First Pump Delivered to the Job Site

Daily Project Management

A special challenge was to coordinate the delivery of all of the pump components to a shipyard that is building the pumps and get them to the job site in a very short period of time. The actual production time of the first pump was 140 days, while Fairbanks Morse is now providing the pumps in an average of 113 days.

With various vendors across the country being employed, we have to coordinate shipment to the assembly area prior to delivery of the product.

Schedule boards for each pump allow us to keep track of and manage the process to ensure that all of the components are delivered on time, exactly when the contractor needs them.

There are ten major components but literally hundreds of parts that have to be coordinated to arrive at assembly at the same time. Every component goes through an extensive QA process. All documentation is kept and submitted to the U.S. Army Corps of Engineers.

We have 12 major vendors providing 14 major components to the pump. Some vendors cast, some vendors fabricate, most of them machine and several vendors paint. The Fairbanks Morse project team coordinates between the vendor and the engineering department to resolve issues and answer the questions the vendors may have.

The project management team’s job is to speak to every vendor every day to understand where they are with regard to schedule and the technical aspects of the project.

Movement and Transport Logistics

Given that we are manufacturing this pump using the services of multiple vendors across the U.S., we must coordinate and manage the process.
We coordinate movement to two places. Most of the parts go to the assembly site, while others go to the job site. Coordinating all that logistical activity is made more complicated because each pump is being manufactured individually at different times. So we have to coordinate all that logistical activity between all the vendors and all the components times 11 pumps.

Each component is so heavy it requires special transportation. Most require escorts. Keep in mind that the components weigh from 20,000 lbs to 60,000 pounds.

Once all the components are at the assembly site for assembly, then the challenge becomes actually putting the components in the proper order so the pump is built to exact engineering specifications.