Welcome to Worley Parsons Project Management
Process (WPMP) Training
Managing Project Procurement
Introduction
Overview of Procurement
Responsibilities for Procurement
Commencing the Procurement Process \Procurement Planning
SmartPlant Materials
Procurement Reports
Procurement Initiation
Procurement Execution
Procurement Close-out
Learning Objectives
On completion of this module, you will be able to:
Identify and understand the procurement methodologies and tools
available to Project Managers for the management of EPCM projects
Learning Outcomes
Early involvement of the Procurement function in project planning
is essential
The project’s procurement strategy and procurement plan must
align with the overall project strategy
Clear definition of the objectives of the Procurement Process is
critical for the project team
On completion of this module, you will be able to demonstrate an understanding that:
Procurement is an integral part of the WorleyParsons’ growth
strategy
Procurement shall support the company to compete more
successfully as a leading provider of professional services worldwide
6
Overview of Procurement
Procurement is the process by which materials, equipment and
third-party services are acquired for projects
Key procurement interfaces include:
•
Project Management•
Engineering•
HSE•
Quality•
Cost Estimation•
Project Controls•
Construction Management•
Legal & Risk What is procurement?Overview of Procurement
At the best possible total cost of ownership
In the right quantity and quality
At the right time
In the right place
For the direct benefit of the customer
What does procurement involve?
Procurement and Capex
The Capital Expenditure (Capex) of a Project can be split into a
few elements:
•
Engineering and design – approx. 10% of Capex•
Procurement:− Materials and equipment – approx. 30 to 45% of Capex
− Contracts – approx. 30 to 45% of Capex
•
Balance is owners’ costs, insurance, land purchases etc The above is indicative only and dependent on the type and
location of a project. However, on average the Capex element managed by procurement ranges between 60% and 90% of the overall project value
Overview of Procurement
Procurement is the bridge between Engineering (design) and
Construction (execution)
Overview of Procurement
Materials Management
•
Purchasing, Expediting, Materials Control, Coordination ofInspection (liaising with Quality), Traffic/Logistics, Warehousing/ Inventory Control etc
•
Legal agreement used is a Purchase Order Contracts
•
Acquisition and management of third-party services•
Legal agreement used is a Contract Both Purchase Orders and Contracts are written and binding legal
agreements between relevant parties to supply either goods or services against agreed conditions
Procurement Executive Directive
To minimise risk exposure, procurement services are usually
provided for and on behalf of Customers, in the Customer’s name or “on Customer paper” – this is the company’s preferred position
However, this does not preclude provision of procurement services
in WorleyParsons’ name or on “WorleyParsons’ paper” – requires CEO to proceed in any event where additional supplier-related risks and liabilities are assumed (eg warranty obligations, delivery commitments, product liability, etc)
In most instances, procurement services are provided on behalf of
the Customer, requiring active interaction with the Customer and their various approvals to proceed
EMS Workflows and Procedures 1/2
Contracts services cover the provision of third-party services such as
construction labor, inspection services, painting and sand blasting
The provision of contract services is governed by the Contracts
Workflow in EMS containing a number of procedures, guidelines, forms and templates
Preferred Terminology:
•
ITT = Invitation to Tender•
Contract = legal agreement for the provision of services13
EMS Workflows and Procedures 2/2
Materials Management includes the purchasing of goods and
equipment, subsequent expediting, inspection and receipt.
The provision of Materials Management services is governed by the
Materials Workflow in EMS containing a number of procedures, guidelines, forms and templates
Materials Management activities are managed and tracked through
SmartPlant Materials, WorleyParsons’ Materials Management system which starts from creation of the requisition through to final material reconciliation on site
Preferred Terminology:
•
RFQ = Request for Quotation•
Purchase Order (PO) = legal agreement for the supply of goodsOverview of Procurement
WorleyParsons procurement process
Pre-award Activities * Materials Management * Contracts
Obtain quotations Select the preferred suppliers
Project Procurement Plan
Determine procurement requirements
Procurement Initiation
Identify potential suppliers
Post-award Activities
Manage the supplier Administer POs and contracts Manage POs/ contract variation
Materials Field Administration Activities
Field Purchasing Transport/ Logistics
Receipt on site Warehousing
Close-out Activities
Conclude the engagement of the suppliers
Record the performance against each order & contract
Responsibilities for Procurement
As Project Manager, you are responsible for the overall
management of procurement activities associated with the project
You are not responsible for the execution of procurement activities
That is the responsibility of your Project Procurement Manager
To fulfill your responsibilities, you should work closely with the
Responsibilities for Procurement
Procurement specialists in each region
Detailed procurement procedures, guidelines and associated
documentation
Deployment of SmartPlant Materials as the company-wide materials
control system to record, track and report on procurement activity
Global supplier database for materials, equipment and services
Global Sourcing initiatives
Supply arrangements with key suppliers
Procurement staff managing the Materials Management and Contracts activities usually:
•
Work either from a core Procurement group in a key companylocation or
•
Form a part of a dedicated project procurement team Procurement activities on the project are usually led by an
experienced Project Procurement Manager
Where warehousing staff are required for specific customers or
projects, they are usually located on site
Inspection may involve in-house or third-party inspectors, depending
on the location of the inspection activities Procurement resourcing
Procurement Process
Establish exactly what the customer requirements are and what
WorleyParsons has committed to do
Establish your procurement team and set out their responsibilities
Procurement to participate in the Project Risk Assessment and ensure that
risk mitigation is included in the Procurement Plan to be developed
Procurement to incorporate appropriate flow-down conditions from the Prime
contract (the agreement between Customer and WorleyParsons) in the Project Conditions to ensure compliance and alignment (e.g. including
customer’s confidentiality requirements, alignment of warranty periods etc.)
Procurement to develop the project procurement procedures, based on EMS
but incorporating as appropriate Customer’s requirements (e.g. approval interfaces)
Arrange to have the project set up on SmartPlant Materials
Ensure WBS is established
Procurement Planning
Planning is at the crux of all project activities
Procurement is no exception
The aim of procurement planning is to:
•
Know what needs to be procured, when, where and how•
Identify critical long lead items and services•
Establish order and consistency in the way the procurementactivities are performed
•
Understand the risks involved in the project environment andidentify mitigating actions
The Project Procurement Plan is part of the Project Execution
Plan Planning
Procurement & Risk Management
Procurement is an integral part of risk management on the project
•
Develop appropriate procurement/ contracts/ materials managementstrategies, identifying the various risks (market, forex, local content requirements, taxation and importation issues, logistics complexities, etc. to be managed)
•
Use EMS procurement procedures to the largest extent, however,recognize Customer requirements in the project specific procedure.
•
Ensure that the project specific procurement procedures areapproved by the customer and shared with the project procurement team
•
Develop the procurement schedule early, in line with the overallproject schedule, resulting in correct priorities to achieve the Required on Site Dates
Procurement Planning
Procurement Planning
When planning occurs
Identify 1 Evaluate 2 Define 3 Execute 4 Operate
Procurement Strategy
Procurement Plan
Materials Management Plan, if required
Purchasing and Contracts Initiation
Materials Management Plan, if required Contracts Plan, if required
Materials Field Administration
Contracts Plan, if required
Procurement Planning
Project Procurement Strategy (PPS) is the:
•
Process for identifying and documenting the procurementopportunities applicable to the project
•
First step in developing the Project Procurement Plan Typically, the PPS is first developed during the scoping stages of a
project
Sometimes the customer provides the initial procurement strategy for
further development in the Project Procurement Plan Project Procurement Strategy
Procurement Planning
Purchasing activities can involve long lead times
Certain materials and equipment may be particularly critical to a
project’s success
Purchasing activities usually involve multiple countries (infrastructure
and logistics, local legislation etc.)
Market and technology developments can impact on the success of a
project and therefore need to be monitored on an ongoing basis
During the development of the PPS, the following factors need to be
considered:
Procurement Planning
The PPS is a hierarchical matrix covering the entire work scope of a
project, broken down into separate ‘work packages’
Only the major critical items are separately identified as work packages
These packages are created and identified according to:
•
Unique technical and commercial attributes of the work activitiesthey comprise
•
Methods by which they are to be executedProcurement Planning
Example of a PPS matrix Components Physical Discipline Special Equipment Item A SpecialEquipment Item B Balance of Plant Civil Works Project
Management
Project Management Services Contractor – Reimbursable Costs with Incentives Fee – $ 70m total
Design Design Contract – Lump Sum – $10m Facilities E & P Contract –
Reimbursable Costs with Fixed Fee – $30m total Procurement Specialist Supplier A – Lump Sum Purchase Order – $200m total Specialist Supplier B – Lump Sum Purchase Order – $100m total Fabrication Construction Contract –
Reimbursable Cost and Equipment Rates with Incentives Fee - $100M total
Materials Control Construction / Erection Services
Installation Contract – Lump Sum – $10m
Quality Inspection Specialist Quality Contract – All-in rates – $10m Part of Project Management Services Commissioning / Start-up Assistance Part of Supplier A Purchase Order Part of Supplier B
Procurement Planning
The structure of the PPS depends on the:
•
Scope of work•
Nature and complexity of the project•
Requirements of the customer The PPS assists in:
•
Administrative and commercial planning•
Cost/schedule control functions of a projectProcurement Planning
Allows a concise, high-level overview of how procurement activities
relate to the execution strategy of the project
Illustrates alternative ways of executing the project procurement
activities
Identifies where:
•
Consolidation (or further break-down) of work scopes can work tothe project’s advantage
•
Gaps may occur in hand-offs during execution A Procurement Strategy is a deliverable that can be provided for
projects in Identify and Evaluate phase
Procurement Planning
When planning occurs
Identify 1 Evaluate 2 Define 3 Execute 4 Operate
Procurement Strategy
Procurement Plan
Materials Management Plan, if required
Purchasing and Contracts Initiation
Materials Management Plan, if required Contracts Plan, if required
Materials Field Administration
Contracts Plan, if required
Procurement Planning
Projects in Identify and Evaluate phases:
•
While you might not be able to fully identify these requirements, youshould be able to identify them in broad scope
Concentrate on Procurement Strategy approach
Projects in Define phase:
•
The procurement needs of the project should be sufficiently identified tosupport the Customer’s overall project schedule
Full fledged procurement plan can be developed
Projects in Execute phase:
•
The procurement needs are clearly identified and a procurement planshall be developed to achieve the timely delivery of the project Full fledged procurement plan must be developed
Procurement Planning
Documents the basis for obtaining and managing materials,
equipment and third-party services required for project execution
Addresses relevant aspects of both materials management and
contracts for the project
Maps out the various anticipated risks and constraints and identified
mitigating actions
Identifies critical supplies (see also Procurement Strategy) and
outlines general strategy
Ensures that the procurement activities align with the overall project
schedule
Procurement Planning
The Project Procurement Plan:
•
Must clearly define the deliverables of the procurement process•
Needs to be ‘fit for its purpose’Procurement Planning
The Project Procurement Plan
may also include details about the targeting of procurement efforts
The Project Procurement
Manager will consider the assessment in the strategy development
Criticality-Value Assessment
Project Procurement Plan
Bottleneck, e.g. special alloy steel grade
Ensure continuity Develop alternatives Revise specifications
Critical, e.g. turbine compressor
Form closer relationships Direct negotiations
Routine, e.g. piping bulk blanket orders
Simplify procurement process
Automate
Rationalise supplier base
Leverage, e.g. customer’s standard agreement Maximise commercial advantage Competitive tender Standardisation Criticality Low Low High Value Potential High
Procurement Planning
Project Procurement Plan
Where the complexity and / or size of the project warrant it, the Project
Procurement Plan may be further developed in separate plans:
•
A detailed Project Materials Management Plan•
Separate detailed Project Contracts Plan for major contractpackages
•
Separate detailed Procurement Plans for key procurementProcurement Planning
The various elements of the Procurement Plan are further defined in the Materials Management Plan, including:
Specific strategies for buying materials and equipment
Associated activities for managing the expediting, traffic/logistics etc
The materials control and reporting systems
Prioritization of procurement activities and associated engineering
deliverables in line with the ROS (Required on Site dates) as defined in the project schedule
Procurement Planning
Level of procurement effort based on cost, schedule, criticality, and
other relevant factors
POs/activities already executed and/or underway prior to
engagement of WorleyParsons
Transition of early purchase agreements from the customer
Material control systems
Quality management, verification and inspection, which includes an
outline of inspection to be undertaken
Site materials management plans
Procurement Planning
Subsets of the Material Management Plan
Engineered equipment planning
Bulk materials planning
Prefabrication planning and modularization
Procurement Planning
The primary objective is to ensure that items are acquired and
released in time to meet the overall project schedule
The dates on which items are required on site to meet construction
needs drive the engineering and procurement planning and activity for engineered equipment
A major equipment list for the project needs to be developed early
Procurement Planning
Planning for bulk materials can be more complex than planning for
engineered equipment
Bulk materials control starts with an examination of the project
schedule to assess:
•
What bulk materials are required over time•
Critical required on site (ROS) datesProcurement Planning
Procurement planning:
•
Is usually very complex for extensive prefabrication•
modularization often involving multiple sites An extensive prefabrication program demands an early procurement
planning effort that addresses the interfaces between vendors, fabricators and site construction
Procurement Planning
The Contracts Plan can be:
•
Subset of the Project Procurement Plan or•
Separate plans—complex projects The main focus of project contracts planning is the selection the best
contractor under the best available terms and conditions
Needs to:
•
Analyze the options and the marketplace for the requiredservices
•
Define the number, type, scope, timing, interfaces, compensationbasis, etc of major contracts to be developed for the project from early planning through start-up
Procurement Planning
For Projects in the Define phase the Project Contracts Plan needs to
document:
•
Critical contracting issues (e.g. labour resource constraints,market constraints) for the major contracts
•
How will the impact be managed and the risk mitigated?•
What is the schedule to meet timely completion of the Project?Procurement Planning
For Projects in the Execute phase, the Project Contracts Plan
review the constraints and identify mitigation measures similar to the Define phase projects but not just for major contracts.
•
All anticipated contracts are identified.•
If the project is a continuation of a Define phase project, theContracts Plan developed for the Define phase will be
reviewed and updated by the Project Procurement Manager to reflect project progress and significant new developments
A list of matters that typically need to be considered are listed on
page 32 of the participants manual Contracts Planning in Execute Phase
Procurement Planning
The customer must approve the Project Procurement Plan as part of
the Project Execution Plan
SmartPlant Materials
WorleyParsons uses a suite of project management systems to
SmartPlant Materials
SmartPlant Materials is used to:
•
Identify•
Record•
TrackSmartPlant Materials
SmartPlant Materials has four integrated modules, which are described on page 36 of the workbook
SmartPlant Materials
Maintains the Material Stock Code catalogue
Generates bulk requisitions via interface to design systems (e.g.
PDS)
Generates equipment and services requisitions
Preparation of RFQs
Supports bid evaluations
Creates and, if required, amends POs
Facilitates expediting
Facilitates Traffic/Logistics
Facilitates stores management
Can undertake invoice reconciliation via Invoice Matching Interface
SmartPlant Materials
SmartPlant Materials imports bills of materials from 2-D/3-D engineering
design software and other sources
SmartPlant Materials supports better material planning on site and material
reconciliation through the ability to track imported bills of materials from Requisition to Material Issue
Materials are identified as being in any of the following phases:
•
Requisition•
RFQ•
Purchasing•
Expediting•
Shipping•
Warehouse receipt•
Storage•
Material IssueSmartPlant Materials
SmartPlant Materials was designed as a system for controlling
materials and equipment, not for administering contracts
SmartPlant Materials can, however, be used to record basic
information about contracts
SmartPlant Materials
Each individual project needs to be set up in SmartPlant Materials so
that its procurement activities can be recorded, monitored and reported
SmartPlant Materials should be set up as soon as the Project
Procurement Plan or Materials Management Plan has been approved
You are responsible for ensuring that SmartPlant Materials is set up
properly
You work with the project Procurement Manager to identify and
obtain the information for the set up
SmartPlant Materials—Training
When you need to start using SmartPlant Materials, you will receive
specific training on how to use it
Contact the Business Systems Group to arrange the training
Procurement Reports
Procurement activities are monitored and reviewed regularly
SmartPlant Materials generates a range of reports which you use to
monitor progress and identify actions to be taken to address issues
Two particularly important reports for the management of
procurement activities are the:
•
Procurement Status Report•
Procurement Expediting ReportProcurement Initiation
The Project Procurement Manager is responsible for completing the activities
that enable purchasing and contracts to be initiated
The initiation activities should be completed during the early stages of the
project
The initiation activities are:
•
Purchasing initiation•
Contracts initiation and formulation Part of the initiation activities is the development of the Project terms and
conditions for purchase orders and contracts.
•
These may be provided by the Customer as we will typically be acting ontheir behalf.
•
The conditions shall be checked for alignment with the Prime contract. Purchasing initiation involves setting up the project base for the Purchasing documentation and databases
The main activities are:
•
Identifying PO provisions (including standard Terms andConditions)
•
Preparing standard documentation, including Instructions toBidders, master Request for Quotation, master purchase order document
•
Carrying out vendor pre-qualification•
Establishing a project vendor listOverview of purchasing initiation (Materials Management)
Contract initiation and formulation involves:
•
Setting up the project base for contracts documentation(including standard Terms and Conditions)
•
Establishing the contracts system for the project The main activities are:
•
Establishing the contract types, sites conditions, HSE etc•
Preparing common enquiry requirements and special contractprovisions
•
Carrying out contractor pre-qualifications•
Establishing the contractor listOverview of Contracts initiation and formulation
Procurement Execution
All procurement execution activities are undertaken by the Project
Procurement Manager and the Procurement team
You are responsible for ensuring that the procurement activities are
executed in accordance with the Project Procurement Plan
You and your Project Procurement Manager need to hold regular
meetings to:
•
Review the status of procurement activities•
Identify issues early and determine the action required tominimize any adverse impact Overview of procurement execution
Procurement Execution
The purpose of the Purchasing Pre-award Process is to award the POs under
which the project’s materials and equipment are obtained
The pre-award process ensures that all bidders are treated fairly and
equitable, that the confidentiality of the information is maintained and that the recommendation to award is in accordance with the agreed evaluation criteria
•
Agreed evaluation criteria may be as simple as ‘Technically acceptable,lowest cost’ or more complex ‘Total Cost of Ownership’ (TCO). Consider that TCO often requires Customer input as well.
•
Competitive bidding is indicated. However, if single source is consideredfor purchase orders, justification must be provided. This may include proprietary technology or customer’s standardisation preference.
Project Purchasing pre-award activities occur predominantly during the
Execution phase
Procurement Execution
Preparing enquiry packages, including special terms and
requirements (for example, supplier data, support, spares)
Issuing the enquiry packages and managing bid preparation and
receipt process
Managing all communications with bidders during bidding and
evaluation
Evaluating the bids
Preparing recommendations for award, conducting post-bid
negotiation and facilitating final issue
Entering all data related to the purchases into SmartPlant Materials
Procurement Execution
Maintains the required level of confidentiality of information
Ensures that engineering deliverables are aligned to support timely
procurement activities
Maintains the interfaces between Engineering, Quality and
Construction
Involves the Project Procurement Manager in the regular team
progress meetings
Undertakes and completes procurement activities in accordance with
the Project Procurement Plan
Materials Management execution—purchasing pre-award process As Project Manager, you will need to ensure that the procurement team:
Procurement Execution
Purchase Order documents are to be prepared by Engineering and
Procurement on receipt of the approved Award Recommendation
Kick-off meetings are arranged as required
Post-award activities are initiated by the project procurement team
Once internal and other approvals have been obtained to place a
contract or a PO the Procurement Manager is the only person with
the authority to confirm the commitment for the contract or PO with
the supplier on behalf of WorleyParsons and/or our customers Materials Management execution—purchasing award process
Procurement Execution
Confirm that the cost of the awarded POs is within the
project budget
Provide relevant information to the project’s Cost Controls
Manager
Materials Management execution—purchasing award process You are responsible for ensuring that the award process is properly undertaken
Procurement Execution
This process covers award of a PO through to receipt at site and
financial close-out
The purpose of the Purchasing Post-award Process is to:
•
Administer the POs to obtain the project’s materials andequipment on schedule and in accordance with specifications
•
Provide cost and schedule information to Project Services•
Identify PO issues for Risk Management activities•
Liaise with Inspection to ensure compliance to specifications The Purchasing Post-award Process covers the technical and
commercial activities in the manufacture and delivery of materials and equipment
Ensure all meetings and vendor contact are coordinated by
Procurement.
Procurement Execution
The main activities in the Purchasing Post-award Process are:
Expediting (including Supplier documentation)
Inspection coordination
Traffic/Logistics
Receiving on site, warehousing and preservation
Change/Claim administration
Invoice payment
Procurement Execution
Effective procurement performance requires:
Use of SmartPlant Materials
Monitoring the vendor’s engineering and manufacturing processes
Meeting documentation obligations
Measuring and assuring conformance to the technical specification
Administering delivery of the materials and equipment
Managing any changes to the PO technical and commercial
provisions
Managing any claims by the vendor for additional payment or
schedule time
Procurement Execution
The Construction Manager involves the Project
Procurement Manager in construction progress review meeting
Materials Management execution—purchasing post-award process As Project Manager you are responsible for ensuring that:
For most items, weekly status meetings are sufficient
For critical items, daily review meetings between the Construction
Procurement Execution
The Materials Field Administration Process governs the day-to-day
procurement activities on site
The actual administration is the responsibility of your Project
Procurement Manager
Materials Field Administration may include site administration,
purchasing and contracting
Materials Management execution—purchasing materials field
administration process
You are responsible for ensuring that the requirements for materials field administration are included in the Project Procurement Plan
Procurement Execution
The purpose of the Contracts Pre-award Process is the contracting of
third-party services
Project Contracts pre-award activities predominantly occur during the
Execution phase
For early contracts, some activities may occur in the Define phase
The deliverables of the Contracts Pre-award Process are:
•
Bidders lists•
Enquiry packages•
Approved recommendations for award•
Contract documents Cost and schedule information provided to Project Services and
contracts issues input into Risk Management activities Contracts execution—contract pre-award process
69
Procurement Execution
Contractor selection
A thorough prequalification process will normally be executed for major
contracts, e.g. fabrication contracts. This will involve multiple disciplines to prepare the questionnaire for the relevant work scope, typically including construction, engineering, quality, HSE as well as project controls and procurement.
Competitive, sealed bids are indicated for major contracts
If single source is considered for service contracts, justification must be
provided. This may include proprietary technology (e.g. software) or customer’s preference.
Once internal and other approvals have been obtained to place a contract or
a PO the Procurement Manager is the only person with the authority to
confirm the commitment for the contract or PO with the supplier on behalf of WorleyParsons and/or our customers
Procurement Execution
The Contracts Post-award Process covers the technical and
commercial activities
The main activities are:
•
Awarding contracts•
Administering and monitoring the contractors•
Managing any changes to the contract•
Managing any claims•
Processing any payments and back charges, reconcilingquantities and finalizing all contract obligations
•
Providing cost and schedule information to Project Services•
Identifying any contracts issues for Risk Management activitiesProcurement Execution
PO and contract variation must be processed in accordance with the
Management of Project Change Process
You and the Procurement Manager must sign-off any variances
before they can take effect
The scenario for the case study is on page 55 of your workbooks
Discussion topics:
What would you say are the key procurement issues on the project?
What can be done to remedy the situation?
Procurement Close-out
The Procurement team completes the procurement close-out tasks
You are responsible for ensuring that the Project Procurement
Manager and the procurement team do this Responsibilities for procurement close-out
Procurement Close-out
Project Materials Management close-out activities generally occur
late in the Execution phase
Close-out must follow the requirements for finalization of supply as
set out in the Project Procurement Plan
The main objectives of materials close-out are:
•
Materials reconciliation•
Surplus management•
Final inspection (this is a Quality activity)•
Receipt Final Vendor Documentation•
Claims resolution•
Closing out of all PDsProcurement Close-out
Close-out must follow the requirements for finalization of supply as
set out in the Project Procurement Plan
The main objectives of contracts close-out are:
•
Provision of acceptance certificates•
Confirmation of warranties•
Handover of documentation•
Final inspections (Quality activity)•
Claims resolution and payment reconciliation Demobilization of the site by WorleyParsons and the contractor does
not necessarily indicate final close-out of the project Contracts close-out
Summary and Feedback
Review learning objectives and outcomes
Summary