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Think you know how to R.E.V.I.E.W. defined costs?

Equipment costs

Assurance basics - Agency

Reimbursable style contracts are widely used today on major construction programmes.

NEC ECC Option C and E contracts tend to be the backbone (currently) of reimbursing high risk infrastructure projects in the UK.

Within these contracts, the basic clauses allow project managers (usually delegated to their cost managers) to inspect accounts and records of their choice in relation to cost items claimed. Z Clauses are commonly added to allow for third party or client auditors to drop in “as and when” to audit or verify supplier cost.

Those suppliers being audited need to be helpful and transparent that’s pretty much it.

The audit side occasionally becomes overly complex, with onerous volumes of records being requested, meaningless conclusions drawn from samples and mischarges extrapolated aggressively (and often incorrectly).

We try and keep it simple, using the acronym R.E.V.I.E.W, which offers pragmatic guidance on how to plan and deliver assurance work.

This paper is one of a series of tip sheets produced by TOP – this one focusses in on equipment costs.

R.E.V.I.E.W RECAP

In case you missed the last blog or just need a quick memory jogger, the acronym R.E.V.I.E.W. should help your thought process when reviewing any cost element. Much of this goes to the heart of smart or risk based auditing.

R - Rules of the contract
A cost type is only allowable if it passes the reimbursement rules of the “specific” contract.

E - Environment
Understanding the importance of the operational and financial control environment in which costs are managed and presented is critically important to your assurance work. Be prepared to speak with project and finance team members (both client and supplier), walk the site and review key contract documentation to better understand the project set up.

V - Visualise data
Intelligent data analysis and visualisation are key tools to better understand how and where money has been spent.

I - Identify risk and design tests
A thorough understanding of the cost area being reviewed should emerge through the first three steps above. This will help flush out specific project and contract risks that require review. This will be over and above core transactions that will provide the bulk of your assurance.

E - Examine and evaluate accounts and records
A good open working relationship with the supplier being reviewed is essential to obtainings ource documents backing up the cost claimed. Throughout your work, make sure you regularly check back in with your client project manager and cost manager too.

W - Write up findings, draw conclusions and report
All examinations should follow a robust and formal recording and reporting process. No ifs, no buts. Always leave an audit trail of work completed and assurances obtained.

EQUIPMENT

So, let’s start our REVIEW process for equipment. First a bit of background.

Yes, we are talking equipment here, NEC speak, whereas the rest of the industry still uses plant with minimal chance of it changing i.e. plant manager, plant yard, heavy plant crossing etc. NEC defines Equipment as items that are used by the contractor to Provide the Works. Plant and Materials are intended to be included in the works.

ECC contracts define what can be charged as equipment based on a number of different scenarios shown in the Schedule of Cost Components (SOCC). Typically, these include for equipment that is: listed in the Contract Data; owned by the contractor or hired from a group company; or cross-hired from third party plant hire suppliers. There is also the proviso that it is used within the Working Areas.

In terms of which scenarios apply, this will be heavily determined by the contractor’s procurement and asset management strategy. Certain contractors are keen to buy and maintain their own equipment (and make available to all live projects they are working on), whereas others will look to hire in everything from third party suppliers. In addition, there will be certain projects which due to their complexity require the sourcing of specific or special equipment, which will need carefully referencing in Contract Data.

When you are about to commence a review of equipment costs on any given project it is therefore always worth trying to understand what the initial equipment budget was and whether an equipment resource plan exists. This will help identify the initial expectation of the types of equipment to be procured, expected durations and perhaps the source of supply i.e. owned or intercompany or third party hire.

The defined cost demonstration for equipment can be complex.

Expect lots of transactions from the cost ledger which are high volume and low value. Effective visualisation of data is absolutely key here and is explained further later.

Where equipment costs are via a third party, expect demonstration to be heavily geared around records such as purchase orders, conditions of hire, invoices, proof of payment etc.

If costs are from contractor owned equipment, expect benchmarking exercises to take place to demonstrate open market rates (core clause 52.1). In addition to accounting records, there are likely to be site records further referenced in the scope (core clause 52.2) which often identify the need for monthly plant reports (incorporating utilisation and telematics data), allocation sheets/site diaries to confirm what equipment was needed and when.

There are many cost components that get tweaked (rightly or wrongly), however equipment is one of the few that doesn’t get heavily amended.

Against the vanilla SOCC, expect regular equipment to be backed up by traditional invoices if third party supplied, and if contractor owned, expect either a price from an internal price list or an intercompany invoice. Value for money in these latter transactions need to be at market rate as explained above.

We regularly see equipment listed in the contract data at industry recognised rates, such as CECA with a + or - % variance.

There will also be equipment which needs to be bought in specific for the project. If so, it should be listed in the contract data with the contract charge being the effective diminution of value (whether sold after use or assessed at its market value).

Then there is special equipment (again which needs to be listed in contract data) which has a value in use but can’t easily be supported by accounting records. A reason for this might be the rarity or age of the item e.g. a specific size of tower crane.

An important rule where equipment is concerned is core clause 52.1, which states that amounts must include deductions for all rebates and discounts which can be recovered. There are many national suppliers of equipment who can offer quite attractive volume discounts, so pay particular attention to these, especially if your contractor has single sourced an equipment supplier.

Although rule changes for equipment are rare, still check your contract in all the usual places (SOCC, Z Clauses, Scope information) for potential amendments.

Also read the contract rules to better understand the cost management aspects relating to equipment whether this be requirements for evidence of hire v buy decisions, on/off hire reports, telematics/utilisation information, monthly resource plans/whereabouts reports, condition/damage reports, monthly budget v actual analysis and forecasting reports (with variance narratives).

The above just gives a flavour of rules and information to look out for when commencing a review of equipment cost. Also, think how the above could easily apply in exactly the same way for key reimbursable subcontract packages (using equipment) especially if main contract terms are passed back to back down the supply chain.

Understand the importance of how equipment costs are prepared, controlled and reported in your project as this heavily influences mis-charging risk.

  • Obtain a good background to the project and the contractor you are auditing. Consider a process review to understand preventative and detective controls to drive robust equipment charging and Application for Payment compilation. A tour of the site, the plant yard and a good conversation with the plant manager (sorry equipment) are all really useful to a) understand the sheer volume of equipment on site b) how it is received and inspected on arrival and c) how it is managed and reported day to day
  • Understand what further equipment data can be produced outside of the basic contract cost ledger report, which may just be a one-liner of a cost per asset type per week or month.
  • Typically, on hire reports show better asset details, coupled with specific daily/weekly or monthly charge rates and periods utilised
  • Understand the wider environment a – is the contractor sharing equipment across multiple projects? If so, you may need to liaise with other audit teams or project commercial staff to see if there is an obvious risk of equipment duplicate overcharging
  • How has the equipment account progressed to date? What can the client cost manager reveal? Has the equipment account been heavily reviewed to date? Is there a good narrative on cumulative equipment costs and a robust understanding of what is currently on hire? Any events or periods of idol time that might suggest equipment costs should be disallowed (in accordance with core clause 11.2 (26))? If so, have costs been withheld or disallowed? Have these been accepted by the contractor or challenged?
  • Has equipment been captured elsewhere, perhaps within “all in rates”? As an example, company cars/site vans/IT equipment might all be rolled up in a pre-agreed hourly rate for people. There could be a duplication charging risk quite easily here
  • Finally, where is your audit going? Is it just basic support for the Project Manager in routine and ongoing AFP assessments or something wider? Does your review have Cl50.9/final account implications?

Equipment data is often the hardest cost ledger data set to understand, analyse and sample. The steer above is therefore very important to help understand the basic hiring process and what additional data and reports are available to help build a better picture of equipment charging.

With a decent data set (both accounting and site records), a lot of equipment analysis is possible, across data fields such as supplier, equipment cost code/type, units, rates, date, free text description etc.

The first tip is to overcome the volume risk.

  • A simple graph showing equipment cost per month will usually show a spend curve aligned to core labour activity.
  • The peak will be when key machines, perhaps earth shifting are on site.
  • The start and end of the graph curve will probably show non operated equipment.
  • A further analysis by equipment type over time will shed light on where the big money is being spent, particularly important for some of those open market/value for money checks.
  • A more detailed analysis, for say one busy month only, will also help capture what the key repetitive themes are for charging. Repetitive is the key word here.

Further data analysis for equipment is possible, including:

  • Spend per supplier (useful for assessing rebatepotential and use of internal companies)
  • Spend versus budget at a work breakdown structure
  • Spend per asset type and lower-level description e.g. hire, transport, maintenance, damage etc
  • Aged equipment accruals (if accounting system picks up initial liabilities pre invoice/matching)
  • Operated equipment hire misaligned to labour hire/cost
  • Operated equipment hire during site closures
  • Operates equipment cost versus telematics usage
  • Retrospective hire v buy analysis
  • Frequency of equipment booking; high hours/low hours/overtime patterns

Add this to useful site information such as allocation sheets and site diaries and you can quickly gain confidence over whether those larger assets have been needed to provide the works, are accurately charged and provide value for money. Larger operated assets often have telematics and cabin CCTV available as well, to help demonstrate activity on your project.

A PRACTICAL EXAMPLE

A recent review we were involved in related to over 5,000 equipment transactions over a 4 year period totalling some £6m – where do you start?

Some quick graphs like those above identified 20 small equipment items (CAT detectors, laser levels, measuring equipment etc) which had been booked to the project every week for four years. This equated to only £100k but accounted for over 4,000 of the costed entries in the contract cost ledger.

The remaining 1,000 transactions actually related to the bulk of the £6m of cost – again most of these related to repetitive hires, approximately 20-30 months per asset.

We quickly identified there were only 35 large assets of this type that we needed to audit.

So very quickly we removed £100k of noise via the small value equipment and then left ourselves with a core asset base to review.

A thorough understanding of the environment, plus good data analysis should help shape where costs may be mischarged against the identified rules.

It is important to consider or link all the rules back to specific tests. This should identify people or trends and patterns of interest for further inspection.

Beyond test design, you must also work up a pragmatic sampling strategy for risk-based and other core transactions giving the assurance coverage required.

You will probably want to look at specific assets or scenarios you see as risky e.g. are special equipment items in accordance with contract data, as well as checking you have properly captured and reviewed all damaged equipment costs, (further to this you will need to understand the conditions of hire and contract rules to see whether these are allowable).

For your core testing you will want to focus on those key hires, across third party and internally hire equipment.

This keeps sampling simple and manageable.

Remember sampling must be relevant to the wider population, so don’t just focus on a few hires in one particular month or an asset type you understand particularly well.

Request the records required from your contractor and inspect what is provided.

If things appear wrong always try to understand why? What is the root cause of the issue? Control problem? Isolated error? Does the supplier response hang together? Should you be widening your sampling to better understand the problem?

Record your work, write it up and report. You never know who may need to access it after.

Too often we hear of equipment audits, with the view being it’s all ok. What was done we ask? What has been documented? Cue blank faces. At best, the cost ledger records were partially reconciled to a monthly equipment on hire report. The volume of data was excessive/complex we are then told!

If you need a hand, please give us a call.

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