BITS Pilani

BUSINESS PROCESS ANALYSIS (MBA

ZG525)
ASSIGNMENT – II
CASE STUDY (PROCESS DISCOVERY)
DEVELOPMENT OF QUALITY MANAGEMENT DASHBOARD IN A MEGA
PROJECT

Prepared by: Submitted to:

Puneet Kumar – 2021HB58534 Prof. Sunil Soni
Submission Date: 07-May-2023 Visiting Faculty (BITS
Pilani)

Acknowledgment
In this case study, I received a great motivation and guidance from some respected
persons, who deserve my greatest gratitude. The completion of this assignment gives me
much pleasure. Firstly, I would like to show my gratitude to Mr. Biplab Kumar
Mukherjee (Joint General Manager & Head – L&T Saudi Heavy Wall Pressure Vessel
Facility), for giving me a good opportunity and guided me throughout project lifecycle.
Secondly, I would like to appreciate the immense patience shown by my colleague, Mr.
Sangeeth NV (Manager - Technical Services, L&T MFY- Oman), while I was working on
this. In addition, I would like to thank him for supporting me wholeheartedly and
providing me with everything I asked for.
I would also like to expand my deepest gratitude to all those who have directly and
indirectly guided me in writing this case study. Many people, especially my colleagues
have made valuable comments, suggestions on this case study that gave me the
inspiration to improve my case study.

Abstract
This case study has been prepared with the intent to capture the need, implementation and
results of Quality Management Dashboard in a Mega Project that involved Engineering,
Procurement, Fabrication, Installation and commissioning of Various Offshore Mega
Structures which included Jackets, Topsides, Pipelines, etc. for a prestigious Customer
(Saudi Aramco) in Oil and Gas Industry.
The project involved numerous stakeholders across the globe and valued more than 1.6
billion USD. This was the first project being executed for the new client that had very
stringent Quality requirements. To successfully execute the project, it was imperative that
the Quality requirements are understood by all relevant stakeholders and implemented
timely while communicating the client representatives.
To successfully map the quality requirements, a Quality Management Dashboard was
developed and implemented which considered various project requirements and focused
on the readiness of different activities involved in the project.
The intent behind developing Quality dashboard was to:
 Plug the existing gaps in quality system,
Increase operational efficiency and
Institute proactive approach in all quality functions
This helped in implementing a System Approach for Project Quality Assurance and
generating an alert before activity start, to ensure full readiness.

Literature Review
The development of Quality Management Dashboard was a new development, which had
a much-focused approach towards readiness of Quality Aspects of various key activities
in-line with Client requirements. Such formal readiness tool was never developed in the
organization, which automatically quantifies the readiness score of upcoming activities.
For developing the dashboard, various documents and plans were referred such as
Client’s Contract documents, planning schedules and project progress reports.

Introduction
L&T’s Sohar facility comprises a Modular Fabrication Yard LLC and a manufacturing
complex for Heavy Engineering. The facility possesses the capability to fabricate and
load out a range of complex structures for Oil & Gas industry like large offshore Process
Platforms, Jack up drill Rigs, SPAR/TLP & Modular Process Plants.
With an annual fabrication capacity of 60,000 MT, it caters primarily to projects in the
Middle East and North Africa region. Located in Sohar Industrial Port Area, L&T-
Modular Fabrication Yard is an all-weather yard. It is the first of its kind in Oman, and
has significantly augmented Oman’s industrial capability since 2007 with its state-of-the-
art facilities for heavy fabrication, sophisticated equipment for testing and load-out of
ultra-large structures. The yard was adjudged as the “Best offshore Construction Yard” in
GCC region at the Marine International Maritime Awards ceremony in 2011.
L&T MFY was executing Saudi Aramco’s Project for the first time. It was very difficult
to understand and maintain a high level of Compliance for Schedule Q requirements at
Yard. Saudi Aramco works of the ZERO Tolerance Policy in case of Quality
Requirements. In order to meet Saudi Aramco’s requirements a Proactive Quality
Assurance System was very important to avoid Customer Compliant / Client NCRs that
would have a major impact on Project Progress and Project PQI score. There were
number of requirements defined in different specifications, which required a detailed
study and alignment of Yard QA system to meet all the requirements.

Case Study
Being new to Saudi Aramco requirements, it was very important to understand the key
requirements. With a deep dive into project specifications, it looked like an iceberg,
which got more stringent as we looked in depth. Below are various client requirements,
which needed full understanding and control mechanism:
• Quality System Requirements & Project Quality Documents
• Quality personnel Competence requirements, Roles and Responsibilities
• Staffing Requirements of Quality Personnel
• Document Control System
• Reporting relationships & Internal and External lines of communication
• Weekly, Bi-Weekly & Monthly Quality Status Reporting
• Product & Personnel Identification and Traceability
• Monitoring and Measurement of processes Performance
• Control of IMTE
• Audits & Assessments
• Control of Non-conformances
• Analysis of Data and Continual Improvements, etc.
Considering above pool of above requirements, a need was envisaged to understand and
fulfil client requirements by:
• Developing & Testing Quality Management Dash Board (QMDB)
 • Reviewing Contract requirements with Client
• Identifying Gaps In terms of Quality deliverables & submittal within the time line
• Providing Quality Submittals in time with compliance
• Other than human support, need for Quality Tool/ Software
Understanding above, various thoughts were integrated in development of Quality
Management dashboard such as:
• Step 1: Meet the Planning Package Date & agreed KOM
• Step 2: Degree of Readiness V/s No of days left for start of Activity
• Step 3: Provide Alerts & Advance information for Quality activity Planning
• Step 4: Quality Tools / Software work on Alert Logic
To prepare the Quality Management Dashboard, All the Major processes were mapped
into system including various requirements for smooth startup of Key activities like:
• Procedures
• ITPs (Inspection & Test Plans)
• WPS (Welding Procedure Specification)
• Quality Personnel & Skilled workmen
Further, the planned activity startup dates were mentioned against each activity.
Completion of Individual activity contributes towards increment in readiness score. An
alert system was made for the readiness score of each activity with respect to the days left
for activity startup. An alert logic was developed in the Dashboard with following
considerations:
Days Left for the Activity = Activity Date as per Planning Package vs Todays Date
• >100 days - Green
• 100 to 60 days - Blue
• 60 to 30 days - Yellow
• < 30 days - Red
In addition, different weightages were given for different inputs based on criticality
which is shown as below:

Combining all above steps, below is a glimpse of the readiness planning, which provided
different alerts:
 PlannedStartDateof
Sr.No. CriticalActivities
Activity
DaysLeftforActivityStartup|Overall%ageProgress Priority Remarks/Concern

ActivityStarted
ActivityStarted
ActivityStarted
ActivityStarted
ActivityStarted
41
ActivityStarted
ActivityStarted
ActivityStarted
ActivityReadytoStart
ActivityStarted
ActivityReadytoStart
76

ActivityReadytoStart
ActivityReadytoStart
93
122
32

32
62
61
183
267
267
366

Quality Management Dashboard was also embedded with following Quality deliverables
in order to have all the key information and actionable items at once place:
• Activity Readiness & Quality Planning
• ITPs, Procedures , WPS approval status
• Manpower mobilization plan vs actuals vs variance
• Receipt Materials Status
• Repair % (Joint & Length wise), JCC Status & NDT Backlog
• LBE / NCR Status
• Proactive Initiatives
• Status of Deliverables as per Schedule Q
Below is the glimpse of actual dashboard which was submitted to Client on weekly basis:
 Conclusion
To enable proper understanding and adequate implementation of Saudi Aramco
requirements towards Quality as a Project Enabler, Schedule “Q” (Quality Requirements)
had its roots in Quality Planning. A robust plan and monitoring the same ensured
adequate readiness in all aspects.
“Quality Management Dashboard” was developed to meet Company Expectations and
Deliver the Project with required Quality within agreed Schedule.
The dashboard was successfully implemented throughout the project and led to
prevention of various quality issues. Saudi Aramco as well as L&T’s Top Management
appreciated the logics and efforts behind development of Dashboard and it has been
implemented in current ongoing projects as well.

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