May 12, 2008

TCS Experience of Maximo upgrade for an Automobile Manufacturing Company

IBM Maximo Mondays12 May 2008

2May 12, 2008

Agenda

Q & A

Benefits

Best Practices

Major Achievements

Major Challenges

Project Overview

Major Drivers for Upgrade

About the Customer

20 Minutes

5 Minutes

5 Minutes

10 Minutes

10 Minutes

5 Minutes

3 Minutes

2 Minutes

3May 12, 2008

About the Customer

• One of the leading Japanese automobile

manufacturers in the world

• Brands span diverse products like

automobiles and SUVs,

motorcycles and ATVs, power

equipments, engines and marines

• State-of-the-art manufacturing unit in Canada

• Current plant production capacity : 1600 units per day (Canada)

• Current employee strength : 5000+ employees

• CMMS System since 2001 : Maximo 4.1.1

• Number of users of Maximo : 478 Maximo user base with

approx 40-50 concurrent users

4May 12, 2008

Major Drivers for Maximo Upgrade

HighProvide robust workflow design and user-friendly GUI

HighEnsure compatibility with LDAP to comply organizational IT security policy

HighProvide seamless interface with Peoplesoft using MEA

HighEnhancement required for existing mobile application

MediumDevelop centralized and powerful reporting system

Low Build multi-site functionality to support future expansion

MediumTake advantage of enhancement of Maximo features

MediumChange in Technology, expect benefits from New Technology

HighContinue with best-of-breed product (Preserve investment)

PriorityDrivers

5May 12, 2008

Maximo 4.1.1 Environment Maximo 6.2.1 Environment

Project Overview

MAXIMO MobileMAXIMO

SQR Crystal MS Access

ActuateReport Consolidation

Data CleansingData Cleaned Data

No installation on Client M/C

Simplified Architecture

Peo

ples

oft 8

.9 Peoplesoft 8.9

MS Active Directory

Simplified Work flow

Robust Interface using MEA

MAXIMO

3rd Party Mobile.

MAXIMO

Enhanced Mobile Functionality

6May 12, 2008

Moving to Maximo 6 - Elements demanding consideration

IBM Upgrade

Multi staged Utility

Maximo 4.1.1

Other customizations

Master Data

Transaction Data

Configuration Data

Reports

Custom Business Logic

Screens / GUI

Data

Process and GUI

Maximo 6.2.1

Consideration for Peripheral Solutions/Add-ons

Maximo 6.2.1

Upgrade?

Migrate?Maximo 4.1.1

Mix of Upgrade and Migrate?

7May 12, 2008

TCS Approach and Methodology

AS-IS Analysis

Information gathering through interviews of 22 Subject Matter Experts Analysis of 59 As-Is business processes across 12 departments 87 Maximo 4.1.1 areas of improvements identified based on AS-IS

workshop

Mapping of 40 To-Be business processes

Organized Workshop to discuss the probable solution for business gaps and mapping issues

Identified application gaps for Maximo 6.2.1 Suggested innovative workarounds for the gaps avoiding many

possible customizations and bought agreement on the final solutionGAP

Analysis

To-Be Analysis

Defined strategy for Data Migration, Interface and Testing.

Construct code for identified gaps and interface

Production Go-live and Post implementation Support

Configure and

Construct

1

2

3

… N

8May 12, 2008

Major Challenges

• Multi-stage OEM upgrade utility for database upgrade

• Heavily customized Maximo 4.1.1

• Compatibility of LDAP with Actuate

• Non availability of standard adapter for Peoplesoft for Maximo 6.2.1

• Implementing Maximo Mobile, a relatively new add-on

• Performance issues w.r.t Maximo application and Maximo mobile (Slow response)

• To comply with organization security policy

9May 12, 2008

• Successful 100% data upgrade of Maximo 4.1.1 using IBM upgrade utility tool

– Proof of Concept

– Multiple iteration done for upgrade to ensure Data Quality and eliminate surprises

• 70% reduction in customizations (Triggers, Maxcust.dll, Screens)

– Advantage of enhanced and new functionality

available in Maximo 6.2.1

– Simplified Business Processes & Workflow

• Standardization of Reports

– Got rid of multiple reporting platforms

– Consolidated similar reports into a single one

– Developed 70 new reports

Major Achievements

10May 12, 2008

Major Achievements – Cont.

• Enhancement of Mobile application for error-free transactions with barcode scanning

– Data refresh removed and used real time lookup to avoid inconsistent data

– Configured additional field validation

• Development of Interfaces with Peoplesoft in crunching

timelines

• Newly designed work flow for more effectiveness

– Look for simplification, wherever possible

– Removed the hard coded logics

• Synchronization of MS Active Directory with Maximo,

Actuate and Maximo Mobile

– Configured WebSphere Global Security

– Modified configuration files

11May 12, 2008

Maximo Mobile-Architecture

• Extends Maximo Application to remote workers

• Hardware: Intermec CK 61 as PDA OS(PDA): Windows Mobile 5.0

Firmware: J9 JVM (must be obtained separately from IBM)

HTTP – TCP:80HTTP – TCP:8080 text

Application Server

IBM Http Server (IHS)

HTTP – TCP:18010

.

Intermec CK61

.

.

.

Websphere Application Server

(WAS)

Maximo Database

12May 12, 2008

Interface with Peoplesoft

Use of JMS queues, no B2B server requiredB2B server used as transaction server

Triggering events are MBO based (through MEA)All the triggering events were based on Database triggers.

Retained all the existing touch points in addition:

7. Unit of Measure Peoplesoft Maximo

1.Item Peoplesoft Maximo2. Vendor Peoplesoft Maximo3. PR Maximo Peoplesoft4. PO Peoplesoft Maximo5. Receipts Peoplesoft Maximo6. GL Peoplesoft Maximo

No standard adapter available.Developed new one. Used http protocol for data transformation.

MRO adapter for Peoplesoft

Maximo 6.2.1 − PeopleSoft 8.9Maximo 4.1.1 − PeopleSoft 8.9

13May 12, 2008

• PoC and Multiple iteration were done for upgrade to ensure Data Quality and performance

• Product orientation to users during requirement and analysis phase

• Discourage customization

• Role based training

• Testing at various stages

• Testing for Maximo mobile connectivity to avoid any blind spots

Best Practices

14May 12, 2008

Benefits

• Availability of Maximo application on any client

• Low system administration cost

• Enhanced security and improved audit trail

• Real time Inventory transactions with the use of Maximo

Mobile with zero error

• Improved role based workflow with use of notification, delegation and assignments

• Real time integration with Peoplesoft

• Availability of Online Reports and KPI’s

• Single Report server Administration

15May 12, 2008

Maximo: Points to Ponder

No standard MEA for PeopleSoft, need to write Java user exitsInterface

Errors occurred during Validation of data, data manipulation required and org site setup done

Data Upgrade

Screen or business logic customizations must meet business requirements

Customization

Version of reports should be compatible with Actuate encyclopediaReporting

Real time look up is useful provided network connectivity between Maximo application server and PDA is robust.

Real time look up (Mobile)

Extended software IDE tool kit from www.intermec.com must be downloaded and installed

IDE tool kit (Mobile)

To enable LDAP authentication, configuration files needs to modified. LDAP authentication

16May 12, 2008

Q & A