BPPII Pilot Project (Year-2) Prof. Bon-Gang (BG) HWANG (Dr.), NUS Prof. Carlos H. Caldas (Dr.), UT-Austin

Transcription

1 BPPII Pilot Project (Year-2) Prof. Bon-Gang (BG) HWANG (Dr.), NUS Prof. Carlos H. Caldas (Dr.), UT-Austin 26 JULY 2017

2 BPPII Method and metric for measuring the implementation level of practices that have the potential to improve craft productivity in: Construction Projects Maintenance Activities Shutdowns/Turnaround 2

3 BPPII: Structure Structure 6 Categories 18 Sections 66 Elements Materials Management Equipment Logistics Craft Information Systems Sources: Experts Manuals & Procedures Craft Professionals Human Resources Management Construction Methods Environment, Safety, and Health 3

4 Better Productivity Performance Factor Higher BPPII Scores Led to Better Productivity Statistical Validation (greater than 95%) % better Low BPPII (<61%) High BPPII (>67%) Productivity Performance Factor = (estimated hours/output) (actual hours/output) 4

5 BPPII Pilot Group Meetings 5

6 BPPII Implementation Schedule 6

7 BPPII Tool Customization The original BPPII Tool was developed for the North American New Industrial Projects and has 6 categories and 53 elements. To customize the tool for the Singapore industry, the BPPII tool was presented to the work group and a separate meeting was arranged to receive the members inputs and feedback on the elements as well as to come up with additional elements for Maintenance and STA projects. The interviews with the individual members were carried out for more in-depth discussions on the customization. The BPPII tool customized for the Singapore industry has 6 Categories and 66 elements with the different weightages given by the three different project types. 7

8 I II III IV V VI Sections and Categories Elements MATERIALS MANAGEMENT Material Management Systems Pre-Fabricated Material Tracking Material Issuing Procedure & Material Usage Tracking Receipt and Inspection of Materials Centralized Ware House On site, Including Storage for Fabricated Materials QA/QC Inspection & Assessment and NDT Testing & Tracking Plan EQUIPMENT LOGISTICS Site Tool Management Machinery Availability Construction Machinery Tracking Fuel Top up Schedule for Equipment and Machinery On-site Construction Equipment Lay Down Area CRAFT INFORMATION SYSTEMS Short Interval Planning Centralized Planning, Work Prioritization, and Process Control Workface Planning Quality Control Systems Constructability Review Work Interface Review HUMAN RESOURCE MANAGEMENT Training and Development Supervisors and Foremen Skills Development and Training Behavior Organizational Structure Employment CONSTRUCTION METHODS Sequence and Scheduling of Work Start-Up, Commission, and Process-Interface (Process technician standby) Turnover Plan Planning for Shut Down (Plan for transient s/o operation) Technology Investigation Site Layout Plan ENVIRONMENTAL SAFETY AND HEALTH New Elements 8

9 BPPII Tools 9

10 BPPII Pilot Projects 3 projects were proposed by the work group members for the Pilot of the Pilot Projects. 10 Pilot Projects were conducted, based on the nominations from the owners paired with their contractors. These pilot projects were conducted as a joint-assessment session facilitated by NUS researchers. 10

11 BPPII Pilot Projects Project Type Number of Projects Pilot of Pilot Pilot Project Total New Construction Maintenance Shutdown Turnaround Total Number of Projects

12 Project Nomination Sheet AN INTEGRATED APPROACH TO MANAGEMENT PRACTICES AND MEASUREMENT AIMED AT PRODUCTIVITY IMPROVEMENT FOR THE CONSTRUCTION & MAINTENANCE SECTORS OF THE SINGAPORE PETROCHEMICAL INDUSTRY PLANT INFORMATION Plant Owner: PILOT PROJECTS - NOMINATION FORM Plant Name: Plant Unit: Plant Overview: Integrated Refinery and Petrochemical Operations PROJECT INFORMATION Project Type (New Construction/Maintenance/Turnaround): Activity Scope: Technology: Main Contractor(s): Subcontractors(s): Estimated Total Cost: Estimated Start Date: Estimated Man-hours: Estimated End Date: Work Shift Schedule: 8 hours shift. Contracting Strategy: Outline Agreement Forecast on the Allocation of Activities Across the Next 3-Years ( ) Work Area Description: % Complete at the Proposed Start Date of the Pilot: Estimated Number of Workers: Craft Disciplines Involved: Contact Person: Submitted By:: Date: 12

13 Pre-Information Sheet The Pre information sheet was developed to extract the information about the project nominated for the Pilot projects. The pre information sheet also includes a guidance table for the companies to identify the project personnel s for Pilot project participation. 13

14 Example Guide for Interview participants on extraction of information for the Pilot Project Sections and Categories Contractor Owner I II III IV V VI MATERIALS MANAGEMENT Material Management Systems Procurement Engineer and Site Engineer Procurement Engineer Receipt and Inspection of Materials QA/QC Inspector QA/QC Inspector EQUIPMENT LOGISTICS Site Tool Management Site Engineer/ Supervisor Supervisor Machinery Availability Site Engineer/ Supervisor Supervisor CRAFT INFORMATION SYSTEMS Short Interval Planning Planner /Site Engineer Planner Workface Planning Planner /Site Engineer Planner Constructability Review Project Manager/ Engineer Project Manager/ Engineer HUMAN RESOURCE MANAGEMENT Training and Development HR manager HR Executive Behavior HR manager HR Executive Organizational Structure HR manager HR Executive Employment HR manager HR Executive CONSTRUCTION METHODS Sequence and Scheduling of Work Planner Start-Up, Commission, and Turnover Plan QA/QC Inspectors Project Manager/ Engineer Technology Investigation Project manager Project Engineer Site Layout Plan Logistics manager and Project Manager/ Planner Engineer ENVIRONMENTAL SAFETY AND HEALTH Job Safety Safety Officer and Safety Supervisor Safety Officer Substance Abuse Programs Supervisor and foreman Safety Officer Safety Training and Orientation Safety Officer and Safety Supervisor Safety Officer /Project Engineer 14

15 Pre-Information Sheet 15

16 Joint Assessment Session 16

17 BPPII Project Report - Sample 17

18 BPPII Project Report - Sample 18

19 BPPII Project Report - Sample 19

20 Reference BPPII Quartiles QUARTILES OVERALL SCORE I MATERIALS MANAGEMENT II EQUIPMENT LOGISTICS III CRAFT INFORMATION SYSTEMS IV HUMAN RESOURCES MANAGEMENT V CONSTRUCTION METHODS V HEALTH, SAFETY, AND ENVIRONMENT First Above 77% Above 77% Above 70% Above 74% Above 68% Above 82% Above 98% Second 68% to 77% 65% to 77% 56% to 70% 62% to 74% 58% to 68% 70% to 82% 94% to 98% Third 60% to 68% 50% to 65% 43% to 56% 52% to 62% 48% to 58% 60% to 70% 90% to 94% Fourth Below 60% Below 50% Below 43% Below 52% Below 48% Below 60% Below 90% Guidelines to Improve BPPII Score 1. Review the BPPII tool results and report. 2. Define improvement targets, using the BPPII Score Quartile Table above as a reference. 3. Obtain the list of all BPPII elements that scored either Level 1 or Level Prioritize and implement the ones of which the Planning and Implementation Levels can easily be improved - Low-Hanging Fruits. *Tip: Use the BPPII tool to simulate the impact of the improvements on the BPPII Score 20

21 BPPII Pilot Projects All Projects 21

22 BPPII Pilot Projects Singapore Score (All Projects. No = 13) CATEGORIES ACQUIRED SCORE MAXIMUM SCORE AVERAGE BPPII SCORE QUARTILE I - MATERIALS MANAGEMENT % THIRD II - EQUIPMENT LOGISTICS % THIRD III CRAFT INFORMATION SYSTEMS % SECOND IV HUMAN RESOURCES MANAGEMENT % SECOND V CONSTRUCTION METHODS % SECOND VI ENVIRONMENT, SAFETY, AND HEALTH % FIRST SINGAPORE BPPII SCORE % (median= 68%) SECOND QUARTILES OVERALL SCORE I MATERIALS MANAGEMENT II EQUIPMENT LOGISTICS III CRAFT INFORMATION SYSTEMS IV HUMAN RESOURCES MANAGEMENT V CONSTRUCTION METHODS V HEALTH, SAFETY, AND ENVIRONMENT First Above 77% Above 77% Above 70% Above 74% Above 68% Above 82% Above 98% Second 68% to 77% 65% to 77% 56% to 70% 62% to 74% 58% to 68% 70% to 82% 94% to 98% Third 60% to 68% 50% to 65% 43% to 56% 52% to 62% 48% to 58% 60% to 70% 90% to 94% Fourth Below 60% Below 50% Below 43% Below 52% Below 48% Below 60% Below 90% 22

23 BPPII Pilot Projects: Singapore Score (All Projects) Actual Category BPPII Score vs. Maximum Category BPPII Score ACQUIRED SCORE MAXIMUM SCORE 98.28% % 64.94% 65.03% 71.53% % I - MATERIALS MANAGEMENT II - EQUIPMENT LOGISTICS III - CRAFT INFORMATION SYSTEMS IV - HUMAN RESOURCES MANAGEMENT V - CONSTRUCTION METHODS VI - ENVIRONMENT, SAFETY, AND HEALTH 23

24 BPPII Pilot Projects: Weak Elements (All Projects) CATEGORIES Average (%) Weak Elements (Level 1 & 2) Neutral Elements (Level 3) I - MATERIALS MANAGEMENT 54.62% II - EQUIPMENT LOGISTICS 48.91% Onsite Material Tracking Technology Material Delivery Schedule Pre-Fabricated Material Tracking Material Issuing Procedure & Material Usage Tracking Control System for Tool Delays Construction Machinery Tracking Fuel Top up Schedule for Equipment and Machinery Project Team Material Status Database Procurement Plan for Materials and Equipment QA/QC Inspection & Assessment and NDT Testing & Tracking Plan Centralized Ware House On site, Including Storage for Fabricated Materials Tool Tracking Systems On-site Tool Maintenance Construction Machinery Productivity Analysis Equipment Maintenance III - CRAFT INFORMATION SYSTEMS IV - HUMAN RESOURCES MANAGEMENT V - CONSTRUCTION METHODS VI - ENVIRONMENT, SAFETY, AND HEALTH Total (%) 64.94% 65.03% 71.53% 98.28% 68.42% Utilization of Software to Assist in Generating Work Packages Project Model Requirements PPMOF Evaluation Centralized Planning, Work Prioritization, and Process Control Quality Control Systems Work Interface Review Career Development Supervisors and Foremen Skills Development and Training Teambuilding and Social Activities Maintain Stability of Organizational Structure Retention Plan for Experienced Personnel Exit Interviews Equipment Positioning Strategy Work Schedule Strategies Schedule Execution and Management Dynamic Site Layout Plan New Equipment Investigation New Material Technologies Investigation New Information Systems Investigation The BPPII score for all types of Projects in Singapore is 68.42%, which falls under the second quartile. 24

25 BPPII Pilot Projects: Recommendations (All Projects) CATEGORIES Weak Elements (Level 1 & 2) Recommendations I - MATERIALS MANAGEMENT II - EQUIPMENT LOGISTICS III - CRAFT INFORMATION SYSTEMS V - CONSTRUCTION METHODS Onsite Material Tracking Technology To attain level-3, materials may be assigned in the laydown or storage areas and the information is recorded and kept up to date in a software system. Well-defined processes are established for developing pick lists, flagging, warehouse organization and other necessary functions. Material Delivery Schedule To attain level-3, the schedule should be automatically updated on receipt of new information on materials as procurement proceeds. Pre-Fabricated Material Tracking To attain level-3, pre-fabricated material is tagged upon delivery and entered in to a proprietary internal software tool but it is not integrated or used by other contractors. Material Issuing Procedure & Material Usage Tracking To attain level-3, a software application may be used for material issuing procedure and usage tracking but not integrated with your company s other information technology systems. Control System for Tool Delays To attain level-3, a formal paper based system (e.g. foremen delay sampling and activity sampling) might be used to track tool delays. Plus the usage of a database (which is regularly updated) is in place to tracks tool delays among craft workers at the construction workface. Construction Machinery Tracking To attain level-3, construction machinery might be tracked via the usage of GPS tracking software with facilities of enabling personnel to locate machinery and sending alerts to the computer system and/or mobile device when a tracked object leaves a fenced/designated zone. Fuel Top up Schedule for To attain level-3, fuel top up schedule might be created and tracked using a software Equipment and Machinery application. Utilization of Software to Assist in To attain level-3, the project uses a software system to generate the work package Generating Work Packages and automatically includes the drawings and material delivery status. Schedule, percent complete, test and inspection status, and closure must be entered manually by review of the work package. Project Model Requirements To attain level-3, a static 4D Model has been established for the project, plus, the model includes basic updates, manually made, and based on scheduled changes. PPMOF Evaluation To attain level-3, members of the constructability review panel are actively searching for opportunities for the use of offsite prefabrication, modular construction, and preassembly. Equipment Positioning Strategy To attain level-3, planning for equipment positioning may include the use of 2D layout studies plus, some 3D modeling studies to aid in constructability review of location and use of equipment might be considered. 25

26 Summary Pilot Projects The BPPII scores: All Projects: 2 nd quartile (68.42%) median = 68% Category VI- Environment Health and Safety was noted to be in the 1 st quartile for all project types. Categories I- Material Management and II- Equipment Logistics were noted to be in the 3 rd quartile for all project types. Category V- Construction Methods was noted to be in the 3 rd Quartile in two project types (New Construction and Maintenance). In order to further improve the scores, companies may focus first and more on implementing improvements in these three categories. 26

27 BPPII Workshop Projects 27

28 BPPII Workshop Projects Project Type Number of Projects New Construction 6 Maintenance 6 Shutdown Turnaround 5 Total Number of Projects 17 28

29 BPPII Workshop Projects Singapore Score (All Projects. No = 17) ACQUIRED MAXIMUM CATEGORIES AVERAGE BPPII SCORE SCORE SCORE QUARTILE I - MATERIALS MANAGEMENT % FOURTH II - EQUIPMENT LOGISTICS % FOURTH III CRAFT INFORMATION SYSTEMS % FOURTH IV HUMAN RESOURCES MANAGEMENT % THIRD V CONSTRUCTION METHODS % FOURTH VI ENVIRONMENT, SAFETY, AND HEALTH % FOURTH BPPII SCORE % FOURTH QUARTILES OVERALL SCORE I MATERIALS MANAGEMENT II EQUIPMENT LOGISTICS III CRAFT INFORMATION SYSTEMS IV HUMAN RESOURCES MANAGEMENT V CONSTRUCTION METHODS V HEALTH, SAFETY, AND ENVIRONMENT First Above 77% Above 77% Above 70% Above 74% Above 68% Above 82% Above 98% Second 68% to 77% 65% to 77% 56% to 70% 62% to 74% 58% to 68% 70% to 82% 94% to 98% Third 60% to 68% 50% to 65% 43% to 56% 52% to 62% 48% to 58% 60% to 70% 90% to 94% Fourth Below 60% Below 50% Below 43% Below 52% Below 48% Below 60% Below 90% 29

30 BPPII Workshop Projects: Singapore Score (All Projects) Actual Category BPPII Score vs. Maximum Category BPPII Score 400 ACQUIRED SCORE MAXIMUM SCORE % % % 50.62% 48.65% % I - MATERIALS MANAGEMENT II - EQUIPMENT LOGISTICS III - CRAFT IV - HUMAN RESOURCES INFORMATION SYSTEMS MANAGEMENT V - CONSTRUCTION METHODS VI - ENVIRONMENT, SAFETY, AND HEALTH QUARTILES OVERALL SCORE I MATERIALS MANAGEMENT II EQUIPMENT LOGISTICS III CRAFT INFORMATION SYSTEMS IV HUMAN RESOURCES MANAGEMENT V CONSTRUCTION METHODS V HEALTH, SAFETY, AND ENVIRONMENT First Above 77% Above 77% Above 70% Above 74% Above 68% Above 82% Above 98% Second 68% to 77% 65% to 77% 56% to 70% 62% to 74% 58% to 68% 70% to 82% 94% to 98% Third 60% to 68% 50% to 65% 43% to 56% 52% to 62% 48% to 58% 60% to 70% 90% to 94% Fourth Below 60% Below 50% Below 43% Below 52% Below 48% Below 60% Below 90% 30

31 BPPII Workshop Projects: Weak Elements (All Projects) CATEGORIES Average (%) Weak Elements (Level 1 & 2) Neutral Elements (Level 3) I - MATERIALS MANAGEMENT 42.06% II - EQUIPMENT LOGISTICS 35.65% III - CRAFT INFORMATION SYSTEMS 50.62% Project Team Material Status Database Onsite Material Tracking Technology Material Delivery Schedule Pre-Fabricated Material Tracking Material Issuing Procedure & Material Usage Tracking Centralized Ware House On site, Including Storage for Fabricated Materials Tool Tracking Systems On-site Tool Maintenance Control System for Tool Delays Construction Machinery Productivity Analysis Equipment Maintenance Construction Machinery Tracking Fuel Top up Schedule for Equipment and Machinery On-site Construction Equipment Lay Down Area Utilization of Software to Assist in Generating Work Packages Project Model Requirements Engineering Work Packages (EWP) Construction Work Packages (CWP) Design Readiness for Construction PPMOF Evaluation Procurement Plan for Materials and Equipment Material Inspection Process Material Inspection Team Post-receipt Preservation and Maintenance QA/QC Inspection & Assessment and NDT Testing & Tracking Plan Site Tool and Consumables Management Strategy Short Interval Planning Centralized Planning, Work Prioritization, and Process Control Dedicated Planner Identify Required Permitting Installation Work Packages (IWP) Quality Control Systems Work Interface Review 31

32 BPPII Workshop Projects: Weak Elements (All Projects) CATEGORIES Average (%) Weak Elements (Level 1 & 2) Neutral Elements (Level 3) IV - HUMAN RESOURCES MANAGEMENT V - CONSTRUCTION METHODS VI - ENVIRONMENT, SAFETY, AND HEALTH Total (%) 51.76% 48.65% 86.34% 54.30% Planning for Start-up Testing Procedures System Turnover Procedure Process-Interface (Process technician standby) Planning for Shut Down (Plan for transient s/o operation) New Equipment Investigation New Information System Investigation New Materials Technologies Investigation Equipment Positioning Strategy Employee/Trades Technical Training Career Development Supervisors and Foremen Skills Development and Training Non-financial Incentive Programs Financial Incentive Programs Teambuilding and Social Activities Maintain Stability of Organizational Structure Clear Delegation of Responsibility Retention Plan for Experienced Personnel Exit Interviews Integrated Schedule Work Schedule Strategies Schedule Execution and Management Dynamic Site Layout Plan Site Security Plan The BPPII score for all types of Projects in Singapore is 54.30%, which falls under the fourth quartile. 32

33 Summary Workshop Projects The BPPII scores: All Projects: 4 th quartile (54.30%) Categories I- Material Management, II- Equipment Logistics, III- Craft Information systems, V- Construction Methods and VI- Environment Health and Safety were noted to be in the 4 th quartile for all project types. Category IV Human Resources Management was noted to be in the 3 rd quartile for all projects and for New construction and Maintenance projects. The assessment helped to identify productivity improvement opportunities for smaller companies. 33

34 Path Forward The results of the BPPII pilot projects were analyzed and the BPPII assessment reports with recommendations were ed to all participants. For the second round, discussions with project participants on the improvements made in the BPPII projects have been conducted in the form of case studies. The research team encourages the companies to assess more projects using the BPPII tool and submit the data to NUS. 34