Project Execution 21-31
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INPLANT TRAINING REPORT
FUNCTIONS OF SUPERVISOR IN THE SHOP WHILE EXECUTING A PROJECT.
Deploy right man on right job.
Distribute the work to the workmen.
Study the job related documents and give proper written instructions to workmen to ensure quality of products.
Make an inspection entry at predetermined stage as per ICL.
Proceed only if inspection clearance is ok.
Hold non-conforming items till NCR is cleared.
Maintain seam wise welder record.
Maintain discipline on shop- floor.
Issue consumable requisition.
Welding parameters to welders.
Use of calibrated m/c.
Use of qualified welders from the list.
Issued by shop welding engg.
Maintain producton programme, job completion targets with the help of continous monitoring of schedules.
Offer completed jobs for inspection.
Interact with maintenance to ensure proper working of Machinery.
Monitor productivity on shop-floor which will result in cost reduction.
Co-ordination with planning, prod.engg, maintenance, inspection, nde departments.
Maintain good & safe housekeeping on shop floor.
Receive & maintain job related documents.
Communicate problems faced & decisions taken to Counterpart.
Job study.
V .J .T. I , MATUNGA
Page 21
INPLANT TRAINING REPORT
WHAT A SUPERVISOR SHOULD KNOW?
Estimated hours for shop scope of work.
CDD/ latest promised delivery date.
Target hours.
Manufacturing procedure/ sequence of Manufacturing.
Welding procedures.
Stages of machining/ PWHT.
Inspection check list.
Weld plan.
Applicable drgs, NCRS, DCRS.
Test plan.
RT/UT reports.
Man-hours booked.
Knowledge of Welding Procedures Positions of welding
Why preheat is necessary?
Why post heat is necessary?
What is interpass temperature Methods of recording temperature while welding
Why PTC (production test coupon) is required?
Permissible weld offset.
Weld reinforcement tolerances.
Type of weld defects.
Positions of welding 1G,2G,3G,4G,5G,6G and 1F,2F,3F,4F,5F,6F.
Why inert gas back purging is necessary in single side full penetration welds?
V .J .T. I , MATUNGA
Page 22
INPLANT TRAINING REPORT
NDE
Various NDE techniques.
What is spot radiography? Can several seams be combined for spot RT?
What is the surface finish required for performing NDE?
What are the types of defects?
How much clear space is required on either side of weld joint for carrying out NDE?
What are the acceptable defects?
Various leak detection tests?
Concept of zero defect- do it right the first time.
HYDROTEST
Why venting is necessary during hydro test?
What care is to be taken during de-pressurizing?
What supporting arrangements are needed during hydro test/pwht/ transportation?
What care is to be taken during high pressure pneumatic test?
What is the necessity of thoroughly drying the vessel after hydro test?
ECONOMICS OF REWORK Increase in manufactuing cost.
Increase in cycle time resulting in increase in WIP interest.
Loss of shop capacity resulting in loss of production.
Increase in material handling.
Inferior job.
V .J .T. I , MATUNGA
Page 23
INPLANT TRAINING REPORT
Repair/rework requires more attention of supervisor, welding engineer.
Delays on job ultimately result into levy of penalties by customer.
SUPERVISOR SKILLS
Distribution of work.
Maintaining drawing folder, weld plan and test plan on shop floor.
Drawing materials from stores.
Check the material received against material challan.
Report material lost / spoilt / rejected on shop floor to planning through foreman.
Transfer of material from shop floor.
Maintaining shift change list/request.
Maintain records of RT/UT reports.
Use reports for communicating with counterpart.
Make proper inspection / maintenance entry giving all the details.
Issue consumable slip after entering all the details
Obtain priority for RT/UT/wagon movement/machining/pwht before positioning the job.
Give requirement for indirect material/jigs and fixture /tools to planning in advance.
Check correctness of dimensions / feedback being given to inspection, planning, welding engineering.
V .J .T. I , MATUNGA
Page 24
INPLANT TRAINING REPORT
SHOP WELDING PRACTICES SL DO'S NO 1 Fix the earthing clamp
DON’T'S Don't fix the earthing to the
2
directly to the job Use properly baked
roller body/positioner Don't use fresh electrode
3
electrodes. Always refer the weld plan
from the Packet Don't issue electrode without
before issuing the electrode
checking the weld plan for
to the welder.
preheating, interpass temperature or post heat
4
5
Use qualified welder on the
temperature. don't use unqualified
job.
fabricator for tacking on the
Issue a consumable slip for
Job Don't issue more than 2-5
the maximum of 15
electrodes to the fabricator
electrodes at the time to the
for tacking.
welder or less as per the job
6
requirement. Start the post heating
Don't allow post heating to
immediately after the welding start below the preheat
7
is completed. Circumferential /Restraint
temperature. Don't tack less than 50mm
joints should be tacked with
long. The tack may crack due
tacks with more than 50mm
to restraint.
in length and minimum two layers of welding should be
8
done. Always weld on clean surface Don't weld on dirty surface to only which are free from rust, avoid defects like porosity grease, developer, oil paint
V .J .T. I , MATUNGA
and crack. Page 25
INPLANT TRAINING REPORT
etc.
9 Always weld only the required Don’t over weld. It will size of the fillet.
increase material cost, labour cost and other overheads. It will also cause distortion.
V .J .T. I , MATUNGA
Page 26
INPLANT TRAINING REPORT
IMPORTANT DOCUMENTS RELATED TO PROJECT 1) ROUTE CARDS (RC): Route cards are basically made for routing jobs, operation wise from machine. Various things which are added on to the route card are: Estimated hours for the job along with the machine on which the job is loaded. P.W.O. NO., Drg. No., Part description, Quantity. Initiating dept., Reference, Inspection dept. Special jigs & Fixtures if any. Material description with size, type & location. Required sketch if any is drawn or attached along with. 2) PURCHASE REQUEST (PR) : Purchase Request is the basic document related to material required for manufacturing the product. It is initiated & prepared by the design dept.It gives the authority to purchase dept. for procurement of material as per customer’s order, design & drawings. It contains PR no. , Item no. , item description. It also covers data & information regarding delivery schedule & transport. 3) PURCHASE ORDER : Purchase order is prepared by purchase dept. after receiving P. R. from the shop planning. Purchase dept. places the P.O. with the concerned supplier after inquiring with various subcontractors/vendors & deciding on the factors like taxes, duties etc.
V .J .T. I , MATUNGA
Page 27
INPLANT TRAINING REPORT
4) MATERIAL REQUISITION (MR) : Material requisition is a document prepared by the product groups. It may also be prepared by planning & other dept. on arising need of some material like jigs, fixtures, templates, gauges etc. It mainly consists of MR No., job No., Material Code, Quantity, Insp. Agency name etc. 5) PLATE CUTTING REQUISITION (PCR): PCR is a document which is prepared by the fabrication shop planning dept. who in turn releases it plate preparation shop. PCR shows about the details of the edge preparation of the plates. This document gives MR No., Drg No., & item No., description & size of the plate. 6) JOB TICKET (JT): Product Group after approval of the drgs. to the related shop ,planning dept. will then prepare the job ticket which describes the item or job to be manufactured in the shop. 7) OPERATION CARD: Operation card is also a document prepared by the planning dept. It gives details of operations such as rolling, pressing, forming, nozzle fabrication, pipe fabrication etc. to be carried out in the particular shop. 8) NON-CONFIRMATIIVE REPORT (NCR) : It is not possible to maintain cent-percent accuracy or perfection in the fabrication of a critical item. The fabricator sometimes makes a mistake due to which the job suffers. Such a mistake has to be rectified. V .J .T. I , MATUNGA
Page 28
INPLANT TRAINING REPORT
A document called Non-confirmative report which is prepared by the inspection dept. shows change in the dimensions of the items which are different from actual dimensions of the job as mentioned in the drawings. 9) DESIGN CHANGE REQUEST (DCR): The design change is initiated by the shop planning people. This document is forwarded with the rectification of some design, item, material, welding, non-destructive testing etc. After the approval of design dept., the rectification is mentioned in the revised drawing. 10) MANUFACTURING SCHEDULE:The Manufacturing Schedule depicts the sequence of operation of the job and the time required to do each operation. This schedule is prepared by the shop planning department. 11) PRODUCTION PROGRAMME:The production programme is made every month giving the targets (CDD & EDD).Completion of jobs in the shop for a period of three months, which should be met for effective control. It also gives a list of MP jobs & TP. 12) SHOP LOADING STATEMENT:In this, the capacity of shop is distributed among the various jobs depending upon the priority, CDD & schedules. It gives a clear picture of monthly distribution of man-hours for each job, and the Quarterly Man-hours Capacity report of the shop based on the workmen data.
V .J .T. I , MATUNGA
Page 29
INPLANT TRAINING REPORT
13) STORES CREDIT NOTE:When the job gets over in all respects, progress department makes this document & along with item list or supply list attached, it is handed over to inspection department. After getting SCN signed from inspection, it is handed over to product group which in turn credits the amount of the job to the concerned shop. 14) MANHOURS PERFORMANCE REPORT:This shows whether a job is being executed by effectively utilizing the man-hours. It shows the estimated man hour and the actual man-hours during and up to a particular period, resulting in under run or over run of the job.
V .J .T. I , MATUNGA
Page 30
INPLANT TRAINING REPORT
SHOP LOADING STATEMENT
Capacity of shop in terms of man-hours, machine hours available per month.
List of all orders available in hand. details of CDD, estimated man hours for each job.
Likely shop estimated man hours booking for each job depending on scope of work, past performance, urgency of job, material availability etc.
Possible man-hours booking for each job in each month depending on material & engineering status and urgency of job.
Summary of total load available per month. compare the load with available capacity per month to establish overload/ under load.
Shop loading statement is used for,
Generating master load which includes forecast orders.
Deciding to augment existing capacity by either permanent or temporary recruitment.
Deciding need for sub-contracting.
Deciding future order booking.
Ensuring proper capacity utilization.
V .J .T. I , MATUNGA
Page 31
FUNCTIONS OF SUPERVISOR IN THE SHOP WHILE EXECUTING A PROJECT.
Deploy right man on right job.
Distribute the work to the workmen.
Study the job related documents and give proper written instructions to workmen to ensure quality of products.
Make an inspection entry at predetermined stage as per ICL.
Proceed only if inspection clearance is ok.
Hold non-conforming items till NCR is cleared.
Maintain seam wise welder record.
Maintain discipline on shop- floor.
Issue consumable requisition.
Welding parameters to welders.
Use of calibrated m/c.
Use of qualified welders from the list.
Issued by shop welding engg.
Maintain producton programme, job completion targets with the help of continous monitoring of schedules.
Offer completed jobs for inspection.
Interact with maintenance to ensure proper working of Machinery.
Monitor productivity on shop-floor which will result in cost reduction.
Co-ordination with planning, prod.engg, maintenance, inspection, nde departments.
Maintain good & safe housekeeping on shop floor.
Receive & maintain job related documents.
Communicate problems faced & decisions taken to Counterpart.
Job study.
V .J .T. I , MATUNGA
Page 21
INPLANT TRAINING REPORT
WHAT A SUPERVISOR SHOULD KNOW?
Estimated hours for shop scope of work.
CDD/ latest promised delivery date.
Target hours.
Manufacturing procedure/ sequence of Manufacturing.
Welding procedures.
Stages of machining/ PWHT.
Inspection check list.
Weld plan.
Applicable drgs, NCRS, DCRS.
Test plan.
RT/UT reports.
Man-hours booked.
Knowledge of Welding Procedures Positions of welding
Why preheat is necessary?
Why post heat is necessary?
What is interpass temperature Methods of recording temperature while welding
Why PTC (production test coupon) is required?
Permissible weld offset.
Weld reinforcement tolerances.
Type of weld defects.
Positions of welding 1G,2G,3G,4G,5G,6G and 1F,2F,3F,4F,5F,6F.
Why inert gas back purging is necessary in single side full penetration welds?
V .J .T. I , MATUNGA
Page 22
INPLANT TRAINING REPORT
NDE
Various NDE techniques.
What is spot radiography? Can several seams be combined for spot RT?
What is the surface finish required for performing NDE?
What are the types of defects?
How much clear space is required on either side of weld joint for carrying out NDE?
What are the acceptable defects?
Various leak detection tests?
Concept of zero defect- do it right the first time.
HYDROTEST
Why venting is necessary during hydro test?
What care is to be taken during de-pressurizing?
What supporting arrangements are needed during hydro test/pwht/ transportation?
What care is to be taken during high pressure pneumatic test?
What is the necessity of thoroughly drying the vessel after hydro test?
ECONOMICS OF REWORK Increase in manufactuing cost.
Increase in cycle time resulting in increase in WIP interest.
Loss of shop capacity resulting in loss of production.
Increase in material handling.
Inferior job.
V .J .T. I , MATUNGA
Page 23
INPLANT TRAINING REPORT
Repair/rework requires more attention of supervisor, welding engineer.
Delays on job ultimately result into levy of penalties by customer.
SUPERVISOR SKILLS
Distribution of work.
Maintaining drawing folder, weld plan and test plan on shop floor.
Drawing materials from stores.
Check the material received against material challan.
Report material lost / spoilt / rejected on shop floor to planning through foreman.
Transfer of material from shop floor.
Maintaining shift change list/request.
Maintain records of RT/UT reports.
Use reports for communicating with counterpart.
Make proper inspection / maintenance entry giving all the details.
Issue consumable slip after entering all the details
Obtain priority for RT/UT/wagon movement/machining/pwht before positioning the job.
Give requirement for indirect material/jigs and fixture /tools to planning in advance.
Check correctness of dimensions / feedback being given to inspection, planning, welding engineering.
V .J .T. I , MATUNGA
Page 24
INPLANT TRAINING REPORT
SHOP WELDING PRACTICES SL DO'S NO 1 Fix the earthing clamp
DON’T'S Don't fix the earthing to the
2
directly to the job Use properly baked
roller body/positioner Don't use fresh electrode
3
electrodes. Always refer the weld plan
from the Packet Don't issue electrode without
before issuing the electrode
checking the weld plan for
to the welder.
preheating, interpass temperature or post heat
4
5
Use qualified welder on the
temperature. don't use unqualified
job.
fabricator for tacking on the
Issue a consumable slip for
Job Don't issue more than 2-5
the maximum of 15
electrodes to the fabricator
electrodes at the time to the
for tacking.
welder or less as per the job
6
requirement. Start the post heating
Don't allow post heating to
immediately after the welding start below the preheat
7
is completed. Circumferential /Restraint
temperature. Don't tack less than 50mm
joints should be tacked with
long. The tack may crack due
tacks with more than 50mm
to restraint.
in length and minimum two layers of welding should be
8
done. Always weld on clean surface Don't weld on dirty surface to only which are free from rust, avoid defects like porosity grease, developer, oil paint
V .J .T. I , MATUNGA
and crack. Page 25
INPLANT TRAINING REPORT
etc.
9 Always weld only the required Don’t over weld. It will size of the fillet.
increase material cost, labour cost and other overheads. It will also cause distortion.
V .J .T. I , MATUNGA
Page 26
INPLANT TRAINING REPORT
IMPORTANT DOCUMENTS RELATED TO PROJECT 1) ROUTE CARDS (RC): Route cards are basically made for routing jobs, operation wise from machine. Various things which are added on to the route card are: Estimated hours for the job along with the machine on which the job is loaded. P.W.O. NO., Drg. No., Part description, Quantity. Initiating dept., Reference, Inspection dept. Special jigs & Fixtures if any. Material description with size, type & location. Required sketch if any is drawn or attached along with. 2) PURCHASE REQUEST (PR) : Purchase Request is the basic document related to material required for manufacturing the product. It is initiated & prepared by the design dept.It gives the authority to purchase dept. for procurement of material as per customer’s order, design & drawings. It contains PR no. , Item no. , item description. It also covers data & information regarding delivery schedule & transport. 3) PURCHASE ORDER : Purchase order is prepared by purchase dept. after receiving P. R. from the shop planning. Purchase dept. places the P.O. with the concerned supplier after inquiring with various subcontractors/vendors & deciding on the factors like taxes, duties etc.
V .J .T. I , MATUNGA
Page 27
INPLANT TRAINING REPORT
4) MATERIAL REQUISITION (MR) : Material requisition is a document prepared by the product groups. It may also be prepared by planning & other dept. on arising need of some material like jigs, fixtures, templates, gauges etc. It mainly consists of MR No., job No., Material Code, Quantity, Insp. Agency name etc. 5) PLATE CUTTING REQUISITION (PCR): PCR is a document which is prepared by the fabrication shop planning dept. who in turn releases it plate preparation shop. PCR shows about the details of the edge preparation of the plates. This document gives MR No., Drg No., & item No., description & size of the plate. 6) JOB TICKET (JT): Product Group after approval of the drgs. to the related shop ,planning dept. will then prepare the job ticket which describes the item or job to be manufactured in the shop. 7) OPERATION CARD: Operation card is also a document prepared by the planning dept. It gives details of operations such as rolling, pressing, forming, nozzle fabrication, pipe fabrication etc. to be carried out in the particular shop. 8) NON-CONFIRMATIIVE REPORT (NCR) : It is not possible to maintain cent-percent accuracy or perfection in the fabrication of a critical item. The fabricator sometimes makes a mistake due to which the job suffers. Such a mistake has to be rectified. V .J .T. I , MATUNGA
Page 28
INPLANT TRAINING REPORT
A document called Non-confirmative report which is prepared by the inspection dept. shows change in the dimensions of the items which are different from actual dimensions of the job as mentioned in the drawings. 9) DESIGN CHANGE REQUEST (DCR): The design change is initiated by the shop planning people. This document is forwarded with the rectification of some design, item, material, welding, non-destructive testing etc. After the approval of design dept., the rectification is mentioned in the revised drawing. 10) MANUFACTURING SCHEDULE:The Manufacturing Schedule depicts the sequence of operation of the job and the time required to do each operation. This schedule is prepared by the shop planning department. 11) PRODUCTION PROGRAMME:The production programme is made every month giving the targets (CDD & EDD).Completion of jobs in the shop for a period of three months, which should be met for effective control. It also gives a list of MP jobs & TP. 12) SHOP LOADING STATEMENT:In this, the capacity of shop is distributed among the various jobs depending upon the priority, CDD & schedules. It gives a clear picture of monthly distribution of man-hours for each job, and the Quarterly Man-hours Capacity report of the shop based on the workmen data.
V .J .T. I , MATUNGA
Page 29
INPLANT TRAINING REPORT
13) STORES CREDIT NOTE:When the job gets over in all respects, progress department makes this document & along with item list or supply list attached, it is handed over to inspection department. After getting SCN signed from inspection, it is handed over to product group which in turn credits the amount of the job to the concerned shop. 14) MANHOURS PERFORMANCE REPORT:This shows whether a job is being executed by effectively utilizing the man-hours. It shows the estimated man hour and the actual man-hours during and up to a particular period, resulting in under run or over run of the job.
V .J .T. I , MATUNGA
Page 30
INPLANT TRAINING REPORT
SHOP LOADING STATEMENT
Capacity of shop in terms of man-hours, machine hours available per month.
List of all orders available in hand. details of CDD, estimated man hours for each job.
Likely shop estimated man hours booking for each job depending on scope of work, past performance, urgency of job, material availability etc.
Possible man-hours booking for each job in each month depending on material & engineering status and urgency of job.
Summary of total load available per month. compare the load with available capacity per month to establish overload/ under load.
Shop loading statement is used for,
Generating master load which includes forecast orders.
Deciding to augment existing capacity by either permanent or temporary recruitment.
Deciding need for sub-contracting.
Deciding future order booking.
Ensuring proper capacity utilization.
V .J .T. I , MATUNGA
Page 31
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