Case Study

Improving Flange Management Efficiency on Offshore Projects

The Challenge

Malaysia Marine and Heavy Engineering Holdings Berhad (MHB) was tasked with constructing platforms for Shell, PETRONAS, and Carigali-PTTEPI.

Historically, flange management was outsourced, but MHB decided to handle it internally for the first time. The company faced challenges with manual processes, such as: MHB partnered with Cumulus to digitize and streamline the flange management process, ensuring real-time traceability, enhanced workflows, and improved quality control. Cumulus was implemented in two key projects: the Rosmari-Marjoram (RM) project and Carigali-PTTEPI Operating Company (CPOC) Phase 6, covering 4,100 flanges in total.

Difficulty maintaining traceability with paper-based records
Inefficient workflows, including improper tool calibration and unstructured documentation
Lack of real-time data and accountability, leading to potential human errors and inefficiencies

The Solution

MHB partnered with Cumulus to digitize and streamline the flange management process, ensuring real-time traceability, enhanced workflows, and improved quality control. Cumulus was implemented in two key projects: the Rosmari-Marjoram (RM) project and Carigali-PTTEPI Operating Company (CPOC) Phase 6, covering 4,100 flanges in total.

Project Timeline

Rosmari-Marjoram (RM)

May 2024 - September 2024
1,500 flanges managed
First internal flange management effort

Carigali-PTTEPI Operating Company (CPOC)

July 2024 - April 2025
2,600 flanges managed
5 wellhead modules

Testimonial

“Cumulus ensured accuracy, accountability, and seamless execution, reducing errors, minimizing rework, and improving cost efficiency while ensuring strict adherence to project timelines.”
— Senior Construction Engineer

The solution consisted of three key steps:

Integration
Cumulus integrated data from Excel into a centralized platform, ensuring real-time updates on flange status, progress, and tool management.
Documentation
Cumulus captured real-time data with checklists and photographic evidence, preventing protocol bypass and ensuring full documentation.
Guided Workflow
A structured workflow was enforced, with pre-set torque and tension values, tool calibration alerts, and step-by-step guidance for workers, ensuring precise execution and minimal rework.

The Results

Improved Traceability

Real-time data collection and systemized documentation increased accountability and enabled more efficient audits.

Enhanced Efficiency

Structured workflows minimized rework and optimized manpower allocation, leading to faster project completion.

Higher Quality

Real-time torque monitoring and automated checks ensured first-time-right execution and reduced errors, improving overall work quality.

Offshore Quality Assurance

Implementing a Digital Bolted Joint Management System for Quality Assurance During a Refurbishment Project

Quality Management Systems Support and Enhance Companies’ Quality Assurance Processes Using Data and Digital Tools

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