Material Management & Project Controls

Johan Kroon
Application Consultants
Intergraph UK & I 2008
18th November London
Agenda
Part 1. Introduction, Overview of SPRD and SPMAT
Part 2. SmartPlant Reference Data (SPRD)
Part 3. SmartPlant Materials (Engineering E&PI)
Part 4. SmartPlant Materials (MSCM)
Part 5. SmartPlant Materials (Construction)
Part 6. PRISM

EMEA & India Industry Tour

Part 1.
Introduction, Overview of SPRD and SPMAT

EMEA & India Industry Tour

 SmartPlant Enterprise Suite
Materials &
Schematics Modelling Project
for Process, Power & Offshore plant Management

Modular COTS products 3D

P&ID Project Cost
Intelligent data centric solutions Layout Control

Windows environment; easy to use

Instruments 3D Design Engineering,
Workflow & data integration
On-Shore & Off-Shore Procurement &
Global workshare & Marine Supply Chain
Electrical
Construction
Many strategic alliance partners 3D
Commissioning
Drafting Visualization Handover

Integration Layer

Plant Information Management

Document Mgt Data Workflow

Engineering Data Repository

November 18, 2008 4

 SmartPlant RefData and Materials
Major Work Processes
OPTION

SPRD export to ERP system for part of the

Procurement cycle

MLCL E&PI MSCM

ERP (SAP, Oracle etc.) SITE
Design systems

Piping Piping Piping Proc. PO Fabrication Materials Work Material

Traffic
Standards BOM REQ Planning Progress Tracking Receiving Packages Issuing

Instrument Instrument Instrument Supplier Inventory Simulation Contractor

Expediting
Standards BOM REQ Mgmt. Mgmt. & Forecast Management

Electrical Electrical Electrical OSD

Inquiries Inspection Reservation
Standards BOM REQ Handling

Civil Civil Civil Construct. Design

VDRs
Standards BOM REQ Equipment Changes

Equipment Equipment Equipment Bid

Standards BOM REQ Evaluation
Inter company
Collaboration
Other Other Other
PO
Standards BOM REQ

Material Life Cycle Library Material Supply Chain Management

Engineering & Procurement Integration SITE

November 18, 2008 5

MARIAN Re-branding

As of Q1 2007. MARIAN brand name was updated.

Same Best of Breed product, functionality and quality

Represents greater integration into SmartPlant Enterprise

Re-bundling of modules gives you more flexibilty

November 18, 2008 6

Part 2.
SmartPlant Reference Data

EMEA & India Industry Tour

 Material Catalogue & Reference Data

Rule-based material libraries on project or

Design Systems enterprise
Engineeringlevel
Systems

PDS, PDMS Civil

Define
Struct
group,
Mech Elect
parts
Instr
& configure part Systems
Financial
numbers
SAP, JDE, ORACLE
Link client catalogue numbers to
Estimating Company catalogue
System Marian

SPRefDat Define and Manage Piping Specs

(MLCL) Manage modifications etc and the
affects of changes to options
Define corporate and/or project rules

Revision & change management down-to-

the-attribute level
Construction
Progress System
Document Design System neutral data entry for
Management
System
design systems (e.g. PDS, SP3D, etc)
Cost
Planning Engineering
System System

November 18, 2008 8

 Fastrack Implementation?...
Standard Database for SPRefDat

Introduction -
Standard Database (SDB) for SmartPlant Reference Data (SPRD)
is a preconfigured recommended practice solution
enables rapid implementation of enterprise reference data
management, and/or materials management
SDB incorporates a comprehensive catalog of industry standard
multi-discipline material parts, organized and described for
out of the box use
Content is pre-configured to enable catalog and piping
specification interfaces to intelligent 3D applications (SP3D and
PDS).
Benefits
When implementing enterprise reference data management,
software configuration and training is minimized
Implementation time and cost is dramatically reduced
Ensures high quality production start-up by eliminating the need for
each customer to re-enter the same standard data.

November 18, 2008 9

 What benefits does the SDB offer?

..Utilise SmartPlant Reference Data, with the

Standard Database Content.
For our Client.

Shortens implementation time = faster return on s/w investment

Lower cost of implementation = faster benefit recognition
Standardised content linked from Design through supply chain
(Left hand knows what right hand means!!)
Standardisation of codification across projects
Lower Client resource costs as Intergraph maintain the data in
SDB
Correct material identification = lower material costs through
correct procurement = greater Return on Investment =

November 18, 2008 10

 Standard Database
- What is available TODAY-

13 Customer bought SDB year-to-date

(EPC and Owners)

SDB contains now also non-metallic

items

PDS configuration is available

Basic structural steel included now

Hot of the press: 3 more clients just

bought SDB

November 18, 2008 11

SmartPlant Reference Data Central control.

Reference DB allows defining Web-based

Web-based system
system means
means
Material components Global
Global Workshare
Workshare of
of Reference
Reference
and Specs used by design tools Data
Data BUT
BUT Centralised
Centralised control
control
Reference DB is a prerequisite, and will typically:
Standardize Materials usage by different Users
Deploy Company Best Practices
Automate execution
Eliminate redundancy

E P C E P C E P C
Contractor A Contractor J Contractor N
Project Standards Project Standards Project Standards

Corporate Standards
2008November
Intergraph Corporation.
18, 2008 All Rights Reserved. 12
.. Thefollowing is a presentation of SPRefDat & SDB
in an example workflow how to mange a Piping Specification

1. Entering Specification Header

2. Entering But-welded Fittings

November 18, 2008 13

 Reference Data Flow

ge s
Chan

Changes

Or PDS
Model MTO data
es
g
an

Integrated Change
Ch

Management and
Exception Handling for
Optimized Workflow

NEW BOM
Revision controlled
from Design to
Supply Chain

Pre-defined Content, Content

Catalog etc. SDB

November 18, 2008 14

.. The
following is a presentation of SPRefDat & SDB
in an example workflow how to export a Piping Specification to
SP3D and PDS

1. Export Catalogue for SP3D

2. Review of the Catalogue

November 18, 2008 15

 SmartPlant Reference Data
New .net User Interface

Phase I Will be released June 2008

Greater flexibility for users
Completely configurable by end user
Sort, Search, Copy/Paste
Scope of Phase I
Commodity Groups & Parts
Commodity Codes
Table detail-based
Attribute-based
Idents (company and interfaces)
Pipe Specification Editor
Spec header & Component groups
Branch table
Press/temp limits
Notes

November 18, 2008 16

UI Functionality
- Complete overview

November 18, 2008 17

copy
New SPRD User Interface

November 18, 2008 18

Part 3.
SmartPlant Materials (Engineering E&PI)

EMEA & India Industry Tour

 Engineering & Procurement Interface
The bridge between DESIGN & PROCURE

Tight and format-neutral

integration with all design
Design Systems Engineering Systems
sources
PDS, PDMS Civil Struct Mech Elect Instr Financial Systems
Provides rule-based control of Bills
SAP, JDE, ORACLE
of material :
SPRefdat & SPMat Project breakdown structures
Estimating
System
MLCL Historical change and revision
E&PI management
Material Engineering
Life &
Cycle
Library
Procurement
Interface
Intelligent and rule-based
requisitioning methods
Set part surplus, re-order
requirements
Manage Assemblies and Construction
Tag
splitting Progress System
Document
Management Cost
System Planning Engineering
System System

November 18, 2008 20

Engineering & Procurement Bill of Material Control

November 18, 2008 21

Engineering & Procurement - Requisitions

November 18, 2008 22

.. The following is a presentation of
SmartPlant Materials E&PI BOM Import

November 18, 2008 23

Major Benefits of SPMat - E&PI

Seamless integration of engineering & procurement

data facilitates the elimination of surplus materials

For EPC & O/O

Bridge between DESIGN and Procurement Cycle

Focussed management of Design Changes into the

Supply Chain no surprises!
The elimination of shortages

Major reduction in risks and construction costs

Quantities needed really will be available

November 18, 2008 24

Part 4. SmartPlant Materials (MSCM)

EMEA & India Industry Tour

 Material Supply Chain Management

Overview
Supplier Design
management
Systems Engineering Systems
Convert Requisitions
PDS, PDMS into Inquiries,
Civil Struct Mech Elect Instr Financial Systems
POs, change orders SAP, JDE, ORACLE

Manage full Procurement cycle

Estimating
System Electronic Bid Processing SPRefdat & SPMat

MLCL E&PI
Integrated to ERP when required MSCM
Material Engineering Material

Milestone Planning Life & Supply

Chain
Cycle Procurement

Management
Expediting and Inspection (Events
Library Interface

and Task management)

Customer defined levels
Shipping Construction
Fabrication management that can be Progress System
Document
updated by supplier
Management Web-based
System
Web-based system
system
Cost means
means
Configurable security forPlanning
third-party
System
Global Engineering
Global management
management
System
and
and
access VISIBILITY
VISIBILITY of
of your
your Supply
Supply Chain
Chain
November 18, 2008 26
Inquire/Evaluate/Purchase

Inquiry
REQ

Bids

Supplier
1
Procurement

Engineering

Tech. Comm Supplier

Eval. Eval. PO ...

November 18, 2008 27

Bid Evaluation.

Bids received by:

Supplier
access
Excel export
Standard
paper docs
Procurement &
Cost Control
review
Price to
budget etc

November 18, 2008 28

 Manage Milestones for Procurement

Info for planning and

progress
measurement in
Cost Control
modules.

November 18, 2008 29

 Major Benefits of SPMat - MSCM

The seamless integration & optimization of procurement & tracking

processes reduces cost

EPC - Electronic vs Manual Bid receipt, analysis and vendor selection

time hugely reduced

The elimination of delivery bottlenecks = reduces risks and construction

costs
Expediting power via flexibility to reflect REAL world
All via easy to implement export & import functions

Enhanced procurement data visibility empowers early and informed

decision making = maximum savings.

November 18, 2008 30

Part 4b. SmartPlant Materials (SITE)

EMEA & India Industry Tour

 SmartPlant Materials - Site

Design Systems Engineering Systems

Links to Site Fab & Isometric completion
PDS, PDMS Civil Struct Mech Elect Instr Financial Systems
Various material receiving methods SAP, JDE, ORACLE

Inventory management:
Estimating
System Physical warehouses SPRefdat & SPMat
Virtual MLCL
warehousesE&PI MSCM

Material Issuing and over issue control

Material
Life
Engineering
&
Material
Supply Site
OSD management
Cycle Procurement Chain
Library Interface Management

Powerful Rule-based forecasts,

reservations and simulations
BUILDABILITY Construction
Progress System
Workpackage/Area prioritisation
Document
Management Cost
System Planning Engineering
System System

November 18, 2008 32

One Site screen full material lifecycle

November 18, 2008 33

 Improved Delivery Control and Construction Planning

Buildability
Highly sophisticated planning
and simulation capabilities

Avoiding on-site delivery

bottlenecks,
Material shortages
Delayed delivery

Optimize resource planning

people, plant and material

2008. Intergraph Corporation. All Rights Reserved.

34
November 18, 2008 35
Major Benefits of SPMat - SITE

Seamless data Integration of Engineering & Supply Chain

data to Site facilitates real fabrication/construction forecasting

Inventory Management with Virtual & Physical Warehousing

Effective site material control reduces construction cost

Integrated information/issue visability (e.g. material

availability)
Enhanced Buildability
Continuous working
Faster completion and TTM!

November 18, 2008 36

Part 5. PRISM

EMEA & India Industry Tour

So, what is PRISM?

Project Cost & Budget Management

Linking ERP, Material Control, Planning and Cost
Project, Progress and Performance reporting
Proactive and accurate Forecasting
Accompaniment to, not replacement of ERP and Planning
systems

November 18, 2008 38

P.P.M. & PRISM Management suite

Capital Cost Estimating Capital Cost Management

Baseline Estimate
Schedule Interface
Cost & Progress

Engineering Management
Engineering Progress
Deliverables control

November 18, 2008 39

EVA in PRISM The key to successful projection..
Its not just what we spent but what we ACHIEVED.
Planned = $500K : Data Date
Actual = $475K
Earned = $300K
1300 1300
Estimate at Completion (EAC) Forecast
Cost
Disaster?
1200 1200
Overrun
= $????K

1000 1000
Budget at Completion (BAC)
Recovery..?

Current Completion Date

Target Completion Date
800 800
In $1,000s

600 600

Schedule Variance ($)

400 Cost Variance 400

Schedule
200 Variance 200
(Time)
Planned
- 4 wks
Actual
Earned 1 2 3 4 5 6 7 8 9 10 11
Months
Forecast Schedule Delay = 4 weeks

November 18, 2008 40

The Control Account

Project Building Blocks

-Level of definition flexible
-Could be CTR, Workpack, individual
activity etc

Up to 26 levels of
user defined WBS
and Group coding
structures, each up
to 10 characters in
length.

November 18, 2008 41

Reporting Features

Flexible level of reporting throughout structures

Roll up or down your reporting levels, with subtotals
at any/all levels
Tabular and graphical reports
Save and store user defined report parameters
Same outputs, month on month!
Not MOTHER OF ALL SPREADSHEETS
Output queue for batch reporting
Print reports for e-mail or website posting
HTML report generator or print to PDF

November 18, 2008 42

Confidential

November 18, 2008 43

November 18, 2008 44
Project Management Outputs

November 18, 2008 45

Benefits of PRISM Implementation

Standardization of Project Management Work Practices

Integrated system to other ERP, Engineering, Material Management
systems
Coding system flexibility (26 coding area/levels)
Measure Physical Progress % Complete
Numerous methodologies to carry these calculations out
Out of the box Reports
FLEXIBLE
Customisable in Crystal if required
Perform Variance Analysis
Track Trends and Changes (adverse & beneficial)

November 18, 2008 46

 Success Stories

PBMR EX

EMEA & India Industry Tour

Any questions
please?

EMEA & India Industry Tour

Thank You

Integrating the
Engineering
Enterprise

November 18, 2008 49