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Project Completion Report. Project Summary Client: MTU Detroit Diesel Australia Contract No.:1161873 PROJECT DELIVERABLESTARGETACTUAL SafetyNil LTINIL.

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Presentation on theme: "Project Completion Report. Project Summary Client: MTU Detroit Diesel Australia Contract No.:1161873 PROJECT DELIVERABLESTARGETACTUAL SafetyNil LTINIL."— Presentation transcript:

1 Project Completion Report

2 Project Summary Client: MTU Detroit Diesel Australia Contract No.:1161873 PROJECT DELIVERABLESTARGETACTUAL SafetyNil LTINIL ScopeDesign, fabricate and assemble skid mounted acoustic enclosure around MTU 12V1600 diesel generator package As per target SchedulePC 31/01/2013 Budget$189,200$199,460 Margin$37,925 (20%)$15,698 (8%) Quality (NCR)00 Customer Satisfaction Score80% or aboveNo feedback at this point

3 Project Overview The generator package formed part of the CSBP initiated NAAN3 project which aimed to increase production in their Kwinana facility. Aerison’s scope of supply included the following main components……… Painted skid base with integral double skinned fuel tank (3500L) Stainless steel acoustic enclosure Inlet and outlet ventilation system Removable roof Roof mounted muffler Fitting of free issue generator set and radiator to skid base Full mechanical assembly of acoustic enclosure package

4 Project Overview Parties Involved Primary Stakeholder:CSBP EPCM:MTU Detroit Diesel Australia Supply Contractor:Aerison Aerison’s Scope Design, fabricate, assemble & transport to site…… One off acoustic diesel generator package with integrated fuel tank

5 Project Overview

6 Design

7 Aerison Similar to units previously supplied Double skinned tank changed in regards to previous designs to incorporate double skin at sides also Stainless steel panels Removable roof Semrad fuel control system

8 Fabrication – In House Base frame and tank Structural frame work Inlet ventilation system Outlet ventilation system Base Frame

9 Fabrication – In House Structural FrameworkInlet / Outlet Ventilation System

10 Fabrication – Sub Contractor Stainless steel panelsCohesive Stainless steel doorsCohesive FlashingCohesive MufflerUniversal Weather louvreBradflow Surface treatmentRPC

11 Fabrication – Sub Contractor Complete Panels Insulation Fit Out Door Trial Assembly

12 Fabrication – Sub Contractor Weather Louvre MufflerElbow & Weather Cowl

13 Project Pictures-Complete Assembly Outlet EndInlet End Fuel ConnectionsExhaust Duct & Blankets

14 Project Pictures-Complete Assembly Fuel InterfaceGenset Installation GensetRemovable Roof

15 Project Pictures-Complete Assembly CSBP Generator Package

16 Project Summary Safety and Environment Target – Nil IncidentActual – Nil Incident Comments Safety and environment record for project excellent No reported incidents from sub contractors

17 Project Summary Scope of Works Target - Original Contract Scope of WorksTotal Number of SCN’s 4 Total Approved 3 Comments Project completed on time $10,260 in variations

18 Project Summary Schedule

19 Project Summary Schedule Original Contract Delivery 31/01/2013Actual Practical Completion – March 2013 (Contractual obligations fulfilled – Extension due to external client issues) Comments Schedule extremely tight from the beginning A lot of initiative and assisting of client required to keep the project on track

20 Project Summary Budget and Margin

21 Project Summary Budget and Margin Original Contract Sum $189,200Expected Final $199,460 Original Contract Margin $37,925 (20%)Expected Final $15,698 (8%) Comments Over budget items were:- Drafting(-$11,408) Management(-$20,017) Fabrication Labour(-$7,315) Assembly Labour Under budget items were:- Materials($1,700) Panels and Doors($8,156) Variations

22 Project Summary Quality Target – Nil Quality Issues or NCR’sActual – Nil Comments Internal fabrication checks Sub contractor quality review documentation Sub contractor external expections

23 Issues Comments Drafting - Significantly underestimated (~$9,000 estimated / ~$20,000 used) Workshop hours - Underestimated in regards to ventilation inlet/outlet system - 370 hours used in total (290 allocated to work shop – Additional 80 hours allocated due to shortfall with inlet/outlet ventilation system) Assembly hours - 140 hours estimated - 80 additional hours used ~ 45 hours covered by variation ~ 10 hours caused by direct work shop error Management and Engineering - Significantly underestimated (~$18,000 estimated / ~$38,000 used) Budget

24 Issues Subcontractors - Subcontractors internal quality inspections poor - Subcontractors external quality inspections not adequate Drafting - Missing detail led to additional work and time expended Engineering - Lack of consideration for a few assembly items (grid mesh / silencer connection to radiator) - Bolt take offs not efficient or correct Management - Greater control needed to be taken of design process at an earlier stage - Due to the lack of document control and an organised process on the clients side a lot of gentle persuasion and recording required to maintain forward momentum of project while maintaining contractual obligations and cover. General

25 Project Summary Human Resources Comments Expeditor – Good - Expediting very good where required QA – Internal Good / External Poor - All internal issues identified and rectified in at work shop stage - Muffler quality and panel quality documentation poor Engineering – Good (Needs to flow more from the start) Document Control – Restricted due to no client document control Safety – Excellent Management – Good - Management was required to be very tight due to lack of budget in critical areas

26 Project Summary Communications Comments Internal Sub contractor Client

27 Project Summary Client Satisfaction Client and CSBP happy to date with final product – Commissioning and noise test yet to take place

28 Project Summary Lesson Learnt Transport Quality Contract management At source inspections

29 Project Summary Project Completion Unfinished Business Comments Thank You Letter Bank Guarantees Future Business or Related Projects Aerison Procedures


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