Alpha3 Blog

Posted by Mark Sanders on February 16, 2012
Forensic techniques are typically used to look back and evaluate failings, but with timely application, they can be used to look ahead and steer toward successful completion.
Some in our industry view forensic schedule analysis as something that is applicable only in claims situations—once a project has taken an unexpected and costly turn for the worse. I view forensic schedule analysis as something that should be done periodically during project execution to recognize trends, identify problem areas, and reorient the parties toward their original goals for mutual project success.

One of the great benefits of performing forensic schedule analysis on a routine basis is that the methods for identifying specific delays and discussing those delays can be established among project leaders on all sides of the table. Instead of worrying about whether the contractor is manipulating the schedule or the owner is constructively accelerating work, the facts are laid out in a simple, straightforward manner, and the parties identify reasons for specific variances to the plan. If those variances include critical path delays, the parties have an immediate opportunity to discuss approaches to re-sequencing or a basis for negotiating time extensions.

Variances to the plan should be reviewed in a standard format on a bi-weekly or monthly basis while the immediate project issues are in the front of decision-makers’ minds. Delays must be addressed before they become so severe that the parties are more concerned with positioning for a claim than with attempting to get the project back on track. Identify the problems and work to solve them before success becomes a lost cause.

I apply the techniques of AACE International’s Recommended Practice for Forensic Schedule Analysis (RP 29R-03) actively during project execution to address delays while they are happening. The CPM schedule is simply a time-scaled model of the project execution plan, and it must be kept up-to-date as the project scope and execution conditions develop. Much as a 3D-CADD model is updated as the design progresses, the CPM schedule must be updated, evaluated, and adjusted as the project progresses. Otherwise, it is unlikely that the schedule will be a good model of what is happening in the engineering office or in the field.

Updating the schedule does not mean simply statusing it with actual dates and distributing a bar chart. Almost all CPM schedule updates include refinements to the plan that involve changes to logic, changes to activity durations, and activities that have been added or deleted. It is critical to identify and discuss these changes and quantify their impact to the overall plan. In doing this, the parties will develop an understanding as to whether the changes are appropriate refinements to address real execution conditions or inappropriate manipulation. In fact, clearly identifying the schedule analysis approach to all parties is the best way to minimize manipulation and refocus scheduling efforts on real mitigation to the benefit of all parties.

Over the past five years, I have prepared detailed, textbook-style examples of the application of the forensic techniques of RP 29R-03. Papers presenting five of the method implementation protocols from the RP are currently available on this website, and the final paper in the series will be presented at AACE’s 2012 Annual Meeting in San Antonio in July. I encourage you to become familiar with these techniques, and to apply them to each schedule update. In particular, I recommend the monthly application of MIP 3.4 to identify schedule variances and discuss revisions that have been implemented during the month.

Despite the gamesmanship, manipulation, and claims analysis that is so often the focus of CPM scheduling, I still believe that most owners simply want their projects executed on-budget and on-schedule without battling the other parties along the way. Similarly, engineers and contractors are in business to make money, and there is no better way to minimize risk and protect margins than by completing projects on time and within the authorized budget.

 

Posted by Mark Sanders on January 22, 2012
Enterprise-wide data can be made readily available to forensic schedule analysts.

In the same way that an enterprise-level scheduling system facilitates the identification and application of best practices for planning and scheduling across an organization’s projects, such a system can be used to prepare an organization for potential disputes and assist in avoiding or mitigating disputes that arise.

Maintaining an enterprise project portfolio management (EPPM) system provides a basic structure for the collection and organization of the schedule information necessary to manage change and avoid, mitigate, assert, or defend against claims.

While CPM schedules can be maintained in a stand-alone scheduling application, maintaining the organization’s baseline schedules and updates in a centralized system facilitates the application of a consistent set of best practices and peer review of schedules. Because schedulers working for the same organization become familiar with the standard formats and practices of the company, they are well equipped to identify elements of a schedule that are outside of the company’s standard practices, and question whether those elements were incorporated into the plan intentionally or by error. Peer review and management review of the baseline schedule outside of the project team can identify logic errors, missing scope, and high-risk areas of the plan. In general, anything that is done to improve the project plan at the outset can serve to reduce the risk of claims, reduce disagreements regarding the plan, and facilitate resolution of disagreements when they arise.

Some practitioners have argued that they need to remain focused on planning their projects, unimpeded by enterprise-level requirements or systems. However, having a standard set of best practices at the enterprise level should never reduce the quality of schedules at the project level. While each project has its own unique requirements and execution strategy, the success of the organization is determined by its ability to successfully execute a set of practices across all of its projects. One major project failure can result in losses that offset profits from all other projects, or even lead to organizational insolvency. Executing a standard set of scheduling practices across the enterprise can ensure that the projects that carry the most risk—or those on which risks increase during execution—receive the appropriate level of attention by company management.

While project personnel may bristle at corporate oversight, it is necessary to manage risk at the organizational level. For the project team, achieving buy-in by company management and an understanding of the project team’s execution plan will be valuable when changes and potential claims arise. Review and acceptance of the project team’s schedule by its own company’s management personnel should be used as a dry-run for review and acceptance by the owner or other project stakeholders. Changes to the schedule that are driven by another party often add risk to the company executing the plan. Company management should understand the original execution plan and be involved in significant changes that add risk.

In addition to allowing the company to identify and focus on projects that carry more risk, an enterprise-level system allows the company to quickly ensure that all of its projects have complete baseline schedules and have been appropriately updated over the course of their execution. These schedules are stored in a central database that can be backed up routinely to prevent loss of the data by hardware damage, viruses, or database corruption. A quick review of the schedule database can identify projects that have not been updated recently, and appropriate inquiries can be made as to the status of the project’s controls systems. Having a complete set of up-to-date project schedules across the enterprise prepares a company for claims that arise, even if they arise on projects that were not thought to carry significant risk.

Having managed the enterprise to ensure that project schedule records are as complete as possible and follow the company’s scheduling standards, the organization is in the best possible position for performing a forensic analysis when required. All methods of forensic schedule analysis are limited by the quality and completeness of available project information. Of the nine method implementation protocols outlined in AACE International’s RP29R-03, seven require the baseline schedule, schedule updates, or both as minimum inputs for the analysis. The remaining two methods require only an as-built record as a minimum input; however, a significant part of that as-built record could be contained within a properly updated CPM schedule.

Regardless of the analysis method chosen, there is a benefit in getting the appropriate information to the analysis team as efficiently as possible. Large organizations may have a specific group tasked with analyzing claims and supporting dispute resolution. For a group such as that, immediate access to all of the company’s schedules would be of certain benefit when they are notified of a dispute on a project. There would be no need to locate, export, transmit, and restore schedules from a separate database. Concerns regarding potential loss of information or changes to information when moving schedules from one database to another would also be eliminated. Even small organizations typically have a few specific individuals with experience in forensic scheduling. Maintaining schedules in a centralized system allows for a limited number of forensic analysis personnel to have immediate access to the company’s schedules.

Once the analysis begins, forensics personnel can prepare numerous analysis schedules. For example, an analyst executing one of the observational techniques may prepare additional schedules while inserting progress into one schedule from a subsequent update and analyzing the critical path on a day-by-day basis. An analyst executing one of the modeled methods may prepare numerous fragnet schedules or schedules with fragnets inserted into them. In either case, an enterprise-level system can be used to make these analysis schedules immediately available to other analysts or to the project team for review, discussion, and validation of the analysis results. Security controls in the enterprise system can be used to ensure that only the appropriate personnel have access to analysis schedules.

Analysts can work together more easily in an enterprise-level environment to prepare analysis schedules jointly. Moreover, as the enterprise-level system can facilitate consistency of practice and peer review in project execution, the same benefits apply to analysis. Senior-level personnel can review analysis schedules prepared across the organization to ensure that the company’s preferred analysis techniques are applied. In cases where a specific analysis technique is required by contract or by the legal jurisdiction in which the dispute is to be adjudicated, personnel with more specific experience in that analysis technique can be called upon for review and support. Even personnel outside of the organization can be given access to prepare or review analysis schedules through a secure channel.

Planning and scheduling tools and practices that were originally developed in the interest of better management of individual projects now are evolving to become incorporated into enterprise-wide management systems. This evolution can place additional burdens on project personnel as there is increased oversight and an increased desire to integrate project-level systems into systems for accounting and management reporting that are more focused on managing the company than on executing one specific project. However, the benefits to the overall company may justify any additional burden if they include an increase in the consistency and quality of its execution plans and better availability of information. A focused and disciplined approach to planning and scheduling can support successful project execution and claims resolution whether the tools used are stand-alone applications or enterprise-level systems. As software tools evolve, organizations will need to continue to evaluate the available tools, the benefits and costs of implementation, and the fit for their individual company.

Posted by Mark Sanders on January 16, 2012
Happy Birthday Alpha3!

It’s hard to believe it, but Alpha3 Consulting is celebrating our 5th Anniversary today, January 16th. It certainly has been a very exciting five years! We moved from our Haddonfield, New Jersey office in early 2010 and now have two offices, one at 1050 Kings Highway, in Cherry Hill, NJ and the other at 20 S. Olive St. in Media, PA.

Yes, not only have we doubled our office space in the past three years, but we have increased our employee base, as well. In the past couple of years, we have welcomed Richard Clark, Mike Sanders and Warren Tasca to the Alpha3 team.  All of these professionals are hard at work for our very diverse client base. As our client’s needs dictate, Alpha3 is ready to respond to the challenge!! We see our Team as “Best-in-Class” in the areas of Project Management/Project Scheduling/Cost Control and Forensic Analysis. If you want it done NOW & you want it done RIGHT, contact Alpha3 Consulting!

Congrats to all at Alpha3!

Posted by Michael Sanders on December 23, 2011
Left unloved and neglected, Furnaces can deteriorate and lose essential thermal efficiency.

Within the industrial process sector as well as in the power industry, there exists a very competitive mind-set towards “Continuous Improvement” regarding internal energy performance. This is certainly a very positive attitude to promote and sets apart the “survivors” from the rest of the pack. Process industries, especially refineries and petrochemical plants are extensive users of energy. Wherever possible, inter & intra-unit component heat integration is the optimal path towards “Best-in-Class” energy performance, or in the parlance of Solomon Metrics, 1st Quartile EII (Energy Intensity Index).

At Alpha3, one of the consulting services offered to these clients is in the area of process furnace optimization. Very often, heaters are overlooked within the plant by both Operations and Maintenance personnel and are considered as a “necessary evil." Left unloved and neglected, these critical pieces of equipment can deteriorate and lose essential thermal efficiency. This condition is cumulative over many years and leads to the attitude that “nothing will ever get done” on this equipment, so why should I be concerned about it? Too often this attitude is contagious within a company at multiple sites.

Alpha3 can provide a process furnace “assessment” of some or all of the heaters within your facility at a very reasonable cost. We examine both mechanical and physical condition of the heater, as well as historical operating performance versus target(s). Additionally we will make recommendations as to the necessary repairs/upgrades that can get the furnace back to intended performance levels. Very often, these recommendations are low-cost in nature and include:

  1. Repair/Replacement of heater efficiency instrumentation (O2 analyzer, draft indicator, stack TI’s, etc.), which can produce a positive impact on operator’s attentiveness to heater performance
  2. Repair of “air-in” leakage conditions, also known as “ingress or tramp air,” which is one of the greatest issues that unit operators have to deal with on any given furnace. Casing repairs, refractory sealing, tube penetration seals, etc. are some of the quite reasonable, and frequently,”on-line” measures that can be performed to obtain 2-3% improvements in thermal efficiency.
  3. Revising “old, historical” operating parameters/targets that no one can remember exactly “Why” or "How” they were developed. 
  4. Reviving or implementing heater training for operators and mechanics so they better understand the “Value” of improved Operating Performance of their Fired Equipment.
  5. “Un-realized” benefits of simply having a PLAN for dealing with Process Heater changing conditions.

At Alpha3, we see ourselves as part of the Team Solution to improving the overall performance of a facilities fired equipment inventory from both efficiency as well as a SAFETY perspective. These two mutually INCLUSIVE concepts cannot fail to show significant benefits to the individual facility as well as the company’s Bottom Line!! 

Michael Sanders is a Director at Alpha3 Consulting, LLC, Cherry Hill, N.J. & Media, Pa. Mike has over 35 years experience in the refining & chemicals business with various companies including Gulf Oil, Chevron USA, and Sunoco Refining & Marketing. He has performed over 20 plant-wide energy assessments as well as ~125 process heater assessments for efficiency as well as process safety improvement.  Mike can be reached at mpsanders@alphathree.com or 610.836.1864 cell

Posted by Mark Sanders on December 22, 2011

I hear the term Integrated Project Schedule more and more often on complex projects, and we’ve been wondering whether there is a common understanding of what it means to have an integrated project schedule. Does it mean that the schedules of many parties have been logically tied together? The schedule reflects all project resources? All parties have bought in to the execution plan? The schedule is integrated with cost management systems? Does it mean all of this?

To start, I focused on whether the project schedule truly integrates the schedules of all project stakeholders. If so, it may include separate schedules developed by parties responsible for various aspects of engineering, procurement, construction, and operations.
 

If these schedules have been developed without a well defined and consistent structure, integrating them into one logically linked plan can be a challenge. If the schedules have been prepared in differing levels of detail and in different software packages, the resultant integrated schedule may create more problems than it solves.
Considering that, there may be an underappreciation for integration of the plan to execute the project scope. If there is not an integrated plan, there cannot be an integrated schedule that will drive cash flow, resource analysis, or other deliverables that are touted as among the benefits of an integrated schedule. How do we restore the focus on development of an integrated execution plan?
First, the project team needs to determine the best approach to schedule integration. Options include the following:

  • Schedules are submitted in a standard coding structure with full integration at the top-tier
  • Higher contract tiers simplify and integrate schedules submitted by lower tiers
  • Standard schedule submittals with top-tier integration through a milestone schedule
  • Top-tier is a separate (e.g., Level 2 project schedule), and lower tier schedules are “coordinated” with that schedule
  • Full access to single database with collaborative development
  • Access to a single database with control over some features (such as logic changes) at higher contract tiers

In determining what approach to use on a recent project for the expansion of a scrubber WWT plant, I considered the fact that all contracts were already in place without detailed scheduling requirements. The two major contracts that required coordination were EPC contracts with one contractor preparing schedules using Primavera Contractor and the other using Microsoft Project. Both had well-developed schedules and little experience with the other contractor’s chosen software package.

Considering these conditions and the extremely tight schedule for the overall project, it made little sense to impose a rigid scheduling regime on either contractor. Why would I want either contractor to develop and maintain a schedule to model their plan in software with which they had little experience and no desire to use? In addition, the owner had a separate contract in place for the main power supply to the new WWT plant and ongoing operations to coordinate with the project. Coordinating all of this in an integrated CPM schedule simply did not appear to be the most effective approach.

 

Instead, all contractor schedules were incorporated into an Integration Analysis Schedule that was used to identify coordination issues, identify the overall critical path of the project, and determine key turnover dates from one party to another.

Release dates for each project area were coordinated, and all contractors bought-in to the turnover targets. Over the course of the project, the contractors maintained their independent schedules, which were reintegrated on a periodic basis for analysis. In the interim, the schedules were reviewed independently for variances and identification of any issues that could impact a turnover date. As the project transitioned from construction to commissioning, a separate effort was undertaken to coordinate the commissioning process.

Ultimately, the selected approach was found to effectively coordinate the efforts of all parties, while allowing them to plan and manage their work in the way that they felt most comfortable. The experience demonstrated that there is more than one effective approach to schedule integration, and that determination of an approach can rely on contractual and project execution conditions that may be unique to a particular project.

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