Fundamentals of Plant Maintenance: Questions to ask before you start John Harrison SAP SESSION CODE: EM623
Objectives
To develop an understanding of SAP EAM / PM To identify those areas where significant preparation needs to be done To identify those areas where key decisions are to be made / understood
Not to be able to create objects (master data etc. ) nor to operate the solutions
SAP Enterprise Asset Management
Design & Specify
Business planning Investment management
Procure & Build
Collaborative specification and design Maintenance engineering
Interfacing CAD systems Project management
Maintenance cost planning
Decommission & Dispose
Asset transfer and disposal Collaborative disposal management Document management Project management Waste management Asset compliance Asset re-marketing
Supplier qualification and candidate selection Bidding and contract management Procurement process Document management Project management Collaborative construction Project and investment controlling
Operate & Maintain
Technical asset management Preventive and predictive maintenance Maintenance planning and scheduling Work order management Mobile asset management and RFID Contractor management MRO and services procurement Work clearance management Shutdown planning Interfacing GIS and SCADA
A Journey Best in class & Advanced Maintenance Techniques A Fully Integrated, Closed-Loop Process Steps of the Enterprise Asset Management (EAM) process are integrated and seamless 1.
Capital Projects
Project Management Collaborative Engineering Cost Controlling
2. Maintenance Management
5. Asset Performance Management
Operator Dashboard Balanced Scorecards Environmental Compliance
4. Reliability
Reliability Centered Maintenance Operating Metrics
Maintenance Planning Resource Allocation Maintenance Execution Mobile Asset Management
3. Inventory & Spare Parts
MRO Purchasing Storehouse Management Spare Parts Optimization
A journey to excellence: What you decide today affect what you do tomorrow Tomorrow
RBI / RCM / RBM Operational Risk
Analytics Procurement / Sub Contracting / Quality Management / PP – PM Integration Maintenance Planning Work Orders / Notifications / Process Simplification
Today
Master Data / Organization Structure / Agree Processes
Get the foundation right
An Over View: The pieces: Simplified
Functional Locations
Characteristics
Measurement Point
Equipment
Maintenance
Item
Plan Planning
Materials
Work Center
Task List
Notification
Work Order
Confirmation
Execution
Maintenance
Bill of Materials
Master Data
Class
And now the questions?
Or, the arguments that you will have
Question: What processes are you supporting? Today & in the Future. Others: STO WCM
Notifications Work
Orders PM
• Inspection Rounds • Automatic Data Collection • Mobile Maintenance Worker • Condition Based Maintenance • Cost Budgeting • Quality in PM • External / Internal Services • Refurbishment • Procurement • …
Question: Do you know what are you maintaining?
An area? E.g. Pump House A piece of equipment? E.g. the Pump Set A part of the equipment E.g. Intake Valve A process? E.g. Bean Blanching
Technical Objects in Maintenance: Equipment & Functional Locations • You should represent an object as a technical object if it is repaired, not exchanged, in the event of a breakdown. If it is exchanged then it represented as a material
Question: Do you know what are your reporting needs?
Do you have regulatory reporting standards? If so what do they require? To what level of detail (object) do you need / want to report to? Are the standard reports enough? Do you need to develop your own reports? What KPI’s do you need?, Create your own?, Procure 3rd party solution, additional SAP product (e.g. OEE) Do you need “what if” or detail drill down capabilities? Might need additional products (Hana, Business Objects ..) Do you need to “model” your PM environment for predictive maintenance? SAP Infinite Insights, Hana Predictive Analytics
Question: What are you modelling?
SAP Definition: Functional Location an organizational unit within logistics that structures the maintenance objects of a company according to functional, process-related or spatial criteria. A functional location represents the place where a maintenance task is to be performed and an area where equipment can be installed.
1. Functional criteria: e.g. pumping station, drive unit 2. Process-related criteria: e.g. polymerization, condensing 3. Spatial criteria: e.g. hall, location
Question: Do you have a hierarchical structure to represent your facility? Structure being represented: • Building • Process • Building & Process To what level • • • • •
Floor Equipment Equipment Part Tag Process Step
How this is represented: Functional Location Structure Indicator The structure indicator determines the edit mask and the number of the hierarchy levels when you create functional location structures. The edit mask defines: •the total length of the functional location number •the lengths of the individual blocks of the functional location number •the characters allowed • Numbers --> Edit mask N • Letters --> Edit mask A • Numbers and letters --> Edit mask X • Special characters and numbers and letters --> Edit mask S
Functional Location: Hierarchical Structure - Example
Note: Location Hierarchy
Note: Use of Structure Indicator PVC from previous slide
Question: To what level are you modelling? Is the breakdown sufficient? •
Too much?
•
Too little?
Does it support your reporting requirements? Do you install multiple equipment in one functional location? Or is it a 1 to 1 ratio?
Too little detail?
Too much detail?
Question: Are you going to use equipment? If so, what equipment are you going define? SAP Definition: Equipment • an individual, physical object that is to be maintained independently. It can be installed in a technical system or part of a technical system (functional location). It represents the object on which the technical tasks are performed. Note: Equipment is installed / de-installed on Functional Locations Note: A piece of equipment that is installed in a technical object can store the history of its installation location. The system records a usage period for each installation location, enabling you to track the complete installation history.
Note: some companies have a policy of the “equipment must be in SAP before you can maintain it”. Thus they are continually adding equipment to the system, as it requires maintenance
Question: Do you use Equipment Structures / Sub Equipment?
Sub Equipment •
Used for transferring of measurement data
•
Used to identify maintainable items of the superior equipment
•
Note: If you use many pieces of equipment as individual objects or equipment hierarchies, without also using functional locations, you should classify the pieces of equipment.
Remember. You are trying to represent something like this
Test: Question: What is it, Equipment or Functional Location?
What do you think of this retort? Equipment or functional location? Floor 2 How about now? Equipment Floor 1
Functional Location Functional Locations?
Question: Do you need to track resources? Production Resource Tools (PRT): Definition – a type of equipment
To perform certain operations in a maintenance order, certain resources are required these are called production resources/tools (abbreviated to PRT ).
PRT’s are involved in the production and maintenance processes process” E.G., tools, measuring equipment, drawings, NC programs, cranes, scaffolds.
Do you need to monitor wear and tear of PRT’s? Can you restore you PRT’s to a working condition? Do you maintain your PRT’s? Do you want to see if the resource is available when you need it? Do you know where (what tasks) the resources are used in?
Question: Do you need to maintain cars and trucks, buses, trains, commercial vehicles (tow-trucks, cranes, …), etc. SAP Definition: a fleet object is an equipment master record with fleetrelevant data. •
Identification data (for example, license plate number, chassis number)
•
Measurement data
•
Transport-relevant data
•
Planning data (for example, criteria based on which the fleet object should be replaced)
•
Further attributes (for example, fuel card number, key number)
•
Engine data
•
Fuel and lubrication data
Question: Do you plan / cost the use of spares, components? SAP Definition: Maintenance Bill of Material • a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure. The components can be stock or non-stock spares or assemblies, which in turn can be described using maintenance BOMs.
Maintenance Bills of Materials are used for • Materials planning (when using maintenance task lists).
• Materials/spares planning (when using maintenance orders) • Locating malfunctions (when using maintenance notifications)
Question: Do use BOM’s by equipment, functional location, or generically (material BOM)? And are they complete? Equipment BOM’s are specific to one piece of equipment (1:1). Equipment BOM’s can contain material specific to that piece of equipment. Functional Location BOM’s are specific to one functional location(1:1). Functional Location BOM’s can contain material specific to that Functional Location. Material BOM’s can be linked to many equipment / functional locations (n:1) via the construction type. Material BOM’s tend to have more materials assigned as they are linked to more technical objects Construction type is on both the functional location and equipment masters
Question: Do you plan report problems down to the assembly level in Notifications? Influences BOM Construction
Bill of Material
Could be a new process?
Will additional training be required?
Do you need to add / record additional information to describe your objects? The classification system allows you to use characteristics to describe all types of objects, and to group similar objects in classes – to classify objects, in other words, so that you can find them more easily later.
Example: Equipment: Class assigned within Equipment
Question: Are you using Maintenance Notification to report problems and corrective actions? By Equipment? By Functional Locations? By … Maintenance Notifications • •
Can you describe the exceptional technical condition at an object? Do you request the maintenance department to perform a necessary task?
•
Do you want to document work that was performed?
Maintenance notifications document maintenance tasks completely, and make them available for analysis in the long term and can be used to perform preliminary planning and execution of tasks.
The following notification types are predefined in the standard system:
Problem notification: Notification of a malfunction or problem that has occurred
Maintenance request: Request for tasks to be performed
Activity report: Documentation of activities that have been performed
Question: Do you need other types of Notifications? E.g. for SIS/SIF reporting, Safety Notifications
Question: Are you going to use Notifications to report problems? Do you have a standardized set of codes for reporting / describing what happened? Do you have / need codes for to represent all the EAM code sets (Catalogs)? • • • • •
Activities “A” Object Part “B” Damage “C” Cause Code “5” Tasks “2”
How many codes to use in a code group?
Do not get too fine (7 – 20) Based on standards? (ISO 14224, …)
Code being used to describe problem part
Catalogs Codes: Object Parts Example – Ball Valve
Ball Valve Object Parts
Valve body Bonnet Flange joints Can be Seat rings grouped Packing/stem seal Seals Closure member Stem Diaphragm Spring Case Piston Stem Seals/gaskets Electrical motor Gear Travel stop Wiring Indicator Instrument, general Instrument, position Monitoring Solenoid valve Pilot valve c Quick exhaust dump valve Internal power supply Limit switch Accumulator Others
Valves Valves Valves Valves Valves Valves Valves Valves Actuator Actuator Actuator Actuator Actuator Actuator Actuator Actuator Actuator Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and monitoring Control and Monitoring Miscellaneous
Question: Do you need to restrict availability of codes? Catalog Profile Example: Object Parts: Profile & Notification
Catalog Profile on Organization Tab of equipment and functional location
Naming Convention is important: Wild card usage
Code Restricted on Notification
Using SAP & Industry Standards to report failures
Establishing your codes / catalogs cross company agreement is difficult. One option is to use codes based on industry accepted standards and map the standard to SAP catalogs. SAP Catalog
Standard
Coding (Coding D)
ISO 14224 Failure Mode: Tables B.6 – B.12 (Failure Mode as observed by operator – RCM Functional Failure
Damage (Damage C)
ISO 14224 Condition; Table B.2 ISO 14224 Failure Mode: Tables B.6 – B.12 (Failure Mode as observed by operator – RCM Functional Failure
Causes (Causes 5)
ISO 14224 Cause Table B.3
Activities (Activities PM A)
ISO 14224 Maintenance Activity Table B.5
Object Parts (Object Part B)
ISO 14224 Maintainable Item; Annex A
For Severity (and other information) create a Classification Class of type 15, and add to Catalog Profile
ISO 14224 Table C.1 Failure Consequences
Question: Do you plan your work? Then you need:
Maintenance Tasks: describes a sequence of individual maintenance activities which must be repeatedly performed within a company. Maintenance Strategy: defines the rules for the sequence of planned maintenance work. It contains general scheduling information, and can therefore be assigned to as many maintenance task lists (PM task lists) and maintenance plans as required Maintenance Item: describes which preventive maintenance tasks should take place regularly at a technical object or a group of technical objects. Maintenance Plan: description of the maintenance and inspection tasks to be performed at maintenance objects. The maintenance plans describe the dates and scope of the tasks
Question: How much detail is required in the maintenance tasks? Do you need additional information? Long Text Or additional operational steps? The detail / steps end up on the work order
Work Order
Question: How may items are being scheduled together?
Task List(s)
Maintenance Item(s)
Maintenance Plan
Do you know how frequently something has to be maintained?
Question: Do you use / track Maintenance Repair Operations (MRO) items? MRO are Supplies consumed in the production process but which do not either become part of the end product or are not central to the firm's output. MRO items include consumables (such as cleaning, laboratory, or office supplies), industrial equipment (such as compressors, pumps, valves) and plant upkeep supplies (such as gaskets, lubricants, repair tools), and computers, fixtures, furniture, etc. Set up in Materials Management
• Do you plan the use / consumption of MRO items? • Do you know which task / op. step the MRO item will be used in? • Is the MRO item in the Equipment / Functional Location Bill of Materials? Or added to the task separately? • Is the MRO item normally kept in inventory or is it a non stock item?
Note: similarly for PRT’s
Work Order Cycle: High Level Overview
PM Notification
PM Order Creation PM Order Release PM Order Material Issue PM Order Confirmations PM Order Technical Confirmation
PM Order Purch. Req PM Order Purch. Order
PM Order Purch. Order Goods Receipts PM Order Invoice
PM Order Business Conformation
Question: Are you and how are you going to use Work Orders?
Are you going to use the combination of notifications and work orders? Associate notifications to order, report causes / tasks etc. back and close out the notification. Are you going to use work order functions to: Are you going to issue materials to the order, or assign people to orders? Are you using capacity leveling, capacity checking, availability checks? How many types of orders do you need? How are costs calculated / budgeted? What approvals for release / execution are needed? What Maintenance Activity Types are required? When is the order Technically Complete vs Business Completion, who does the completion? •
What Shop Floor Papers and other documentation is required to go with the order?
Question: How are you going to confirm activities on the order?
Individually? One Order One Step
Collectively? Many Orders Many Steps
Record actual hours? Estimate remaining hours? Record cause codes etc.? Record Material usage?
Who performs these activities?
Overall Confirmation: Everything about one order
Question: How do you control materials for the Order / and for Maintenance?
These are Materials Management functions: •
Who generates the purchase requisition? Manually, or via the order
•
What is the approval process for a requisition?
•
Who generated the purchase order?
•
What is the approval process for Purchase Order?
•
Who performs the goods receipt?
•
Who performs the invoice receipt?
•
Who reconciles the invoice?
•
Who issues the material to the order?
Thoughts in conclusion: Details, Knowledge, & Objectives Measurement is the first step that leads to control and eventually improvement. If you can’t measure something, you can’t understand it. If you can’t understand it, you can’t control it. If you can’t control it, you can’t improve it. Dr. H. James Harrington
If you don't understand how to run an efficient operation, new machinery will just give you new problems of operation and maintenance. The sure way to increase productivity is to better administrate man and machine W. Edwards Demming
Management by objective works – if you know the objectives. Ninety Percent of the time you don’t Peter Drucker
Technical:
Transactions: •
Functional Location: IL01, IL02, IL03
•
Functional Location Structural Display: IH01
•
Equipment: IE01, IE25 (PRT’s), IE31 (Fleet Object), IE02, IE03
•
Notification: IW21, IW22, IW23
•
Work Order: IW31, IW32, IW33
•
Confirmations: Individual IW41, Collective IW44, IW48, Overall IW41
GUI: NetWeaver Business Client
Co Author:
Keith Lapeyrouse is a reliability engineer working on Dow's CMMS upgrade project.. He has worked within the petrochemical business in inspection, maintenance, reliability, project, consulting engineering and now IT tool development groups and functions for the past 35 plus years. He is a member of the steering team for the Mary Kay O’Conner Center for Process Safety’s Instrument Reliability Network. He is a Registered Professional Engineer in Louisiana and has a B.S. in Mechanical Engineering and a M.S. in Engineering Science
.
Thank you
Contact information:
John Harrison Senior Solution Specialist Toronto, Canada M: 416-505-5841 E:
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