Please enable JavaScript.
Coggle requires JavaScript to display documents.
Cost Optimization Opportunity at Fadhili Site - Coggle Diagram
Cost Optimization Opportunity at Fadhili Site
Root Causes of Wastage
Over-application of Material: Inconsistent thickness beyond specification.
Frequent Reworks: Due to improper curing, surface contamination, or application in unsuitable weather.
Improper Mixing Ratios: Leading to unusable batches.
Excessive Spray Loss: During windy conditions or from faulty equipment.
Poor Storage Practices: Expired or contaminated materials.
Inefficient Planning: Surplus material at end of shift or pour.
🔄 2. Affected Processes
Material Receiving & Storage
Surface Preparation
Application (Spray/Hand Trowel)
Inspection & Testing (e.g., DFT check)
Waste Collection & Disposal
👥 3. Key Stakeholders
Project Manager
Procurement & Material Controller
QA/QC Inspector
Site Engineer & Supervisor
HSE Officer
Fireproofing Applicators
Client/Consultant
💰 4. Impact on Cost & Time
Impact Area Effect
Material Cost 10–25% increase due to rework/waste
Schedule Delays Rework impacts productivity & progress
Labor Cost More man-hours needed for repeat jobs
Storage & Handling Extra cost for expired/discarded items
Client Penalties Risk of non-compliance or NCRs
🎯 5. Strategic Solutions
Pre-job Training on Mixing/Application Standards
Use of Wind Screens and Protective Covers
Small Batch Mixing (based on usage rate)
Monitor Daily Consumption vs Planned Usage
Weather Monitoring before Application
Supervised End-of-Shift Material Return
🛠️ 6. Tools & Methods Used
Daily Material Usage Log Sheets
Spray Equipment Calibration Checklist
Root Cause Analysis (RCA) on High-Waste Incidents
Fireproofing Procedure Adherence Audits
Thermal Imaging for Thickness Verification
Barcoding or RFID for Batch Tracking
✅ 7. Expected Outcomes
15–20% Reduction in Material Wastage
Better Forecasting of Material Needs
Improved Productivity and Crew Efficiency
Compliance with Aramco Standards
Enhanced Site Safety & Cleanliness
Cost Saving for Company & Client