Asset Management Council 0902 SAP

8/12/2019 Asset Management Council 0902 SAP

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PLANNING FOR RELIABILITY

ITS SAP THAT BRINGS IT ALL

TOGETHER


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PRESENTATION

Introduction

Fundamentals

Planning & Scheduling Reliability Engineering


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EVOLUTION OF QENOSAPC(Esso)

Hoechst

(1997)

ASR

(Esso)

Compol

(Mobil)Kemcor

Orica

(1998)

This mixed parentage has lead to problems in agreeing best SAP

implementation


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SAP AT QENOS

SAP has been used as an ERPsystem since 1995 integrating

materials management, maintenance

and financials Commenced with SAP R2 in 1995 and

upgraded to SAP R3 later the same

year

Upgrade to SAP ECC 6.0 Mar 2008


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SAP PM MODULE

IS A MULTI-PURPOSE TOOL

WILL SUPPORT WORLDS BESTMAINTENANCE AND RELIABILITY

PRACTICE

JUST AS WELL AS IT WILL SUPPORTWORLDS WORST MAINTENANCE AND

RELIABILITY PRACTICE

IT DOES NOT DISCRIMINATE


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FUNDAMENTALS

Technical Objects

Work Centers

Failure Codes


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TECHNICAL OBJECTS

FUNCTIONAL LOCATIONS

- Structures the maintenance objects of acompany.

- A functional location represents the place atwhich a maintenance task is performed.

EQUIPMENT

- An individual, physical object that ismaintained as an autonomous unit.

MATERIALS / ASSEMBLIES

- The goods that are the subject of businessactivity.

- A technical object can be divided into

assemblies to separate it into more clearlydefined units.

- Assemblies are used for maintenance billsof material and maintenance task lists.


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WORK CENTER - DEFINITION

Work centers can be:

- Machines

- People

- Production lines

- Groups of craftsmen

The activities performed at or by the work

center are valuated by charge rates, which

are determined by cost centers and activity

types.

The work center has an available capacity.

QENOS


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WORK CENTER - CAPACITYHEADER

We target 100%

utilisation for

scheduling


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INTERVAL AVAILABLECAPACITY

Intervals created to reflect theactual available capacity available

for the period


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WORK CENTER -HIERARCHYAvailable capacity is

entered for work centers atlowest level.

SAP sums this up to the

higher level which is then

used in Capacity Planning


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FAILURE CODES


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FAILURE CODES

Codes used should be consistentthroughout the organisation to enableeasy comparison

Guidance on code selection and useis available in ISO 14224 SecondEdition 2006; Petroleum, petrochemical and natural

gas industries Collection and exchange of reliabili ty andmaintenance data for equipment


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CATALOGS

Catalogs can be

assigned to

- Notification

Types

- Technical

Objects

Functional

Locations

Equipment


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CODING

Failure Mode as observed by operator

Not currently used at Qenos

= RCM Functional Failure

See ISO 14224 Tables B.6 B.12

Examples:

- Low Output

- No Output

- Vibration

- External Leakage process medium


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SAP ISO 14224

Maintainable Item; Annex AObjectParts

Maintenance Activity; Table B.5Activities

Cause; Table B.3Causes

Condition; Table B.2Problems

Failure Mode; Tables B.6 B.12

(Failure Mode as observed by operator

RCM Functional Failure)

Coding

ISO 14224SAP Catalog


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OBJECT PARTS(MAINTAINABLE ITEMS)


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DAMAGE CODES


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CAUSES


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ACTIVITIES


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PLANNING & SCHEDULING

NOTIFICATIONS

ORDERS

SCHEDULING


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PLANNED WORK LIFE CYCLEANYONE

BUDGET

OWNER

MTCE

PLANNER

WORK

CENTER

Create

Notification

Review

Notification

Create &

Scope

Order

Detail Plan

Approve

Order

Schedule

Perform

Work

Confirm &

History

Review

Order

Complete

Order


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NOTIFICATIONS

Used to request maintenance work

Record as a minimum

- Short description of task

- Location (to equipment level preferred)

- Priority

All SAP PM users can create notifications

Note: SAP does not enforce the use of notifications forwork requests. You may choose to create work orders

directly or notifications and orders in the onetransaction Choose one option and stick to it.


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ORDERS

Contain data for planning and executing

tasks

Functions in orders integrate with other

modules

- Materials Management (MM)

- Project System (PS)

- Controlling (CO)

-


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ORDER HEADER DATA

REVISION

COST

ESTIMATE

JOB OWNER

LOCATION

INFORMATION


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PLANNED ORDER MULTIPLE

OPERATIONS


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MULTIPLE ORDERSNETWORKED

ORDER PLANNING

COMPLEX

Networked ordersmust be scheduled asa total network using

transaction IW70


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COMPONENTS

Components can be easily

added from Bil ls of Materials


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IMPROVEMENT CYCLE


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Task Lists

Set-up operations data in task lists for re-uselater

Reduce planning effort Capture learning

Three Types

- Functional Location

- Equipment

- General - Assembly

Hierarchical Task Lists - task lists canreference other task lists

NEW


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Planner should always ask is there a task list for this job (or similar). If yes thenuse it.

If not, then consider whether a new task list should be created.


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SCHEDULING

SAP Planning Board is used forscheduling

If the work order hasnt been planned

then it cannot be scheduled.


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Scheduling Overview

W00W00

W01

W01

W02W02

WR1WR1

WR2WR2

WR3WR3

WR4WR4

WR5WR5

W..W..

W..W..

W..W..

W51W51

W52W52

STANDING

ORDERS

CONSIDER

FOR ALLSCHEDULES

MUSTD

OJOBSIN

INDICATED

PERIOD

RAN

KEDJOBS

SORT ORDERS BY ASSIGNING APPROPRIATEREVISION


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W00W00 W01W01

W02W02

WR1WR1

WR2WR2

WR3WR3

WR4WR4

WR5WR5

W..W..

W..W..

W..W..

W51W51

W52W52

PLANNING BOARD

SCAF

Work Center

Capacity

determinessize of

bucketWELD

MECH ELEC LAGG


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Review backlog of ready orders andassign to appropriate revision

Check material availability: Go To

List of Available Material

Select orders to take to planningboard

Go to Planning Board


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SOMETIMES OLD WAYS ARE


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SOMETIMES OLD WAYS ARE

STILL THE BEST

LABELS PRINTED FROM SAP USING WORD

MERGE


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RELIABILITY ENGINEERING

Notifications

Work Order History

Analysis


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Malfunction Data


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Malfunction Data

Used in MTBF calculations

Used in MTTR calculations

Failure counted in MTBF and

MTTR calculations


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What happened?

Wh did it h ?


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Why did it happen?

What was done?


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What was done?

Object Services can be used to

attach/link to documents, photos etc.


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WORK ORDER HISTORY


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ANALYSIS


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ANALYSIS


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Example of Information SystemReport

Tip


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Tip

SAP Report MS Excel File

MS Access MS ExcelReport/Chart

For regular reports can use combined

functionality of MS Excel and MS

Access to minimise set-up effort

MS Access tables

linked to MS Excel

file

MS Excel

worksheets linked

to MS Access

tables

IN SUMMARY


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Fundamentals- Technical Objects

- Work Centers

- Failure Codes

Planning & Scheduling

- Notifications

- Orders incl. Task Lists

- Planning Board

Reliability Engineering

- Notifications

- Work Order History- Analysis

Conclusion


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Conclusion

SAP has all the features needed to support a world classmaintenance and reliability program

Take time to understand SAP On-line helpdocumentation is very comprehensive

Read SAP release notes

Most problems I have seen relate to poor processdefinition and implementation rather than SAP

inadequacies


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QUESTIONS?

[email protected]

Documents

Asset Management Council 0902 SAP