8. Case Study: Implementation in Large Copper Concentrator EPC – Fluor A major copper concentrator project in Chile required the fabrication and delivery of approximately 12,000 tons of steel across six fabrication shops located in China, Chile, and Peru. Managing more than 50 engineers, multiple subcontractors, and five separate databases created serious visibility and coordination challenges for an initiative exceeding US$50 million. The typical EPC sequence consisted of modeling steel in SmartPlant 3D, issuing IFC (Issued for Construction) drawings in Coreworx, detailing and shop fabrication, shipment updates in spreadsheets, warehousing receipt, and site issuance in the warehouse software. Between each of these steps gaps naturally occurred; it was project critical for the execution team to find these gaps / bottlenecks as fast as possible to ensure that the engineering was completed in time and that the material arrived at site when construction needed it protecting the project cost and schedule. In the traditional manner each of these databases requires excel exports and integration on a weekly basis required constant back and forth. Without integrated data, the project risked late deliveries and miscommunication among engineering, shops, and construction. Implementation of the Five-Phase Framework: System Integration & Data Centralization (Phase 1): The team deployed Fluor’s EPIC database (EPC Integrated Console), a central data lake that automatically drew from key systems: engineering (SmartPlant), document control (Coreworx), material management (MatMan), and others; creating a single source of truth for all steel-related data. Automated Dashboards & Stakeholder Visibility (Phase 2): Custom dashboards in Power BI provided area-by-area status of engineering, detailing, fabrication, and material arrivals. Dashboards were tailored for different stakeholders: senior management, fabrication shop leads, advanced work package planners, and warehouse teams and updated automatically every 24 hours without manual intervention. o Management Level: Highlighting high level metrics at a project level. Total quantities vs quantities at site. Material availability and progress per each Workfront. o Shop Manager Level: providing the next level on detail status for drawings (engineering and shop) as well as material fabrication status for all the major buildings. o Advanced Work Package: providing an integrated view to answering the essential questions for the AWP team. (1) What is the scope? in terms of drawings, quantities, and number of elements? (2) Is the engineering ready?; this includes home office engineering and shop detail drawing and (3) is the material at site? o Material Management: A dashboard as well as a detailed list of the status of every single component, nut and bolt received at site, waiting to be delivered and installed by construction. Figure 5 – Steel EPC Funnel
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