Procurement controlling in industrial plant construction

Beschaffungs-Controlling im Industrial plant construction ist Teilbereich des Projekt-Controlling im Industrieanlagenbau, dem aus dem computerunterstützten Akquisitionscontrolling im Industrieanlagenbau bereits eine Vielzahl von Daten zur Verfügung steht. Ein Beschaffungs-Controlling ist im Industrieanlagenbau aufgrund des hohen Vertragswertes der zu errichtenden Industrieanlage unerlässlich. Die aus dem hohen Investitionsvolumen resultierende Zinsbelastung (Financing controlling in industrial plant construction) sowie der Produktionsgewinn aus möglichst frühzeitiger Fertigstellung der Anlage führen zur vertraglichen Festlegung durchweg kurzer Arbeitsfortschritts- und Endtermine mit dem Kunden, so dass zur Einhaltung dieser Termine mit der Beschaffung der Ausrüstungsgegenstände schon begonnen werden muss, wenn die erforderlichen Spezifikationen des engineering noch nicht oder erst unvollständig vorliegen.
Pre-orders, however, result in corresponding changes and often additional costs, which - if possible - are already included in the offer calculation. For the customer, however, these additional costs can be well invested if the interest relief and the production profit from earlier completion of the plant are higher. Due to the tight deadlines, procurement specifications are processed more quickly. As soon as the industrial plant has been process-technically calculated with the help of data processing programs and optimized by means of iterative calculations (basic engineering) and the first data for the required equipment is available (e.g. how many turbines, compressors, pumps, reactors, etc., with what power and other requirements ), the first negotiations with the eligible suppliers begin; It is possible that advance orders will be placed with the cheapest provider.

Should the progressive structural planning of the system (detail engineering) result in changes, additional costs are to be expected, whereby the advantage of accelerated delivery by the manufacturer and the insofar guaranteed compliance with penalized contractual deadlines is the criterion of the extent to which the possibility of pre-orders is used is made. All of this makes it clear how important it is to accelerate the process engineering design of the plant with the help of IT programs. Because of the relatively low costs and speed, these calculations are largely carried out in the offer phase for the offer calculation. In this case, pre-orders can even be placed immediately after the customer order has been placed.
On the basis of the basic engineering continues

• the location, installation, building and infrastructure planning of the plant using CAD. From the building planning, if it is not done in detail by the construction company to be commissioned, mass extracts for the award of construction work can be obtained.

• The determination of basic data for the creation of flow diagrams for pipeline planning, which makes up about 40% and more of the overall planning (including detail engineering and monitoring of the plant construction) and the material value of the plant and is also created with the help of CAD. This also involves dimensioning the pipelines, so that quantity extracts (pipeline specifications) can be derived from the flowcharts, which are forwarded to the suppliers under consideration for the purpose of submitting offers and, after selecting the cheapest supplier, taking into account the negotiated delivery prices and any corrections Are the basis of electronic order placement.

• the determination of quantities and placing of orders for electrical installations including the measuring and control instruments (process control) as well as the associated electrical cables.
In this planning phase, the process-related calculation and optimization of the system (basic engineering) and CAD-supported detailed planning (detail engineering) up to the ordering of equipment and services (construction and assembly work), about 10% to 15% of the entire planning and Monitoring costs, but it "pegs" approximately 60% of the total cost of the facility. This is the most important starting point of project controlling, because after this planning phase there are only a few control options.

The quality control of the procurement (material and production quality) is aimed at the suppliers of the equipment, usually even up to the upstream suppliers of the manufacturer, despite the effort involved; because errors that are not recognized can then result in costs that are several times the value of a turbine, for example. The monitoring effort for quality control has increased considerably in recent years due to the internationally necessary purchasing, since additional qualifications of the inspectors are required.

However, the cheaper shopping opportunities abroad are often sufficient to more than compensate for the additional effort for monitoring, which can only be decided in specific cases and is a question of cost-benefit analyzes. In addition, the monitoring of suppliers includes comprehensive deadline monitoring (deadline and capacity controlling in industrial plant construction).

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