green field project making of production plant

17/ JAN/ 2012 TO 31 SEPT 2012EIGHT MONTH RECORD TIME WORK

Experience serves not only to confirm theory, but differs from it without disturbing it,

it leads to new truths which theory only has not been able to reach.

BY LT COLONEL VIKRAM BAKSHI (RETD) PROJECT HEAD

GREEN FIELD PROJECT FOR SETTING UP A

LEAN WORLD CLASS MANUFACTURING PLANT

Safety OathSafety Oath

We individually and jointly take an oath that, for We individually and jointly take an oath that, for

the observance of safety cause, for ourselves, our the observance of safety cause, for ourselves, our

family, our organization and our societyfamily, our organization and our societys welfare, s welfare,

we will adhere to our safety norms, rules and we will adhere to our safety norms, rules and

instructions to prevent accidents.instructions to prevent accidents.

We individually and jointly take an oath that, for We individually and jointly take an oath that, for

the observance of safety cause, for ourselves, our the observance of safety cause, for ourselves, our

family, our organization and our societyfamily, our organization and our societys welfare, s welfare,

we will adhere to our safety norms, rules and we will adhere to our safety norms, rules and

instructions to prevent accidents.instructions to prevent accidents.

Introduction

Purpose of this presentation Objective: To present different phases of

a plant construction

Outcome: It will help in deciding the time lines and preparation for future green and brown field plant

PART ONE:BASIC INFORMATION FOR GREEN FIELD PROJECT

Vendors

Consultant

OWNER SHIP VALUE OWNER SHIP VALUE NET NET PROJECT WORK WITH OTHER FUNCTIONAL DEPARTMENTSPROJECT WORK WITH OTHER FUNCTIONAL DEPARTMENTS

PROJECTPROJECTPROJECT Purchaser

SystemHR/Safety

Finance

Internal Customer

University of Pretoria

PROJECT MANAGEMENT

Initiation ActivityGot over in 2011

FROM JAN 2012 TILL DEC 2012

The quality management plan describes how the project will comply with the companys quality policy in terms of the project procedures for quality assurance (QA), quality control (QC), and continuous process improvement.

QA is the planned processes the project will follow to make certain that the quality policy is met through: QA audits to examine whether project activities are in compliance with project procedures,and process analysis to examine the effectiveness of project activities, learn from experience and problems encountered and thereby improve the process.

QC is the monitoring of specific project results to determine whether they meet with predetermined quality standards and metrics. Continuous process improvement is the iterative application of process analysis over the length of the project and from project to project.

Each consultant and construction contractor performing work on the project must have a QA plan that is acceptable to the Agency, so that the company can assess that the contractors quality standards meet the Agencys quality management plan.

The risk management plan describes how the project is organized and the procedures used to manage the project risks, addressing in the plan:

Roles and responsibilities of project staff in risk management

Identification of project risks

Categorization of risks in terms of probability of occurrence and impact on project cost, schedule, scope, and/or quality

Risk handling should the risk event occur, through either

Assumption Accepting the consequences of the risk.

Avoidance Changing the project deliverable design or work methods that lead to the risk.

Control Developing measures to reduce the risks probability of occurrence, continually re-evaluating the risk, and having in place contingency plans to adopt that mitigate the impacts of the risk.

Transfer Sharing or transferring the consequences of the risk with others, for example, through insurance or warranty provisions

Contract Procurement Planning

Procurements for most projects are undertaken by the company procurement department that has in place associated procurement procedures. The project managers role is tomake certain that the departments procurement activities on behalf of the project fit in with the project plan. The contract management plan sets out how this is to be achieved, by addressing:

Types of contracts to be used. Choice of contract type depends on the nature of service/product purchased and choices on the division of risk between the owner and contractor;

Who estimates the expected contract price.

Who develops the scope of work statement for the contract.

Use of standardized procurement documents and any special documents needed.

Integration of procurement lead times into the project schedule.

Incorporating contractual delivery dates into contracts that coordinate with the project schedule.

Use of performance bonds and/or insurance contracts to meet the projects risk management objectives, including liability and insurance conditions and minimum limits to be met by the contractor.

Establishing evaluation criteria to assess the selection of contractors;.

Definition of the procurement procedures for: preparation of procurement documents, advertising, bidder conferences, any bidder prequalification, receipt of proposals/bids, bidder interviews, selection, contract price negotiation, contract award and handling of protests. (In many instances the procedures used for project procurements will be those the company already has in place.)

The contract management plan sets out how this is to be achieved, addressing:

Who has the authority to direct and approve the contractor to perform work

How the contractors work is monitored and performance reported

Process by which changes to the contractors work are requested, approved, and the contract modified

What inspections and audits are to be conducted of the contractors work

How the contractor requests payment and payment requests are reviewed and approved

What financial audits are to be conducted on contractor payments

How contract documents, correspondence, and other records are managed. good project documentation for handling important contract administration activities such as contract changes and request for payment.)

Purchasing and receiving

A. Procuring - Locating, buying, ordering, and receiving materials, supplies, and equipment Purchasing - involves locating and buying of

materials, supplies, and equipment; there is a great need for discipline in the purchasing process

Purchase orders Responsibility for purchasing Terms and conditions of the purchase to be specified

in the purchase order Purchase control system Office and field purchasing Short form P.O. (used mostly for field purchases)

Purchasing and receiving(Contd)

B. Expediting - Coordinating the ordering and receiving of purchased items Responsibility for expediting must be clearly

defined Expediter must have ALL information required Expediting is a key coordination function; it

requires experience and skills

Purchasing and receiving(Contd)

C. Receiving materials and supplies - 5 steps Jobsite unloading - be careful to minimize

handling Material inventory - count! Material inspection - for damages, conformance

with the order Delivery receiving report Logging in delivery

Cost Control Cost control is based on continually refining the projects cost estimate at

completion as the project progresses and taking management action to address adverse variances in the cost estimate compared to the baseline budget.

As with the scope baseline, the cost baseline isdeveloped at the conclusion of preliminary engineering.

Schedule ControlThe WBS is again the starting point for schedule control. Work activities are identified for each of the WBS work package elements and formthe building blocks of the project schedule. For relatively simple projects you can represent the activities using a bar chart schedule and thetime from the beginning of the first bar (start) and the end of the last bar (finish) is the duration of the project

Subcontractor management

A. Issuing a subcontract A contract creates obligations for both parties; to deal effectively with all contractual obligations, all team members must fully know and understand the contract

Subcontractor management(Contd)

B. Subcontractor management: a big part of the job - 5 major areas Analyzing bids and issuing subcontracts Review of subcontractor site requirements Processing submittals and change orders Scheduling and coordinating Controlling quality, safety, and payments


C. Subcontractor coordination meetings Purpose

Keep communications between GC and subs open and candid

Maintain communications among the subs give all contractors an opportunity to discuss their

problems and learn about the problems others are facing

Help to schedule and coordinate the project


Types of meetings Management meetings

Monthly or bi-monthly meetings with a set agenda for an in-depth status review of job progress, schedule, submittals, quality, and safety, and any special problems

Attendance - Owner, A/E, project manager, superintendent, and major subs

Minutes should be taken and sent to all who attended plus everybody involved in the subjects discussed


Weekly project meetings These meetings are centered primarily on scheduling and coordination, but can also cover cleanup, quality, safety, etc.

Pre-construction planning meetings To discuss scope of work, long lead time items, material handling and storage requirements, and activity duration


D. Subcontractor default Be sensitive to early warning signs Follow notification requirements if

subcontractor performance falls below acceptable standards

Follow contract provisions exactly for termination procedures

Try to work problems out with banks, bonding company, etc., so no new subcontractor has to be employed

GUIDELINES FOR MACHINE COMMISSIONING

Task of Project and Production Maintenance team

Verifies operation of components under various conditions

Verifies interaction between systems and subsystems

Documents performance of systems to design criteria

Instructs building personnel on proper operation of systems

Ongoing after building occupancy as requirements change

Documentation Required

Owners Project Requirement Document Commissioning Plan Basis of Design Contract Documents FAT Report Draft of the Final Commissioning Report Warranties O & M Manuals

Approved Change Orders AS-Built Drawings All testing data verification and

documentation. Sequence of Operation Minutes of Meetings Local jurisdictional inspection documentation

and records

INDUCTION IN NEW EQUIPMENT

O & M Manuals Should be received within

60 days after approved submittals have been returned

Review with owner and give comments back to contractor for compliance

Use this training Bible Be careful what we get

in the O & M You do not need

installation material

TRAINING

Factory witness testing on major pieces of equipment

Get factory training out of way up front

Training should be in a classroom setting and also at the respective piece of equipment

Use factory trainers not the local sales rep

LIST OF DUTIES TO BE DONE FOR PLANT MAKING

Conceptual Planning of the Project

Planning and Estimation of Site Infrastructure

Resource Mobilization

Overall administration of the Project.

M.I.S. (Management Information System )

Timely submission of monthly RA bills, labour bills, purchase bills preparation and certification of Final

Bills and reconciliation of material.

Minimize wastage of Construction Material.

liaison with Client / Consultants

Motivating and managing site personnel as team leader.

Timely completion of project within the given time frame and maintaining quality

Execution of structural and Architectural works as per relevant drawing.

Micro planning to deliver the project.

Planning day to day activities of Project.

Coordination with architects and consultants.

Monitoring of construction activities as perform by contactors/other agencies with quality norms.

Interaction with prime contractors and other agencies.


Review contractor's structural change order proposals. Prepare recommendations to t Engineer for review. If warranted, assist in negotiations with contractors regarding changes in contract value or project duration.

Review contractors' claims related to structural works. Prepare recommendations for claims approval or rejection. Assist in negotiations with contractors regarding the value of claims or changes in schedules.

Witness testing and commissioning of the works.

Approve the contractors' as-built drawings and O&M manual submittals. Assist with the final inspection of the work. Review the adequacy and accuracy of punch lists.

Monitor final completion of the work.

Review of structural drawings for projects designed by others.

Review is to be undertaken for code compliance.

Work out the quantities of material used in projects.

Material requirements.

Documentation and MIS related to Project. Bar bending Schedules.

Serve as the Senior Site Representative for all matters related to construction quality assurance of structural works.

Monitor the structural works for conformance with the provisions of the Contract Documents and the Procedures manual.

Review, approve and process all structural technical submittals.

Coordinate and supervise the work of all structural activities and operations.

Liaise with local authorities and ministerial agencies having jurisdiction over the project.

Receive/action Request for Information (RFI) that apply to structural works. RFI's requiring design feedback will be directed to the Designer for response. Review the responses for adequacy.


Close coordination with Architectural and MEP trade designs

Planning, monitoring & controlling all site activities including manpower planning, resource planning & material planning of multiple project sites.

Ensuring all site activities of various project sites are carried out as per SOPs (standard operating procedures), as per ISO 9000, OSHO, site quality plan.

Approving the Project construction & erection Schedule prepared as per the Contract guidelines using Primavera for all projects under execution. Providing guidance in developing

the site progress calculation sheet & monitoring the same.

Analyzing the major scope of work at site (as per the Contract) and discussing with various disciplines for criticalities & strategies for timely completion of site work of various projects under execution.

Attending major site coordination meetings with client for reviewing site progress & resolving pending problems for various projects under execution

Implementing a periodic MIS reporting of site progress, customer invoicing & payment voucher collection at site of various projects under execution.

Making important correspondences with Client to build Customer relationship and sort out any disputes (technical or commercial) occurring at various project sites.

Responsible for Project Cost control and analysis for site activities

Control on-site activities for erection progress through site-in-charge and resolving site discrepancy reports with engineering.

Coordinating with Procurement department for shortage/ damage report.

Identifying the training needs for own department and arrange for the same, through Personnel Department, as and when required.

Leadership, delegation, communication, interfacing and presentation skills. Experience in handling multi-functional management role is mandatory


Banking Construction loans Financial Structure Legal matters Business organization Auditors & audits General books of account Subsidiary records Cost records and reports Financial reports Tax returns and payments

Payment of invoices Billing Collections Assignments Bank deposits Personnel records Payrolls and records Wage and personnel reports to

public agencies Office services Construction Material Testing Geotechnical Investigations Petrography Radar Non-destructive testing at sites

DUTIES OF PROJECT HEAD Conceptual Planning of the Project

Planning and Estimation of Site Infrastructure

Resource Mobilization

Overall administration of the Project.

M.I.S. (Management Information System )

Timely submission of monthly RA bills, labour bills, purchase bills preparation and certification of FinalBills and reconciliation of material.

Minimize wastage of Construction Material.

liaison with Client / Consultants

Motivating and managing site personnel as team leader.

Timely completion of project within the given time frame and maintaining quality

Execution of structural and Architectural works as per relevant drawing.

Micro planning to deliver the project.

Planning day to day activities of Project.

Coordination with architects and consultants.

Monitoring of construction activities as perform by contactors/other agencies with quality norms.

Interaction with prime contractors and other agencies.

Work out the quantities of material used in projects.

Material requirements.

Documentation and MIS related to Project. Bar bending Schedules.

Planning, monitoring & controlling all site activities including manpower planning, resourceplanning & material planning of multiple project sites.

Ensuring all site activities of various project sites are carried out as per SOPs (standard operating procedures), as per ISO 9000, OSHO, site quality plan

DUTIES OF PROJECT HEAD Approving the Project construction & erection

Schedule prepared as per the Contract guidelines using Primavera /MSP for all projects under execution. Providing guidance in developing the site progress calculation sheet & monitoring the same.

Analyzing the major scope of work at site (as per the Contract) and discussing with various disciplines for criticalities & strategies for timely completion of site work of various projectsunder execution.

Attending major site coordination meetings with client for reviewing site progress & resolving pending problems for various projects under execution.

Implementing a periodic MIS reporting of site progress, customer invoicing & payment voucher collection at site of various projects under execution.

Making important correspondences with Client to build Customer relationship and sort out any disputes (technical or commercial) occurring at various project sites.

Control on-site activities for erection progress through site-in-charge and resolving site discrepancy reports with engineering.

Coordinating with Procurement department for shortage/ damage report.

Identifying the training needs for own department and arrange for the same, through HRl Department, as and when required.

Leadership, delegation, communication, interfacing and presentation skills. Experience inhandling multi-functional management role is mandatory.

Responsible for Project Cost control and analysis for site activities

DUTIES OF CIVIL/ELECTRICAL AND STRUCTURAL ENGINEER Serve as the Senior Site Representative for

all matters related to construction qualityassurance of structural works.

Monitor the structural works for conformance with the provisions of the Contract

Documents and the Procedures manual.

Review, approve and process all structural technical submittals.

Coordinate and supervise the work of all structural activities and operations.

Liaise with local authorities and ministerial agencies having jurisdiction over the project.

Receive/action Request for Information (RFI) that apply to structural works. RFI'srequiring

design feedback will be directed to the Designer for response.

Review the responses for adequacy.

Review contractor's structural change order proposals

Prepare recommendations to Resident Engineer and or Client for review. If warranted, assist in negotiations with contractors regarding changes in contract value or project duration.

Review contractors' claims related to structural works. Prepare recommendations for claims approval or rejection. Assist in negotiations with contractors regarding the value of claims or changes in schedules.

Witness testing and commissioning of the works.

Approve the contractors' as-built drawings and O&M manual submittals. Assist with the final inspection of the work. Review the adequacy and accuracy of punch lists. Monitor final completion of the work.

Review of structural drawings for projects designed by others

Review is to be undertaken for code compliance.

Close coordination with Architectural and MEP trade designs

ARCHITECT

Furnishing the contractor with drawings and information

Issue of variation orders altering extent, nature or quantity of the works

Suspension of the works

Nomination of sub-contractors and suppliers

DESIGN HEADFinalize project scope of work and budget.

Make certain that the design team is performing the work and services required by the scope.

Provide assistance and guidance to the design consultant.

Prepare and monitor the project schedule.

Monitor project cost including cost of design, ROW acquisition, utility relocations, construction, etc., to keep costs within budget.

Review and coordinate reviews of all design submissions, preliminary and final real property and ROW plans, design drawings, special provisions, specifications, and estimates.

Accept and evaluate the quality of deliverable. Verify adherence of the design consultant to the QA/QC plan.

Coordinate and oversee design review meetings, constructability reviews, and plan checks.

Coordinate between the Agency and involved third parties (e.g., environmental agencies, municipal officials, municipal authorities, utility companies).

PART TWO

SAVLI PROJECT

AIM: Project completion of manufacturing plant by 31 Sept 2012 and production operational with first product delivery on 12/12/12.

Scope : Civil work/PEB/ Elect Work/ Mechanical work/ Machine Commissioning/ Utilities

Terms of Reference: Master Schedule Plan

KEY MILE STONES DATES DECIDED BY MANAGEMENT

Construction of Plant Shed: 02 Oct 2012

Procurement of Electrical Items and Utilities: 27Aug 2012

Procurement of Machinery and Installation:12Dec 2012

Production of First product Unit:12Dec 2102

PROJECT CHARTER

Civil & Elect Consultant : Shah & TalatiConsultantCivil Contractor : Shri Ganesh Engineers & fabricatorsPre-engineered Building Contractor : Lloyd InsulationCrane: AnupamElectrical : Rama Engineering

Project HeadT Remesan

Project HeadT Remesan

Head Engg &ContractingN V Belsare

IJ M Muthe

Head Engg &ContractingN V Belsare

IJ M Muthe

Group Head ProjectVikram Bakshi

Group Head ProjectVikram Bakshi

Procurement Committee *

Nitin V BelsareBhaskar Pathak

Nagesh Shekhdar

Procurement Committee *

Nitin V BelsareBhaskar Pathak

Nagesh Shekhdar

Proj.Eng. CivilBhavik Sheth Bhatt

Proj.Eng. CivilBhavik Sheth Bhatt

Proj.Eng. MechSantosh ( yet to Join)

Proj.Eng. MechSantosh ( yet to Join)

Proj. Eng ElectriTapan Desai

Proj. Eng ElectriTapan Desai

Ofiice Assistant.

Smit Joshi

Ofiice Assistant.

Smit Joshi

RESPONSIBILITY ASSIGNED MATRIX

Other key Note Contributors

Safety officers > Neeraj Sharma and AlpishBhatt and Pragnesh ParikhCommercial > Sriram Kadam/DigvijayPharkate/ Gaurav GediaFinance> Anirudh and Nehal

Savli front end site team

No one can whistle a symphony. It takes a whole orchestra to play it.But You need a good Conductor

Mr T RemesanLt Col Vikram Bakshi

Civil vendorMr Viral

Fantastic Front end team

Civl Vendor Engr KapilThermax Mech Engineer Sachan

Thermx Civil Engineer BhavikSafety officer and for any task NeerajPEB Looyd engineer Harry and Anish

Crane Team from Anupam

Crane engineer Alpsih

Eectrical Engoneer Tapan

Project Adminand Mech engineer Smit

None of us is as smart as all of us. "

Alone we can do so little; together we can do so much."

SNAP SHOTMASTER SCHEDULE PLAN

ID Task Name Finish

0 final Savli execution plan 0990611R2 Wed 12/12/121 Bi Drum Project at a glance ( Plant construction to first unit Invoice)Wed 12/12/12

Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar AprQtr 2, 2011 Qtr 3, 2011 Qtr 4, 2011 Qtr 1, 2012 Qtr 2, 2012 Qtr 3, 2012 Qtr 4, 2012 Qtr 1, 2013 Qtr 2, 2013

ID Task Name Finish

39 Release Cloumn reaction design to client for structure consultant approval Tue 1/31/1240 Revise based on comments and release for PEB manufacturing & civil wrokFri 2/10/1241 Manufacturing of Bi drum PEB structure Sat 6/16/1242 Civil construction of shed for Bi-Drum at Savli Vadodara Wed 12/12/1243 Civil consultant finalisation and release of civil drawings Thu 1/12/1244 First Round of discussion with all consultants / agencies Mon 10/17/1145 Shortlist people and have interaction Mon 11/7/1146 Finalise the consultant scope and Release LOI Thu 10/20/1147 Get Column reaction from PEB structure supplier Thu 1/12/1248 Release civil design work for Bi drum mfg set-up Fri 12/30/1149 Manpower planning & Recruitment Mon 1/2/1250 Prepare the organisation structure for the Bi drum Tue 10/4/1151 Identify people from Thermax, Pune Wed 10/12/1152 Prepare recruitment plan for balance local people Thu 10/20/1153 Conduct interviews and select right Staff people Fri 11/11/1154 Approach the development zone to get skilled workers Mon 11/21/1155 Recruit workers Mon 1/2/1256 Construction of plant shed Tue 10/2/1257 Prepare comparative statement and fair price estimation Fri 10/7/1158 Finalise the contractor Wed 10/12/1159 Release LOI / PO Thu 1/12/1260 Civil Construction of plant Bi drum shed Wed 5/30/1261 Errection of PEB structure Thu 8/16/1262 Civil construction of Flooring,wall & windows , paintingMon 9/10/1263 Bi drum shed readyness after water and LPG piping Tue 10/2/1264 Construction of office and utilities & interiors Fri 6/22/1272 Procurement of machinery for Bi- Drum and Installation Wed 12/12/12

Jan 27 Jan 31

Feb 1 Feb 10

Feb 13 Jun 16

Oct 4 Oct 17

Oct 18 Nov 7

Oct 20

Jan 4 Jan 12

Nov 28 Dec 30

Oct 4 Oct 4

Oct 5 Oct 12

Oct 13 Oct 20

Oct 21 Nov 11

Nov 14 Nov 21

Nov 22 Jan 2

Oct 4 Oct 7

Oct 10 Oct 12

Jan 6 Jan 12

Mar 23 May 30

May 31 Aug 16

Jun 20 Sep 10

Sep 11 Oct 2

Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar AprQtr 1, 2011 Qtr 2, 2011 Qtr 3, 2011 Qtr 4, 2011 Qtr 1, 2012 Qtr 2, 2012 Qtr 3, 2012 Qtr 4, 2012 Qtr 1, 2013 Qtr 2, 2013

SITE WORK PREPRATIONS

FOUNDATION BOLTTEMPLATES

MISC CIVIL WORK

PEB RAFTERSMISC CIVIL WORK

PEB CLADDING /ROOF

CRANE FITMENTS

10 SEPTCIVIL WORK COMPLETE

PRODUCTION FROM

BIDRUM AND PANLE

PEB COLUMNSANCILLARY BUILDING

WORK AND MISC CIVIL

WORK

PEB CRANE BEAMS/ROOF MISC CIVIL WORK

:MACHINE FOUNDATION LAYOIUT

CRANE COMMISSIONING

PEB COMPLETION

Coil PEB WorkAncillary Building

completed

COIL SHOP PEB CRANE AND MACHINE WITH

ELECTRICAL WORK

12/12/12

Productiionoutput

CIVIL FOUNDATIONSMISC CIVIL WORK

MILE STONES FOR BIDRUM PANEL SHOP TILL 12/12/12

PROJECT TRUISM > You can con a sucker into committing to an impossible deadline, but you cannot con him into meeting it.

CivilConstruction

Of plantShed/LPG/Water

02 0ct 2012

ErectionOf PEB Structure

16 Aug 2012

CIVILCONSTRUCTIONOF FLOORING

WALLWINDOWPAINTING

CompleteInside

Civil workWith windows

Example text

CIVIL FOUNDATIONS.

10 SEPT

20 OCT

PEB WORKCOMPLETION.

30 OCT

FLOOR & M/CFOUNDATIONS.COIL MACHINEINSTALLATION

10 NOV

CRANE FITMENT.RADIOGRAPGHY WALL

10 NOV

PRODUCTION START

12 /12/12

FINAL OUT PUT

MILE STONES FOR COIL SHOP TILL 12/12/12

SOME RULES OF THE GAME Good Planning: forward planning, which includes detailed planning of the

process implementation stages, task timeliness, fall-back positions, and re-planning

Clear Responsibility and Accountability of Team Members: We had a clear understanding of their roles and duties in the project. They must understand how expectations vs. achievements will be measured and graded .

Schedule Control: We had continual monitoring and measurement of time, milestones, people, and equipment schedules

Guard Against Lack of Efficient Internal Communication Links, Lack of Efficient External Communication Links, Lack of Responsive Decision Making Lack of Effective Teamwork

Communications was kept honest and open between team members and vendor to know exact status of situation.

Define scope of project Identify stakeholders, decision-

makers, and escalation procedures

Develop detailed task list (work breakdown structures)

Estimate time requirements Develop initial project

management flow chart Identify required resources and

budget Evaluate project requirements

Identify and evaluate risks Prepare contingency plan Identify interdependencies Identify and track critical

milestones Participate in project phase

review Secure needed resources Manage the change control

process Report project status

HOW WE ALL WENT ABOUT THE PROJECT WORK

Functions of project management for construction Specifying project objectives and plans which include the delineation of

scope, budgeting, scheduling, setting performance requirements, and selecting project participants

Maximizing efficient resource utilization through procurement of labor, material, and equipment according to the prescribed schedule and plan

Implementing various operations through proper coordination and control of planning, design, estimating, contracting, and construction in the entire process

Developing effective communication and other mechanisms for resolving conflicts among the various project participant

SUMMARY OF TASK

ID Task Name Start Finish % Complete Baseline Finish Milestone

0 Tue 1/17/12 Wed 10/10/12 86%Wed 10/10/12 Yes2 1 CONSTRUCTION OF PLANT SHED BI DRUM Tue 1/17/12 Fri 8/31/12 86%Tue 10/2/12 Yes4 1.1 JAN /FEBURARY NO I TASK :

PREPARATORY WORKMon 1/30/12 Fri 3/9/12 100% No

20 1.2 JAN/FEBURARY NO 2 TASK : CIVIL CONSTRUCTION OF BIDRUM SHED TILL FOUNDATION

Wed 1/25/12 Sat 4/14/12 100%Wed 5/30/12 Yes

22 1.2.1 A: SITE INITIAL WORK Mon 1/30/12 Wed 3/28/12 100% No30 1.2.2 B: CIVIL WORK FOUNDATION BOLT Thu 2/2/12 Sat 4/7/12 100%Wed 5/30/12 Yes44 1.3 FEB TO AUG NO 3 TASK

:CONSTRUCTION OF OFFICES UTILITIES ANDINTERIORS

Wed 2/1/12 Fri 8/31/12 85%Fri 8/31/12 Yes

46 1.3.1 UG TANK Fri 2/10/12 Fri 3/30/12 100% NA Yes53 1.3.2 WELDING AND MAINTENANCE SHOP Fri 3/23/12 Wed 8/22/12 85% Yes66 1.3.3 SERVICE OFFICE Wed 3/28/12 Fri 8/31/12 55% Yes78 1.3.4 TOILET No 1 Fri 3/23/12 Thu 8/30/12 83% NA Yes91 1.3.5 TOILET No 2 Wed 5/30/12 Thu 8/30/12 96% NA Yes

104 1.3.6 RADIO GRAPHY Wed 2/1/12 Thu 8/2/12 96% NA Yes117 1.4 NO 4 TASK> ERECTION

OF PEB STRUCTURE Wed 2/1/12 Thu 8/16/12 99% Thu 8/16/12 Yes

119 1.4.1 Prepration Wed 2/1/12 Sat 4/14/12 100% No125 1.4.2 ERECTION GRID 1 TO 13 Tue 4/10/12 Mon 4/30/12 100% Yes135 1.4.3 ERECTION Grid 13 to 23 Tue 5/1/12 Sat 5/19/12 100% NA Yes145 1.4.4 FIXING OF ROOF SHEETS Sat 6/16/12 Sat 6/30/12 100% NA No154 1.5 NO 5 TASK> BRICK

WALL ON PLINTH BETWEEN PEB COLUMNSat 3/31/12 Mon 9/10/12 89% NA Yes

167 1.6 NO 6 TASK Electrical Works

Tue 5/1/12 Wed 10/10/12 68% Mon 8/27/12 No

174 1.6.7 Installation & commissioning Fri 8/17/12 Wed 10/10/12 6% NA No190 1.7 < JUN TO AUG > NO 7 TASK >

CONSTRUCTION OF MACHINE FOUNDATION BEFORE FLOOR WORK

Fri 6/1/12 Thu 8/30/12 100% NA Yes

192 1.7.1 PLATE BENDNG Fri 6/15/12 Sat 6/30/12 100% NA Yes201 1.7.2 PANEL BENDING Fri 6/15/12 Sat 6/30/12 100% NA Yes210 1.7.3 SHOT BLASTING Wed 6/6/12 Thu 8/30/12 100% NA Yes219 1.7.4 PEMA Fri 6/15/12 Sat 6/30/12 100% NA Yes220 1.7.4.1 EXCAVATION Fri 6/15/12 Sat 6/30/12 100% NA No244 1.8 NO 8 TASK > FLOOR

WORKSat 4/14/12 Fri 8/31/12 94%Mon 9/10/12 Yes

246 1.8.1 GRID 1 to 13 Sat 4/14/12 Wed 5/30/12 100% NA No250 1.8.2 GRID 23 to 13 Tue 5/1/12 Thu 5/31/12 100% NA No255 1.8.3 RCC FLOORING FROM GRID 1 TO 23Fri 6/1/12 Fri 8/31/12 90% NA Yes260 1.9 TASK NO 9 >

WALL WINDOW AND DOOR FITMENTSMon 7/2/12 Thu 8/30/12 85%Tue 10/9/12 Yes

280 1.13 NO14 TASK >CRANES FITMENTS AFTER PEB CRANE BEAM COMPLETION

Mon 7/2/12 Wed 8/29/12 35% Yes

8/31

4/14

4/7

8/31

3/308/22

8/318/308/30

8/28/16

4/30100%5/19100%

100%9/10

8/30

6/30100%6/30100%

8/306/30100%100%

8/3194%

100%100%

8/3190%8/3085%

8/29

Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep4th Quarter 1st Quarter 2nd Quarter 3rd Quarter

CIVIL FOUNDATIONS

ANCILLARY BUILDINGS

PEB WORKS

PLINTH WALL

MACHINE FOUNDATIONS

FLOOR

WINDOWS AND PAINT

CRANE

PRE LIMINARY WORK

ELECTRICAL

Green Field Project layout

A. Organizing the project layout Proper placement of yard,

office, roads, material storage and fabrication

60% to 70% of all labor cost to install materials is spent to get the materials to the location where it is installed

Items to consider Site access and

security, number and location of entrances

On-site access roads: materials, drainage, maintenance, etc.

Job office: location and layout

material storage areas: include subs!

Stockpiling of dirt for backfill

Fabrication areas Trash removal

X. Project layout (Contd)B. Material storage and

protection Storing materials so

they can be found; record the location

Protection from weather; follow manufacturers instructions

Allow for mechanized handling

Protection from theft; lights, locks, security devises

Controlling its use; define responsibilities for control

C. Controlling small tools and supplies Limit access to small

tools and supplies Limit the way they can

be obtainedD. Material handling and

fabrication Mechanize when

possible Use assembly line

techniques: plan the location, plan the flow of materials, plan the special tools and equipment needed

X. Project layout (Contd) The secrets of efficient

prefabrication Minimize the moves for

materials and workers Minimize the hand labor Remember that the shortest

distance between two points is a straight line

PART THREE

RISK MANAGEMENT

Outstanding Risks and Issues PROJECT DELIVERBALE RISKS

ELECTRIC PANEL DELIVERY LATE FOR ELECTRICAL WORK

Solution :Risk resolved by visit and liaison but needs follow up. Delivery commited by 10Sept

MACHINE DELIVERY LATE FOR COMMISSIONING

Solution: Needs Follow Up

PEB COIL DELIVERY TIME LINES

Solution: Clear time lines to be followed wrt design to production to delivery to erection .Closing Committed by 30 Oct 2012

PROJECT ISSUE RISK

SAFETY ISSUE BEING NEGLECTED

COORDINATION OF PEOPLE WORKING TO PREVENT ANY OVER LAP OF ANY MOVEMENTS

- AREA EARMARKED FOR MATERIAL

- WATER AND GLUCOSE ARRANGEMENTS FOR PREVENTING DEHYDRATION

- SAFETY KITS AND MEASURES UNDER SAFTEY OFFICER

- CLEARANCE BY CIVIL AND MECH ENGR FOR OVER TIME WORK AND ENSURING SAFETY ASPECTS.

NO WORK AT HEIGHT AFTER DARKNESS

TRAINING

CIVIL FOUNDATION BOLT Start: 2/1/12 ID: 2

Finish: 4/13/12 Dur: 53 days

Res:

PEB COLUMNStart: 4/16/12 ID: 3


Res:

PEB SHEET/ROOFStart: 5/28/12 ID: 4


Res:

FLOORINGStart: 5/28/12 ID: 5


Res:

CRANEStart: 5/28/12 ID: 6


Res:

ELECTRICALStart: 4/16/12 ID: 7


Res:

FOUNDATIONStart: 4/16/12 ID: 8


Res:

MACHINE FITMENTStart: 6/18/12 ID: 9


Res:

ANCILLARIESStart: 4/16/12 ID: 10


Res:

RADIO GRAPHYStart: 4/16/12 ID: 11


Res:

INAUGRATION Start: 8/15/12 ID: 13

Finish: 8/15/12 Dur: 1 day?

Res:

TRIAL PRODUCTIONStart: 8/1/12 ID: 12


Res:

BIDRUM PLANTPROJECT EXECUTION

START : 2/2/12FINISH; 15/9/12

TOTAL:141 DAYS

CRITICAL PATH

Impact of Risk on success/failure for Balance Project

HOW FAILURE OF MACHINES CAN BE PREVENTED IN LONG

RUN WRT NEW FACILITY

5 S Strictly followed by Production team with proper upkeep of Equipment.

Separate TEAM for Maintenance of machines

Enforce Production Team to do daily preventive maintenance

Plan its own Corrective and Schedule Maintenance

HOW SUCCESS CAN BE USED BY TIMELY CONSTRUCTION OF

NEW FACILITY

Completing Civil/PEB work 10 Sept will give One month advance preparation time as original 10 Oct.

Enough time for coordination of various activities of Manpower training / Processes of production line to align start by 12/12/12 and make it a sustainable production line

If need be advance production also before 12/12/12

PART FOUR: QUALITY AND SAFETY MANAGEMENT

Work Smart Not Hard !!!

QUALITY

DPR FILE TEST CERTIFICATE DRAWING FILE RA BILL FILE LEGAL DOCU OF CONTRACTOR CONCRETE POUR CARD FILE

QUALITY COMPLIANCEExecution and Quality Control procedures

As per Construction Quality requirements In compliance with Contract Documents.

Latest issues of applicable drawings and documents

Activities performed according to relevant execution procedures .

No stage started without the previous one verified.

Responsibility for each control task is clearly identified

Control of the quality identification of incoming materials.

Control of non-conforming materials.

Surveillance and control of work processes.

Communication between personnel involved in quality and those involved in material control and Construction.

Inspections and tests Documents

DPR file

Excavation and Lay out measurements

Test certificateFine AggregateCoarse AggregateReinforcement SteelCube Test and Compressive StrengthConcreteConcrete Reinforcement bars

Drawing fileRA bill fileLegal documents of contractorConcrete pour card file

SAFETYTRAINING PREVENTION AND PRECAUTIONS

LECTURES ON SAFETY WORKING AND EQUIPMENT TRAINING DEMO REGISTER FOR OBSERVATION OF ANY DONTS DOES AND DONTS GLUCOSE AND WATER ARRANGEMENT REST AND RECOUP MEDICAL

Part Five: Budget High Light

THE TEAM HAS SAVED APPRX 35 LACS ON SITE WORK IN CIVIL WORK TILL DATE .

THE TEAM ALSO FINISHED WORK MUCH IN ADVANCE AT LEAST ONE MONTH BEFORE TO ENABLE PRODUCTION TEAM TO SET UP INETRNAL SHOP AND PROCESSES ALSO

PART SIX

Areas of Concern in Savli Unit RoadSTPFire Hydrant around the PlantPlantation as per GIDC NormsSpace for Storage , Packing and Dispatch

PART SEVEN: PROJECT RECOMMENDATION AND LESSONS LEARNED

Learning From Negatives

We could have closed the Project on 15 Aug instead of 10 Sept

Poor Communication Between Designer/Purchasers and Project /Vendor team

Solution: They should be Positioned in site once a month to resolve issue and then only clear off

Lack of IT management to speed up work

Lack of User Input wrt existing Plant records of Shell shop led to couple of Incomplete requirements . ( Records of Shell Shop were not there)

Solution: Bidrum / Panel/ Coil records will be there in soft and hard copy

CHANGES CHANGES CHANGES THEY ARE THE REAL KILLERSChanging requirements and Specifications led to many Restarts/Cost overruns/ Time overruns

Solution : Proper Planning with all stake holders with one to onemeeting with fixed time schedule for closing issues.

TOO MANY COOKS AND SOUP GETS SPOILED

Slow Executive Support for almost everything : Ownership was not there and taken as additional task.

Solution: Clear defined Structure to be filled up before Project starts and support staff in back end to be integrated for some kind of parallel reporting and feedback on response

Lengthy Processes for Approvals: Solutions: Less Bureaucracy stops and reduced number of people in Approvals.A study can be undertaken to reduce the process and make it Lean way under Six Sigma

CONCLUSION

A successful project must be on time, on budget, and deliver quality (features and functions) as promised.

Anything less will be either a failed project or a challenged project.

Resolution Type 1 is a Project Success it completed on time and budget, with all features and functions as specified. Only 16.2% of projects fell in this category.

Resolution Type 2 is Project

Challenged. These were completed, but were over cost, over time, and/or lacking all of the features and functions that were originally specified. 52.7% of all studied projects fell into this Resolution Type 2 (Challenged) category.

Resolution Type 3 is termed Project Impaired/Failed. These projects were abandoned or cancelled at some point and thus became total losses. A disturbing 31.1% of all studied projects fell into this category.

PROJECT CLOSE OUT PREPARE A PUNCH LIST OF

INCOMPLETE CONTRACTOR ITEMS.

LEAD A FINAL WALK THROUGH INSPECTION OF CONSTRUCTED FACILITY.

RESOLVE OUTSTANDING CHANGES/CLAIMS.

DEVELOP A PLAN TO DEMOBILIZE AGENCY AND CONSULTANT STAFF.

KEEP PROJECT TEAMS ATTENTION

FOCUSED ON CLOSEOUT ACTIVITIES.

ASSESS AND DOCUMENT LESSONS

LEARNED ON PROJECT.

OBTAIN PROJECT ACCEPTANCE FROM PRINCIPAL STAKEHOLDERS.

CELEBRATE PROJECT COMPLETION.

A CONTRACTS TERMS AND CONDITIONS SPECIFY THE ACTIONS NEEDED FOR FINAL SETTLEMENT AND CLOSURE.

A CONTRACT IS SUBSTANTIALLY COMPLETE WHEN THE PERMITTING AUTHORITY ISSUES

CERTIFICATE OF BENEFICIAL OCCUPANCY.

A CONTRACT AUDIT IS NEEDED TO VERIFY APPROPRIATENESS OF COSTS INVOICED ON COST PLUS TYPE CONTRACTS.

A CONTRACT AUDIT EXAMINES DIRECT LABOR, OTHER DIRECT COST, AND INDIRECT OVERHEAD CHARGES.

Important administrativecloseout items

Demobilization of project team.

Closure of project funding and financing.

Securing the disposition of project records.

Conducting a lessons learned project evaluation.

Achieving closure with stakeholders.

Celebrating project success.

Typical closeout activities for a professional service contract include:

Verification of Scope Completion Confirm that the professional service contractor has satisfactorily delivered the services called for in the contract scope of work.

Contract Audit Where contract payments are on a cost plus fee basis, the contract provisions should give the Agency the right to audit the contractors costs. The audit should verify items such as direct labor rates, support for time charges, support for other direct costs, and justification for overhead rates.

Final Payment and Release of Retention With scope completed satisfactorily and audit completed, you can approve the final payment and release of any retention held back from prior contract payments pending satisfactory completion of services and audit of costs

SNAP SHOTS GREEN FIELD

PROJECT SAVLI

BHOOM PUJAN BY MANAGEMENT IN 2011

BHOOMI PUJANBY PROJECT TEAM IN JAN 2012

Site Preparation

Remove trees and any debris

Remove top soil (4-6 below surface)

PREPARATORY WORK

Guard Cabin under completion.

Barricading Work under wayWater tank for site

Industrial official documentation and liaison over Legal Documents for Workers handed over to HR dept. PO and Contract documents completed Initial safety training completed Dumping of Barricading material Dumping of water pit /office site Positioning of JCB and Construction Equipment Meeting with Consultants for drawings

SITE LAYOUT

Corner Footing Marking

Ensure lot lines are known & setbacks are complete

Layout building perimeter

Use batter boards

Establish building corners & building perimeter

Auto level used to determine floor level with existing shed

SURVEY AND AUTOLEVEL

SURVEY

9.430 NET FALL

1.131 1.57

0.439

2.16 2.55

0.39

3.068 3.488

0.42

3.071 3.231

0.16

FALL(m) FORESIGHT (m)

BACKSIGHT (m)

BENCHMARK --- Benchmark was taken as a nearby road as 0.0m level.LAYOUT---Layout is done in order to locate exact position of building components on the site as mentioned in

drawingGRID LINESThese are the reference lines in which whole plot is divided symmetrically. So its easy to locate

and communicate about any particular point by referring it with respect to Grid Lines.

Excavation, Layout and Foundation

Excavation is a process of making trenches by digging up of earth for the construction of foundations and basements.

Excavation level at escape site is 219.825 mm Excavation is done by the JCB on the hourly basis After the excavation the surface is leveled called

surface dressing Layout is done on the PCC poured over leveled

surface. Column and foundation (raft ) steel is then laid as

per drawings.

Points to take care:- layout should be checked properly. Check any difference between architectural and

structural drawings regarding location of column. After excavation check the stability of temporary

structures built near the excavated ground. Before laying raft reinforcement, shuttering wall which is

mainly brick wall should be built and should be filled with soil on other side.

Check the direction of chair bars in the raft

Excavation

Excavate foundation along line created by batter boards

Excavate remainder of soil inside perimeter

Dont excavate inside soil if slab on gradeIf deep foundation, taper edges to prevent collapse

If soil unstable, or very deep - use shoring

EXCAVATION

LAYOUT

RAFT FOUNDATION

EXCAVATION

Total Depth of Excavation to be done---10.2 meters Total Excavation to be done---53409 cubic meters .

FOUNDATIONS

Isolated footings Strip footings Combined footings

Grade of concrete--- M25.

Clear Cover--- 50 mm.

16 FEBCONCRETING WORK STARTS

POOJA BEFOREFIRST FOOTING RCC

POUR CONCRETE FOOTINGSSMOOTH / FINISH SURFACE

STEEL

For Reinforcing Concrete now a days HYSD (High Yielding Strength Deforming) steel bars are used. Steel can handle both tensile and compressive stresses. Mainly steal in R.C.C is used to take Tensile stresses but can also be used to take Compression if Concrete in a section is not enough to take Compressive stresses.

Now a days TMT (Thermo Mechanically Treated) Bars are used. Thermo mechanically treated steel known as TMT steel can be described as new-generation-high-strength steel having superior properties such as weldability, strength, ductility and bendability meeting highest quality standards at international level

Brands Of Steel Used At SiteBHUSHAN STEEL

JYOTI STEEL

32mm

28mm

25mm

16mm

12mm

10mm

8mm

Diameter of bars required on site on Site

16 FEBCONCRETING WORK APART FROM FOOTING EXCAVATION /PCC/ STEEL

FOUNDATION SHUTTERING

Pour Concrete Foundation Walls

Construct formwork (include sleeves / doors / windows)

Install reinforcement into formwork

Pour concrete foundation wall

Install anchor bolts into semi-cured concrete

Pour Concrete Foundation Walls

Allow concrete to cure adequately (7-10 days)

Strip forms

Apply waterproofing

Install perimeter drain tile

Backfill

Install Concrete Block Foundation Walls

Allow concrete footing to properly cure

Install first course of concrete block on bed of mortar

Continue to lay block on top of first course until desired height reached

Install horizontal reinforcement as courses proceed

Install Concrete Block Foundation Walls

Install vertical reinforcement at significant heights

Install grout into cells with vertical reinforcement

Tool joints and clean masonry

Install waterproofing

Rules of Thumb

Footing shall be below frost line

Footing width usually 2x height

Typical size (24 wide x 12 tall)

Rebar is usually 3 from edge of concrete

Crawl spaces should have rigid insulation along the interior face of the foundation wall

DESIGN MIX

182.3 kgWATER

644 kgSAND(Badarpur)

372 kg10 mm COARSE AGGREGATES


475 kgCEMENT

It is a mix which have calculated quantities of Cement, Coarse Aggregates, Fine Aggregates and Water to have required strength of concrete as per IS:456-2000 .

Grades of Concrete used M20 for Slabs and Beams M25 for Foundations and Retaining Walls M40 for Columns and Shear Walls

181.6 kgWATER

630 kgSAND(Badarpur)



352 kgCEMENT

DESIGN MIX OF M40 GRADE CONCRETE DESIGN MIX OF M25 GRADE CONCRETE

READY MIX CONCRETE

Ready-mix concrete is a type of concrete that is manufactured in a factory or batching plant, according to a set recipe, and then delivered to a worksite by truck mounted transit mixers

17 FEBMEASUREMENTS AND QUALITY

Foundation Components

Footing

FITTING FOUNDATION BOLT

POURING CONCRETE

CURINGBACK FILLING

FOUNDATION BOLTFOR ERECTION OF PEB

COMPLETED IN FEB

1

43

2

Foundation Components

(to attach wood stud sill plate)

(to keep water off of foundation wall)

(separates slab from foundation wall)

(to keep water off of slab)

(to keep water off of slab & moisture barrier)(moves water away from building)

(moves water away from building)

Foundation Types

Pour Footings

Construct formwork (if required)

Install reinforcement (rebar) for footings

(protrudes above footing to tie-into foundation wall)

Pour concrete footings

Smooth / finish surface

Pour Slab on Grade

Install gravel base (to keep water off of slab)

Install moisture barrier (to keep water off of slab)

Install reinforcement (welded wire fabric)

Pour concrete slab

Finish slab surface

CONCURRENTOTHER ACTIVITY IN MARCH

Text

ANCILLARYBUILDING FOUNDATION

EXCAVATION

FLOOREXCAVATION

AND PCC

SITE ACTIVITY APARTFROM

FOUNDATION WORK

PLINTH BEAM FOR BOUNDARY WALL

CLOSINGLOI /PO / VISITS

AND LIASION

PEBMANUFACTURERS

CRANE MANUFACTURER

MACHINEMANUFACTURER

ELECTRICAL

COULMN CASTING On the raft the column layout is done. Layout for starter. The column ties and link bars are provided as per

column reinforcement drawings and general specifications.

Displacement of main bars should be provided with L bar

The plumb of formwork should be checked. Height of cast should be calculated accurately. Avoid caps as far as possible.

LAYOUT , PEDESTAL & STARTER

LINKS & TIES

PLUMB & FORMWORK, CASTING,CURING

PLINTH BEAM WORK CONNECTING ALL FOUNDATIONS FOR WALL WORK TO START

RETAINING WALL

Grade of concrete--- M25.Clear Cover--- 25 mm.

COLUMN

Grade of concrete--- M40.Clear Cover--- 50 mm.

SHEAR WALLS

Clear Cover--- 50 mm.Grade of concrete--- M40.

Foundation Bolt work under Completion

Excavation Work of Ancillary Building ( Bathrooms/ Service office/ Welding )

UG TANK

FLOOR FROM GRID 1 TO 23 EXCAVATION AND COMPACTING

LLOYD PEB INSPECTION

MACHINE INSPECTION

CRANE INSPECTION

SAFETY EQUIPMENTS

HELMETCAUTION SIGNALS

SAFETY BELT

SAFETY GLOVESSAFETY SHOES

SCAFFOLDING

Scaffolding is a temporary framework used to support people and material in the construction or repair of buildings and other large structures

The purpose of a working scaffold is to provide a safe place of work with safe access suitable for the work being done.

Scaffolding used for supporting shuttering of slab is called Staging

APRIL

SITE

FLOORRUBBLE WORK

RADIOGRAPGHY

ANCY BUILDING

ERECTION

TRAININGON HEIGHT

UNLOADING

GRID 13 TO 23

GRID1 TO 13

CIVIL WORK IN ROGRESS

IN APR

ANCILLARYBUILDING

FOUNDATION

UG TANK IN

PROGRESS

PLINTH BEAM WORK IN PROGRESS

FLOORCOMPACTNESS

TEST

FLOORRUBBLELAYING

RADIOGRAPGHY WORK START WITH DIGGING AND RUBBLE LAYING

PEB WORK STARTS IN APR

THE FIRST

COLUMN

Text

PEB

UNLOADING

& STACKING WITH WOODEN

BRACKET

POOJACEREMONY

FOR SAFETY

EARLY MORNING WORK

COIL SHOP PHASE ONE BEGINS

COIL FLOOR

DIGGING OF FLOORYELLOW SOIL

PREPARING FIRST LAYER RUBBLE NEXT LAYER

ACTIVITY IN MAY

APR TO

MAY

ERECTION OF COLUMN LIFTING OF RAFTERS

JOINING RAFTERS AND COLUMN ADDING PURLINE FOR CONSOLADTION

MUTUALDISCUSSION

ON BEST PRACTICES

WORKING ATHEIGHT

WITH FALLARRESTOR

SITE SAFETYAUDIT

SPECIAL TRAINING CONDUCTED

PEB ERECTION WORK

Personal Protective Equipments

BEING USED

BY LAST WEEK OF MAYDIVISION OF AREA BETWEEN PEB AND CIVIL WORK

CIVIL WORK AND HEIGHT PEB WORKDIVIDED BETWEEN TWO ZONES WITH BARRICADING TO PREVENT CROSS MOVEMENT OF WORKERS AND ALSO WORK ON TWO ENDS TO SAVE TIME

PEB ERECTION FROM GRID 1 TO 13

PCC WORK IN GRID 13 TO 23

CIVIL WORK IN MAY

Text

Text

Text

M/CFDN

RADIOGRAPGHY

WALL

PCC INFLOOR

BRICK WORK ON PLINTH

ANCYBUILDING

FDNS

CONCURRENTCIVIL WORK

IN MAY

SAND FILLINGIN RADIGRAPGHY PIT

UG WATER TANK ANCY/ SERVICE OFFICE FOUNDATION

BRICK WORK ON PLINTH

PCC ON FLOOR IN GRID 13 TO 23

PLATE AND PANEL BENDING M/C FDN

STATUS IN LAST WEEK OF MAY

PEB WORK IN FULL SWING ALONG WITH CIVIL WORKAIM WAS TO COMPLETE ROOF AND PCC BEFORE RAINS

MULTI TASKING IN JUN

PEB WORK

CIVIL WORK ANCILLARY BUILDING

MACHINE FOUNDATIONS

STORAGE ROAD/BAY WORK

COORDINATION FORDRAWINGS AND

EXECUTION

CONCURRENTLY COIL SHOP

EXCAVATION WORK AND FLOOR WORK

BIDRUM

ADMIN BUILDING INTERIOR AND IT CABLE LAYING

PEB WORK IN JUN

Text Text

Text

Text

Ancillary Building Bidrum

SERVICE OFFICE SLAB Maintenance shed WallWIP

Welder Plinth WorkToilet Slab

JUN

BIDRUM SHOP FLOOR

STEEL BINDING FOR RADIOGRAPHY WALL

SHOT BLASTING PIT WIP -PCC

PLATE ROLLINGPIT COMLPETED

PANEL BENDING PIT COMPLETED

PEMA Machines Foundation PIT

WIPCNC Machine PIT WIP

ROAD WORK IN FRONT OF BI DRUM-WIP

WBM work

ALL 50 FOUNDATION DONE TILL SECOND STAGE LESS ONE

DUE TO IT CABLE PASSING THROUGH

ADMIN BUILDING INTERIOR WIP

IT CABLE PIPE LINE WIP

MISC ITEMS OF PEB

Polycarbonate sheet Turbo ventilator

Walk way /Cage ladder

PEB STATUSROOF AND CLADDING 98 % OVER

ANCILLARY BUIDLING SIDE

FRONT 5 % LEFT CLADDINGAS CRANE WERE BEING FITTED

ROAD SIDE

CRANE INSTALLATIONS

PANEL SHOP

10 T AND 20 T

BIDRUM30 T AND 20 T

ANCILLARY BUILDINGS

MAINT SECTIONMILE STONE> FLOOR DONE

WALL IN WIP

SECOND BATHROOM

SLAB WIPFIRST

BATHROOM COMPLETED WALL 10 % LEFT IN WIP

SERVICE OFFICE SLAB

WALL AND FLOOR IN WIP

WELDING SHOP

MILE STONE> FLOOR COMPLETED

WALL IN WIP

MULTI TASKING PROJECT MANAGEMENT

MILESTONE>BIDRUM SHOPTWO CRANES FITTED

FLOOR WORK 25%IN PANEL SHOP WALL COMPLETED

70%

MULTI TASKING PLAN

HALF BAY OF BIDRUM AND PANEL SHOPMACHINE FOUNDATION

HALF BAY OF BIDRUM AND PANEL SHOP

RADIOGRAPGHYSECOND RCC LIFT

FLOOR IN HALF PORTION OF PANLE SHOP

CRANE IN HALF PORTION

OF BIDRUM

MACHINE FOUNDATIONS IN WIP

MILESTONE> FOUR COMPLETEDREST IN LAST STAGES

MACHINE FOUNDATIONS

COIL SHOP FOUNDATION BOLT WORK AGAINST RAIN DEWATERING

MILESTONE >PCC FLOORCOMPELETED

FOUNDATION BOLTWIP IN RAINS

AUGUST

COMPLETE ROOFING AND CLADDING DONE AND MISC ACCESSORIES UNDER FITMENT

DRAINAGE PIPE FITTED

CAGE LADDER FITTEDTHREE MORE IN WIP

VIEW FROM TOP

TURBO AND RIDGE VENTILATORS FITTED

TURBO VENTILATOR

RIDGE VENTILATOR

CRANE COMMISSIONING

WALL WORK 90 PERCENTCOMPLETED ON SHOP FLOOR

FLOOR WORK85 PERCENT COMPLETED

MACHINE FOUNDATIONCLOSING ON SHOP FLOOR

WINDOWS UNDER FITMENTIN SHOP FLOOR

CONCURRENT WORK ALSO ON SLAB STAGES IN OFFICE BUILDING

IMPORTANT COMPONENTS

Key in column

Water bar

Binding materials

Expansion joint

KEY IN COLUMN

since the height of column is very large, hence it is not possible to cast the column at one time, to cast the column later the key is made at the junction so that the proper bond between the old concrete and new concrete is formed.

KEY IN COLUMN

EXPANSION JOINT Since concrete is subjected to volume change. Provision

must be made to cater for the volume change by way of joint to relieve the stresses produced.

Expansion joint is function of length Buildings longer than 45 m are generally provided with

one or more expansion joints. Material used as expansion joint material is armour

board whose thickness is 25 mm.

EXPANSION JOINT

Expansion joint material, size is 25 mm

Expansion joint in building

WATER BAR

Water bar is provided in the retaining wall o that the moisture cant move from the soil to the joint. Water bar is basically provided at the constructions joints of retaining wall of two different towers

WATER BAR

BINDING MATERIALS

Since the thermal expansion of concrete is different from that of masonry. The interface between the concrete and the masonry is liable to crack. To avoid this crack the chicken wire mesh is used to avoid the crack and also provides the better grip for Masonrywith concrete.

Similarly when the drainage pipes are laid along with the outer wall then again the connection between the pipe and the wall hasdifferent coefficient of temperature change hence they are joint to the concrete by lead keys.

In the toilets and kitchen sunken portion the joints in any caseare packed by water proof and non shrinkable material.

BINDING MATERIALS

Chicken wire mesh between brick masonry and concrete

Connection of pipes with concrete

Chicken wire mesh in conduits through concrete

WATER PROOFING Water proofing has remained as an unsolved complex

problem

Use of plasticizers, super plasticizers, air-entraining agents helps in reducing the permeability of concrete by reducing the requirement of mixing water, hence can be also be regarded as waterproof material.

Some of approved water-proofing compound by the companyare:- pidilite, cico, fosroe, baushimine, unitile.

Water-proofing cement paint:- super snoweem

WATER PROOFING

Water proofing in sunken portion of kitchen and bathroom

WP in sunken portion at ground level

WP in retaining wall

WATER PROOFING IN GARDEN AREA

For water proofing in garden area the soil is first leveled and then rammed to achieve the maximum density

The PCC is then laid down mixed with tape Crete (a water proofing compound)

After PCC the plaster of fibrous material is done. the bituminous sheets are laid by heating it with the welder. On those

sheets the drainage pipes are laid down with suitable slope and these pipes are covered with geo-fabric sheets.

Again the plaster is done. On the plaster the 40 mm aggregates are laid. On the aggregate the geo-fabric sheets are laid down on which the sand is

placed & on the sand the soil ,along with fertilizers, is placed on which the gardening is done for the non tower area.

WATER PROOFING IN GARDEN AREA

Sandy soil PCC mixed with tape

Crete (water proof compound)

Texas (bitumen) sheet

Drainage pipe 40 mm aggregate Geo-fabric sheet Sand

BEAMS AND SLABGrade of concrete--- M 20.

Clear Cover--- 25 mm for BeamsClear Cover--- 20 mm for Slab

RADIOGRAPGHY 5 TH LIFT RCC

ELECTRIC CABLE TRAYS ELECTRIC CABLE LAYING

ARRIVAL OF MACHINES

COIL SHOP AREAD2 FOUNDATION BOLT WORK UNDER WIP

AMDIST RAIN

D1 & D2 FOUNDATION BOLT WORK UNDER WIPAMDIST RAIN

TOTAL 14 LAST STAGE FOUNDATION DONE

26 FOUNDATION LEFT

MACHINE INSTALLATIONS AS PER PLANT LAY OUT

IN SEPT AND OCT AND HANDED OVER TO

PRODUCTION TEAM FOR FIRST PRODUCT

Fixed product layoutAdvantages Limitations

Reduced material moves Highly flexible Job enrichment Promotes pride & quality Responsibility

Personel-equipment moves Equipment duplicates Greater skill Close control& coordination Increased space & greater

work-in-process

Product LayoutAdvantages Limitations

Smooth, simple, direct flow Small work-in-process inv. Short production time/unit Reduced material handling Less skill Easy production control

Line stoppage Product design changes Slowest station paces the line General supervision High equipment investment

Product-Oriented Layout

BeltConveyor

Operations

A

Precedence Diagram

Draw precedence graph (times in seconds)

C

FD

B

E

H

G

I J20

515

125 10

8

3

7

12

Cycle Time

The more units you want to produce per hour, the less time a part can spend at each station.

Cycle time = time spent at each spot

C = 800 min / 32 = 25 min

CT =Production Time in each day

Required output per day (in units)

Number of Workstations

Given required cycle time, find out the theoretical minimum number of stations

Nt = 97 / 25 = 3.88 = 4 (must round up)

Nt =Sum of task times (T)

Cycle Time (C)

Assignments

Assign tasks by choosing tasks:with largest number of following tasksOR by longest time to complete

Break ties by using the other rule

Number of Following TasksNodes # after

C 6D 5A 4

B,E,F 3G,H 2

I 1

Choose C first, then, if possible,add D to it, then A, if possible.

A

Precedence Diagram

Draw precedence graph (times in seconds)

C

FD

B

E

H

G

I J20

515

125 10

8

3

7

12

Number of Following TasksNodes # after

A 4B,E,F 3G,H 2

I 1

A could not be added to firststation, so a new station must becreated with A.

B, E, F all have 3 stations after,so use tiebreaker rule: time.B = 5E = 8F = 3 Use E, then B, then F.

Group LayoutAdvantages Limitations

By grouping, higher machine utilizations

Smoother flow lines and shorter travel distances

Team spirit and job enlargement

Greater labor skills for team Balancing individual cells Unbalanced flow may result in

work-in-process

Process LayoutAdvantages Limitations

Increased machine utilization General purpose equipment Highly flexible Diversity of tasks

Increased material handling Complicated production

control Increased work-in-process Longer production lines Higher skills required

Plant layout procedure

1. Procure the basic data.2. Analyze the basic data.3. Design the productive process.4. Plan the material flow pattern.5. Consider the general material handling plan.6. Calculate equipment requirements.7. Plan individual workstations.8. Select specific material handling equipment.9. Coordinate groups of related operations.10. Design activity interrelationships.11. Determine storage requirements.12. Plan service and auxiliary activities.13. Determine space requirements.14. Allocate activities to total space.15. Consider building types.16. Construct master layout.17. Evaluate, adjust, and check the layout with the appropriate persons.18. Obtain approvals.19. Install the layout.20. Follow up on implementation of the layout.

ACTIVITY

RELATIONSHIP

CHART

Process-Oriented LayoutFloor Plan

Office

Tool Room

Drill Presses

Table Saws

1995 Corel Corp.

1995 Corel Corp.

Process Layout+ Allows specialization - focus on one skill+ Allows economies of scale - worker can

watch several machines at once+ High level of product flexibility-- Encourages large lot sizes-- Difficult to incorporate into JIT-- Makes cross-training difficult

Product-Oriented Layout

Facility organized around product Design minimizes line imbalance

Delay between work stations Types: Fabrication line; assembly line Examples

Auto assembly line Brewery Paper manufacturing.

Cellular Layout (Work Cells) Special case of process-oriented layout Consists of different machines brought

together to make a product May be temporary or permanent Example: Assembly line set up to produce

3000 identical parts in a job shop

Work Cell Floor Plan

Office

Tool RoomWork Cell

Saws Drills

Work Cell Advantages

Reduces:InventoryFloor spaceDirect labor costs

Increases:Equipment

utilizationEmployee participationQuality

Work Cell Layout+ Facilitates cross-training+ Can easily adjust production volumes+ Easy to incorporate into JIT-- Requires higher volumes to justify-- May require more capital for equipment

Process-Oriented ExampleYou work in facilities engineering. You want to find the cost of this layout. The cost of moving 1 loadbetween adjacent dept. is $1. The cost between nonadjacent dept. is $2.

60 ft.

40 ft.Dept. 1 Dept. 2 Dept. 3

Dept. 4 Dept. 5 Dept. 6

There are 6! or 720 possibilities! Clearly, we cant look at them all.

50 100 0 0 20

30 50 10 0

20 0 100

50 0

0

From-to-Matrix

5

1 2 3 4 5 6Department

Dept.

1

234

6

Number of Trips

20

100

50 30

50

50

10

20

Schematic Diagram & CostDept. Dept.Cost

1 3 $200

1 2 $501 6 $404 2 $504 3 $404 5 $502 5 $102 3 $303 6 $

Total Cost $570

1 2 3

64 5100

20

30

50 100

50

50

10

20

Schematic Diagram & CostDept. Dept.Cost

1 2 $501 3 $

1001 6 $204 2 $504 3 $404 5 $502 5 $102 3 $603 6 $

Total Cost $480

2 1 3

64 5

100

Line Balancing

Situation: Assembly-line production. Many tasks must be performed, and the

sequence is flexible Parts at each station same time Tasks take different amounts of time How to give everyone enough, but not too

much work for the limited time.

MACHINE INSTALLATIONSPRODUCTION SET UP

Manufacturing Industry Transformation Operations

Machine Processing Assembly

Adding value* Other Operations

Material handlingInspection and testingCoordination and control

Transformation ProcessRaw

MaterialPart or Product

PowerTools

MachinesLabour

Scrap or Waste

Classification of manufacturing processes

Processing Operations Shaping operations

Solidification processes Particulate processing Deformation processes Material removal processes

Property-enhancing operations (heat treatments)

Surface processing operations Cleaning and surface treatments Coating and thin-film deposition

Assembly Operations Joining processes

Welding Brazing and soldering Adhesive bonding

Mechanical assembly Threaded fasteners (e.g., bolts and nuts,

screws) Rivets Interference fits (e.g., press fitting, shrink

fits) Other

Material Handling Material transport

Vehicles, e.g., forklift trucks, AGVs, monorails

Conveyors Hoists and cranes

Storage systems Unitizing equipment Automatic identification and data

capture Bar codes

Time Spent in Material Handling

Inspection and TestingInspection conformance to design

specifications Inspection for variables - measuring Inspection of attributes gauging

Testing observing the product (or part, material, subassembly) during operation

Coordination and Control Regulation of the individual processing

and assembly operations Process control Quality control

Management of plant level activities Production planning and control Quality control

Manufacturing Capability Technological processing capability - the

available set of manufacturing processes Physical size and weight of product Production capacity (plant capacity) -

production quantity that can be made in a given time

Lean Production

Operating the factory with the minimum possible resources and yet maximizing the amount of work accomplished

Utilisation of Resources - workers, equipment, time, space, materials

Minimising time Maximising quality (accuracy) Minimising cost

Programs Associated with Lean Production

Just-in-time delivery of parts Worker involvement Continuous improvement Reduced setup times Stop the process when something is

wrong Error prevention Total productive maintenance

12 DEC 2012SAVLI NEW PLANTS PROJECT ENDS

AND PRODUCTION BEGINS

THANKS