Automating the task of tracking the delivery and receipt.docx
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Automating the task of tracking the delivery and receipt.docx
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Automatingthetaskoftrackingthedeliveryandreceipt
Automatingthetaskoftrackingthedeliveryandreceipt
offabricatedpipespoolsinindustrialprojects
JongchulSonga,CarlT.Haasa,
CarlosCaldasa,EsinErgenbandBurcuAkincib
aDepartmentofCivilEngineering,UniversityofTexasatAustin,Austin,TX78712,USA
bDepartmentofCivilandEnvironmentalEngrg.,CarnegieMellonUniversity,Pittsburgh,PA15213,USA
Accepted2March2005.
Availableonline1June2005.
Abstract
Pipinginindustrialprojectsisacriticalandcostlyprocessasthousandsofuniquepipespoolsgothroughdesign,fabrication,interimprocessing,
delivery,
storage,installationandinspection.Currentmethodsfor
tracking
pipespoolsthroughthislongsupplychainaresubjecttomanyproblems.ThispaperevaluatestheuseofRFIDtechnologyasapossiblesolutiontosomeoftheseproblemsthroughautomationofthecurrent
tracking
process.ThetechnicalfeasibilityofRFIDapplicationsisanalyzedbasedonfieldtests.Amodelofcurrent
tracking
processispresentedtoidentifypotentialeconomicbenefitsfromusingRFIDtechnologyinautomated
tracking.
Keywords:
Automateddatacollection;Radiofrequencyidentification;
Tracking
;Pipespool
ArticleOutline
1.Introduction
2.Relatedeffortsandenablingtechnologiestoautomatetracking
3.Overviewoffieldtests
4.DescriptionandresultsofPhaseIfieldtests
5.PhaseIIfieldtests
5.1.RFIDsystemusedandthetestingprocedure
5.2.Technicalperformancemetricsandresultsoffieldtests
5.3.Factorsinfluencingreadrate
6.PotentialbenefitsfromusingRFIDinpipespooltracking
6.1.Inefficienciesassociatedwiththecurrenttrackingprocess
6.2.Potentialbenefits
6.2.1.Reducedtimeinidentifyingandlocatingpipespools
6.2.2.Moreaccurateandtimelyinformationonmaterialavailabilityandforcraftworkplanning
6.2.3.Reducedtimeinsearchingformisplacedpipesandpotentialimprovementsonthepipefittingschedule
7.Conclusions
Acknowledgements
References
1.Introduction
Oftheelementsthatcompriseaconstructedindustrialfacility,constructionmaterialsandinstalledequipmentmayaccountfor50–60%ofthetotalcostofaconstructionproject[13].Materialsforaconstructionprojectcanbeclassifiedintothreecategories:
off-the-shelf,long-leadbulks,andengineereditems[8].Thedifferentcategoriesofmaterialsvaryincost,supplyleadtime,andinterchangeability.Generally,engineereditemsareavailableathighercostsinsmallerquantitiesandwithmoreuniqueproperties,thusrequiringlongerleadtimeandmorefront-endplanning.
Amongengineeredmaterials,pipespoolsareofparticularinteresttoindustrialprojectsaspipinghasbeenrecognizedasacriticalandcostlyprocess[22].Industrialprocessfacilitiesofteninvolvehundredsorthousandsoffabricatedsectionsofpipespools,manyofwhichareuniqueinmaterial(e.g.,castiron),shape,finish,andotherpropertiesincludingfinalinstallationlocationonsite.InatypicalsizeindustrialprojectwithtotalinstalledcostrangingfromUS$200to$300million,theremaybeasmanyas10,000piecesofpipespools[21].
Manyindustrialprojectsareexecutedonfasttrack,duetothepressingneedtobringproductstomarketfast.Giventhischaracteristic,someindustrialprojectsmaytaketheopportunitytofabricatepipespoolsoff-sitewhileprerequisiteworkisoccurringonsite.SeveralprocessmodelsbasedonthisscenariohavebeenstudiedbyTommeleinusingthediscreteeventsimulationapproachimplementedinStroboscope[22].Infact,pipinghasseensignificantincreaseintheuseofprefabricationandpreassemblyoverthepreceding20years[6].However,pipinginfast-trackprojectsstillposespotentialuncertaintyin
deliveries
andincompletingprerequisitesitework,leadingto“mis-matchesthatfoulupscheduledworksequences”[22].
Underthisuncertainty,theconstructors'materialsmanagersmaychoosetorelyonlargebuffersofpipespoolsinanefforttosecureflexibilityinworkablebacklogsforpipefittingcrewssothattheyhave“atleast60percentofallpipeonsitewhen20percentofthepipehadbeeninstalled”[9].Interviewsconductedaspartofthisstudyindicatedthatthissituationisstillthenorm.Suchlargebuffersofpipespoolsareaccumulatedinaconstructor'slaydownyardfrom
deliveries
received5to6monthspriortoscheduledinstallation,andreceivedpipespoolsdwellinthelaydownyarduntilpipefittingcrewsfilerequisitions.Thispracticeinindustrialpipingiscomparabletothecasewithprecastcomponentswhichareoftenstoredintheplant'sstorageareas,possiblyaslongas6months,untilshippingtotheerector[2].
Whenpipefittingcrewsmakearequisitionforcertainpipes,theconstructor'slaydownyardpersonnelwilllocateandidentifythepipespoolsandissueand/orstagethematthecrew'sworkarea.Insomecases,theymaynotbeabletolocatepipespoolsintheirlaydownyardwithinareasonabletimeandhavetosearchforthe“misplaced”pipespools.Whilesuchmisplacedpipespoolsmayrepresentabout2%ofallpipesforasingleproject[21],theconstructor'ssearchformisplacedpipespoolsoftenrequirescollaborationandcoordinationwithotherprojectentities.Ifspecificpipespoolscannotbelocatedwithinthelaydownyard,itislikelythattheyareinotherpremises,forinstance,inthefabricator'sstorageareas.Thus,successfulrecoveryofmisplacedpipespoolswouldrequireextensivesearcheffortacrosstheentiresupplychain.
Fieldmaterialsmanagementwasidentifiedbyarecentconstructiontechnologyneedsassessmentasoneoftheareaswiththegreatestpotentialforimprovementandthegreatestpositivedevelopmentimpactonengineeringconstructionworkprocesses[23].Thefundamentalfunctionoffieldmaterialsmanagementistoassureavailabilityofmaterialswhentheyareneededforinstallationandmakesuchavailabilityinformationreadilyaccessibleforcrewlevelworkplanning.Thus,underlyingthisfunctionalityoffieldmaterialsmanagementisthecapabilitytotrackmaterialsaccuratelyandinatimelymanner.ThispaperisconcernedwiththewaysinwhichtheuseofcurrentRFIDtechnologycanbeextendedto
tracking
uniquelyidentifiedpipespoolsduringtheir
deliveryandreceipt.
Jointdeploymentwithcomplementaryautomateddatacollectiontechnologiesisconsideredaswell.
2.Relatedeffortsandenablingtechnologiestoautomate
tracking
Automated
tracking
ofmaterials,equipmentandlaboronsitehasbecometechnicallymoreviablewithrecentadvancesinautomateddatacollection(ADC)technologies.AmongADCtechnologies,GlobalPositioningSystem(GPS)technologyhasdrawnmuchattentionfromresearchersendeavoringtofindeffectivewaystoautomaticallytrackthelocationofconstructionlaborandequipmentonsite[14],[16]and[18].
NavonandGoldschmidtshowedin[14]thatworkers'locationscanbeautomaticallycollectedbyGPSandconvertedintolaborinputsbasedonabuildingprojectmodeldevelopedbySacksetal.[18].SincetheregulatorymeasuretodegradecivilianGPSsignals,knownastheselectiveavailability,wasdiscontinued,state-of-the-artGPScannowprovidepositionsofcentimeteraccuracyundernon-stationarysituations[15].Undoubtedly,thepresentGPScanbeusedtopreciselytrackthelocationofcraftworkersandmachinesoveragreatrangeofgeographicandgeometricscales,butthetechnologyisstillexpensivefordensedeploymenttoautomate
tracking
individualmaterialitems.TagginghundredsofindividualpipespoolswithGPSreceiversfor
tracking
purposeswouldbeprohibitivelyexpensive,andstillothermeansforidentificationwouldberequired.
Otherenablingtechnologiesforautomated
tracking
includeRadioFrequencyIdentification(RFID).Likebarcodes,RFIDisanADCtechnologyforidentifying,locating,or
tracking
objectsorassetsandpeople,butpresentsseveraladvantagesoverbarcodinginthatitsoperationdoesnotrequirephysicalcontact,line-of-sight,orcleanenvironmentsdevoidofnoise,contaminants,glareanddirt.CurrentRFIDsystemsconsistoftranspondersortags,interrogatorsorreaders,andahostcomputer.Attachedtohostobjectsorpeopletobeidentifiedortracked,anRFIDtagcarriesdataaboutthehost,suchasidentificationanditemspecificinformationorinstructions,onitsinternalmemory.AreaderisafixedormobiledevicethatreadsandmaywritedatatothetagthroughRFwirelesscommunicationwhentagscomewithinitsreadrange(varyingfromoneinchto100ftormore)andpassesthedatatothehostcomputerforparticularapplicationneeds.
RFIDtagsvaryinmanyspecifications,suchaspowersource,carrierfrequency,readrangeandrates,datastoragecapacity,memorytype,size,operationallife,andcost.Sincetheirpowersourcedictatesothercharacteristicsdirectlyorindirectly,RFIDtagsareprimarilyclassifiedaspassive,semi-passive,oractive,dependingonthemannerinwhichtheyderiveoperatingpowertorunthedigitallogiconthechipandtransmitthestoreddatatothereader[19].Withanindependentpowersupply,activeRFIDtagsallowgreatercommunicationrange,highercarrierfrequency,higherdatatransmissionsrates,betternoiseimmunity,andlargerdatastoragecapacitythanpassivetags,andaretypicallyread/write.Thetrade-offisafinitelifetime(optimally,5ormoreyears),andgreatersizeandhighercostcomparedwithsemi-passiveandpassivetags.
WhileRFIDtechnologyhadalreadyseensignificantbeneficialapplicationsinmanufacturing,retailing,andtransportandlogisticsindustries,its
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