ENGINEERING &
MATERIAL CONTROL

Effortless Material Control: Streamlining Design to Execution with Seamless BOM and MTO Processes

Streamline your projects with Effortless Material Control. Once your design is ready, our system generates a seamless Bill of Materials (BOM) or Material Take-off (MTO), transforming it into a quick requisition for purchase.

What is Material Control ?

Material Control should ideally be a straightforward process, where a Bill of Materials (BOM) or Material Take-off (MTO) is generated after the design is completed and then used for purchasing materials.
However, in reality, the different phases of material control often overlap, leading to situations where installation begins before the design is even finished.
Managing the purchasing of materials while the design is still in progress and dealing with material shortages can be complex, time-consuming, and costly.
Additionally, controlling sub-contractors during these intermediate phases can further add to the challenges and expenses involved in material control.
Material control is the system that ensures the provision of the required quantity of material of the required quality at the required time with the minimum of capital investment. It covers the following functions:

Scheduling of requirements
Purchasing
Receiving and Inspecting
Storing and Issuing
Stock Control

ENGINEERING & MATERIAL CONTROL Solution Includes

1

PGOLD

Office Productivity Suite With Resource Assignment Analysis, Time Booking, File Tracking, To Do List, Calenders etc.

PROPLAN

2

Project Network Scheduling, Forecasting and Resource Lookahead Analysis Solution

4

PRODOCS

Electronic Document Management System, MDR/VDR, Commenting & Approvals, Workflows & Transmittals

ICGP

5

Databank for all disciplines, Item Codification

PROCHAL PROSAFE

Project Risk/Challenges Management System, Risk Register, Matrix, Heat Map, Mitigation, HSE Management, Compliances, Audits, Meetings

6

7

TRACK N TRACING

Material, Inventory, Progress Tracking using Barcode & RFID Mobile app

PRODASH

8

Organization MIS, Project MIS, Productivity Analysis, Interactive Dashboards, NLP

13

MATCONTRK

Material MTO evaluation, Substitution, Look Ahead Material Planning, Planning Analysis Reports

ISOMEC 🞹

Piping Isometric creation, Material Specification, Valve Data Sheet, Wall Thickness Calculations, Isometric Construction Drawings and Reports

15

16

AUTOSPOOL 🞹

Automatic Piping Spooling, Fabrication & Erection Isometrics, BOQ, Weld data, Inch-Dia, Inch-Meter / Feet, Pipe Cut-List and more

EFA MFA

17

Engineering Front & Material Front Analysis, Indent for WHAM, Construction Job Cards

Need of Material Control ?

Planning the proper control of materials and supplies is one of the initial steps in installing a Cost System.
Material is a significant asset and the largest cost item in most businesses.
The success or failure of a concern depends largely on efficient material purchasing, storage, accounting, utilization, and control.
Improper material control can lead to excess stock, tying up capital, and loss through deterioration and obsolescence.
Shortages of materials can cause production delays.
Purchasing materials requires specialized skills to order the right quantity and quality at the best price and ensure timely delivery.
Efficient material control reduces losses, waste, theft, misappropriation, deterioration, breakage, and storage costs.
Availability of materials reduces idle time in the plant and meets production staff demands.
Reliable costing information relies on satisfactory records of material issues.

Issues with Material Control

No Quote Items : Communication on No Quote Items is not made either by C&P or Project after unpriced bids opening. This delays in procurement of such items apart from confusion at Piping Department
Suggestion : E-mails to be sent to all the concerned the same day.
Reconciliation of Materials : At present, reconciliation of materials are done by the contractors at the end of project work. This causes great problems in tracking, monitoring & control of materials at contractors end leading to shortage and generation of surplus.
Suggestion : A comprehensive system has to be implemented which will provide real time reconciliation / stock status of each material.
Offloading of Jobs : During course of piping execution, sometimes, the main contractor fails which warrants off-loading of jobs. In such situation, more than one contractors work in the same zone. This leads to material issue problem.
Suggestion : MTO to be prepared area-wise instead of zone-wise. Offloading of part line to be avoided.
Accuracy of MTO : Correctness of MTO(II) is not in line with requirements. Lot of lines/qty. are added/deleted from one MTO to next MTO. This is one of the main reasons for generation of Surplus. Mismatches in MTO data w.r.t drawings is another big problem. Delay in release of MTO Dump.
Identification of Piping Spools & Substituted Items : Due to non-availability of procedure for management, tracking and identification of spools & substituted items becomes difficult. Sometimes spools are lost resulting in additional procurement apart from adverse impact on project schedule.
Suggestion : A proper procedure needs to be developed which may include System / Line-wise stacking of spools.
Excess Issue to the Contractors : There are changes in Qty. from one MTO to next MTO. This is either due to reduction in Qty. or deletion of Lines or both. Adequate material control system is not available to take into account the excess issues of materials to various agencies while generating shortage reports.
Transfer of Materials across the Projects : To minimise surplus and also to avoid delay in procurement, proper MTO analysis needs to be done before preparation of Material Requisition.
Delivery Forecast of Piping Materials :In the present systems, month-wise delivery forecast of piping materials is not available. As a result material front calculation against ordered materials is difficult. Besides, equivalent ID/IM against a particular MR/PO is not available in the systems.

Requirement of a System for Material Control?

The important requirements or essentials of adequate and satisfactory system of material control are as under;

Proper Co-ordination

Proper co-ordination of all departments involved, in material purchasing, receiving, testing, approving, storage, issue and in accounting, is essential.

Competent Purchasing Officer

Centralization of purchasing in a purchasing department under the direct and authority of a competent and trained purchasing officer is also considered essential.

Use of Standard Forms

The use of standard forms for orders, requisitions etc, upon which written and signed instruction are given, are essential for proper control of materials.

Control by Budgeting Material and Equipment

Use of materials, supplies and equipment budgets so that the economy in purchasing and use of materials can be realized, is important factor for adequate control of material.

Storage Location

Storage of all materials and supplies should be in a designated location properly safe guarded under supervision and proper planning should be there for storing and issuing of materials.

Operation of perpetual Inventory

Operation of proper perpetual inventory system should be used so that it is possible to determine at any time the amount and value of each kind of material in stock. It also enables the comparison of book inventory with the results of physical counting.

Standards or Levels to be fixed

A minimum quantity of each item of material, below which point the inventory is not allowed to drop, and a maximum quantity, above which stock is not carried should be fixed. In the same manner ordering level and Economic Order Quantities may be determined.

Storage Control and Issue

The proper operation of a system of stores control and issue is introduced so that there will be delivery of materials upon requisitions to departments in the right amount at the time they are needed.

Internal Check

The operation of internal check should be introduced to ensure that transactions involving materials and equipment are checked by reliable and independent officials.

Development of Controlling Accounts and Subsidiary Records

Controlling accounts and subsidiary records reveal summary of detailed materials costs at each stage of material receipt and consumption from the store room to finished goods.

Regular Reports

Regular reports and information should be provided to the management in connection with the purchases of materials, issues from stock, inventory balances, obsolete stock, goods returned to vendors, and spoiled or defective units.

Systems available with Parascadd

Procurement Management (PROMA)

Major features of PROMA System for Tag & Bulk Items is as under;

MTO Analysis for probable Substitution
Generation of Material Requisition (MR)
Bidders List
Issue of Request for Quotation (RFQ) to placement of PO
Monitoring of Manufacturing & Delivery
Inspection and Expediting

Material Control (MATCONTRK)

Major features of MATCONTRK System is as under;

Generation of Look Ahead Planning of Material based on Piping MTOs and CDD of Purchase Orders as well as Expediting Reports. MATCONTRK Reports will help in Construction Planning.

Material Control ( AutoSpooling )

Major features of AUTOSPOOLING System is as under;

Generation of Spool-wise MTO from IDF/PCF & other files
Generation of Isometrics as well as Spool Drawings
Taking inputs from PROMA, it makes Material Front Analysis
Allocation of Materials for Lines as well as for Spools
Generation of Indents for WHAM for issue of MIVs
Real Time Reconciliation & Stock Status of Materials
Optimum utilization of Materials. Scrap generation is bare min.

Warehouse Management (WHAM)

WHAM is an End to End Warehouse Management System.

S.No.	SOFTWARE MODULES	DESCRIPTION	SOFTWARE FUNCTION PACKAGES
S.No.	SOFTWARE MODULES	DESCRIPTION	APEXMIS	PROJECT PLANNING & CONTROL	ENGINEERING & MATERIAL CONTROL	PROCUREMENT & WAREHOUSE	CONSTRUCTION & COMMISSIONING
1	PGOLD-ERP (PGOLD-BASE + PGOLD-PLUS + PGOLD-PRO)	Organogram, Calendar, MOM, Unit Converter, Report Designer,Time Sheet Booking, Job Order Management, Project Charter, Project Photos, Areas of Actions, Project Function Input, Customer Relationship (Sales) Management, Resources Planning & Management, Assets Management, Ticketing System	✔ 3X**	✔ 3X**	✔ 3X**	✔ 3X**	✔ 3X**
2	PROPLAN	Project Network Scheduling, Forecasting and Resource Lookahead Analysis Solution	✔	✔	✔	✔	✔
3	PROCOST	Cash flow, Cost Estimation & Profit Evaluation, Budgeting & Control (Including Cost Forecasts)	✔	✔	❌	❌	❌
4	PRODOCS	Electronic Document Management System, MDR/VDR, Commenting & Approvals, Workflows & Transmittals	✔	✔	✔	✔	✔
5	DATABANK-ICGP	Databank for all disciplines, Item Codification	✔	✔	✔	✔	✔
6	PROCHAL-PROSAFE	Project Risk/Challenges Management System, Risk Register, Matrix, Heat Map, Mitigation, HSE Management, Compliances, Audits, Meetings	✔	✔	✔	✔	✔
7	TRACK N TRACING	Material, Inventory, Progress Tracking using Barcode & RFID Mobile app	✔	✔	✔	✔	✔
8	PRODASH	Organization MIS, Project MIS, Productivity Analysis, Interactive Dashboards, NLP	✔	✔	✔	✔	✔
9	FLS5	Detailed Functional Scheduling & roll-up progress calculations at Project, WBS, Discipline Activity level	❌	✔	❌	❌	❌
10	PDIM#	Constructability, Erectability with advanced work packages dynamic information modeling	❌	❌	❌	❌	❌
11	COCOSYS	Construction & Contractor Activities Scheduling System, Contract Work Items, Scope Quantity Distribution, Schedule & Actual S-Curves	❌	✔	❌	❌	❌
12	PROMA	Procurement, Manufacturing & Delivery, Tender Management, Vendor Performance Evaluation	❌	❌	❌	✔	❌
13	MATCONTRK	Material MTO evaluation, Substitution, Look Ahead Material Planning, Planning Analysis Reports	❌	❌	✔	❌	❌
14	WHAM	Warehouse Management, RFIs, Inspections, OSRDs, Reconciliation	❌	❌	❌	✔	✔
15	ISOMEC	Piping Isometric creation, Material Specification, Valve Data Sheet, Wall Thickness Calculations, Isometric Construction Drawings and Reports	❌	❌	✔	❌	🞹
16	AUTOSPOOL	Automatic Piping Spooling, Fabrication & Erection Isometrics, BOQ, Weld data, Inch-Dia, Inch-Meter / Feet, Pipe Cut-List and more	❌	❌	✔	❌	🞹
17	EFA & MFA	Engineering Front & Material Front Analysis, Indent for WHAM, Construction Job Cards	❌	❌	✔	❌	❌
18	SPOOLMAN-ERMAN	Fabrication & Erection Automation, Progress Monitoring & Reporting for Piping Works	❌	❌	❌	❌	✔
19	CIVILMAN STRUCTMAN	Civil & Structural Works Progress Monitoring & Reporting	❌	❌	❌	❌	✔
20	EQUIPMAN	Equipment Fabrication & Erection Progress Monitoring & Reporting	❌	❌	❌	❌	✔
21	ENIMAN	Electrical & Instrumentation Progress Monitoring & Reporting	❌	❌	❌	❌	✔
22	PCAM	Pre-commissioning & Commissioning	❌	❌	❌	❌	✔
23	PROCCPL	Material, Inventory, Progress Tracking using Barcode & RFID Mobile app	❌	❌	❌	❌	✔
24	DCAD	Web Digital Computer Aided Design	❌	❌	releasing soon	❌	🞹
* AUTOSPOOL & ISOMEC are available separately and can be merged into the above-mentioned solution packages. Each software purchased from Parascadd entitles the customer to receive XX licenses of PGOLD-PRO (Named licenses). # PDIM module is available for time-bound (subscription-based) licenses only. Note: For SaaS (On-Cloud), 100 GB space** is default available for organization accounts up to the active license period. Additional space needs to be purchased separately.