Commissioning and Operations

Aakash MehrotraAchal Gupta

Imran Ali

Purpose of the Commissioning Plan

• Provide direction for the commissioning process during construction

• Providing resolution for issues such as– scheduling – roles and responsibilities – lines of communication and reporting– Approvals– coordination

Commissioning Goals

• The three main goals of the commissioning process are: – Facilitate the final acceptance of the

project at the earliest possible date. – Facilitate the transfer of the project to

the owner’s maintenance staff. – Ensure that the comfort systems meet

the requirements of the occupants.

Commissioning Objectives

• Equipment is installed and started per manufacturer’s recommendations.

• System performance with thorough functional performance testing and monitoring.

• Verify the completeness of operations and maintenance materials.

Commissioning Process

1. Commissioning Scoping Meeting •The scoping meeting brings together all members of the design, construction, and operations team

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2. Final Commissioning Plan •The commissioning agent finalizes the draft Commissioning Plan using the information gathered from the scoping meeting.•The timeline is fine-tuned as construction progresses.

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3. Design Intent Documentation •The Design Intent Summary reflects the underlying assumptions and requirements that become represented in the construction documents.

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4. Submittals •The subcontractors, general contractor or A/E notify the commissioning agent of any new design intent or operating parameter changes, added control strategies and sequences of operation, or other change orders that may affect commissioned systems.

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5. Site Observation •The commissioning agent makes periodic site visits to witness equipment and system installations.

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6. Pre-functional Checklists and Startup Procedures •A Pre-Functional Inspection Checklist are developed and completed for all mechanical equipment being commissioned. •The checklists ensure that the systems are complete and operational and document the installation of components and completion of systems.

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7. Development of Functional Test and Verification Procedures •The systems are run through all of the sequences of operation and the response of components is verified. •Testing proceeds from components to subsystems to systems, and finally to interlocks and connections between systems.

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8. Execution of Functional Testing Procedures •The commissioning agent schedules functional tests through the general contractor and subcontractors. •Under the supervision of the commissioning agent, the installing subcontractor performs the hardware and/or software manipulations required for the testing. •Any deficiencies found from functional performance testing will be documented in a Deficiency Report.

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9. Short-Term Diagnostic Monitoring •record system operation over a two to three week period, may be used to investigate the dynamic interactions between components in the building system.

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10. Operations and Maintenance Manuals •The operation and maintenance manuals prepared by the contractors for the owner’s maintenance personnel are reviewed for completeness. •A database of preventative maintenance information may also be created from the materials in the O&M manuals.

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11. Training and Orientation of Owner Personnel and Occupants •Effective maintenance personnel training is critical to the long term performance of the new building. •The commissioning agent may witness any of the training sessions.

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12. Warranty Period •During the warranty period, seasonal testing and other deferred testing is completed as required to fully test all sequences of operation.

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13. Commissioning Report •A final Commissioning Report will be compiled which summarizes all of the tasks, findings, and documentation of the commissioning process.

OPERATION OPERATION MANAGEMENTMANAGEMENT

Operation ManagementOperation Management

1.1. The Transformation ProcessThe Transformation Process

2.2. Productivity IndexProductivity Index

3.3. Process PlanningProcess Planning

4.4. Material Requirement PlanningMaterial Requirement Planning

5.5. Layout PlanLayout Plan

6.6. Selection of LocationSelection of Location

7.7. Calculation of Operational CostsCalculation of Operational Costs

1. The Transformation 1. The Transformation ProcessProcess

INPUTINPUT______ ______ • LABOURLABOUR• RAW MATERIALSRAW MATERIALS• MACHINES & MACHINES & EQUIPMENTSEQUIPMENTS• TECHNOLOGY & TECHNOLOGY & METHODSMETHODS• CAPITALCAPITAL

TRANSFORMATIONTRANSFORMATIONPROCESSPROCESS

OUTPUTOUTPUT______

SERVICESSERVICES

OROR

PRODUCTSPRODUCTS

External Environment ForcesExternal Environment Forces

2. Productivity Index2. Productivity Index

The productivity index (P.I) can be more or The productivity index (P.I) can be more or less than 1. less than 1. P.I > 1 = business running P.I > 1 = business running efficientlyefficiently

P.I < 1 = business running P.I < 1 = business running inefficientlyinefficiently

InputofValueTotal

OutputofValueTotalIndextyProductivi

3. Process Planning3. Process Planning

SymbolSymbol Type of Type of ActivitiesActivities

DescriptionDescription

OperationOperation Activities that modify, transform or Activities that modify, transform or give values to the outputgive values to the output

TransportatiTransportationon

When materials are transported from When materials are transported from one point to another.one point to another.

InspectionInspection Measures standard of the in-process Measures standard of the in-process material, finished product or servicesmaterial, finished product or services

DelayDelay When in-process material is restrained When in-process material is restrained in a location waiting for next activityin a location waiting for next activity

StorageStorage When in-process materials or finished When in-process materials or finished products are stored in the storage products are stored in the storage area.area.

4. Material Requirement 4. Material Requirement PlanningPlanning

Step I :Step I : Identify and list down the Identify and list down the raw raw materials required materials required

Step II :Step II : Prepare the bill of Prepare the bill of materialsmaterials

Step III: Step III: Calculate the quantity of Calculate the quantity of raw raw material required material required

Step IV:Step IV: Identify supplierIdentify supplier

Capacity PlanningCapacity Planning

• The capacity of any production The capacity of any production operation refers to the amount operation refers to the amount of output that can be produced of output that can be produced within a specified time.within a specified time.

• It is a method to calculate It is a method to calculate machinery and manpower machinery and manpower requirements so that production requirements so that production demand based on sales forecast demand based on sales forecast can be met.can be met.

Purchasing of Purchasing of ‘tudung’ materials‘tudung’ materials

Storage of ‘tudung’ Storage of ‘tudung’ materialsmaterials

Cutting of raw materials to Cutting of raw materials to size. i.e large, medium and size. i.e large, medium and smallsmall

Quality inspectionQuality inspection

Transport the materials Transport the materials that have been cut to that have been cut to tailor’s tabletailor’s table

Sewing by Sewing by tailorstailors IroningIroning PackagingPackaging Storage before Storage before

shipping outshipping out

5. Layout5. Layout

• Layout refers to the arrangement of Layout refers to the arrangement of machinery, equipment, workers and machinery, equipment, workers and other facilities used in the operation.other facilities used in the operation.

• The arrangement should be made in The arrangement should be made in such a way that the production of such a way that the production of goods and services can be done goods and services can be done efficiently.efficiently.

• It should take into consideration the It should take into consideration the integration of several factors integration of several factors including work station, tool room, including work station, tool room, store, office, prayer room and toilet.store, office, prayer room and toilet.

Types of layoutTypes of layout

Layout based on productLayout based on product– The design is done according to the The design is done according to the

sequence of activity to produce the sequence of activity to produce the product.product.

Layout based on processLayout based on process– The design is based on the The design is based on the

production process. production process. – It is suitable for a factory producing It is suitable for a factory producing

several products that undergo a several products that undergo a similar process.similar process.

Layout based on marketingLayout based on marketing– The layout is designed to utilise the The layout is designed to utilise the

available space to display goods.available space to display goods.– Example: retailed shop and bookshop.Example: retailed shop and bookshop.

• Arrangement of goods are interactiveArrangement of goods are interactive• Goods are easily accessible and Goods are easily accessible and

convenient for the customersconvenient for the customers• It is easy for the entrepreneur to protect It is easy for the entrepreneur to protect

goods from theftgoods from theft• The entrepreneur can maximize the return The entrepreneur can maximize the return

of investment form the space used.of investment form the space used.

6. Physical Location6. Physical Location

• It is crucial to choose the right It is crucial to choose the right location for the business because a location for the business because a strategic location can contribute to strategic location can contribute to the success of the business.the success of the business.

• The choice of location will depend on The choice of location will depend on the following factors:the following factors:– Distance from the source of raw Distance from the source of raw

materialsmaterials– Availability of manpowerAvailability of manpower

– Transportation facilitiesTransportation facilities• LPTLPT

– Distance from customerDistance from customer– Price of premisesPrice of premises– Other factorsOther factors

• Utilities, banks, schools and housing, Utilities, banks, schools and housing, government policies and safety of government policies and safety of surrounding.surrounding.

7. Operations Costs7. Operations Costs

• It is essential to determine the total It is essential to determine the total operational cost in order to calculate operational cost in order to calculate the cost per unit of the goods the cost per unit of the goods produced.produced.

• Operations costs include costs of Operations costs include costs of direct material, direct labour and direct material, direct labour and overheadsoverheads

• Direct materials costsDirect materials costs– Money spend on materials that are directly Money spend on materials that are directly

used to produce the products or services.used to produce the products or services.

• Direct labour costsDirect labour costs– The money paid as wages, salaries and The money paid as wages, salaries and

benefits to the workers involved directly in the benefits to the workers involved directly in the production of the products and services.production of the products and services.

• Overhead costsOverhead costs– Include rents, insurance, wages of indirect Include rents, insurance, wages of indirect

labour, maintenance and depreciation.labour, maintenance and depreciation.

(Units)OutputofNumberTotal

(RM)CostOperationsTotalUnitperCost

OverheadlabourDirectmaterialDirectCostsOperations

35

Enterprise Risk Framework

Strategic Risk

Credit Risk Market Risk

Operational Risk

Liquidity RiskInvestment Risk

Regulatory Risk

Reputational Risk

Project Risk