EAM Overview

Enterprise Asset Management

Product Management, SAP AG

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 2

Contents


Technical Assets Management

Preventive and Predictive Maintenance

Breakdown Maintenance

Refurbishment Process

Integration and Platforms

Work Clearance Management


Service Management

Customer Service Management

Service Sales & Marketing

Service Planning & Forecasting

Service Parts Management

Service Procurement Management

Service Operations Management

Customer Service Management

Analytics


Investment Planning & Design

Procurement & Construction

Maintenance & Operations

Decommission & Disposal

Asset Life-Cycle Analytics

Service Management Solution Map, Edition 2004


Service ManagementEnterprise Asset Management

SAP Product Available

SAP Product Available with Future Releases

Future Focus

Partner Product Available

Partner Product Available with Future Releases

Collaborative Business Map Available

Sxx, Vxx, Bxx SAP Product & ServicePxx Partner Product

For more information see: http://www.sap.com

Investment Planning & Design

Business Planning (S12)Investment Management (S12)Collaborative Specification and Design (S8, P103, S140, S141)Document Management (S8, P103)Interfacing CAD, GIS and SCADA systems (S8, P103)Project Management (S8, S141)

Procurement & Construction

Supplier Qualification and Candidate Selection (S6, S13)Bidding and Contract Management (S25, S6, S140)Procurement Process (S25, S6, S12, S120)Document Management (S8, P103)Project Management (S8, S141)Collaborative Construction (P103, S8, S140, S141)Project and Investment Controlling (S12, S8)

Maintenance & Operations

Technical Assets Management (S8)Preventive and Predictive Maintenance (S8)Work Clearance Management (S134, S8)Maintenance Execution (S8, P28)Shutdown Planning (S8)

Mobile Asset Management (S8, B35)Web-Based Processing (S8)Contractor Management (S8, S6, S25)MRO and Services Procurement (S6, S25, S120, S12)Service Parts and Inventory Management (S4)Document Management (S8)Employee Management (S8, S9)Maintenance BudgetingIntegrated Asset Accounting (S12, S8)

Decommission & Disposal

Asset Transfer and Disposal (S12, S8)Document Management (S8)Collaborative Disposal Management (S8, P103, S140)Project Management (S8, S141)Waste Management (S125)Asset Compliance (S125)Asset Remarketing (S4, S2)

Asset Life-Cycle Analytics

Asset and Maintenance Reporting (S8)Asset Performance Management (S8, S13)Reliability Centered Maintenance (S8, S13)Asset Life-Cycle Costing (S13)Damage Analytics (S13, S8)Object Statistics (S13, S8)Spend and Supplier Performance Analytics (S13, S6)


The Overall View of the Asset Life Cycle

ProcurementManufacture

Installation & Test

OperationMaintenance

Refurbishment

Modification

Replacement Selection orDesign

Asset

Requirement

MarketplacesEBP

AvailabilitySafety

Status Quality

ImplementationEfficiency

Investment Management

Project Management


Contents









Maintenance-Relevant Objects

Company premises Buildings Machinery Assets Resources EDP infrastructure Fleet Electrical fixtures Rails Replacement parts And many more


Technical Object Types

Equipment

Assembly

Spare Parts

Functional Location


Asset Structure

Production Plant

Production street 1

Press shop

Welding plant

Assembly area

Production street 2

Shipping area

Asset structure = multi-level, hierarchical structure, organized by ...

Criteria

Technical

Functional

Spatial


Individual physical object to be maintained as an autonomous unit

Equipment

Installation and dismantling in asset structure


Master Record of a Technical Asset

Multilingual texts

Classification

Documents /Technical drawings

Addresses / Partners

Implementation

Measuring points / Counters

Permits

General

Master Record

Location

Organization

Structure


Bill of Materials

Production street 1

Press shop

Press 1

Motor ABC

Motor casing

Functional location

Functional location

Assembly

Material

Drive shaft

Press plate XYZ

Coil

Equipment

Material

Material

Material

Spare parts configuration of a piece of equipment


Web Catalogs

Transparent structure Web interface BOMs may be superfluous


Synchronisation between Equipment and Fixed Asset

Automatic data synchronization possible


Interfaces to Non-SAP Systems

R/3-Database

Asset Life-Cycle

ManagementStandard interfaces

SCADA

CAD systems

Internet

Barcode scanner

Process Control System

Geographical Information Systems

System openness through standardized interfaces


Fleet Management with Enterprise Asset Mgmt.

Standing PM order

Equipment with fleet segment

PMIS

AssetPost depreciation to PM standing order

Measuring points

Totalcost collection

Performance analysis

Asset/Equipment synchronization

Mileage and fuel

Maintenanceprocesses

Fuel entrytransaction


Technical Assets Management: Advantages

Asset transparency Meaningful history of equipment maintenance Flexible analysis options


Contents









Preventive Maintenance: Reasons

Legal regulations (for example, technical inspection of vehicles)

Quality assurance (for example, customer demands)

Reduction of breakdown frequency of assets, thereby:

Lowering costs of restarting,Prolonging the lifecycle of assets

Environmental considerations

Manufacturers’ requirements

Lowering of maintenance costs


Reduction of Maintenance Costs?

Cost of repairs

Cost of preventive maintenance

Overall cost of maintenance

Cos

ts

Degree of intensity of preventive maintenanceM0


Preventive Maintenance: Categories

Time-Based Performance-Based Condition-Based

Preventive Maintenance

Temperature

ThicknessPressure


Order/Notification

Schedule plan

WHAT?Task listsWHEN?

Time- or counter-basedstrategies

Order/NotificationOrder/

Notification

WHERE?

Preventive Maintenance

Maintenanceplan

- Single cycle- Strategy- Multiple counters


Preventive Maintenance Processing

Order/NotificationOrder/

NotificationOrder/Notification

Maintenanceplan

Scheduling

Worklist

Dispatching

MaintenanceExecution


Preventive and Predictive Maintenance: Advantages

Increase equipment reliability Reduce maintenance inventory More effective use of all resources


Contents









Business Process: Breakdown Maintenance

Production Supervisor/Maintenance Planner

Maintenance work center

Call /Notification

Create order and release

Fix malfunctionConfirm and complete order

Order

0010 Inspect pumps

0020 Replace seals


Functional Process (Acute Maintenance)

Techn. Object Condition

description Item data Activities /

Tasks Priorities

Notifica

tion


Maintenance Notification

Catalog entries Paging function Solution database

Notification with

Configurable screen areas and tab pages


Catalogs

Catalogs can contain object parts, damages, tasks, activities...

Damagecatalog

Mechanicaldamage

Code010 Corrosion020 Broken glass030 Engine defect. .. .. .

Example:



Internal / External resource- planning

Release / Print Control /

ExecutionPM

Order



Tasks Priorities

Notifica

tion


Maintenance Order

Order header:Reference object, dates, priority, description

Operations:Work center, duration, description, external services

Components:Material, services, quantity, availability check

Object list:Technical objects, notifications, material

Further information:Costs, Partners, Maintenance plan information...


Component Planning with Catalogs

Available in standard for R/3 Enterprise

Branch directly from the order to a web catalog

Copying of stock and non-stock materials into the order


External Services

Integrated service request in the maintenance order

Display of short- and long-term external services Continuous posting and tracking of costs

Service entry sheets allow later verification of services performed


Time- / Material confirmation

Technical completion

Order settlement

Comple

tion



Release / Print Control /

ExecutionPM

Ord

er



Tasks Priorities

Notific

ation


Completion Confirmation

Reference order Technical completion

Time confirmation

Material confirmation


Objects Orders /

Notifications Costs Downtimes

Histor

y


Time- / Material confirmation

Technical completion

Order settlement

Comple

tion


Release / Print

Control / Execution

PM O

rder



Tasks Priorities

Notifi

catio

n


Maintenance History

Change Documents

Action Logs

Complete history and cost tracing for technical objects


Maintenance Information System

Strategically important standard evaluations are for example Cost analyses

Site analyses

Malfunction and breakdown analyses

Manufacturer analyses

…

Drill down

Drill down

Example: Cost Analysis


Business Warehouse for Maintenance Analyses

SAP BW provides a complete data warehouse solution.

The predefined Business Content in SAP BW allows analyses of Quality-, maintenance-, and service notifications

Notification items, -causes, -tasks, -activities

Maintenance- and service orders


Breakdown Maintenance: Advantages

Increase plant availability Reduce equipment stops and downtime Minimize maintenance costs substantially


Contents










Order

0010 Refurbish pump

0020 Settle order

Refurbish Equipment

Stock

Dismantle Equipment

Re-install Equipment

Issue Equipment

Re-stock Equipment


Refurbishment

Dismantling of faulty equipments and return to warehouse for refurbishment

Material with condition-based value linked to the equipment is used to monitoravailability of stock in inventory management

Materialcondition-based valuation

Valuation type C2 (refurbished)

$ 2500

Valuation type C3 (damaged)

$ 200

Valuation type C1 (new)$ 3000


Refurbishment Process: Advantages

Completion of the life cycle of a technical asset Uniqueness through serialization Life cycle trading of equipment


Contents









Enterprise Portals: Uniform Access to All Systems


Characteristics of a Portal

High level of integration through the latest technology

Uniform interface for various applications

Simple access and high usability

Simple adaptability and thereby simple re-design of business processes


Individual Page Construction: Example


Business Package for Assets: Contents

Information on technical objects as well as corresponding notifications and orders

Simple creation and tracking of notifications

Installation and dismantling of equipments

Time completion confirmation

Material availability check

Creation, changing and display of document


Mobile Asset Management

Suite of tools tailored to the needs of the field service & field maintenance personnel

Extends Plant Maintenance and Customer Service functionality

Offline processing using mobile engine


Mobile Asset Management - Functional Overview

Technical Object Management

SAP Backend Data update in backend

Measurement & Counter Readings

Inventory Management

Notification Management

Business Partner Management

Contract Management

Order Management

Data creation and assignment


Advantages of Mobile Asset Management

Extended mobility through location-independent work Immediate on-site data entry Improved data quality Direct access to up-to-date data Lower process costs


Integration to mySAP SRM

Catalog

OCI Compliant Cataloge.g. BugsEye

Select spare parts / services

R/3 System

PM / CS

Maintenance Order

Purchase Requisition

Purchase Order (Copy)

Goods Receipt / Service Entry

Invoice

SRM

Enterprise Buyer

Sourcing

Purchase Order

Confirmation / Service Entry

Invoice

Requirement

Replication of purchase order

Follow-ondocuments can

be created in backendor in EBP


SAP R/34.6C and below

Enterprise Buyer

Order 4711 Operation 10 Operation 20

ReservationPurchaserequisition

Order 4711 Operation 10 Operation 20

Selectorder

Order 4711 Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10

Transfercomponents

Go tocatalog

Order 4711 Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10

Transfer to shopping cart

External parts catalog

Pump P1000Gears Gx01

Washer 10-10

Component Planning with Enterprise Buyer


Integration into Investment Management

Asset under Construction

Depreciation Simulation Fixed Assets


Project Oriented Shutdown Planning

mySAP PLM Project Management

mySAP PLM Program Management

Idea & Concept

Planning & Approval

Project Execution Closing

Documents Workforce

Procurement

Schedule

Project StructureBudget Claims

Costs/Revenues

StatusProgress

Payments

Project Information System

Shutdown Project Life-Cycle

Project Management


Shutdown Planning with Project-Oriented Maintenance (POM)

mySAP PLM Asset Life-Cycle Management offers an interface to Primavera P3, which you can use to plan shutdowns with reduced costs and downtimes. This includes:

Shutdowns (Processing industry) Revisions (Utilities) Checks/Overhauls (Aerospace)

POM supports the following core processes: Identification and selection of the work Planning/Budgeting Optimization/Simulation Performance and support of unplanned work Evaluations/Reporting


cFolders for Enterprise Asset Management

Defined partners receive controlled access to documents and materials as well as material BOMs outside of the R/3 system

Simple call-up using Internet Explorer and user ID

Own status management allows "Mini-Workflow" and version concept

Documents and notes can be edited and selected


Example: Info Exchange with Service ProvidersOperator Service providerOrdering of services

Construction of the cFolders structure

Info call up of updated data

Call up of the cFolders structure

Technical confirmation, completion of documents, for example, on handheld devices


Example: Information Exchange with Customers

Service Provider Customer

Provision of services

Construction of thecFolders structure

Notification recording

Call up ofcFolders structure

Notifications for cFolders objects


Integration and Platforms: Advantages

User-friendly interface in Enterprise Portal

Realtime documentation of maintenance

work through Mobile Asset Management

Tailored shutdown planning

Company-wide exhange of information with cFolders


Contents










Comply with legal safety standards

Observe additionalcompany-specific guidelines

Maintain plant safety andhigh system availability

Adhere to health and safetyrequirements in the workplace

Follow environmentalprotection regulations


Work Clearance Management: Basic

Isolation of technical objects to ensure safe and secure working conditions for personnel during maintenance work or controlled tests


Architecture

Work Approval

Applications

Work Clearance Application (WCA) Application for Fire Protection ...

Work Clearance Documents

Work Clearance Document Template Operational Work Clearance Document

Order

Work Approval

Work Clearance Application

Operational WCD

Enhanced Model

Further Applications

Order

Work Clearance Application

Operational WCD

Standard Model


Maintenance Process

Notification

SCADA

Work ClearanceManagement

CreateOrder

ReleaseOrder

ConfirmOrder

CompleteOrder

Analyze Histories

PlanOrder

Maintenance plan

Work ClearanceManagement


Objects

Status processing and audit trail:system status and user status

Assignment of partners:different roles possible

Long text processing:several internal remarks

Assignment of documents:link to document management system

Assignment of permits:process relevant, interactive, ...

Use of catalog technique:code groups and codes

General data

Reference object

Areas of responsibility

Location data

Planning data


Work Clearance Management: Advantages

Maximize your employee's safety

Improve work efficiency

Enhance your assets' productivity


Summary

Enterprise Asset Management: Your

Benefits


Advantages for Asset Operators

Increased asset efficiency and lower TCO

Sustained optimization of asset usage

Reduced expenditure for service providers and materials

Higher production capacities


Key Customers

http://www.basf.de/de/

http://www.coca-colamediacentre.com/broad_stage.html

http://www.aventis.com/

http://www.kone.com/index.html

http://www.pratt-whitney.com/profile

http://www.siemens.de/

http://www.volvo.com/group/business_overview/group.asp

http://www.becks.com/index.asp

http://www.becks.com/index.asp

http://www.becks.de/index.asp

http://www.exxon.com/index.html

http://www.akzonobel.com/index.asp

http://www.abb.com/global/ABBZH/abbzh251.nsf!OpenDatabase&mt=html&l=us