Lessons Learnt

No

Problem

Area

There were delays in receiving project materials - parts

such as corner castings, doors, locks

Procurement
Planning

Loading/Unloading of containers timing of transport

2 forklift/crane availability&capability
forklift/crane operators
type of lorry - legality, tolerances

Installation of door rubber requires more time that was

unaccounted for

Malfunction of equipment - compressor, forklift,

overhead crane

5 Lack of control on manpower

Planning
Logistic
Manpower

Planning
Maintenance
Management

Consumables - Certain consumables are not taken into

account in budget

Engineering
Costing

Equipment - Certain equipments are not taken into

account in budget

Engineering
Costing

8 Scope of work was not clear cut

Line of contact - contractor, client, upper client, sub-

9 con (transport, load test,rubber,MPI)

(especially in terms of transportation)

Management
Planning
Costing
Management
Logistic
Planning

10 Drawings and dimensions

Engineering
Quality Control

11 Quality control of work done

Quality Control

Piping Fabrication
Problem
No
1 Design of Piping was not correct
2 Lack of time

Area
Engineering
Planning

3 Hydrotest arrangements
4 Fit-up, Hydrotest, Visual, RT, Painting Report
5 Blasting and painting time

Engineering
Quality Control
Planning
Engineering

Reason
No lead time provided
Lack of proper planning
No proper line of communication
Incompetent agent (client's)
Faulty lifting facilities
Incompetent operators
Should not be using 40' trailer
It is a delicate procedure that requires time and
about 3 persons (2 containers per day)
No proper maintenance or checkup done
berforehand
Some are lacking in work ethic
Money or payment oriented (without the work
discipline to go with it)
Insufficient consumables calculated
Some are left out
We only took into account welding machine and
compressor, none for painting

No proper written agreement and arrangement

that should be taken into account

Problems in conveying reports and activities

especially in delivery/receiving
Drawings were conflicting - no proper email sent
for variation (dimensions, door tolerance)
Should be paying extra attention to the work done
in terms of welding, painting and surface
preparation quality

Reason
No proper drawing was given
No clear cut schedule or dates were given

Chart recorder, pressure gauge was not calibrated

due to lack of time. Many fittings, valve were hard
to find
No planning done, no one was aware
Not enough time

Future
Confirm with vendors/supplier
Establish planning (client&contractor)
Establish procedure
Use reliable transport company
Check maintenance etc
Hire/prepare competent personnel
Use low loader truck (multiple axles)
Allocate time and manpower for the installation
Preventive Maintenance Schedule (even if it is
rental equipment)
Screen the man to be used
Do not use the ones that are not OK
Use punch card etc.
Oxy/acy gas, welding electrode, grinding disc,
cutting disc, power brush cup, thinner
Painting equipment, air manifold, hand tools
(grinder,power brush), air hose, scaffold,
cutting wheel, cutting torch, electrode holder,
forklift, crane
Clear SOW should be verified Loading/unloading, door rubber installation,
sticker and slings, certification (design, load
test, MPI)
Proper email should be given
Establish line of contact
Deal directly with end user (no need for middle
man)
Use certified design, allow for proper change
order
Pay extra attention to details, be more
inquisitive in checking

Future
Only use AFC drawings
Plan

Plan
Do WPS/WQT correctly, assign QC Engineer
Power tool pipe earlier (directly after receive),
allow for drying time as per paint data sheet