Week 3_ Ejeh Udoka_ Drawing Conflict

Week 3_ Ejeh Udoka_ Drawing Conflict

Problem statement

Non conformance has been issued on the on going fabrication due to drawing conflict in the fabrication shop.

Possible causes

-Drawings are not properly revised- due to continuous comment and changes especially by the clients, the CAD designers fail to thoroughly revise the drawings

- Poor document control- the document control unit is situated at the head office which is far away from the fabrication shop. This results in:

• Conflict in drawing numbers- CAD designers are requested to generate drawing numbers.
• Nobody willing to take up document control responsibility.

Possible solutions/ alternatives

-Increase the drawing approval bureaucracy- this will minimize error resulting from drawing revision

-Creating a small document control unit or team at the fabrication shop- this will ensure control and eliminate drawing conflict. The unit will be responsible for generating drawing numbers, ensuring the use of global numbering practice, retrieving obsolete drawings.

-make foremen responsible for controlling drawings within their unit.

Comparing the alternatives

Creating a small document control unit be the most efficient. The reasons are clear as stated in the previous section. The disadvantage is that it is immense. More personnel is required, office space and office accessories are required.

Making foremen responsible for document control within their unit can serve as an ad hoc measure until the recommended practice is adopted.

Week 2_ Ejeh Udoka_ Quality Control

Problem Statement;

QC weekly report from the Fabrication shop records increased weld rejection rates within the last month.

Possible Causes;

-individual welders performance making the welds,

-use of damp or contaminated electrodes,

-use of un- calibrated equipment.

Action Plan;

-isolate the weld defect types,

-check trend if any

- establish the exact cause of the rejects.

Possible Solutions / Alternates;

-identify and withdraw the welder(s) and subject to retraining / requalification.

-ensure electrodes conditions are used as manufacturers recommended conditions,

-strengthen the process control measures,

-improve inspection and QC supervision / monitoring,

-train shop floor personnel.

Possible Outcome; Coordinated effort will improve the metrics.

Acceptance Criteria; developed quality metrics matched with project/ contract requirements.

Compare and analyze the alternatives (solutions); each of the alternatives as listed will not work in isolation if implemented, instead an integrated process approach is recommended to achieve the desired result.

And for this to be effective, personnel must be adequately trained, process control procedures enforced and a motivated work force.

References

GP 29-03-06 Onshore Structural Welding and Inspection

GP290309 Offshore Structural welding and Inspection

GP 20-01-04 Upstream Project Quality Assurance - General Requirements

Client specifications and control procedures.

Week 3_ Ejeh Udoka_ Drawing Conflict

Problem statement

Non conformance has been issued on the on going fabrication due to drawing conflict in the fabrication shop.

Possible causes

-Drawings are not properly revised- due to continuous comment and changes especially by the clients, the CAD designers fail to thoroughly revise the drawings

- Poor document control- the document control unit is situated at the head office which is far away from the fabrication shop. This results in:

• Conflict in drawing numbers- CAD designers are requested to generate drawing numbers.
• Nobody willing to take up document control responsibility.

Possible solutions/ alternatives

-Increase the drawing approval bureaucracy- this will minimize error resulting from drawing revision

-Creating a small document control unit or team at the fabrication shop- this will ensure control and eliminate drawing conflict. The unit will be responsible for generating drawing numbers, ensuring the use of global numbering practice, retrieving obsolete drawings.

-make foremen responsible for controlling drawings within their unit.

Comparing the alternatives

Creating a small document control unit be the most efficient. The reasons are clear as stated in the previous section. The disadvantage is that it is immense. More personnel is required, office space and office accessories are required.

Making foremen responsible for document control within their unit can serve as an ad-hoc measure until the recommended practice is adopted.

Lessons learned

-We experienced delay in fabrication because we had to suspend work in order to reconcile the drawings. Had ad-hoc measure been adopted, the delay may have been eliminated.

-We were lucky to have arrested the situation in good time else rework, rejection would have been the case.