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© GiS – Gesellschaft für integrierte Systemplanung mbH
GiS – Gesellschaft für integrierte Systemplanung mbH
Asset Performance Management mit SAP &
© GiS – Gesellschaft für integrierte Systemplanung mbH 2
Why Optimizer+
Risk based maintenance leads to
preventative maintenance plans
Use of ‘generic maintenance strategies’
Balance between financial results,
operational results and risks
Use of asset tree EAM system
Maintenance plans lead in determining
the yearly budget
Sharing knowledge with other
maintenance organisations
Decisions have to be objective and
reproducible
Strives toward continuous improvement
in the maintenance process
© GiS – Gesellschaft für integrierte Systemplanung mbH 3
Relation between Optimizer+ and EAM
system KPI
EAM reports
OEE
Failure analysis
Present
5-10 year maintenance budget
Risk based PM optimization
Maintenance strategy simulation
Life cycle costing
Future looking ahead ‘leading’
Asset Performance Optimization Operational Maintenance
Past looking back ‘lagging’
Asset
Performance
Management
D
o Check
Adapt Plan
SAP
© GiS – Gesellschaft für integrierte Systemplanung mbH 4
Process flow of Optimizer+
• ‘What if’ scenarios
•RCA
•Adjust maintenance
•Export to EAM
•Maintenance concepts
•Export to EAM
•Business Objectives
•Asset tree
•Quick RCM
•Asset library
•RCM
•RBI (EEMUA 159)
Plan Do
Check Adapt
© GiS – Gesellschaft für integrierte Systemplanung mbH 5
Functionalities of Optimizer+
Optimizer+ consists of the following modules:
ptimizer+ consists of the following modules:
Stock management is
used for optimization of
spare parts Root Cause Analysis uses
problem solving to identify
the root cause of faults or
problems
FlexGrid is a user friendly
functionality to review
and edit mass data
© GiS – Gesellschaft für integrierte Systemplanung mbH 6
Business objectives: severity
Risk = Probability x
Severity
Go to risk matrices
© GiS – Gesellschaft für integrierte Systemplanung mbH 7
Business objectives: probability
Easily configurable by the user
© GiS – Gesellschaft für integrierte Systemplanung mbH 8
Business objectives: risk matrix
Easy to update from red
or green with the click of
a button
© GiS – Gesellschaft für integrierte Systemplanung mbH 9
Asset tree: asset importer
Generic Excel template
used to import asset
structures into Optimizer+ Resulted asset tree in
Optimizer+ from the
excel import
© GiS – Gesellschaft für integrierte Systemplanung mbH 10
Asset tree: DIS importer for additonal data
Generic Excel template
used to import additonal
information into Optimizer+
such as failure data,
maintenance and costs. Enhanced Asset tree from
DIS import into Optimizer+
© GiS – Gesellschaft für integrierte Systemplanung mbH 11
Asset tree: interfaces
Optimizer+ has
interfaces available with
SAP and other EAM
systems. All interfacing is
based on webservices.
© GiS – Gesellschaft für integrierte Systemplanung mbH 12
Quick RCM: goals
Spend time, money and energy on only important assets
Provide insight into the criticality of a (sub)system as a
whole in a fast and efficient way
Prioritize (sub)systems on criticality
Deliver a fast and efficient Preventive Maintenance
review
© GiS – Gesellschaft für integrierte Systemplanung mbH 13
Quick RCM: grid
Apply to (sub)systems
Assign effect to (sub)systems
Easy to export to
Excel Configurable
layout
© GiS – Gesellschaft für integrierte Systemplanung mbH 14
Quick RCM: example
Gas processing & compression
Mean time to Failure = 4 months
Technically unavailable
10 – 100K minor damage
Failure cause
Effect
© GiS – Gesellschaft für integrierte Systemplanung mbH 15
Quick RCM: view in asset tree
Non-critical
Prioritize systems on a high level based on
the business objectives
Critical
© GiS – Gesellschaft für integrierte Systemplanung mbH 16
Asset library: content
• One-off building of Parts, Components, Failure behaviour &
Preventive or corrective maintenance.
• Easy to build up asset registers with the help of the library
• Create your own generic PM libraries
© GiS – Gesellschaft für integrierte Systemplanung mbH 17
Asset library: drag and drop
Able to drag and drop items directly from your
library to your FMECA system
© GiS – Gesellschaft für integrierte Systemplanung mbH 18
Asset library: applying multiple FM library templates
Match FM library data to FMECA data with a
corresponding mark
© GiS – Gesellschaft für integrierte Systemplanung mbH 19
Asset library: applying multiple FM library templates
Select which data from FM library should apply
to FMECA data
© GiS – Gesellschaft für integrierte Systemplanung mbH 20
Property grid: failure cause & Maintenance data
By navigating through the
asset tree, it’s possible to
directly see all properties
per asset
Direct access to change
data
© GiS – Gesellschaft für integrierte Systemplanung mbH 21
RCM: grid
For each piece of equipment you are able to see the
effect the failure has on the business objectives
Easy to export to
Excel
Configurable
layout
© GiS – Gesellschaft für integrierte Systemplanung mbH 22
RCM: example
X3501 FWHL MODE/INDI IN
35XX828 (equipment)
Led cluster (component)
No / reduced loading arm movement
10 – 100K minor damage
Defective Led clusters
Mean time to Failure = 10 years
Failure cause
Effect
© GiS – Gesellschaft für integrierte Systemplanung mbH 23
RCM: risk matrix
See where your critical assets rank in
the risk matrix
Click to see
which items
Links directly to
asset structure
© GiS – Gesellschaft für integrierte Systemplanung mbH 24
Clustering activities: CLM
Able to consolidate maintenance
actions into a CLM
© GiS – Gesellschaft für integrierte Systemplanung mbH 25
Maintenance program: optimization
Cost savings: See all non critical failure causes with
PM
Compliance: All critical failure causes without PM
© GiS – Gesellschaft für integrierte Systemplanung mbH 26
Maintenance program: report
© GiS – Gesellschaft für integrierte Systemplanung mbH 27
FlexGrid: customizable user interface
• Views with only relevant
information
• Directly change, add or
delete data
• Design your own views
• Extensive filter & sort
options
• Obliged fields
© GiS – Gesellschaft für integrierte Systemplanung mbH 28
Simulation: what if analysis What if analysis are performed with the available data in
Optimizer+.
Scenarios are performed with a time frame, for example of 10
years. During the simulation Optimizer+ calculates data like
costs, numbers of failures, availability in production.
The simulations are based on the Monte Carlo Method.
Possible scenario’s
• What is the impact of redundancy?
• What is the cost of maintenance and what will happen
when less maintenance is performed?
• Where to s tart when the maintenance budget is 10%
lower?
• What are the performance outliers and how can they be
reduced?
• What is the influence of a modification?
• How can availability be increased?
© GiS – Gesellschaft für integrierte Systemplanung mbH 29
Reports: totals
© GiS – Gesellschaft für integrierte Systemplanung mbH 30
Reports: downtime
© GiS – Gesellschaft für integrierte Systemplanung mbH 31
Reports: maintenance cost per period per strategy
© GiS – Gesellschaft für integrierte Systemplanung mbH 32
Reports: maintenance costs - top 10
© GiS – Gesellschaft für integrierte Systemplanung mbH 33
Reports: scenario comparison, totals
© GiS – Gesellschaft für integrierte Systemplanung mbH 34
Reports: scenario comparison, downtime
© GiS – Gesellschaft für integrierte Systemplanung mbH 35
Unique Selling Points
Covers the whole FMECA process in
a natural way
PM-library functionality that enables
users to accelerate and standardize
the RCM process
Simulation/ optimization functionality
to perform what-if analysis and
scenario comparison
Web based interfacing with SAP
EAM, Infor EAM and IBM Maximo
Integrated RCA and RBI modules
Professional development, support
and roadmap
Strong (technology) partners
© GiS – Gesellschaft für integrierte Systemplanung mbH 36
Detlef Aden Seit 1984 Beratungs- und Integrationspartner im
Bereich Instandhaltungs- und
Betriebsführungssysteme für komplexe Anlagen.
GiS - Gesellschaft für integrierte Systemplanung mbH
Junkersstr. 2
69469 Weinheim
Deutschland
Ronald Jansen
Business Development Manager
Tel: +49 (6201) 503-91
Fax: +49 (6201) 503-66
E-Mail: [email protected]
http://gis-systemhaus.de