Test Pack

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

BLDGS & INFRA

ELECTROMECH & INDL

THE CONSTRUCTION PHASE

THE CONSTRUCTION PHASE

BENEFITS OF GOOD QUALITY

Higher project team morale

THE CONSTRUCTION PHASE

QUALITY CONTROL PROCESS MAP

Inspection & Final Test