REVISION DATE:

Problem
Methodology for
communicating system
changes
Need to have access to
current status of IPMS
system

IPMS startup process

Merlin Piping Specifications
Misunderstanding and
resistance to the IPMS work
package setup

Developing Work Packages

before Plot Plan frozen
IPMS packaging of the
work, assigning hours,
listing deliverables,
assigning the correct WBS
and matching requisition
numbers in IMPS with
engineering requisitions
worksheet numbers was
very time consuming
Vessel Mechanical
packaged the work by
groups of vessels for
requisition to reduce
number of requisition
packages

Category

Source

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Communication Shell OP2

Jul-00

Need to develop online system

Communication Shell OP2

Jul-00

Need to develop online system

Dec-99

Action Taken / Resolution

Status

Develop online system for read only access

the new Change Control System

Complete

Short term: Issue hard copy of report:

Long term: Issue PDF versions
Start-up meeting in place as required.
Holding weekly meetings. Recommend use
of same IPMS startup process on all
projects

Set-up

QChem

Dec-99

Coordination between groups is

essential with the direction of the
IPMS Support Team
All KBR piping specs had to be
developed since none existed

Training

QChem

Dec-99

Not a clear understanding that IPMS

is "deliverable based".

Work Packaging QChem

Dec-99

Additional training and communication

Determining for each project the minimum
Plot Plan must be frozen before Work level of WBS required to start IMPS. Assure
Package / IPMS chains can be
this requirement is include in the Project
completed
Execution Plan

Personnel having IPMS Chain/WorkPackage experience should be

assigned to assist and train during
initial project set-up

Communication QChem

Training

QChem

Dec-99

Training

QChem

Dec-99

KBR developing new piping spec process

Complete

Complete
Ongoing
Training ongoing
as required

Ongoing

Recommend experienced start-up teams

Complete be assigned to assist new projects
ongoing
This is another training and communication
Not all items assigned to a requisition issue. The packaging concept in IPMS is
Recommendation
were available at the same time
"make the plan, work the plan, progress the
will be
therefore IPMS credit had to be
plan". It the plan changes, there is rework.
considered on
manually fixed because the requisition Recommend each vessel be tracked
each new
needed to be issued
individually.
project

REVISION DATE:
Problem
Paperless and IPMS do not
fit hand in glove. With IPMS,
progress is measured as
deliverables are issued,
milestones are reached
(discipline comments). IPMS
requires the disciplines to
log their review/comments
with documentation for
IPMS credit.

IPMS requisitioning is much

more difficult than
IDMS/EQIS requisition
process
New milestone chains as
result of merger; still in flux
even after the merger.
WGLs and controls
personnel are unfamiliar
with them causing reporting
problems.
Some of the milestone
chains have wide gaps
therefore not allowing for
intermediate progress
reporting

Inflexibility reporting
capabilities

Category

System
Development

Training

Training

Training

System
Development

Source

QChem

QChem

QChem

QChem

QChem

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Action Taken / Resolution

Status

Dec-99

Hard copy approach give

documentation physical evidence
when an activity is completed. When
comments are transmitted paperless,
documentation has difficulty
determining which comments apply
and packaging them to return to the
originator of the document under
review.
The IPMS process needs to be
communicated and trained to
Engineering. The significant benefit of
IPMS process over the previous MWK
process is redundant entry is no
longer required.

Feb-00

Freeze the chains and conduct

intensive training of WGLs and
controls personnel

A team is in place to review milestones and

chains

Team in place

Feb-00

Revise the milestone chains for more

intermediate milestones and make the
system more friendly to claim
intermediate progress

A team is in place to review milestones and

chains

Team in place

Feb-00

Make system flexible to produce high Custom reports are possible. But
level reports and flexible in formatting recommendation forthcoming from IPMS
per client and JV partner requirements start-up team.

Dec-99

No resolution, still working

Action deferred
until
documentum is
beta tested.

Recommended that a flow chart be

developed t show the requisition engineers
how the documents flow through the
system. Train.

Part of start-up
training

Working

REVISION DATE:
Problem

Category

IPMS links (electronic) with

other systems do not work
or are cumbersome or
requires a lot of manual
intervention: Financial; P3;
EQIS; & Merlin

System
Development

IPMS access to client and

JV partner
IPMS has awkward or no
forecasting capabilities

System
Development
System
Development

Work packs for IPMS were

different from First Planner
schedule activities causing
the electronic linking of IPMS
and P3 later on in the
project almost impossible
The methodology used
setting up IPMS caused
excess work for the
controls personnel. The
system was set up with
six different sub-projects
Purchase order commitment
was delayed because
vendor ID number is not in
IPMS.
IPMS does not have a "field"
for "drawing received
date."
IPMS should be up and
running with trained
personnel before
Construction is in full swing

Training

Source

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

QChem

Feb-00

QChem

Feb-00

QChem

Feb-00

QChem

Feb-00

Make systems integration work and

easy to effect.
Need company policy; then make
system flexible to implement
discretionary access as appropriate
to various parties under PM control
Make the system more cost control
friendly and totally flexible
From outset of the project, ensure full
understanding by all team members of
the importance of making the First
Planner schedule activities match the
work packs to be inputted to IPMS
with the objective to electronically link
the two systems.

Action Taken / Resolution

Interface set-up and testing is now part of

start-up schedule

Under review; Client can begin some

access
Needs further review

The planning process has been established

to address first planner and IPMS. We are
implementing new version of 1st planner

Status

Complete

Review required
for each project
Under review

Complete training ongoing

System
Development

ARCO
CARSON

Each project is
reviewed to
This resulted in handling the subdetermine the
projects individually, then
Recommend setting up projects as one large
best WBS
incorporating into the primary projects. job segregated by multiple cost areas
structure
The project buys material from local
vendors, but Purchasing cannot
Project purchasing needs to request
commit PO in IPMS due to the local
Houston to put vendor ID's on the list.
vendor not on the approved vendor
Purchasing has given the authority to input
list.
vendor ID's
Complete

System
Development

ARCO
CARSON

The "comment field" has to used for

this information.

Provide a "field" so drawing receive date

and be maintained and can be sorted

More training personnel required.

Training classes are now available for cost

and tracking.

Shell GPP Geismar, La.

Training

Phenolchemie

Nov-98

Nov-99

Will not change

field at this time

Ongoing

REVISION DATE:
Problem
IPMS was not operational in
the material control offices
when we moved to the
field. Lost 2 weeks
Not all disciplines used IPMS
as their materials catalog
and index.
Staff IPMS earlier on the
project
Third party (Lurgi) piping
specifications and material
identification did not meet
the needs of IPMS, PDS and
KBR procurement
Schedulers had problems
getting Early Start Dates
from Primavera into IPMS
IPMS start-up team did not
include Engineering
Roll-up drawing milestone
progress item level to
package level was
extremely difficult to
execute; too many bugs
existed.
Need to be aware of
shortcuts
Had problems printing when
Cost puts in a lot of their
runs at one time

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Category

Source

Training
Set-up

Phenolchemie

Nov-99

Set-up

Phenolchemie

Nov-99

Set-up

Phenolchemie

Nov-99

Follow the plan

Phenolchemie

Nov-99

Interface programs is needed to

translate third party data to PDS

Phenolchemie

Nov-99

Training

Following the 120 start-up plan

Action Taken / Resolution

Status

Educate individuals on the 120 start-up plan.

Ongoing

Interfaces have been developed to all KBR

engineering materials systems

Complete
Ongoing

Will be done as required. Better planning.

Schedulers are being trained on how to
make transfers

Deploy multi-skilled (all module

coverage) startup team to support the
project set-up
Startup Teams now includes Engineering

As required

Ongoing

Set-up

Phenolchemie

Nov-99

Complete

Training

Phenolchemie

Nov-99

Engineering are being trained on the

packaging effort.

Ongoing

Training

Phenolchemie

Nov-99

IPMS users manual include short cuts

Complete

Systems
problem

Phenolchemie

Nov-99

The new redwood processor made resolve

this

Complete

REVISION DATE:
Problem

Category

The project team was not

familiar enough with the
different IPMS modules to
setup a project to run the
way it should. Several
tasks had to be entered
manually each week
because a module was not
used.
Training
Large reports by cost,
accounting, material control
(work plans) should be
started late in the day to
prevent system tie ups
during normal working
hours
System problem
Field personnel should be
able to change addresses
and material groups at will
rather than duplicating line
items and then deleting the
incorrect line item
Training
After a requisition is
released, it is a time
consuming process to
change line item quantities
or delete unwanted line
items.
System
The setup support did not
help us by letting us know
how decisions we were
making wold impact the
project team through the
execution phases of the
project
Training
IPMS training needs to relate
how the modules affect one
another.

Training

Source

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Phenolchemie

Nov-99

Phenolchemie

Nov-99

Have start-up team available

Action Taken / Resolution

Status

Start-up available to assist projects

Complete

The new redwood processor made resolve

this

Complete

We are not
changing to
system at this
time.

Phenolchemie

Nov-99

The take-offs must be input correctly

Phenolchemie

Nov-99

This is true and it should work this way.

Phenolchemie

Nov-99

More training required.

Start-up teams are addressing these

issues.

Ongoing

Phenolchemie

Nov-99

More training required.

Start-up teams are addressing these

issues.

Ongoing

No action, leave
as is.

REVISION DATE:
Problem
All project leadership needs
to understand how the
modules are integrated,
work and impact the
project, cost and timing.
Process 5040 , importing
Control packages from IPMS
to ACLS does not work at
all. When attempted, all of
the existing Control
packages.
BOM's should be completely
updateable by field
personnel (remove
spool/class splits, etc.)
The Work Plan is a
cumbersome operation;
taking a week to process a
work plan is not realistic
and a waste of time.
Expediting Report needs to
be able to be sorted by
P.O., tag, current promise,
ETA date.
Document Control should be
connected to Expedition if
data is being tracked.
Needs to be easier to move
between expediting screen
and multi-line expediting
status screen. It would
help if both screens cold be
open a the same time.
When performing mass
updates, the screen will go
back to a previous P.O.
when complete. This
causes errors in updating.

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Category

Source

Training

Phenolchemie

Nov-99

Training

Phenolchemie

Training/
Security

Action Taken / Resolution

Status

Start-up teams are addressing these

issues.

Ongoing

Nov-99

This is working correctly.

Complete

Phenolchemie

Nov-99

This is working correctly.

Complete

Training

Phenolchemie

Nov-99

Training required.

Ongoing

System

Phenolchemie

Nov-99

IPMS/Documentum interface being

developed.

To review

Training

Phenolchemie

Nov-99

IPMS/Documentum interface being

developed.

Ongoing

Training

Phenolchemie

Nov-99

System issue resolved!

Complete

Training

Phenolchemie

Nov-99

System issue resolved!

Complete

More training required.

Work plan works well, training is

required.

REVISION DATE:
Problem
Need prompt or flag for
partial deliveries or
automatic subline for
remaining items.
An icon or key is needed to
ascertain warehouse
request numbers rather
than going through a time
consuming 8 step process
from the BOM line to the
request number
Obtain an illegal operation
message 95% of the time
when in summary and
searching for an item/PO
Cannot back a material
reference item out unless
everything received against
the material ref. Which
requires backing out pick
tickets or doing a lump sum
return.
Enlab labor and SAP
interface download into
IPMS (not timely with no
control) depended on the
IPMS support person make
the file available.
When a problem occurs,
sometime it takes hours or
the next day before we can
get some one in Houston

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Category

Source

System

Phenolchemie

Nov-99

Will not change at this time.

To review

Training

Phenolchemie

Nov-99

Will submit an enhancement

Ongoing

System

Phenolchemie

Nov-99

This is fixed.

Complete

Training

Phenolchemie

Nov-99

This is the way it should work.

Complete

System

Phenolchemie

Nov-99

Download labor and SAP problems

corrected

Complete

Set-up

Phenolchemie

Nov-99

IPMS start-up available

Complete

Need a person in Mobile Office

Action Taken / Resolution

Status

REVISION DATE:
Problem

Category

Source

KBR IPMS LESSONS LEARNED

ID Date
Lesson Learned

Action Taken / Resolution

Status