Method Statement for Handling, Storage, Packaging, Preservation and Delivery1
Short Description
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Description
Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 1 of 14
25-07-2016
METHOD STATEMENT
MATERIAL HANDLING AND STORAGE Client: Contractor:
DG Khan Cement Zealcon Engineering (Pvt.) Ltd
Rev. Description No 00
MS for Material Handling And Storage
QHSE
Farhan
A. Hafeez
Ahmad
Khan
Sohail Rabbani
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Zealcon Engineering (Pvt.) Ltd
Zealcon-DGK-9000 TPD-MS-004
Method Statement for Material Handling And Storage
Issue # 001
Issue Date
Page 2 of 14
25-07-2016
1. PURPOSE This MATERIAL HANDLING AND STORAGE PROCEDURE is intended to define the requirements, storing, care and custody etc., from receipt through to issue of the MATERIALS supplied by the VENDOR to the CONTRACTOR and to set forth the respective CONTRACTOR's responsibilities and obligations in this respect. 2. SCOPE OF APPLICATION This Method Statement is to apply to all aspects of MATERIALS handling and Control carried out by the respective Contractor. 3. DEFINITIONS & KEY PERSONNEL 3.1 Definitions In this Method Statement, the following words and expressions are used, and they have the respective meanings hereby assigned to them, except where the context otherwise requires, COMPANY:
DG Khan Cement
CONTRACTOR:
ZEAL Construction Engineering
SITE:
The place or places so designated by the Company for
the construction of the PLANT including such places adjacent there
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 3 of 14
25-07-2016
to which are for storage and assembly of equipment and materials. WAREHOUSE OPEN STORAGE AREA REQUISITION
Any Indoor Storage Facilities. Any Outdoor Storage Facilities. A written request for MATERIALS, to be prepared
by the Contractor. VENDOR
Any party whose services are obtained by the
Company or Contractor for supply and construction. 3.2 Key Personnel The following key personnel of the Contractor’s may be assigned in respect of MATERIALS Handling and Storing 3.2.1 Incharge Warehouse A person employed and assigned who shall be responsible to the overall control of MATERIALS, which includes receiving, storing, issuing, stock taking and disposal of MATERIALS and also includes forecasting of MATERIALS availability and arranging of replacement for shortage, damaged or shortfall MATERIALS. 3.2.2 Store Officer A person employed and assigned, who shall be reporting to the Incharge Warehouse, for the receiving, storing, issuing and stock taking of MATERIALS at the Warehouse And Open Storage Area. 3.2.3 Store Keeper
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Zealcon Engineering (Pvt.) Ltd
Zealcon-DGK-9000 TPD-MS-004
Method Statement for Material Handling And Storage
Issue # 001
Issue Date
Page 4 of 14
25-07-2016
Persons employed and assigned, who shall be responsible to the Store Officer, For The Receiving, Storing and issuing of materials at the Warehouse and Open Storage Area. 3.2.4 Material Coordinator A person employed and assigned, who shall be responsible to the Head of Construction Co-ordination Department of the Contractor’s for the supervision and co-ordination of the construction work assigned to him, carried out by the Contractor. 4. OUTLINES OF MATERIAL HANDLING AND STORING
MATERIALS handling and storing commences with receipt of the MATERIALS at the SITE, and includes the unloading of the MATERIALS into the WAREHOUSE or OPEN STORAGE AREA, and the issue of the MATERIALS which is in the control of the Contractor.
The final operation shall be the disposal of all surplus or residual MATERIALS upon completion of the construction work by Contractor.
The duties and scope of the persons of Contractor involved in MATERIALS Handling
and
Storing
activities
are
listed
as
follows,
including
mobilization of all labour, equipment, tools and materials required. 1. Planning and preparatory works 2. Receiving and unloading of MATERIALS 3. Unpacking and inspection, which includes: a. Issuing of Excess, Shortage or Damage Reports, b. Issuing of Request for Urgent Procurement, if any, 4. Storing MATERIALS by Contractor’s shall include
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 5 of 14
25-07-2016
a. Securing the land area provided by Company for MATERIALS storage. b. Provision of suitable, weather-tight warehouse facilities, and where required within the area allocated to the respective by the Contractor’s. c. Optimizing the use of available space within the STORAGE FACILITIES and providing all racks, pallets, sleepers, natural drainage etc., necessary for the appropriate storage of MATERIALS in advance of their receipt. d. Storing all MATERIALS in accordance with the requirements, e. Ensuring that all MATERIALS stored in the OPEN STORAGE AREA are adequately protected, i.e., by tarpaulins or the like, to prevent deterioration, f. Maintaining a high degree of housekeeping within the STORAGE g. FACILITIES h. Ensuring that all hazardous MATERIALS shall be stored and handled with the utmost care and in accordance with the laws and regulations applicable thereto. 5. Requisition and issuing, which includes: a. Producing and submitting REQUISITIONS to the DISCIPLINE COORDINATOR for his approval b. Approval of issue of MATERIALS to the construction Engineer. c. Control and co-ordination of issue of MATERIALS. 6. Stocktaking 7. Return and disposal
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 6 of 14
25-07-2016
5. MATERIAL HANDLING ACTIVITIES 5.1 Planning and Preparatory Works Prior to receiving of MATERIALS at the SITE, the following planning and preparatory works shall be carried out by the Contractor. 1. Receiving the following reference documents for planning a. Overall Shipping Schedule, b. Over Dimension Cargo List and drawings thereof, c. Storage Area General Drawing d. MATERIAL Handling Procedure 2. Receiving the Detail Packing Lists 3. Planning for required manpower and construction equipment for unloading. 4. Planning of unloading place and designation of storing areas 5. Filling the Package No., Item No., etc. in the Cargo Receiving Report accordance with the received Detail Packing Lists 5.2 Material Receiving And Unloading 5.2.1 Receiving of Materials The MATERIALS received at the Site shall be delivered to one of the following areas as designated by the Store Officer 1. At The Warehouse 2. At The Open Storage Area 3. At
any given place in the Site (Direct Delivery Materials)
Upon receipt, all MATERIALS shall be recorded on a Cargo Receiving Report describing the MATERIALS, the requisition under which they are delivered, their storage location, etc. 5.2.2 Unloading of materials
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 7 of 14
25-07-2016
Delivery schedules for all types of MATERIALS shall be reviewed by Site Warehouse Incharge as and when required and updated by the Store Officer in order to allow the pre-arrangement of manpower and suitable equipment to assist with unloading. The schedules shall be reviewed by the Site Manager or Project Manager at any time.
Utmost care shall be taken by Warehouse Incharge in the unloading to ensure that no damage occurs to MATERIALS.
Prior to any unloading, packing cases or crates Store Officer shall inspect for signs of damage during transportation, and where evident, this shall be recorded on the Cargo Receiving Record, and as necessary, photographs of the damage shall be taken for possible use in the event of a later claim.
On unloading, Cargo Weigh Bill, which shall be issued by Transportation Company, shall be received, checked and filed as record by the Store Officer.
5.3 Unpacking And Inspection 5.3.1 Unpacking Inspection Schedule
Unpacking Inspection schedule for respective packages shall be prepared by the Store Officer and submitted to the Warehouse Incharge for his review.
Packed MATERIALS procured overseas shall not be opened without the appropriate customs clearance, which, at the discretion of the customs officials, may be carried out at the SITE.
5.3.2 Non-scheduled Unpacking Inspection
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Zealcon Engineering (Pvt.) Ltd
Zealcon-DGK-9000 TPD-MS-004
Method Statement for Material Handling And Storage
Issue # 001
Issue Date
Page 8 of 14
25-07-2016
In case any damage to the packing is found, Unpacking Inspection shall be carried out by Store Officer and put to the notice Warehouse Incharge officials for further actions. 5.3.3 Preparation of Unpacking Inspection The Store Officer shall make the necessary preparations prior to Unpacking Inspection and which are:
Establishing the inspection procedure according to the kind of packing
Provision of, as necessary, the area for the Unpacking Inspection making available all necessary manpower, equipment, tools, MATERIALS, etc., for unpacking and re-packing the MATERIALS
Designation of the place for storing of the MATERIALS after Unpacking Inspection.
5.3.4 Unpacking Inspection
All Unpacking Inspection shall be carried out by the store officer or
Store keeper..
If any damage to packing is found prior to Unpacking Inspection, the Store Officer Or Store keepers shall notify it to the Incharge Warehouse and seek for his instruction.
All Unpacking inspection shall be carried out with the utmost care, to ensure that no damage occurs to the MATERIALS.
Unpacking Inspection shall be carried out for the following checks. 1. Visual appearance inspection for a. Damage to, and/or deformation of the MATERIALS b. Rust or stains,
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 9 of 14
25-07-2016
c. Damage to, paint, coatings or linings, and/or blistering thereof due to underlying rust. 2. Verification of Tag Nos., Valve Nos., ID Stamps, ID Markings. Etc. 3. Quantity verification. a.
Damaged MATERIALS shall be stored separately by Store Officer
b.
The Store Officer shall prepare Unpacking Inspection Report and submit it to the Incharge Warehouse for recording.
5.3.5 MATERIAL Excess, Shortage or Damage (ESD)
Where excess, shortage, or damage of the MATERIALS shall be discovered, the Storekeepers shall prepare the Excess, Shortage or Damage Report, and present it to the Store Officer with the relevant Unpacking Inspection Report.
The Store Officer shall submit both reports to the Warehouse Incharage for review and confirmation.
The Warehouse Incharge shall arrange for distribution of copies of the ESD to the Site Manager/ Project Manager and the appropriate departments of Site Office and, as necessary, shall request a subsequent inspection by the Quality Control Department to determine whether repairs are possible and what methods are to be adopted.
The Warehouse Incharge shall take any necessary steps for the replacement of irreparable MATERIALS, or to make up any deficiency in quantities, through one of the following actions: 1. Checking whether the available spare quantities can cover the damage or shortage quantities, 2. Requesting local procurement and necessary approval by Site Manager/ Project Manager.
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 10 of 14
25-07-2016
3. Preparing Request for Urgent Procurement.(RUP)
The Excess Shortage or Damage Report shall be prepared by Store Officer for any excess, shortage and/or damage of MATERIALS, and issued to the Site Manager/ Project Manager for their claim action to VENDORs.
Request for Urgent Procurement (RUP) shall be prepared only when resending of replacement is required and issued to the Company (If purchased by Company). (Where the damage or shortage can be covered by the available spares, RUP is not required.). One (1) copy of the relevant ESD shall be attached to.
5.3.6 Insurance Claim Insurance claims for items of MATERIALS damaged, stolen shall be processed, on behalf of the Company, by the Head of the Administration Department, with all assistance provided by Warehouse Incharge and the Store Officer in respect of reports, photographs, etc.
6. STORING 6.1 General The Store Officer shall instruct his Storekeepers, the following
Correct storage of materials at the prescribed location.
Storing of MATERIALS by item, class, size, etc.
Maintenance of up-to-date records of quantities of the MATERIALS held in the STORAGE FACILITIES.
Correct identification and marking of the various storage areas.
6.2 in Open Storage Area
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 11 of 14
25-07-2016
All MATERIALS stored in the OPEN STORAGE AREA shall be landed on pallets or sleepers, and shall be tagged or marked for easy identification by the Store Keeper. 6.3 Storing in Warehouse
All MATERIALS stored in the Warehouse shall be landed on pallets, on shelves, on racks, or in bins, and shall be tagged or marked for easy identification by the Store Keeper under the direction by Store Officer.
Pallets, racks, shelves, and bins must be designed to carry the materials envisaged, in respect of size, weight and quantity.
6.4 Care and Protection of MATERIALS
Responsibility for the care and protection for stored materials lies with the Storekeeper, under the direction of the Store Officer, until the MATERIALS are issued to the respective Construction Engineer, and after which, lies with the Construction Engineer until the Completion of Work.
The periodical care and protection for the MATERIALS is to be carried out, taking into consideration of the manufacturer's or Vendor's recommendations.
6.5 Material Requisition And Issuing 6.5.1 Issuing of MATERIALS
MATERIALS shall be issued in accordance with the following conditions and procedures to the Construction Engineer, 1. Free at the stored area in the WAREHOUSE, usually in an unpacked condition, or
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 12 of 14
25-07-2016
2. Free on the ground in the OPEN STORAGE AREA, in a re-packed condition, or in an unpacked condition as bulk material, or 3.
Free on the inland transportation carrier in the PLANT area, usually in a packed condition as imported (Direct Delivery Materials)
MATERIALS shall only be issued from the Storage Facilities i.e. warehouse and/or open storage area against Requisitions submitted by the Construction Manager. The responsibility for the transportation of MATERIALS from the Storage Facilities to the PLANT location or the Construction storage facilities lies with the Construction Manager.
Issue of the MATERIALS is deemed complete when the Construction Manager signs the copy of the REQUISITION acknowledging receipt.
The Storekeepers must enter daily, on the Stock Book and/or Bin Card, the type and quantity of MATERIALS issued.
When the Construction Engineer has prepared the requisition, he must receive approval from the Construction Manager for the construction work on which the MATERIALS are to be used, and then from the Warehouse Incharge.
REQUISITIONS consist of 04 sheets and both the Storekeepers and the Construction Engineer shall sign at time of issue of the MATERIALS. as proof of receipt.
REQUISITION copies are, subsequent to issue of MATERIALS, to be distributed, as follows: a. NO.1 – Warehouse Incharge b. NO.2 - Store Officer/Storekeepers c. NO.3 - Material Coordinator d. NO.4 - Construction Engineer
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 13 of 14
25-07-2016
6.6 Stock Taking
The storekeepers will carry out monthly stocktaking of all MATERIALS being in the storage facilities, both within the Warehouse and Open Storage Area.
The purpose of the exercise is to compare actual quantities of MATERIALS held in stock with the quantities indicated on the Stock Book, Bin Cards and/or Materials Issued Control Report.
The results of the exercise, i.e., surplus or shortfall of MATERIALS shall be recorded by the Store Officer on Stock Book, and reported to the Warehouse Incharge.
Additional stocktaking may be requested by the Warehouse Incharge from time to time and the results will be recorded and reported in the same manner as the regular stocktaking.
6.7 Return Of Issued Materials
Returning of issued MATERIALS may be required, due to mistake in issuing, over-issuing, cancellation of planned works, etc.
In such cases, the form of Requisition shall also be used for returning of MATERIALS having been once issued to the Store Keepers
. Where previously issued MATERIALS are to be returned to the storage facilities, the construction engineer
shall submit the
Requisition by describing the returned items, with a red stamp saying "RETURN"
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Zealcon Engineering (Pvt.) Ltd Method Statement for Material Handling And Storage
Zealcon-DGK-9000 TPD-MS-004 Issue # 001
Issue Date
Page 14 of 14
25-07-2016
The Storekeepers shall confirm that, the returned MATERIALS are not defective, and shall sign the "RETURN" on Requisition, of which copies are retained by the Construction Engineer, as proof of return.
When any MATERIALS are returned, the Store Officer shall record the quantities on "Issued Quantities" of Stock Book as minus(-) values.
6.8 Disposal Of Surplus Or Residual Materials
The Construction Engineer shall return all surplus or residual materials, scrap Materials and packing materials, to the Storage Facilities, at a place designated by the Store Officer.
On completion of the construction work, the Storekeepers shall carry out the final stocktaking in the Storage Facilities.
A list of surplus and residual MATERIALS will be produced and submitted by the Store Officer to the Incharge Warehouse, along with a request for instructions for their disposal.
The disposal of surplus and residual MATERIALS, scrap MATERIALS and packing MATERIALS shall only be carried out on receipt of a written instruction by the PM/SM.
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