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International Journal of Project Management 20 (2002) 253–262

www.elsevier.com/locate/ijproman

Integrating supply chain and critical chain concepts


in engineer-procure-construct (EPC) projects
K.T. Yeo*, J.H. Ning
Centre of Engineering and Technology Management, Division of Systems and Engineering Management,
School of Mechanical and Production Engineering, Nanyang Technological University, Nanyang Avenue, Singapore

Received 21 September 2000; received in revised form 28 November 2000; accepted 2 March 2001

Abstract
The present practice of Engineer-Procure-Construct (EPC) projects in the engineering and construction industry receives many
criticisms and requires improvement. This paper examines the nature and characteristics of EPC projects with special interest in
project procurement management. An enhanced framework for procurement is proposed by coupling the concepts of Supply Chain
Management and Critical Chain Project Management, with the latter drawing ideas from the Theory of Constraints. The proposed
framework broadly embraces three streams of approaches namely, cultural, process and technological. Special attention is given to
a systems approach of buffer management as a mechanism to improve the management of uncertainty in procurement. # 2002
Elsevier Science Ltd and IPMA. All rights reserved.
Keywords: Supply Chain; Critical Chain; EPC projects; Procurement; Uncertainties

1. Problematic engineering and construction industry De la Garza [6] thinks that the construction industry
productivity has been static for almost two decades. An
The engineering and construction industry faces for- investigation on time waste reveals that the site work-
midable challenges. As a whole, the industry worldwide force spends a considerable amount of time waiting for
continues to perform unsatisfactorily. It suffers from approval or for materials to arrive on site. The amount
low profit margin, persistent project overruns in sche- of work on non-value-adding activities was found to be
dule and budget, and is plagued with claims and coun- as high as 40% of the overall project duration from
ter-claims. A recent UK construction industry survey inception to completion [4].
showed that the profit margin on construction work is The CII in the US, in their industry-wide investiga-
1–2% [1]. American Construction Industry Institute tion, concludes that project performance, measured in
(CII) finds that approximately one-third of the projects terms of cost, schedule, technical, quality, safety, and
miss cost and schedule targets [2]. A critical aspect of profit objectives, has room for substantial improvement
project failure is construction delay, which often results for the industry as a whole [2]. The Construction
in construction claims. Another survey in UK shows Industry Board (CIB) of the UK specifically suggested
that 52% of UK construction projects end up with that the construction industry should be more competi-
claims of some type [3]. tive and aim at reducing construction costs by 30% [7].
The construction industry receives many criticisms. Mohamed [4] reckoned that 25% time saving is achiev-
Mohamed [4] claims that the current practices and able in a typical construction work package without
mechanisms of the construction industry are inherently increasing allocated resources.
inefficient, which inevitably leads to wastes [4]. Lim’s [5]
study on construction productivity in Singapore shows
that the industry is perceived as a low-productivity sector. 2. Integrated EPC activities

* Corresponding author. Tel.: +65-799-5502; fax: +65-791-18-59. An EPC project can be a complex one-of-a-kind
E-mail address: mktyeo@ntu.edu.sg (K.T. Yeo). product development, made up of a large number of
0263-7863/02/$22.00 # 2002 Elsevier Science Ltd and IPMA. All rights reserved.
PII: S0263-7863(01)00021-7
254 K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262

interconnected subsystems and components, requiring agencies, end users, facility operators, maintenance
considerable human efforts and financial commitment. teams and demolition firms are some of the participants
The EPC activities are time-phased according to specified involved in the life cycle of any constructed facility. The
precedence and resource requirements and constraints. large number of participants in the project causes the
Engineering/Design (E) is the process by which the problems of fragmentation. Project participants exchange
needs, wishes, and desires of an owner or developer are information back-and-forth at all times. Adversarial
defined, quantified, qualified into clear requirements which relationships between organisations may also arise due
will be communicated to the builders or contractors. to work fragmentation.
The engineering/design phase has the highest level of The duration of some activities is unpredictable, espe-
influence of the project, as many key decisions will be cially in negotiation, obtaining approval from autho-
made during the pre-project planning and engineering rities, and in international materials procurement and
phases. These decisions will lead to the commitment of a supplies. Capital equipment from international suppliers
large sum of the funds and other resources necessary for usually has longer lead-time, and hence, higher uncer-
the successful implementation and completion of the tainty in timely arrival on site. The need to exchange
project. The design of an engineering system is usually information and drawings between suppliers may fur-
accomplished through a series of steps to include con- ther delay the procurement time. The technical specifi-
ceptual design, preliminary design and detail design [8]. cations of capital equipment may interrelate with other
The engineering and design phase is closely followed equipment and subsystems from different suppliers [12].
by the procurement (P) phase. A contractor begins to Phase overlaps of engineering/design, procurement
procure project equipment and construction materials and construction as shown in Fig. 2 increase the risk of
upon receipts of engineering drawings, specifications project overruns in schedule and cost, due to the lack of
and other relevant documents. The main procurement/ complete information and frequent changes, especially
logistics activities include sourcing, purchasing, contract- those attributed to external factors.
ing, and on-site materials management. A contractor Surveys by Ogunlana [13] and Chan [14] demonstrate
begins to construct specified facilities in construction that the project changes and variations are critical fac-
(C) phase according to work packages prepared during tors that cause project delay and failure. It is generally
the engineering phase, and use equipment and materials perceived that the engineering construction industry has
obtained in the procurement phase. The sequencing of become inflexible and unresponsive to the needs of its
construction will be initially planned to reflect the most customers, which caused project changes and rework. It
logical and cost-effective approach to meet startup and has been estimated by the US’s Construction Industry
handover dates [9]. Institute that rework constitutes 12.4% of the total
installed-project cost in industrial projects [15].

3. Challenges of EPC projects

EPC projects face a number of challenges namely, inter-


dependence of activities, phase overlaps, work fragmen-
tation, complex organizational structure, and uncertainty
in accurate prediction of desired outcomes. In the engi-
neering and construction industry, larger firms usually
use matrix organisation for the management of projects.
Matrix organisation remains a complex structure. Fig. 1. Interdependence of activities.
Project activities are highly inter-dependent as they
are intricately connected and have a complex process
relationship. For example, it is not only upstream
activities, which affect the downstream activities, but the
reverse is also true. Austin [10] gives an example on the
interdependence of the design activities, as illustrated in
Fig. 1. Thousands of these interdependent activities
make up an intricately linked human activity system, in
the case of a large engineering project. Information
transfer is essential and iterations typical [11].
De la Garza [6] considers work fragmentation invol-
ving multiple organisations, a major challenge [6].
Owners, design firms, construction firms, equipment
and material suppliers, bankers, lawyers, government Fig. 2. Phase overlaps [9].
K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262 255

These project challenges always act together, and fur- . Use partnering as a way to deal with the problems
ther complicate the project execution. The management of work fragmentation, lack of integration and
of interdependence of project activities will become adversarial relationship.
increasingly critical as the phases are extensively over- . Break down the boundaries between project func-
lapped in order to compress schedule. Fig. 3 lists the tions to improve communication, coordination
present practice of EPC project as an ‘As Is’ model. and collaboration [19].

4. Ways ahead to better performance 5. Focus on procurement

There has been no lack of effort to improve the per- Different researches focus on different aspects of
formance of engineering projects. ‘New’ models abound. improvement to EPC projects. This paper gives emphasis
Fast-track, Concurrent Engineering, JIT Logistics on the importance of procurement and logistics to meet
Management, Business Process Re-engineering and on-site requirements as a major area of constraint and
Partnering are well known examples. Each model has its opportunity, which can be exploited to dramatically
own focal point and emphasis on how higher perfor- improve the overall performance of project delivery.
mance can be achieved. The following is a sample list of Engineering project procurement covers bulk construc-
such proposals to improve project performance. tion materials, major equipment and services. The critical
. Use or re-use proven and conservative design to importance of procurement is due to the following facts:
reduce risk of engineering changes.
. Select and use familiar and reliable vendors to 1. it is a connecting function between engineering
simplify and shorten procurement process and to and construction. Procured materials are the
cut project duration [16]. foundation of constructed facilities;
. Involve the downstream participants to play a more 2. material costs represent a major portion of total
active role in upstream activities to reduce the problems costs in EPC projects;
of design iterations and rework. Encourage project 3. it is highly dependent on external companies, who
team members to work together at an early stage to are the suppliers and subcontractors;
help avoid and resolve conflicts at later stage [17]. 4. procurement needs more communication and
. Emphasise closer co-operation between the pro- negotiation with these external parties;
curement and construction functions to enable a 5. the control is not as strong as in the case of engi-
direct receipt of materials from suppliers to con- neering and construction, especially in outsourcing
struction site as work-in-progress (WIP) [1,18]. and purchasing long lead-time equipment;
. Re-organise the business processes and the flow of 6. unlike the manufacturing industry, neither the
project activities and information. Minimise or major equipment suppliers nor the client keeps
eliminate non-value-adding processes. Employ buffer inventory for the project;
information technology to improve the informa- 7. the capital equipment is very costly and requires
tion storage, retrieval and processing [4]. long lead-time to manufacture;

Fig. 3. An EPC process model.


256 K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262

8. suppliers and prime contractors separately use 1. enhancing trust among supply chain members;
time buffers to protect themselves from uncer- 2. re-engineering the business process to build a net-
tainty due to unforeseen circumstances; and worked enterprise model; and
9. successful procurement management can lead to 3. employing IT/IS to accelerate information flowing
superior performance in overall project cost and in both intra and inter organisations.
delivery. SCM is the integration of all activities across the
Each engineering project is unique even if similar supply chain through improved supply chain relation-
design is involved. Procurement planning is unique for ships, to achieve a sustainable competitive advantage.
each project. A new site condition, a new client in a SCM has three components: information system man-
different country or new suppliers can lead to new pro- agement, strategic material management and managing
ject requirements. The considerable overlaps of engi- supply chain relationships. The drivers of supply chain
neering/design phase with the procurement phase management are hence:
increase uncertainties. The procurement decisions on
1. real time information sharing;
long lead-time items are usually made soon after the
2. co-ordinated procurement process in the whole
preliminary designs are finished and before the con-
chain; and
struction designs and drawings are completed. The
3. collaborative attitude among all of the chain
uncertainty of procurement may affect the entire con-
members.
struction process and overall project schedule.
The more advanced level of the supply chain system is
an outward-looking, extended and networked constella-
6. New management paradigms tion that span across traditional organisational bound-
aries; leverage on and link together critical competencies
The profit margins in construction are extremely of supply chain partners. Poirrer [22] gives a laconic on
squeezed often to a mere few percentages, due to fierce the essence of SCM, that future success belongs to the
competition through price-cutting among the con- best value chain constellations, not individual corpora-
tractors. A few percentage-point improvements in pro- tions. The real power of SCM lies with its ability to
curement costs can go a long way to improve the overall provide today’s enterprise with radically new opportu-
profitability of the construction industry. Such improve- nities to create marketplace advantage by leveraging
ment is achievable if some of the currently available supply channel partnerships, information and commu-
management paradigms can be exploited for the nication technologies, and the knowledge and innovative
management of uncertainties in project procurement. capabilities of the entire chain’s resources.
We will just concentrate on the relevance and cou-
pling of two related ideas of supply chain manage- 6.1.2. Some lessons for project procurement
ment (SCM) and critical chain project management The following are some of the lessons learned in
(CCPM). manufacturing based SCM and adapted as appropriate
for project procurement:
6.1. SCM
1. treat procurement as a strategic link in the project
6.1.1. The essence of SCM delivery value chain, in the context of a single
SCM is the process of strategically managing the extended virtual enterprise, and use it to maximise
movement and storage (if necessary) of materials, parts stakeholders’ value;
and finished product from supplies, through the manu- 2. develop strategic and tactical plans to ensure
facturing process and on to customers or end user, as timely delivery of materials and equipment to
well as the associated information flows. SCM is prob- protect project completion date;
ably the latest procurement and logistics philosophy 3. develop a networked information system to ensure
being adopted. Initially, the objective of logistics is to timely information on project schedule, site
reduce the procurement cost. Now the objective is being requirements, tracking material movement, and
extended to build logistics as a strategic corporate com- the latest promised delivery dates;
petence. Further objectives of logistics include 4. business process redesign to reduce administrative
improvement of production flexibility, order fill rate and delays by streamlining or eliminating paperwork
reduction of order fulfilment lead-time. The strategy is and non-value-adding procedures;
to integrate core logistics functions with marketing, 5. process redesign to reduce the length of the pro-
production and financial functions. The SCM approach curement pipeline;
advocates that a company should extend its internal 6. continuously improve to remove process bottlenecks
focus to suppliers and supplier’s suppliers [20]. The or constraints and to increase project throughput, by
essences of supply chain management are [21]: eliminating supply and demand uncertainties;
K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262 257

7. push procurement of non-critical materials as late customer interactions, from order entry through paid
as possible, while executing order placement of invoice; all physical material transactions, from suppli-
critical items as early as possible; er’s supplier to customer’s customer; and all market
8. achieve JIT logistics for on-site material delivery interactions, from the understanding of aggregate
to avoid temporary on-site storage, double hand- demand to the fulfilment of each order. The SCOR
ling, and maintenance; model consists of a series of Plan-Source-Make-Deliv-
9. improve supply chain relationship management: ery functions by an extended supply chain constellation
select reliable and quality supply chain partners as illustrated in Fig. 4.
who have the capabilities and commitment; pro- Translate the SCOR model for engineering procure-
tect the partners’ interests and be sensitive to their ment, and the sequence is similar to that stipulated in
needs, and demand the same of your partners if PMBOK’s project procurement processes [24], which
necessary. can be combined as shown in Table 1.
The SCOR model suggests that the Plan-Source-
6.1.3. The SCOR model for project procurement Make-Deliver building blocks can be used to describe
The Supply Chain Operations Reference (SCOR) supply chains that are very simple or very complex
model is developed by the Supply Chain Council, to using a common set of definitions. Consequently, dis-
describe the business activities associated with all phases parate industries can be linked to describe the depth and
of satisfying a customer’s demand. It integrates the well- breath of virtually any supply chain. The SCOR model
known concepts of business process reengineering has been able to provide a basis for supply chain
(BPR), Benchmarking and Best Practice Analysis into a improvement for global projects as well as site-specific
cross-functional framework [23]. SCOR model spans all projects.

Table 1
The Plan-Source-Make-Deliver model of project procurement management

Plan Source Make Deliver

Procurement planning Source selection Contract administration Transportation and installation


Understand project needs, supplier Contract negotiation according to Systems and processes for quality Management of traffic, freight,
availability and market conditions; organisation’s procurement policies; control, engineering and contract import/export requirements,
make-or-buy decision; contract screening, weighting, and evaluation change control, performance installation schedule,
type. systems (expediting) reporting, and temporary storage
payment

Solicitation planning
Prepare tender or bid documents,
supply chain configuration.

Solicitation Placement of orders Final contract close-out


Bidders conference or briefing (if documentation
necessary), advertising or soliciting Procurement audits, close-out
contract file and Formal
acceptance and closure

Fig. 4. SCOR model [22].


258 K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262

6.2. Critical chain method Law strikes, the deadline is missed. If he crashes
the task, quality would likely be compromised.
Goldratt [25] proposes a Critical Chain Project Man- 2. Parkinson’s law: work expands to fill the time
agement (CCPM) method, to overcome some of the available due to the ‘‘padded’’ due dates.
problems inherent in the traditional project planning 3. Multi-tasking: the effect of multitasking is that
and scheduling methods, notably the basic Critical Path fragmentation of task and equipment’s set up time
Method (CPM). The critical chain method, applying the would cause tasks to delay due to loss of con-
Theory of Constraints (TOC), offers an enhanced centration. The impact is more serious when deal-
approach to manage the associated risk and uncertainty ing with creative work.
in the project value chain and to achieve improved per- 4. Merging events: because tasks can have multiple
formance in project time management. necessary predecessors, delays are usually passed
on, while gains are not. In a dynamic situation,
6.2.1. Theory of Constraints subcritical project paths may turn into a critical
Theory of Constraints (TOC) is a common-sense way path when they slip.
of understanding a system’s performance. TOC states
that, ‘‘Any system must have a constraint that limits its
output.’’ The system’s constraint is like the weakest link
of a chain. No matter what you do to improve other
links in the chain, the chain does not become stronger
until you improve the strength of the weakest link [26].
Goldratt proposes a five-step process to achieve con-
tinual improvement and to get the most out of a pro-
ductive system, in relation to the stated system goal.
Fig. 5 illustrates the sequence of the five steps.

6.2.2. Uncertainties in project chain


Goldratt reckons that there are three kinds of uncer-
tainties in project planning and scheduling namely,
‘‘task time uncertainty’’, ‘‘path time uncertainty’’, and
‘‘resource uncertainties.’’ Generally, when a project
planner making a schedule, he would add a ‘‘safety’’
allowance or ‘‘padding’’ in his time estimation to pro-
vide localised protection to a task [25].
For illustration as shown in Fig. 6, each activity is
assigned a segment of time tg, the target time. The pos-
sibility of the activity executor to finish the activity by tg
is, for an example, 80%, which is 30% above the mean
time, tm. The problem is that, in practice, not all activities
need tg to finish. The activity executor may well finish
the activity in less than tg or even tm. However, the
executor will only submit his work at tg, which was the
estimated ‘‘due date’’. Therefore, Goldratt opposes the
idea of paying too much attention to intermediate ‘due
dates’ as this encourages the wasting of time. The time
Fig. 5. Five steps in TOC approach [26].
wastage is due to a number of causes, which include:
1. Student’s Syndrome: once a resource has nego-
tiated a tg, which contains ‘‘safety’’ margin which
is viewed as a ‘‘padding’’, the executor re-evaluates
the task and decides how long it will most likely
take, say tm. Then he gets caught up working on
other tasks, knowing he has built-in ‘‘safety’’.
When he realises the remaining duration is squeezed
to become just enough to meet the due date, he
quickly ramps up the effort level. At that point, if
he encounters an unexpected problem as Murphy’s
Fig. 6. Activity time uncertainity.
K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262 259

6.2.3. Critical chain approach chain, critical or non-critical, will be considerably less
In CCPM, Godratt suggests that when making plan than the sum of all the individual variances for tasks on
and schedule, the planner, firstly, assumes that each the project chain. In other words, the amount of buffer
activity executor finishes his task at the mean time tm. necessary to protect a project chain would be much less
All the ’paddings’ in activities should be removed [25]. than the summated safety paddings removed from the
Further suggestion is made that for a 95% level of con- individual tasks. Goldratt makes the following impor-
fidence (that the estimate will not be exceeded) estimation, tant recommendation that the originally aggregated
all the originally padded time estimates could be cut by buffer is to be cut by half (Fig. 7c). This recommenda-
half to obtain the mean time estimates (Fig. 7) [27]. tion is of course arbitrary and needs further validation.

6.2.3.1. Project buffer. After the cut in time duration, 6.2.3.4. Resource de-conflict. In Fig. 7d, a critical
the planner would then add a dynamic project buffer at resource ‘‘B’’ is simultaneously deployed in more than
the end of the project for overall schedule protection. If one path, and it has to be ‘‘de-conflicted.’’ The resource
an activity is finished earlier than scheduled, the next de-conflict is necessary due to critical resource con-
activity will start earlier. If a critical activity is finished straint and, as a result, it may cause the critical chain to
latter than its scheduled due date, the project buffer will shift and extend.
absorb it (Fig. 7a,b)

6.2.3.2. Feeding buffers. For non-critical chains, nota- 7. Framework for improved engineering procurement
bly the sub-critical chains, an appropriate amount of
‘‘feeding buffer’’ will be inserted at the end of each of This paper proposes an enhanced framework for
these non- or sub-critical chains in order to protect the improved project procurement by incorporating both
longest path, which is the critical chain, from being the supply chain and critical chain concepts.
‘‘penetrated’’. Any slip in a sub-critical chain will be
absorbed by the feeding buffer (Fig. 7b). 7.1. Importance of ‘‘partering’’ relationship

6.2.3.3. Buffer estimates. By the random number A positive partnering relationship requires carefully
Aggregation Theory, the overall variance of a project pre-qualifying and the selection of reliable materials and

Fig. 7. Critical Chain Schedule [27].


260 K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262

equipment suppliers. The supply chain can be extended 7.2. Feeding buffers for procurement uncertainties
and built around them. Such a partnering relationship
may be selectively cultivated in which partners can Though each procurement activity individually does
negotiate and make strategic contracts flexibly and not have padding, there is still a project buffer to protect
rapidly. Purchasing commiment may be negotiated and the required project completion date. The enhanced
made even before a project starts. framework proposes that discrete ‘feeding’ buffers be
In the networked enterprise, information systems may added to all major materials and equipment procure-
be extended and linked so that information flows in and ment parallel chains, which have been already tightened
among organizations are enabled, especially through considerably, to provide ‘protection’ so that the critical
Internetworking. chain for construction can be protected.
Upon building the trust and information systems inte- Fig. 8 shows an improved procurement performance
gration among the partners, certain intermediate pro- using buffer management under the new framework.
cesses can be eliminated or simplified. For example, the For the procurement of the major equipment, the two
sourcing, negotiating and contracting procedures may be important control dates are ‘Promised Delivery (PD)’
streamlined and made simple. Suppliers will be in a better dates by the equipment vendors and the ‘Required-on-
position to provide inputs to project planning and Site (ROS)’ dates according to the master project sche-
improve the planning efficiency and project performance dule. Between these two dates, an appropriate amount
due to timely availability of more accurate information. of feeding buffer is inserted. Estimation of the buffers is
The partnering relationship with the vendors and sub- based on a careful and systematic classification of per-
contractors allows and enables the inplementation of the ceived risk and uncertainties associated with the entire
Critical Chain methodology. The uncertainty in time esti- procurement and logistics process for each major pro-
mation can be reduced due to focus on task execution and curement item. The risk identification and assessment
improved confidence in estimation. ‘Padding’, a local pro- will be conducted in the procurement planning stage
tection for procurement activities may be removed. The based on past experience, historical data, supplier’s
procurement/logistics schedule can be made ‘tighter.’’ Stu- inputs, and current market forecast.
dent syndrome and multi-tasking will be discouraged. In the critical chain management, project activities
Activitiess are more likely to be completed in the reduced including those of procurement are to be made critical on
mean time. Partnering helps to cut short the procurement a ‘‘tight’’ 50/50 even-chance time estimates. Unnecessary
pipeline, and reduces sources of variations and uncertainty. early placement of orders for non-critical materials and

Fig. 8. Buffer management in procurement.


K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262 261

equipment is to be avoided, while advanced materials as appropriate, in the entire procurement chain, in a
planning is, however, necessary for long lead-time critical continuous process improvement effort. The strategically
equipment from overseas manufacturers. Goldratt sug- inserted feeding buffers will be simultaneously and jointly
gests that non-critical paths should be started as late as planned, tracked and managed by both the contractor
possible (ALAP), but it should be protected with feeding and vendors concerned. The critical chain approach,
buffers to prevent any delay from passing on to the cri- provides a powerful basis for raising the criticality and
tical chain thus causing project schedule overrun [25]. performance of procurement. The outcome will be fur-
Based on TOC, major constraints and bottlenecks will ther enhanced with the supply chain system, process,
be continually identified, exploited, removed or elevated and IT infrastructure as well as a partnering mindset

Fig. 9. From‘‘As-Is’’ to ‘‘To-Be’’ EPC project performance.


262 K.T. Yeo, J.H. Ning / International Journal of Project Management 20 (2002) 253–262

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