دانلود استاندارد CII RR257-11:2012 خرید An Analysis of Global Procurement and Materials Management Practices in the Construction Industry

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خرید استاندارد تجزیه و تحلیل تدارکات جهانی و شیوه های مدیریت مواد در صنعت ساخت و ساز

CII RR257-11:2012
An Analysis of Global Procurement and Materials Management Practices in the Construction Industry
Publication Date : Dec 01, 2012
Pages : 285
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دانلود استاندارد CII RR-257
Materials management is a complex and comprehensive process involving people, organizations, technologies, and processes that manage the definition, sourcing, planning, quantification, supplier qualification, purchasing, supplier QA/QC, expediting, transportation, logistics, and control of materials and associated information across the life cycle of a capital project. Materials and related services account for a large percentage of a capital project’s total installed cost (TIC). Implementation of a materials management program contributes to predictable project outcomes, reduced costs, improved productivity, and quality.
دانلود استاندارد تجزیه و تحلیل تدارکات جهانی و شیوه های مدیریت مواد در صنعت ساخت و ساز
مدیریت مواد فرآیندی پیچیده و جامع است که شامل افراد، سازمانها، فناوریها و فرآیندهایی است که تعریف، منبعیابی، برنامهریزی، کمیسازی، صلاحیت تامینکننده، خرید، QA/QC تامینکننده، تسریع، حملونقل، تدارکات، و کنترل مواد و مرتبط را مدیریت میکنند. اطلاعات در طول چرخه عمر یک پروژه سرمایه ای مواد و خدمات مرتبط درصد زیادی از کل هزینه نصب شده یک پروژه سرمایه ای (TIC) را تشکیل می دهند. اجرای یک برنامه مدیریت مواد به نتایج قابل پیش بینی پروژه، کاهش هزینه ها، بهبود بهره وری و کیفیت کمک می کند.
فهرست مطالب CII Research Report 257-11
An Analysis of Global Procurement
and Materials Management Practices
in the Construction Industry
Carlos H. Caldas
Cindy L. Menches
Laure Navarro
Daniel M. Vargas
The University of Texas at Austin
Pedro M. Reyes
Baylor University
Table of Contents
List of Tables …………………………………………………………………………………………. viii
List of Figures ………………………………………………………………………………………… xiv
Chapter 1 – Introduction ………………………………………………………………………………1
Problem statement ……………………………………………………………………………….1
Motivation and purpose ……………………………………………………………………….1
Research objectives ……………………………………………………………………………..2
Scope …………………………………………………………………………………………………3
Limitations and assumptions…………………………………………………………………4
Organization of report ………………………………………………………………………….4
Chapter 2 – Research methodology ……………………………………………………………….5
Chapter 3 – Background information …………………………………………………………….8
The origins of supply chain management ……………………………………………….8
Supply chain management in the construction industry ………………………….10
Why materials management is important ……………………………………………..14
Materials management in the construction industry today ………………………16
Literature review conclusions ……………………………………………………………..22
Chapter 4 – Phase I survey ………………………………………………………………………….23
Purpose and content …………………………………………………………………………..23
Participants ……………………………………………………………………………………….24
Analysis……………………………………………………………………………………………24
Results ……………………………………………………………………………………………..25
Chapter 5 – Phase II survey ………………………………………………………………………..51
Purpose and content …………………………………………………………………………..51
Participants ……………………………………………………………………………………….52
Analysis……………………………………………………………………………………………53
Results ……………………………………………………………………………………………..53
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Chapter 6 – Case studies …………………………………………………………………………….80
Purpose and content …………………………………………………………………………..80
Participants ……………………………………………………………………………………….80
Analysis……………………………………………………………………………………………81
Results ……………………………………………………………………………………………..81
Chapter 7 – Implementing Global Procurement and Materials Management
Programs ………………………………………………………………………………………….94
Core functions …………………………………………………………………………………..96
Support functions …………………………………………………………………………….119
Chapter 8 – Current and foreseen issues ……………………………………………………..125
Workforce issues: shortage, retirement, and qualification ……………………..128
Project of growing size and complexity………………………………………………131
Strategic supplier relationships ………………………………………………………….134
Global sourcing: identification, risk assessment, and access ………………….137
Materials, manufacturing, and fabrication quality ………………………………..140
Environment and sustainability………………………………………………………….143
Chapter 9 – Conclusions and recommendations …………………………………………..149
Research summary …………………………………………………………………………..149
Conclusions …………………………………………………………………………………….150
Implementation recommendations ……………………………………………………..151
Recommendations for future research ………………………………………………..152
Appendices ……………………………………………………………………………………………..153
Appendix A – RT257 team members ………………………………………………….154
Appendix B – Participating organizations ……………………………………………155
Appendix C – Phase I survey form ……………………………………………………..156
Appendix D – Phase I survey results …………………………………………………..169
Appendix E – Phase II survey form…………………………………………………….192
Appendix F – Phase II survey results ………………………………………………….211
Appendix G – Case study interview guide …………………………………………..235
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Appendix H – Case study summaries ………………………………………………….241
References ………………………………………………………………………………………………280
List of Tables
Table 1 – Comparison of survey results: 1999 vs. 2008 (owners) …………………….26
Table 2 – Comparison of survey results: 1999 vs. 2008 (contractors) ……………….26
Table 3 – Possible names for the Materials Management department ……………….27
Table 4 – Functions embraced by the different departments …………………………….28
Table 5 – Responsibility for subcontracts ……………………………………………………..29
Table 6 – Assigned person dedicated to MM at the home office ………………………30
Table 7 – Assigned person dedicated to MM at the jobsite………………………………30
Table 8 – Centralization vs. decentralization …………………………………………………30
Table 9 – Foreign office for international procurement …………………………………..31
Table 10 – Involvement of the MM group in project front-end planning …………..31
Table 11 – Design need and spares compatibility …………………………………………..32
Table 12 – Preferred strategy to procure long-lead equipment (owners) ……………33
Table 13 – Established procedures for managing bulk materials’ MRP ……………..33
Table 14 – Assessment of the MRP process: estimated vs. actual quantities ……..34
Table 15 – Unique ID numbers for major equipment ……………………………………..34
Table 16 – Schedule requirements for major equipment ………………………………….34
Table 17 – Supplier terms and conditions ……………………………………………………..35
Table 18 – Multiple projects procurement databases ………………………………………35
Table 19 – e-procurement ……………………………………………………………………………35
Table 20 – Reverse auctions ………………………………………………………………………..36
Table 21 – Mature import/export compliance system ……………………………………..36
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Table 22 – Import/export compliance system rating ……………………………………….36
Table 23 – Proactive expediting programs …………………………………………………….37
Table 24 – Liquidated damages for late deliveries ………………………………………….37
Table 25 – Incentives for early deliveries ……………………………………………………..38
Table 26 – Materials Management process audits ………………………………………….38
Table 27 – Design quality reviews ……………………………………………………………….39
Table 28 – Suppliers’ database ……………………………………………………………………39
Table 29 – Formal supplier quality evaluations before selection ………………………39
Table 30 – Inspection plans …………………………………………………………………………40
Table 31 – Agreements with carriers …………………………………………………………….40
Table 32 – Routing guide ……………………………………………………………………………40
Table 33 – Use of tracking systems ………………………………………………………………41
Table 34 – Central warehousing of equipment ……………………………………………….41
Table 35 – Systematic inventories ………………………………………………………………..42
Table 36 – Surplus reducing programs ………………………………………………………….42
Table 37 – Potential surplus report/list ………………………………………………………….42
Table 38 – Use of outsourcing to implement MM functions ……………………………43
Table 39 – Functions outsourced (owners)…………………………………………………….43
Table 40 – Functions outsourced (contractors) ………………………………………………43
Table 41 – Integrated MM computer system ………………………………………………….44
Table 42 – Integrated MM computer system rating ………………………………………..44
Table 43 – Functions covered in the MM computer system …………………………….45
Table 44 – Type of MM computer system …………………………………………………….46
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Table 45 – Quality of communications and data interchange rating ………………….46
Table 46 – Rating of the quality of interfaces between own electronic
MM systems and those of external organizations …………………………………..47
Table 47 – Technologies used in the MM process ………………………………………….47
Table 48 – Use of metrics to assess the MM process ………………………………………48
Table 49 – Tracking of “on-time” delivery ……………………………………………………48
Table 50 – Definition of “on-time” delivery ………………………………………………….49
Table 51 – Counterfeit materials ………………………………………………………………….49
Table 52 – Materials Management as a component of the corporate strategic
plan ………………………………………………………………………………………………….54
Table 53 – Use of alliances as a component of the corporate strategic plan ……….54
Table 54 – Outsourcing of MM functions as a component of the corporate
strategic plan …………………………………………………………………………………….54
Table 55 – Written materials management plan for each capital project ……………55
Table 56 – Materials Management plan as a living document …………………………55
Table 57 – Advanced lock-in of shop manufacturing capacity …………………………56
Table 58 – Modularization ………………………………………………………………………….56
Table 59 – Formal procedures for evaluating suppliers’ financial stability ………..56
Table 60 – Use of supplier’s terms and conditions ………………………………………….57
Table 61 – Evolution of competitive bidding …………………………………………………57
Table 62 – Evolution of split awards …………………………………………………………….57
Table 63 – Development of a subcontracting plan for each capital project ………..58
Table 64 – Implementation of subcontractors’ qualification programs ………………58
Table 65 – Subcontractors’ performance tracking …………………………………………..58
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Table 66 – Scheduling challenges due to competing demand on
subcontractors’ capacity ……………………………………………………………………..59
Table 67 – Reduced pool of qualified subcontractors due to increased
safety standards …………………………………………………………………………………59
Table 68 – Electronic transfer of vendor data ………………………………………………..60
Table 69 – Expediting of second and third-tier suppliers …………………………………60
Table 70 – Third-party providers to perform expediting …………………………………60
Table 71 – Increase in late deliveries ……………………………………………………………61
Table 72 – Evaluation of suppliers’ quality system ………………………………………..61
Table 73 – Metrics to assess suppliers’ performance ……………………………………….61
Table 74 – Suppliers’ requalification …………………………………………………………….62
Table 75 – Third-party providers to perform in-shop supplier surveillance ……….62
Table 76 – Frequency of non-conformances and defects …………………………………62
Table 77 – Transportation and logistics third-party providers ………………………….63
Table 78 – Relying on equipment suppliers for shipping …………………………………63
Table 79 – Advanced agreements to reserve space on vessels ………………………….63
Table 80 – Dedicated trade manager …………………………………………………………….64
Table 81 – Up-to-date procedures for import/export compliance ……………………..64
Table 82 – Influence of post 9/11 requirements on timely delivery …………………..64
Table 83 – Site Materials Management: coordination with procurement teams ….65
Table 84 – Site Materials Management: involvement in project execution
strategies ………………………………………………………………………………………….65
Table 85 – On-site supplier stores ………………………………………………………………..65
Table 86 – Planning for first year operations spares ……………………………………….66
Table 87 – Spare parts assessment process ……………………………………………………66
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Table 88 – Engagement of operations and maintenance in the materials
management plan ………………………………………………………………………………66
Table 89 – IT systems: transfer of engineering requirements into the
MM system ………………………………………………………………………………………67
Table 90 – IT systems: synchronization of project schedule across major
supply chain tiers ………………………………………………………………………………67
Table 91 – Client access to the IT MM system ………………………………………………68
Table 92 – Training to increase the effective utilization of MM IT system ………..68
Table 93 – Impact of workforce issues rating ………………………………………………..69
Table 94 – Potential solutions to workforce issues: training …………………………….69
Table 95 – Potential solutions to workforce issues: mentoring …………………………69
Table 96 – Potential solutions to workforce issues: global work sharing …………..70
Table 97 – Impact of projects of ever-growing size and complexity …………………70
Table 98 – Measures to address project size and complexity: workforce training .70
Table 99 – Measures to address project size and complexity: recruitment of
experienced personnel ………………………………………………………………………..71
Table 100 – Measures to address project size and complexity: extensive risk
assessment ………………………………………………………………………………………..71
Table 101 – Level of concern with strategic supplier relationships …………………..71
Table 102 – Supplier strategic relationships as a component of the corporate
strategic plan …………………………………………………………………………………….72
Table 103 – Specific policies or procedures to have and maintain supplier
relationships ……………………………………………………………………………………..72
Table 104 – Supplier strategic relationships to address speed to market and
lock in shop space ……………………………………………………………………………..72
Table 105 – PEpC model …………………………………………………………………………….73
Table 106 – Long-term partners: requalification …………………………………………….73
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Table 107 – Long term partners: competitive pricing evaluation ……………………..73
Table 108 – Involvement in sourcing from emerging markets …………………………74
Table 109 – Global sourcing: dedicated resources ………………………………………….74
Table 110 – Global sourcing: specific policies and procedures for low-cost
country sourcing………………………………………………………………………………..74
Table 111 – Impact of quality issues …………………………………………………………….75
Table 112 – Tracking quality from global suppliers: internal resources …………….75
Table 113 – Tracking quality from global suppliers: third-party resources ………..76
Table 114 – Tracking quality from global suppliers: involvement with
second and third-tier suppliers …………………………………………………………….76
Table 115 – Concern with issues related to the environment and sustainability ….77
Table 116 – Sustainability objectives as a component of the corporate
strategic plan …………………………………………………………………………………….77
Table 117 – Sustainability practices: dedicated resources ……………………………….77
Table 118 – Sustainability practices: supplier assessment on environmental
practices …………………………………………………………………………………………..78
Table 119 – Sustainability practices: supplier assessment on social impact
practices …………………………………………………………………………………………..78
Table 120 – Sustainability practices: carbon footprint reduction ………………………78
Table 121 – Sustainability practices: fuel consumption reduction …………………….78
Table 122 – Sustainability practices: metrics to measure environmental
performance ……………………………………………………………………………………..79
Table 123 – Current and foreseen issues ……………………………………………………..127
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List of Figures
Figure 1 – Research methodology ………………………………………………………………….5
Figure 2 – Multi-project network supply chain (Vaidyanathan and
O’Brien, 2004) ………………………………………………………………………………….12
Figure 3 – Aging workforce (Rappaport A., Bancroft E., Okum L. (2003))……….20
Figure 4 – Survey I participants …………………………………………………………………..24
Figure 5 – Survey II participants ………………………………………………………………….52
Figure 6 – Case studies participants ……………………………………………………………..81
Figure 8 – Quality Management cycle ………………………………………………………..109
Figure 9 – On a 1 to 5 scale, how is your organization impacted by
workforce issues such as shortage, qualification or retirement? ……………..128
Figure 10 – Our organization has seen an increase in the use of
modularization due to the lack of local resources …………………………………130
Figure 11 – Our organization uses global work sharing in materials
management ……………………………………………………………………………………131
Figure 12 – On a 1 to 5 scale, does your organization face projects of
ever-growing size and complexity? ……………………………………………………132
Figure 13 – Our organization plans for and implements specific procedures
such as workforce training to address the growing complexity and
size of projects ………………………………………………………………………………..133
Figure 14 – Our organization specifically looks for people with experience
to work on mega projects ………………………………………………………………….134
Figure 15 – Our organization implements specific policies or procedures to
have and maintain supplier relationships …………………………………………….135
Figure 16 – In long term supplier relationships we continue to evaluate
competitive pricing ………………………………………………………………………….136
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Figure 17 – Our organization is familiar with PEpC (Procurement –
Engineering – procurement – Construction) and implements it ……………..137
Figure 18 – On a 1 to 5 scale, how involved is your organization with
sourcing from emerging markets? ……………………………………………………..138
Figure 19 – Our organization implements specific policies or procedures for
low cost country sourcing …………………………………………………………………139
Figure 20 – Our organization has well established procedures to address the
logistical challenges with global supply ……………………………………………..140
Figure 21 – On a 1 to 5 scale, how is your organization impacted by issues
with the quality of materials, manufacturing and fabrication? ……………….141
Figure 22 – Our organization has 3rd party resources tracking the quality
of materials, as well as the manufacturing and fabrication quality
from global suppliers ……………………………………………………………………….142
Figure 23 – Our organization ensures that second and third tier suppliers
meet the quality standards …………………………………………………………………142
Figure 24 – Our organization has dedicated internal resources tracking the
quality of materials, manufacturing and fabrication quality from
global suppliers ……………………………………………………………………………….143
Figure 25 – On a 1 to 5 scale, how concerned is your organization with
issues related to environment and sustainability? …………………………………144
Figure 26 – Sustainability objectives are part of our organization’s
strategic plan …………………………………………………………………………………..145
Figure 27 – My organization has dedicated resources to plan for and
implement sustainability policies ……………………………………………………….146
Figure 28 – Our organization assesses suppliers on their environmental
practices …………………………………………………………………………………………147
Figure 29 – Our organization looks into reduced travel cost or reduced
usage of oil for fuel and manufactured goods ………………………………………147
Figure 30 – Our organization implements metrics to measure its
environmental performance (e.g.: balanced scorecard: a set of metrics
that not only focuses on financial outcome, but also on social and
environmental factors) ……………………………………………………………………..148