Major Project in CIS (non-ERDF financial institutions)Reasons for Cost Over-RunsIn general, the underlying theme for cost over-runs is inexperience in the CIS system, compounded byoverconfidence in the Western system. In the planning and development stages, the project was approached toomuch from the Western perspective, applying Western project rationale without adequate attention to theproject country’s perspective and cultural differences. Insufficient attention was given to important details,labour resources, construction equipment, logistics and scheduling that would be affected by the culture,traditions and labour practices.The primary reasons for cost over-runs are as follows:General Lack of Experience in Foreign ProjectsThe sponsor and the consultant company relied too heavily on the assurances offered by their local partnersin the joint venture. The sponsor should have insisted on a more thorough investigation of the localconstruction company’s capabilities, including their ability to supply the promised construction equipment andskilled labour, and their past project experience. The lack of investigation and follow-through greatly impactedupon the completion of construction and of increased costs throughout the entire project. There was acomplete underestimation of the local labour force regarding their productivity and technical proficiency. Thesponsor and the consultant company did not verify the validity of the local construction company’s costestimate and did not budget sufficient contingency funds in view of the extremely tight construction and startup schedule for an operation of this magnitude.
Freight Costs
An inadequate assessment of the complexity of the project site along with the long logistic chain proved very
costly. Equipment which the local construction company failed to supply had to be air freighted from the USA
to mitigate construction delays. More costly air and truck transportation replaced rail transport in order to
speed delivery of the spare parts and maintenance inventory requirements of the operation.
Underestimation Of Costs For Spare Parts and Maintenance
The need for replacement parts and maintenance costs for the processing cycle were underestimated. Delivery
delays necessitated a storage of 12 months of inventory on-site rather than the initial 3 months plan.
Operating Cost Over-Runs
These are driven mostly by labour, maintenance, power and freight. The labour costs were higher and
productivity lower than budgeted. Higher maintenance costs were due to the fact that more replacement parts
were required than budgeted for. Power rates were raised after the project was operational, making them
higher than originally estimated. Freight costs were much higher than planned driven by a substantial use of air
and truck freight to satisfy maintenance inventory requirements.
Inadequate Design of the Plant
The initial feasibility study was inadequate. Final engineering and design changes had to be made to include more
buildings and equipment. Extra costs were incurred for materials, engineering, procurement, equipment, labour
and general management throughout the entire fabric of the operation.
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