Material control in projects
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This document describes warehouse management services for a materials control project. It includes: 1. An overview of the warehouse workflow including pre-inspection, unloading, quality checking, storage, registration, material release, and inventory. 2. Details of main warehouse activities like management, storage planning, barcode implementation, system registration, documentation, and technical support. 3. Examples of a warehouse management system, preservation processes, and storage areas from previous projects.
Material control in projects
- 1. Project Warehouse MATERIAL CONTROL MANAGEMENT
- 2. Summarized Workflow Warehouse Service 2. Unloading 3. Conference 4. Storage 5. Registration 7. Inventory 6. Material Release 1. Pre-inspection Inbound Outbound Additional Control Pre-inspection of the cargo outside the project gate house prior to the receiving, checking visible damages and documentation. Unloading the goods with cranes and/or forklifts, based on the size and weight, separating on pre-defined areas for further checking. Quantity and quality conference based on packing lists and delivery notes, identifying possible non conformances. Storage of the materials in pre- defined areas, with pre-defined locations and according to the storage plan and TAG. Registration of all packing lists received, confirming the locations and comparing the estimated x received quantities and specs. Separation and issuance of material when requested by the contractors. Periodic inventories, to check the completeness of the items, location and specs.
- 3. Main Activities Warehouse Service • Management of the warehouse operations, such as, inbound, outbound and inventories of all the items procured by the client for the project, providing reports and controlling pre-established KPI´s; • Preparation of storage layouts and storage plans, to define the warehouse locations and position of each material prior to the receiving; • Implementation and definition of the barcode labels in steel structures and conveyor systems together with the suppliers, to guarantee a visual and clear information about each part, improving the warehouse operation and the erection performance; • Registration in the Warehouse management system of all inbound and outbound operations, providing reliable and controlled information over the material received and issued to the contractors at site; • Provide support to the client for the payment of invoices related to material supply, keeping available all necessary documents and reports; • Document control and archiving of all the packing lists, delivery notes, pick slips, Non Conformance Reports, PO´s, supplier manuals and certificates received during the project; • Inventories at the warehouses and storage areas to ensure the completeness of the items, avoiding surprises with missing and damaged parts during the erection; • Control over the preservation/conservation plan, ensuring the integrity of the materials and equipments during the storage period; • Technical support to the erection teams on meetings and action plans, with reports and statistics regarding the material received;
- 4. Warehouse Mangement System Warehouse Service Reports / Inventory Sheets Pick Slips Packing Lists Input Output NCR´s PO´s MTO´s System Warehouse Management System
- 5. WMS & ERP SAP (Payment and Transfer of Spare Parts) - Example Warehouse Service Input OutputSystem Confirmation of receiving by the warehouse (TAG, Weight and Quantities) Goods Receipt in SAP (MIGO) and Payment according with the material received by the warehouse Invoice Payed The spare parts identified by the warehouse are transferred to the SAP system Warehouse Management System Spare Parts are registered and identified in the WMS using the SAP number from the Master Data The Spare parts are now stock items in SAP and can be physically transferred to the operation warehouse Warehouse Management System
- 6. Warehouse Service The necessary Preservation services are carried out Equipment is TAGGED with the preservation label The preservation control sheet is update with relevant informations The next preservation checking dates are defined Equipment inspected Cargo is inspected with the preservation check- list of each discipline - The equipments that need some kind of preservation during the storage period are checked during the receiving using the check-list of preservation created based in other projects. Preservation Process Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec See note 1 Responsible: 2013 Preservation Label of Material and Equipment TAG: Monthly activities concluded: E M I TAG: Description: Location: W1 W2 SY1 SY2 Area: ITEM Yes No NA 1 2 3 4 5 6 7 8 9 10 11 12 13 14 PRESERVATION RECORD - ELECTRICAL EQUIPMENT Inspector: Date: Inspection Number: GU-C-013E Rev.0 The insulation resistance was measured in a period not older than 1 month from the delivery date? The non-terminated cable ends are sealed with heat shrink or shrinking shroud? All spare cable entrances in panels and boxes are plugged? Manufacturer: DESCRIPTION The electric or electronic equipment exposed to humidity is protected with desiccant or vapor corrosion inhibitor? The electrical heater is being preserved according with the supplier's preservation instructions? The electrical heater resistance or another anti-condensation system is safely connected electrically? Electrical panel cable termination point protected with temporary blind plug? Lubricate door hinges, grease nipples and fastener? Sensitive equipment stored indoor in heated and humidity controlled storage areas? All the gaskets and O-rings are greased with acid free vaseline or equal? All exposed unpainted-machined surfaces coated with rust preventive wax? Stored level for electrical transformer is in recommended hight? Openings of electrical panels is protected againts moisture or dust contaminations? Equipment supplied with inert gas, the pressure is measured periodically according to the manufacture's instruction?
- 7. Preservation/Conservation of Materials (Examples) Warehouse Service Conveyor Drives energized and protected from rain and sun. Cold Room for storage of fragile instruments. Pulleys and Idlers protected from sun and rain.
- 8. Previous Project – Storage Areas Warehouse Service
- 9. Previous Project – Storage Areas Warehouse Service
- 10. Previous Project – Storage Areas Warehouse Service