Matl Control ProcedureCSPC.docx
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Matl Control ProcedureCSPC.docx
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MatlControlProcedureCSPC
FOSTERWHEELER
CSPC
CSPCDebottleneckingProject
RevNo
ReasonForIssue
Issue
Date
PreparedBy
CheckedBy
ApprovedBy
QAReviewBy
ProjectApprovalBy
CONFIDENTIAL
PROPRIETARYINFORMATIONFOR
AUTHORISEDCOMPANYUSEONLY
DOCUMENTTITLE
MATERIALCONTROLPROCEDURE
FWCONTRACTNO.1-PD-XXXX
FWDOCUMENTNO:
PD0XXXX-XX/XX-XXX
CSPCDOCUMENTNO.
DSN:
CONTENTS
SECTIONSUBJECT
1.PURPOSE
2.SCOPE
3.DEFINITIONS
4.WORKPROCEDURE&GUIDELINES
4.1MaterialDeliveries
4.2WarehouseReceiving
4.3MaterialPlanning
4.4IssuingofMaterials
4.5MaterialStorage
4.6MaterialPreservation
4.7StockInventoryControl
4.8MaterialLeavingatSite
5.CONSTRUCTIONMANAGEMENTSYSTEM(SMILE)
6.SURPLUSORSCRAPMATERIALHANDLING
7.CLOSEOUTANDRECONCILIATION
8.QUARANTINEAREA
ATTACHMENTS
ReceivingCheckList(IN-1)……………………….1
ProformaAdviceNote……………………………..2
DailyReceivingReport(SMILE)………………….3
SupercheckRequest………………………………4
MaterialReceiptSlip(IN-2)……………………….5
DiscrepancyReport(SMILE)……………………..6
DiscrepancyReportDistributionMatrix(SMILE)..7
MaterialShortagesReport(SMILE)……………..8
OutstandingIN-1Report(SMILE)………………..9
OutstandingDiscrepancyReport(SMILE)………10
MaterialIn-TransitReport(SMILE)………………11
EarlyAvailabilityReport(SMILE)…………………12
WorkPackageReport(SMILE)…………………..13
AvailabilityCheck/AllocationRequest(STAT-1)...14
AvailabilityReport-(SMILESTAT-2)…………….15
MaterialIssueRequest(OG-1)…………………...16
MaterialIssueRequestSummary(OG-2)……….17
MaterialAllocationStatisticsReport(SMILE)……18
ReceiptofShortageReport(SMILE)…………….19
ExtraIssueLog(SMILE)…………………………..20
MaterialIssueRequest…………………………….21
AllocationReport(SMILE)………………………...22
MaterialReturnAdvice…………………………….23
AdviceNote…………………………………………24
GatePass…………………………………………..25
FabricatorsAdviseNote…………………………..26
SpoolReceivingCheckList............………………27
SpoolMaterialReceipt…………………………….28
ProvisionalMaterialTransmittal…………………..29
1.PURPOSE
ThepurposeofthisWorkPracticeistosupportassociatedExecutionProceduressothatparticularoperationalactivitiescanbeeffectivelyundertaken.
2.SCOPE
ThisprocedureisapplicableforallmaterialsandequipmentsforthePROJECTfromthemomentofreceiptatsite,atlaydownareasincludingunloadingwork,unpacking,receiving,inspection,materialstorageincludingpreservationuntilissuanceoutaswellassurplus/scraphandling.
Subcontractorsshallestablishtheirmaterialhandlingprocedureindetailreferringtothisprocedure.
3.DEFINITIONS
Forthepurposeofthisprocedure,followingshallapply;
CLIENT:
ProjectOwner
FW:
FosterWheeler
4.WORKPROCEDURE&GUIDELINES
Receiving,Storing,Planning,PreservationandIssuingofallitemsofequipmentandmaterialsshallbeestablishedasdetailedbelow.
4.1MaterialDeliveries
PriortoDeliveriesofeachShipment,theFWShippingCoordinatorshalldistribute“ShippingReleaseNotice“toFWProjectMaterialControllerforhisreference.
4.1.1RoutingofDeliveries
MaterialwillbedeliveredtotheWarehouseReceivingArea.
a)BulkmaterialandequipmentitemsbeingsupplieddirectbyroadfromSupplier.SuchdeliverieswillbeaccompaniedbySupplier'sAdviceNoteseachrelatingtoasinglePurchaseOrder.
b)MajorequipmentitemsandmodulesrequiringheavyliftfacilitieswillrequireadvancenoticeallowingspecialarrangementstobemadewiththeResidentConstructionManager,TrafficPoliceandtheTransportCompany.
NB:
FWshallensureeffectivecontrol,verification,identification,safestorageandhandlingofallfreeissuematerial,suchmaterialsmustalsobecoveredbyadequateinsurance.
4.1.2MaterialAcceptanceChecks
Allmaterialarrivingatthesiteshallbesubjecttothefollowingchecks:
InitialInspection
Checksofconsignmentduringoff-loadingshallbecarriedoutbySiteMaterialControlPersonnelandshallinclude:
a)Validityofdelivery
b)Boxorpackagecount
c)Visibledamagetopackingortogoods
d)Properdocumentsandmaterialcertificatesasrequired
PositiveMaterialIdentification(PMI)–
Alloypiping(iftobeusefortheproject)materialsshallbesubjecttoPMIchecksinaccordancewithprojectrequirements.ThisisusuallytheresponsibilityofFW,thoughcanbethatofanassignedsub-contractorforthispurpose.
APMIReportshallbeissuedforeachbatchofmaterialschecked.
GoodsInwardsInspection
FollowingthegenerationoftheReceivingCheckList(IN-1..Attachment-1)detailedreceivingchecksshallinclude:
a)ScrutinyofCertification
b)Checkingofmarkingandcolourcoding(ifany)
c)Dimensionalandqualitychecks
d)EndorsementofCertificationandReceivingCheckListconfirmingAcceptance.
InspectionChecks
FollowingsatisfactorycompletionoftheappropriateInspectionchecks,theCheckershallreleasethematerialtogetherwith:
-
a)InspectionReport
b)Certification
c)PMIReport(whereapplicable)
d)ReceivingCheckList
QuantityChecks
FWAPACSiteMaterialControlshall:
-
a)Conductanitemcount
b)CompletetheReceivingCheckList(IN-1)
c)Storethematerialinappropriatelocation
dMaterialReceiptSlip(IN-2)(seeattachment5)
e)Filethecertification
f)FilethePMIReports(whereapplicable)
Intheeventthatmaterialfailsanyoftheacceptancechecks,itshallbethesubjectofaDiscrepancyReport.
AllpartiesinvolvedincarryingoutthequalitychecksshallhaveacoordinatingfunctionwiththeFWAPACQualityAssuranceEngineer.QA/QCinspectorisresponsibletojudgesuchexceptionandissuetheInspectionReportforthatitemtonotetheactionrequired.
4.1.3ReportingDeliveries
InordertomaintainanaccuraterecordofmaterialdeliveriesandstatusfromtimeofdespatchbySuppliertoacceptanceatsitesitisimperativethatDailyReceivingReportsarefaxedtoMaterialsManagementattheHomeOfficebytheendofeveryworkingday
ItismandatorythataReceivingChecklist(IN-1)isgeneratedforalldeliveriesandthatallspecifiedchecksarecompletedpriortothegenerationoftherelatedMaterialReceiptSlip(IN-2).
4.2WarehouseReceiving
Beforecargoes(equipmentand/ormaterials)arriveatProjectsite,necessarypreparationsforreceivingcargoesshallbecarriedout.Itshallbedoneforeachshipment,basedonPackingList.MaterialControllershallcloselymonitorthearrivalofeachscheduledshipmentasperShippingReleaseNoticeforpreparationofunloadingandstorageplanpriortoactualarrivalatsite.
4.2.1ReceiptofConsignments
AllconsignmentsshallbereceivedinadesignatedreceptionAreaforinspectionandcheckingagainstdocuments.
OnarrivalofadeliveryvehicleattheWarehouseReceivingPointtheReceivingOfficershallcarryoutthefollowingprocedure:
-
a)Ensurethatthedriverhandsoveralltherelateddeliverydocuments.
b)ExaminetheAdviceorConsignmentNotetoconfirmthattheConsignmentisintendedfortheProject.
c)Conductapackagecountandcheckforvisibledamagetopackagingorgoodswhereverpossiblepriortooffloading.
d)ThePurchaseOrderNumbershownoneachSupplier'sAdviceNoteorPackingListshallbekeyedinattheSMILEWarehouseterminalinordertoproduceaReceivingCheckList(IN-1).
e)TheCarriersdeliverynoteshallbestamped"ReceivedbyFW-Unexamined",datedandsigned.
4.2.2DailyReceivingReports
DailyReceivingReport(Attachment.3)informationisautomaticallypickedupbySMILEfromdetailsinputatthetimeofIN-1Checklistgenerationandincludesbasicdeliveryinformationi.e.
Supplier
AdviceNoteNo
Number&TypeofPackages
PurchaseOrderNumber
BriefDescriptionGoods
MRSNumber
DiscrepancyReportNo
WarehouseCode
MMTNo
ItismandatorythatDailyReceivingReportsareproducedanddistributedforeverysitebythecloseofeachworkingday.
Distributionasfollows:
-
a)HOMaterialsManagement
b)ProjectManager
c)SiteResidentConstructionManager
d)FieldSuperintendent
e)PlanningGroup
f.)Client
4.2.3DetailedReceivingChecks(Inspection)
SiteReceiptInspectionshallbecarriedouttoallarrivedcargoesinaccordancewiththeprojectrequirementcautiouslywithadditionalcaretothosefragileorsensitiveitemspervendor’sinstructionoradvicefromconcernedcategoryengineer.Unlessotherwisespecifiedas“NotToBeUnpacked”,allreceivedpackagesshallbeopenedaftertheirarrivalatstorage.Priorityshallbegiventothosepackagessustaineddeliverydamagesinappearance.Thiswouldensureearlydiscoveryofconcealeddamagesandproceedtoclaimingwithineffectiveterm.
TheInspectorshallwithdrawacopyoftherelevantPurchaseOrderfromtheSiteMaterialControlFile.
HeshallidentifyalldelivereditemsagainsttheirrelatedPurchaseOrdersandMaterialRequisitions.
Checkmaterialreceivedforcompliancewith:
-
a)Specifications,CertificationandQuantitiesasintheSupplier'sPackingList,Advice/DeliveryNote.
b)SpecificationsCertificationandMarkingsasinthePurchaseOrderandRequisition,includingMaterialColourCoding(ifany).FailurebytheSuppliertosupplytherequiredcertificationortocarryouttherequiredmarkingconstitutesadiscrepancy.
Whereadiscrepancyrelatingtocertificationormarkingisdiscoveredthedetailedreceivingcheckofthesubjectitemsshallcontinueinorderthatpossibleadditionaldiscrepanciescanbereportedsimultaneously.
c)Quantitiesdueinaccordancewiththemarkedup
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