SPARE PARTS IDENTIFICATION · Transformation to correct master data record structure Yet incomplete, but correct form of CZ/EN short text (subject to complete by physical ... 6627

15th INTERNATIONAL OPERATIONS & MAINTENANCE CONFERENCE IN THE ARAB

COUNTRIESUNDER THE THEME: “SMART MAINTENANCE” CONICIDE WITH THE 15TH ARAB MAINTENANCE

EXHIBITION

TOMAS HLADIK, ONDREJ STEJSKAL

Logio, Prague

SPARE PARTS IDENTIFICATIONA CASE STUDY FROM A PETROCHEMICAL PLANT

2

EUROPEAN PETROCHEMICAL AND RAFINERY PLANT

MULTINATIONAL HOLDING – GROUP OF COMPANIES

AREA OF 10 SQUARE KM

MORE THAN 1000 BUILDINGS

THOUSANDS OF KM OF ELECTRICAL WIRING,

TELECOMMUNICATIONS WIRING, PIPES, PIPE BRIDGES

ROAD, RAIL AND PIPES

INTRODUCTION TO CASE – SITUATION

CASE STUDY – AGENDA

1) SITUATION

2) METHODOLOGY

3) PHYSICAL IDENTIFICATION USING SMARTPHONES

4) MATCHING – FINDING DUPLICATE ITEMS AND FIRST BENEFITS

5) PROJECT PITFALLS

3

PRODUCTION FACILITIES

REACTORS, TANKS, COLUMNS, HEAT

EXCHANGERS, SILOS, FURNACES,

FLARE STACKS, PIPING, ENERGETICS,

AND OTHERS

MORE THAN 50 000 ACTIVE ITEMS

WORTH OF 100sM EUR

FASTENERS, FITTINGS, POWER

EQUIPMENT, CHEMICAL EQUIPMENT,

CABLES, LOADERS, CONVEYORS,

FEEDERS, COUPLINGS, ROTATING

MACHINES, DCS SYSTEMS, BEARINGS,

ELECTRICAL EQUIPMENT, SEALS,

MEASUREMENT AND CONTROL, FILTERS

AND OTHER SPECIAL DEVICES

INTRODUCTION TO CASE

4

INTRODUCTION TO CASE – SPARE PARTS EXAMPLES

PHYSICAL IDENTIFICATION ON SITE

6

SQUIRREL WAREHOUSES

CREATED HISTORICALLY FROM UNCONSUMED ITEMS AND ITEMS

UNDERGOING RENOVATIONS

SPARE PARTS MANAGEMENT – INITIAL SITUATION

7

SQUIRREL WAREHOUSES


8

IMPERFECTIONS IN MASTER DATA

INCOMPLETE INFORMATION IN MASTER DATA (LACK OF LINKS TO

DOCUMENTATION AND NORMS, LACK OF BOMs OF DEVICES

DUPLICATES - IDENTICAL ITEM UNDER SEVERAL ID NUMBERS

NO UNIFIED METHODOLOGY OF IDENTIFICATION (NAMING) OF SPARE PARTS

DIFFERENT NAMES FOR IDENTICAL ITEMS

NO COMMON REQUIREMENTS ON TECHNICAL PARAMETERS

INCOMPLIANCE WITH METHODOLOGY OF OTHER COMPANIES IN HOLDING

NO DIVISION TO GENERIC ITEMS AND SPECIFIC SPARE PARTS

ENTIRE STOCK MANAGED BY SAME STRATEGY


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1. TO CREATE COMMON METHODOLOGY OF IDENTIFICATION FOR

MAINTENANCE MATERIAL

TO REACH COMPATIBILITY AMONG EXISTING METHODOLOGIES WITHIN THE

HOLDING

2. TO PERFORM PHYSICAL IDENTIFICATION

TO CONDUCT PHYSICAL IDENTIFICATION OF ITEMS IN SQUIRELL WHS AND IN

SAP MANAGED WHS ACCORDING TO CREATED METHODOLOGY

3. TO ELIMINATE SQUIRREL WAREHOUSES

TO MATCH SQUIRREL ITEMS WITH SAP MANAGED ITEMS AND UNIFY THEIR

STOCK, OR TO CREATE NEW MASTER DATA FOR UNMATCHED ITEMS

4. TO SET SAFETY STOCK LEVELS FOR GENERIC ITEMS

TO CALCULATE ONE COMMON SAFETY STOCK LEVEL FOR EACH ITEM,

BASED ON JOINT NEEDS OF ALL CONSUMERS IN PLANT

PROJECT OF MAINTENANCE MATERIAL IDENTIFICATION – GOALS

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PROJECT OF MAINTENANCE MATERIAL IDENTIFICATION – STRUCTURE

Develop standards to unify identification of Spare parts and Generic items

• One identification standard - Identical names for identical spares and Identical categories for Spare parts and Generic items

• Development of database, parsing of current SAP master data and reshaping to master data record according to new identification standard

• Development of software (App) for collection and processing ofdata for physical identification on site

• Fixing Master data structure in SAP

• Definition of responsibilities and approval processes

Physical identification of spare parts in warehouses and fix SAP data in the system

• Physical identification/inspection of maintenance materiál in warehouses

• Summarization and correction of data in SAP (master data clean-up)

• Elimination of temporary warehouses without SAP management

Preparation Stage

Identification Stage

SHORT NAME OF MATERIALPLANT AND WAREHOUSE NUMBER

UNITS OF MEASURMENTMATERIAL GROUP NAMEDIVISION ON SP AND GI

CATEGORY OF STOCK (CRITICAL ITEM, STRATEGIC ITEM)

By parsing and cleaning of data strings we can prepare correct master data form

Current SAP master

data record

Purchasing orders

Transformation to correctmaster data record structure

Yet incomplete, but correct form of CZ/EN short text (subject to

complete by physical identification)

VUZA PRIR V. 111 PN??/DN65.0 Flanged globe valve DN65 PN?? 422643

PARSING OF CURRENT SAP MASTER DATA

LINKS TO STANDARDSATEST NUMBERS, SPECIFICATIONS

(DIMENSIONS, TEMPERATURES, PRESSURE, SURFACE

ADJUSTMENTS)

11

Each item is identified in the following steps:

Step Description Output

1 SELECTION OF MATERIAL CATEGORY Fasteners

2 SELECTION OF KEY WORD (ITEM NAME) Stud screw with bolt

3 SELECTION OF MATERIAL GROUPPIP_FAS

Screws, bolts, washers – general, not atested

4 FILLING INDD REQUIRED INFORMATION

CZ: Svorník s maticí 40x200xW ¾“ NEREZEng: Stud with nut 40x200xW ¾“ Stainless

SHORTCUT: SVOR+M 12050.6 100MM W ¾“

5FILLING IN MAXIMUM OF OTHER REQUESTED

ATTRIBUTESMaterial of bolt: 12050.6; Logistic dimensions:

30x15x15; Norm: ČSN 2515.2

6 ASSESMENT OF TECHNICAL CONDITION NEW/OLD/REPAIRED

STEPS OF IDENTIFICATION

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Identification tree – example

Rotary machinesPumps

Whole pumps

Spares for pumpsPlunger pumps

Plunger crank systemHousing set

Pump housingHousing lidExcenter

Crankshaft setCrankshaftCrankshaft bushingOil flinger ring

Plunger pumpCentrifugal pumpScrew pumpGear pump

Centrifugal pumpsImpeller

Centrifugal pump…

…

……

……

CategorySubcategory

Keyword

Keyword EU

Keyword ENG

Keyword CRC

Keyword N16

13

How the name is created?

Added to name according to defined syntax

Categories and key words as selected by identificator Basic name

Key Identification attributes Přivařovací koncentrická [DN1]/[DN2] [various text]

Redukce

Redukce přivařovací koncentrická nerez DN80/50 40/VII

Přechod přivařovací koncentrický DN80/DN50 Z 17248.4

Welding-neck concentric reduction SS DN80/50 40/VII

RED PRIV KON 17248.4 3/3 DN80/50

Name example CZ:

Name example N16:

Name example ENG:

Name example CRC:

Redukce přivařovací koncentrická [material] DN[DN1]/[DN2] [various text]

Přechod přivařovací koncentrický DN[DN1]/DN[DN2] [type] [material]

Welding-neck concentric reduction [material] DN[DN1]/[DN2] [var text]

RED PRIV KON [material] [thicknes1]/[thicknes2] DN[DN1/DN2]

Syntax example CZ:

Syntax example N16:

Syntax example ENG:

Syntax example CRC: All identification data stored in database.

The syntax can bechanged EX POST, ifneeded, all created

names will be updated

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Android Application IND

PHYSICAL IDENTIFICATION ON MOBILE DEVICE

15

Add item

Plan of Identification – Warehouses

Building Description Unit Progress

0515 + oplocený venkovní sklad na jižní straně budovy 0515 POX Physical identification completed, validation in progress

bez označení odkrytá plocha na severní straně budovy 1510, jižne od ulice E a mostu Za POX

1431 POX Physical identification completed, validation in progress

bez označeníodkrytá plocha přilehlá k severní straně boduvy 1431, průsečík ulice 5a a železnice

93a, (volbě ložené armatury a potrubí)POX Physical identification completed, validation in progress

bez označeníodkrytá plocha SV od budovy 1442, mezi železnicemi 99 a 93a, (volně ložené

armatury a potrubí)POX Physical identification completed, validation in progress

bez označeníodkrytá plocha přilehlá k západní straně budovy 1421, ulice 5a (volbě ložené

armatury a potrubí)POX Physical identification completed, validation in progress

bez označení oplocená plocha severně od budovy 1442, jižně od ulice E (armatury a potrubí) POX Physical identification completed, validation in progress

1443 POX no materials to identify

1443/1 POX no materials to identify

1424 pouze volné plochy POX Physical identification completed, validation in progress

1523 pouze sklad v jižní části budovy Močovina Physical identification in progress

3630 překladiště 3630, západní strana budovy 3607 (volně ložená zařízení) NH3 Physical identification completed, validation in progress

3610 volná plocha NH3 no materials to identify

3609 NH3 Physical identification completed, validation in progress

3612 NH3 Physical identification completed, validation in progress

0623 Haly A,B,C Hlavní sklad Physical identification to be started DEC2016

0625 Haly 4,5,6,7 Hlavní skladBlind physical stock counting completed,

Physical identification to be started JAN2017

2515 Hlavní sklad Physical identification to be started 2Q2017

0621 Hlavní sklad Physical identification to be started FEB2017

0512 venkovní plocha Hlavní sklad Physical identification to be started MAR2017

1111 Haly A,B Hlavní sklad Physical identification in progress

1139 Jeseník u kolejiště (Fanta) JESL Physical identification to be started NOV2016

1130 Plechová samostatně stojící budova (jeseník) (Kašpar) JESL Physical identification to be started NOV2016

1131Budova dílen údržby T700 sklad oddělený oplocením v jihovýchodní části budovy

(Kašpar)JESL Physical identification to be started NOV2016

1143 Sklad olejů a těsnění (dobře evidovanej - štítky); Fanta JESL Physical identification to be started NOV2016

6655 sklad VH (Šiška, Mrišo) VH Physical identification to be started JAN2017

6822 VH Physical identification to be started JAN2017



0315 sklad VH Kopisty (Šiška, Mrišo) VH Physical identification to be started FEB2017

0213 VH Physical identification to be started FEB2017





6627 sklad VH (Pavel Kepl) VH Physical identification to be started JAN2017




No. Building Description Unit Progress Pozn.

; 0515 + oplocený venkovní sklad na jižní straně budovy 0515 POX Physical identification completed

2 0515 VNR Physical identification completed

3 bez označení odkrytá plocha na severní straně budovy 1510, jižne od ulice E a mostu Za POX Physical identification completed

4 1431 POX Physical identification completed

5 bez označeníodkrytá plocha přilehlá k severní straně boduvy 1431, průsečík ulice 5a a železnice 93a,

(volbě ložené armatury a potrubí)POX Physical identification completed

6 bez označeníodkrytá plocha SV od budovy 1442, mezi železnicemi 99 a 93a, (volně ložené armatury

a potrubí)POX Physical identification completed

7 bez označeníodkrytá plocha přilehlá k západní straně budovy 1421, ulice 5a (volbě ložené armatury

a potrubí)POX Physical identification completed

8 bez označení oplocená plocha severně od budovy 1442, jižně od ulice E (armatury a potrubí) POX Physical identification completed

9 1443 POX no materials to identify

10 1443/1 POX no materials to identify

11 1424 pouze volné plochy POX Physical identification completed

12 1523 pouze sklad v jižní části budovy Močovina Physical identification completed

13 3630 překladiště 3630, západní strana budovy 3607 (volně ložená zařízení) NH3 Physical identification completed

14 3610 volná plocha NH3 no materials to identify

15 3609 NH3 Physical identification completed, validation in progress

16 3612 NH3 Physical identification completed, validation in progress

17 0623 Haly A,B,C Hlavní sklad Physical identification in progress

18 0625 Haly 4,5,6,7 Hlavní skladBlind physical stock counting completed, warehouse

removed to another location

19 2515 Hlavní sklad Physical identification to be started

20 0621 Hlavní sklad Warehouse removed

21 0512 venkovní plocha Hlavní sklad Physical identification to be started

22 1111 Haly A,B Hlavní sklad Physical identification completed, validation in progress

23 1139 Jeseník u kolejiště (Fanta) JESL Physical identification completed, validation in progress

24 1130 Plechová samostatně stojící budova (jeseník) (Kašpar) JESL Physical identification completed, validation in progress

25 1131 Budova dílen údržby T700 sklad oddělený oplocením v jihovýchodní části budovy JESL Physical identification completed, validation in progress

26 1143 Sklad olejů a těsnění (dobrá evidence - štítky); Svoboda - pod Fantou JESL Physical identification completed, validation in progress sklad olejů

27 6655 sklad VH (Šiška, Mrišo) VH Physical identification cancelled strojní

28 6822 VH Physical identification cancelled strojní



31 0315 sklad VH Kopisty (Šiška, Mrišo) VH Physical identification cancelled strojní




35 3333 VH Physical identification cancelled elektro a mar


37 6627 sklad VH (Pavel Kepl) VH Physical identification cancelled elektro a mar




41 0524 Technip Physical identification completed elektro a mar

42 7211 Sklad MaR vedle vrátnice PCH Physical identification in progress MaR

43 8401 Sklad Elektro Rozvodna EJ (volné plochy + zamykatelné sklady) 1. patro + přízemí PCH Physical identification to be started before at 2017 elektro a mar

44 7522 Sklad Elektro a MaR Rozvodna Farrel v patře PCH Physical identification in progress before at 2017 elektro a mar

45 7512 Sklad Strojních ND - Peletizace PCH Physical identification to be started strojní

46 7723 Sklad Stroní + Elektro Farrel 2 PCH Physical identification to be started Strojní, Elektro

46 98 Plocha mezi blokem 98 a plotem PCH Physical identification to be started Strojní

47 0524 Elektrodíly pro PCH, správce Inelsev (Velké motory 5M Kč bez temperace) PCH Physical identification to be started before at 2017 elektro

48 1718 Velký sklad AGRO Physical identification to be started before at 2017 MaR

49 8411 Velín EJ - dílna strojní údržby PCH Physical identification to be started Strojní

50 7411 Energoblok - strojovna PCH Physical identification to be started Strojní

51 7521 PE1 granulace - bude zrušeno s nájezdem PE3 PCH Physical identification to be started

52 7512 PP Farrel1 PCH Physical identification to be started

53 7723 PP Farrel2 PCH Physical identification to be started

54 7511 Velín S+E - dílna strojní údržby PCH Physical identification to be started Strojní

55 7301 PCH Physical identification to be started

56 1433 Rozvodna POX AGRO Physical identification to be started before at 2017 Elektro

57 1423 POX AGRO Physical identification to be started before at 2017 Elektro

58 3612 Elektro 1.p AGRO Physical identification to be started

09/08/201728/02/2017

16

1717

NH3

POX

CENTRAL WAREHOUS

E

CW

JESL

CW VNR

CWPOX

VH

VH

VH

VH

VH

Investment

s

PHYSICAL IDENTIFICATION COMPLETED, VALIDATION IN PROGRESS

IDENTIFICATION NOT STARTED YET

IDENTIFICATION IN PROGRESS

POSTPONED

Project plan:NH3 – validation readyPOX – validation readyCW – started NOV2016JESL – started NOV2016VH – start in 2017PCH+EJ postponed by UniRPAINVESTMENTS – started DEC2016

DECISION PENDING

POX 1319

Started28. 8. 2017

PCH + EJ

Started20. 9. 2017

WEB-BASED IND – DETAIL OF IDENTIFICATIONApplication for Validation and Administration of created records

18

WEB-BASED INDApplication

for Validation

and Administration

of created records

19

Progress of Identification

Centralwarehouse

„Black“ warehouses

20

Key numbers – progress

Since the project started, 36 827 materials were identified,

out of them 27 878 on central warehouses and 8 949 in temporary warehouses.

In central warehouse, 19 551 items were stock counted.

Validation of Hi-pressure parts in Ammonia unit was accomplished.

1820 items validated in Ammonia unit in total (validation 1).

Matching of hi-pressure parts in Ammonia unit finished (coupling black materials with SAP items

in Central warehouse). Validation 2 of matched pairs to be started.

21

Validated by master data admin

Validated by responsiblemaintenancetechnician

VALIDATION OF IDENTIFICATION

Name + attributes

VALIDATION OF DUPLICATES

SQUIRREL – CentralWH

VALIDATION OF DUPLICATES IN CENTRAL WH

VALIDATION OF MRP CONTROL LEVELS

REVISION AND VALIDATION OF IDENTIFICATION METHODOLOGY Keywords, identifikation trees, translations

Validated by responsiblemaintenancetechnician

Validated by master data admin

Validated by Maintenance Engineer nominated for particular material category

1 2 3 4

0

VALIDATION LEVELS

0

200

400

600

800

1000

1200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

V1 V3 V4 V5 V6

Progress of validation states of items in Ammonia unit

For validation

Rejected

Corrected

Validated

Risk: Validation

of identifieditems takes

time!

Weeks

23

Progress of validations Ammonia – activity of maintenanceengineers responsible for validation(states Rejected and Validated)

0

200

400

600

800

1000

1200

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

V1 V4 V6

Rejected

Validated

Risk: Validation

of identifieditems takes

time!

Weeks24

WEB-BASED IND – VALIDATOR ACCOUNT

Application for Validation and Administration of created records

25

Matching of black spares with central warehouse

UNIRPA COOPERATION

844 N16 items in black warehouses ofNH3 unit

Lxxxxx

377 N16 items on Central warehousein Planning group

210

Objectives:

1 Joining duplicates2 Estimate of value

26

844 items

in black warehouses

Matching of black inventories – Searching for duplicates

Paired black items 844

100% match (similarity = 1) 172

No match (max similarity = 0) 641

Partial match (similarity between 0 and 1) 31

377 items

in Central warehouse

Perfectmatch

27

Black items paired so far 844

100% match (similarity = 1) 172

No match (max similarity = 0) 641

Partial match 31

Estimate of nominal value of black items 3 500 000 EUR

Estimate of scrap value of black items 20 000 EUR

Matching of black spares with central warehouse

28

Transfer of black inventories into SAP

29

ACTIVITY CONTRACTOR CUSTOMER

To provide App for identification and to service App during identification x

To provide initial and operational trainings to explain identification procedure x

To register handling and consumption of items in WHS during identification x

To provide personnel and equipment for material handling for purposes of identification

x

To ensure security during identification x

To validate correctness of master data records x

To provide sufficient human resources according to scope of items to be identified x

To accomplish minimum volume of data records agreed in contract x

To prepare and hand over all documentation related to identified parts x

PREREQUISITES FOR IDENTIFICATION

30

Kategorie CCT

Kategorie CRC

Comparison of material groups of different methodologies

Some annexes are not finished yet

Some categories can not be simply linked

PROJECT PITFALLS

31

32

REVISIONS AND CUSTOMIZATION OF IDENTIFICATION METHODOLOGY

MUST BE DONE BEFORE PHYSICAL IDENTIFICATION STARTS

TIME OF PERMANENT EMPLOYEES IS LIMITED, THUS THERE IS NEED

TO PLAN TIME OF TECHNICIANS AND IT ADMINS, AND

OUTPUT QUALITY CONTROL OF PERFORMED IDENTIFICATIONS PRIOR

TO VALIDATION HAS TO BE INTRODUCED

WHEN USING SUB-SONTRACTORS FOR IDENTIFICATION, NEED TO SET

MONITORING AND REPORTING ACCORDING TO DEFINED INDICATORS

OF PERFORMANCE

PROJECT PITFALLS

THANK YOU

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SPARE PARTS IDENTIFICATION · Transformation to correct master data record structure Yet incomplete, but correct form of CZ/EN short text (subject to complete by physical ... 6627