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Turnkey Construction Industry: Caught in the crux of challenges
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Turnkey Construction Industry: Caught in the crux of challenges

In this fast-paced era of globalization and pioneering technological advancements, Turnkey Construction has turned into a fast expanding, multi-million dollar industry. A typical Turnkey construction company is pressured by time, driven by quality, excessively dependent on resources, documentation-intensive and subject to stringent regulations. The EPC industry is susceptible to numerous challenges and the risk factor is also immensely high. The modern global engineering & construction industry faces some of the most perplexing business problems, that include:

Manual monitoring
Organisation standards and procedures defined in ISO and special laws such as the FIDIC govern the proccess of a Turn-key Construction Industry. One of the biggest challenges is that all the stages in this long-drawn process from the conceptual stage to commissioning are monitored and documented 100% manually with only pockets of automation. This leads to deliverable delays, lack of accountability, low quality and the inability to systematically enforce processes across the enterprise.
Lack of centralized data management

2Project management in the EPC industry is a rather time-consuming, daunting task and is, undoubtedly, a core problem faced by this industry. In an EPC industry, a typical project comprises around 3000-4000 tasks, thousands of documents and approx. 2000-3000 drawings, document, emails, correspondences, etc. generated as part of the whole product development process. It is difficult to manage such a huge volume of documentation in a manually-operated environment. Lack of centralized data management leads to inaccurate documentation, inability to retrieve the latest versions of documents, project delays, low or mostly non-existent reusability and non-optimal utilization of resources.

Lack of a common platform for interaction between groups
3Close interaction between the internal & external entities in the project team such as the client, design consultant, main contractor, vendor etc, is a prime requisite for change management. Quite often, geographical constraints hinder the smooth flow of communication as the teams are located in multiple locations around the globe. Communication usually takes place via emails, phone, face-to-face or through hardcopy files sent by courier, thus resulting in heavy expenses, travel costs & delays.
Fixed budgets & staggering costs
4Most projects are executed on fixed budgets and a considerable amount of increase in costs can either derail the project or make it non-viable for the client. Increase in the cost of materials caused by delay in turn pushes up the cost of the project, leading to decline in quality, postponement in Project end date & invoking of Late Delivery Clause by the client.

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WRENCH- Enterprise, you can:
a) Define and monitor the online status of all deliverables defined per project.
b) Automatically enforce all quality management process for each deliverable.
c) Automatically capture all data/documents created and transacted for each deliverable.
d) Get online access to all project data - for all users across all locations.

a) Reduce engineering cycle time by over 50% by reusing old data
b) Get instant access to latest and 100% accurate project status information.
c) Eliminate any possibility of human errors and thus ensure quality.
d) Ensure on-time delivery (prevent LD) by monitoring project tasks in real-time.
e) Optimize human resource utilization and capture their knowledge in the system.

There are 3 main elements of PM, where today there is complete dependency on human effort:
a) Project task scheduling (one-time)
b) Project task status updation (ongoing)
c) Project task monitoring using reports (ongoing)

In a typical project management software, after defining deliverables, schedule start, schedule finish date and assigning resources to each task, the status of each task has to be updated manually by the project manager or the resource - this naturally means that updation is a slow, tedious and inaccurate process. But in Wrench EPC™, when the schedule is released, a To-Do-List is automatically sent to the specific user assigned to that activity, and thereafter, progress on that activity or task is captured and updated automatically by the system, where it can be viewed online by the manager. Thus, reports on ‘actual' vs. ‘scheduled' progress can be made quickly, and the responsible resources can be alerted immediately to prevent delays.

Two main differences:
1- In a DMS or content management system all the drawings, documents, data sheets, correspondence etc., are uploaded manually by a resource to specific folders after these documents are transacted so that it can be accessed by others. This upload is done by a resource as soon as the document is created or after the document is released. The document upload is at the discretion of the individual user, and often delayed or put off as it is an additional work for him. In Wrench EPC™ all drawings documents etc, are captured along with the activities of the task and all transaction are done automatically by the system. So the system always has latest version of drawings and document along with the transaction details. The rights of access is also controlled based on the user role and workflow.

2- In a DMS system there is no system to identify a document printed from the DMS system - which means the enduser has to verify with the document creator to ensure that the document printed is the latest version. But in WRENCH, all documents printed from Wrench EPC™ are identified by a watermark which displays the status of the document along with the date and time stamp.

In such DMS systems, you can define the workflow for a type of document, and then the software ensures that the document file is routed through it. But when a document file is modified, the user has to still manually increment or update that document's revision/version number, and send it again through the workflow. This manual increment of revision is very prone to errors. The revision history is maintained in the software and date and time when the file was received at each stage in the workflow is also captured.

In Wrench EPC™ the workflow process can be set as per the EPC industry practices where the increment of the revision and version is defined based on the existing workflow process. The revision series can also be specified based on the client's specification. When a document is routed through this workflow, the revision or version number gets incremented automatically. Also, in Wrench EPC™ a workflow can be assigned to a deliverable and multiple documents can be attached to the deliverable. So multiple sheets of a document can be routed through a single workflow instead of routing individual sheets. Schedules for a task, % weightage and budgets can be specified for each stage in the workflow so that the task can be scheduled and monitored.

Wrench EPC™ is a fully web enabled application built on Microsoft .NET technology which can be deployed over the internet. The central server and database can be located at the corporate office and satellite servers can be deployed at other office and sites. Also Wrench EPC™ is built to handle huge file sizes (since most drawings are created using CAD software which outputs bulky files).

Internet bandwidth: With any other solution, transacting over the internet is a bottleneck, because in India internet bandwidth at remote locations is very low. WRENCH solves this in the following way: The user from remote offices uploads the file to Wrench EPC™ satellite server over the local area network and then the same file is replicated over the internet when internet usage is low. The large files are then retrieved locally at the other location. This makes Wrench EPC™ a practical solution to work over the internet across multiple offices and sites.

Ans: With Wrench EPC™ , our clients today can:
a) Monitor each and every task online, and so enable on-time completion.
b) Prevent losses caused by rework. The main cause of rework is human error, especially in things like sending wrong revision of data to vendor/client/internal department
c) Reduce the engineering cycle time by enabling the engineers to access and reuse past project data, and past problem + solutions.
d) Be assured of all quality-control process like ISO is being enforced 100% across the organizations - ie. They are now working as a process-driven company.
e) Greatly lessen their dependency on human resources as in WRENCH all information and history is available online.
f) Greatly improve the productivity of human resources by closely monitoring them against budgets and set targets for continuous improvement
g) Achieve higher client satisfaction by giving online reports on project status to client periodically, ensure delivery of item as per specification through internal processes and able to handover As-built designs immediately on completion of project.

The steps followed in implementing Wrench EPC™ for a client are:
a) Basic Orientation to the Key users on the feature of Wrench EPC™
b) Study of the existing process, resulting in an AS-IS document
c) Define an optimum process (TO-BE process) with highest level of automation based on the AS-IS document.
d) Configure Wrench EPC™ as per the client approved TO-BE process.
e) Deployment and training.

This whole exercise takes about 8-12 weeks time based on size of the organization. An additional 4 weeks time is allotted to hand-hold the users until they are comfortable.

If a client company is implementing the system, then all the deliverables can be defined in Wrench EPC™ (For EPC) and the consultant, vendors, contractors can transact on the system. The client company can monitor all the deliverables online and also capture all the data along with the transactions.

If Wrench EPC™ is implemented by the consultant or the contractor then the client can be a member of the project and do the approvals and review online. This will drastically reduce the manual efforts and automatically log the interactions. Also the client can monitor the status the deliverables identified online and set notification and escalation in case of delay.

Definitely Wrench EPC™ (For EPC) can be used to distribute the drawings between the design office and the site. We will need to install a satellite server at the project site location. All those drawings identified to be distributed to site is to be identified and when it is released Wrench EPC™ will automatically replicate the drawing to the project site Satellite server. The transmittal created by the approver will notify the site PM at site after the document is replicated. The Site PM can take the print of the drawing or document and it is identified by a Watermark. When a change is done by design the file which was earlier replicated is made obsolete on the Site satellite server and the updated file is automatically replaced.
The out of the box reports available are the following:
a) Document Pending Status.
b) Document Release and approval status report.
c) Master List of drawings documents.
d) Transmittal Report.
e) Percentage completion report.
f) Man Hour report.
g) Expediting query report.
h) Resource loading report.
i) Things gone right Things gone wrong report.
j) Project status report.
k) Minute of the meetings.
l) Print log report.
m) Structure wise Drawing Report.
n) Project Task Force Report.

Using Wrench EPC™ enables managers to standardize deliverables. He can set clearly budgeted durations and allot individual or group resources for each deliverable. All this data is recorded and updated by the system. As each resource works on his allotted tasks/activities, the manager can at any time check the actual time-spend vs. the budgeted time-spend. Thus the performance of each human resource can be monitored during the process, and course corrections can be made as required.