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Benjamin J Mansi, PE B j i J. M i Vesta Partners, LLC April 22 A il 22, 2010
1. We can use SAP EAM as our tool implement basic to g g advanced maintenance management strategies and solutions 2. Hmmm – I t 2 H Interesting i l ti implementation approaches t ti h 3. We can use SAP EAM better than we have in the past – there is room to improve and optimize 4. We are pretty good at how we use SAP EAM but recognize there are more opportunities
Exposed The Implementation Approach Big bang Phased approach Pilot and roll-out A l t d model Accelerated d l SAP EAM Optimization EAM Continuous Improvement .Agenda Roadmap to SAP EAM and Maintenance Excellence The SAP EAM Decision Functional Considerations – Quick Demo Hidden Features .
Schedule. Plan.Why SAP EAM? – The Decision Master Data Work M W k Management Process P Identify. Approve. Execute. Evaluate. Analyze/Report Preventive / Predictive / Condition Maintenance Hidden features . Complete.
Master Data – The Basics SAP Functional Locations – Multi level hierarchy Equipment Sub-Equipment – Multi level Bills of material – Multi level Material Serialization Components Work centers .
Structured Master Data in SAP .
process based Linear Accounting / Cost Center g based Area based Single asset based g Simple or complex Industry Applicability ALL Industry Limitations NONE .Functional Locations = Locations What are they? Provide a place for things to operate Multi level hierarchy of p plant locations By physical location Spatial Production line based.
Functional Location = Location Why Flocs? Organization of Data Roll up of costs p Tracking “LOCATION” and “USAGE” history in addition to equipment history i hi Free data in work management g One time set up and simple mass change if needed Total security as needed .
Transportation Etc. Industry Applicability ALL Industry Limitations NONE .Equipment = Equipment/Asset What is an Equipment? Physical assets Production equipment Medical equipment IT Equipment Buildings and grounds g g Rotables Utilities and infrastructure Fleet.
Equipment = Equipment Wh create? t ? Why Core / fundamental reason why many companies are in business ! Document physical asset details and specifications C ll t and track lifecycle cost history Collect d t k lif l t hi t Collect and track lifecycle technical history Track capital work (modifications and improvements) k l k ( df d ) Track location and use Track uptime (or downtime) Coordinate preventive. predictive & condition maint. Disposal .
list of common repair parts Industry Applicability ALL Why? Facilitate planning of repairs Industry Limitations NONE .Bills of Material = Spare Parts List What is a BOM? In maintenance.
Equipment What is a WC? Identifies the type of skills and list of available resources to do work Industry Applicability ALL Industry Limitations d NONE Why Support capacity planning. scheduling and dispatching of resources .Work Centers = Crafts.
Serialization Components Purchased Stored in i St d i inventory t MRP relevant Costed Quality inspected Flexible UO e b e UOM Linked to Documents Used on Bills of Materials for planning Serialized Components Purchased Stored in i St d i inventory t MRP relevant Costed Tracked individually Warranty tracking option a a y a g op o Lifecycle history Commonly Repairable Might not be equipment Be careful – gauge level of effort!! .MRO Materials and Components.
Work Management Process 1) Work Identification 2) Evaluation 3) Approval 4) Planning 5) Scheduling 6) Dispatching Di t hi 7) Completion 8) Rework k 9) Work Analysis and 10) KPI Reporting SAP .
One Page Planned Work Order .
Proactive Maintenance Preventive Maintenance Maintenance plan 1 Single cycle plan Strategy plan Multiple counter plan Time based Time-based Performance based Performance-based Just about all scenarios – Some exceptions like aging equipment .
Integration Intuitive nature Scalability Traceability Audit trail Ease of use Visibility Security Open Architecture Standard business processes
Integration – Pre-wired and real time
Integration between modules is pre-wired, seamless and real-time.
- Material master - Inventory management - Purchasing - Contractor - Cost center controlling Order -Od controlling
- Project structure and controlling - Budgets
- Asset master - Depreciation - Capitalization
- Technical objects - Resource - Planning + processing of tasks - History + Analysis
- Availability check for production resources
- Test equipment - Calibration tasks - Calibration results
- Qualifications - Manpower planning - Documents - Archiving
Integration with Material Management
Work Management and Material Integration: •BOM Selection •Material Availability
Integration with Internal Cost Controlling .
Project Report .Integration with Project System Simple assignment on the work order provides full logistic integration with a simple or complex project.
Integration with Asset Management Integration between maintenance equipment and i t d financial assets a simple synchronized master record data point. .
Integration with Production Planning In SAP show equipment master and PP confirmation .
Calibrations .Integration with Quality Management .
Intuition Built in to “SAP Environment Menu” (or double click) ( ) In SAP show IH01 .
Traceability and Audit Trail – Status Changes .
History .Traceability and Audit Trail .
Traceability and Audit Trail – Action Log .
Ease of Use – The User Interface Many options to simplify the user interface Standard configuration Custom transaction Adobe Forms P Portal screens l SAP I&I (Integration and Intelligence) GUI T screens – S GUIxT Synactive D i ti Designer Tool T l 3rd party solutions – NRX-VIP (Visual Information for Plants) Best B t practice – Si lif high use screens ti Simplify hi h Work Identification W k Completion Work C l ti .
One Screen Order (Plan and Schedule) .
One Screen for All Master Technical Objects .
Visibility and Security d ’ l Reporting and KPI’s across plants Business objects – BOBJ Business Intelligence All master data managed consistently in one data base across plants Change in one plant while view of other plants – Flexible and robust authorization and security In SAP show BW report example .
Implementation Roadmap Making the decision then what Roll out Roll-out options Big bang Ph d approach Phased h Pilot and roll-out Accelerated model .
>1 legacy g y Data Conversion Training Security Support – Team bandwidth .Big Bang EAM Definition – Multi-site/plant go live at all sites at once Considerations Data sources .
Phased Approach – Groups of Plants/Sites Considerations Si il or different plants Similar diff t l t Size Organization Change management Training resources Legacy systems Common across or disparate Support .
Pilot site Choosing location Representative plant Plant size Legacy conside ations Legac considerations Mature in processes or in most need? How many relevant sites? Ability t t d di Abilit to standardize Controlled roll-out with overlapping teams!! Advantages Less time to implement Leverage project team for roll outs roll-outs Test the design Reduced risk – Better end user support and coverage Retire legacy sooner Disadvantages Longer time to go-live Larger implementation team How many relevant sites? More risk – thinner resource coverage Legacy costs .
Accelerated Implementation Generally speaking [3 .6 months] Considerations Single plant Pilot for other locations Business processes in place – little change mgt Single legacy with full data Standard use of SAP Pre configuration Pre-configuration of best practices Custom development .
result of one great idea. but many good ideas.Project Delivery Approach Thought Project success is rarely a g . TEAMWORK!!!!!!! .
Session Summary .
Optimized? Life Cycle decisions Does Finance know that we deactivated the equipment? q p Decommission and Disposal Specify and Design What was it designed to do do? Continuous Improvement Modify and Improve Operate and Maintain Procure and Build Details on start up issues What are the operating conditions? .
SAP EAM Health and Usage Check I your current EAM solution t l ti Is providing the expected performance? Was your system configured with best practices in mind? Consistent is data entry: For Equipment. Materials Co p ete a d deta ed preventive a te a ce o Complete and detailed p e e t e maintenance work instructions Overhauls . y g q p component level .pre-planned as task lists Complete and updated BOM’s Check parts issued to orders and check to see if missing on reference object BOM Performance based PM s instead of Time Based PM’s Condition based instead of performance and/or time based Master data warranty tracking – Equipment level vs.
SAP EAM Health and Usage Check I your current EAM solution providing th expected t l ti idi the t d Is performance? Tracking to >75% proactive <25% reactive maintenance Above >>>>> enables longer term planning/scheduling g p g/ g allows a leaner workforce translate into higher reliability and less downtime Maximize M i i OEE? Completion of PM’s on time Creation and sharing of KPI s across all plants KPI’s .
PM Optimization Life cycle information – Cost and technical Able to measure and maintain reliability/equipment health Schedule and capacity Assignments to resources Material requirements planning Reporting C Corporate level KPI’s l l ’ Maintenance Dept level KPI’s Optimization .
Schedule and capacity Focus on the M – Management Good schedules are very important Job J b assignments. skills planning i t kill l i Are you planners really properly trained in using SAP? Did you set up good scheduling in SAP? Proper configuration? Time to revisit? MRS ? Multi-resource scheduling Interface? .Optimized? People .
Get it right with Organized MRO storeroom All parts bar-coded Consider visual BOM’s or catalogs Revisit MRP and your planning process Refurbishment of critical and repairable spares .Optimized? Inventory .
Optimized? Have you created catalog profiles? Functional Location Catalog Profile • Each functional location/equipment can have a specific list of Cat Codes • The Catalog Profile displays the Codes for that ‘class’ of equipment 3000 .
Optimized? Symptom Coding Symptom code Symptom code • Usually entered by Production • Global list of choices Symptom .
3 Object Part .Optimized? Failure coding 1. Breaker? 3. 2. Rotary valve? ota y a e 2. Motor? Object Part 3. Object Part 1.
Optimized? Failure coding Damage and Cause codes Damage .
EAM is more than just PM Improve what you have done BW KPI Reporting Basic Basic Maintenance CMMS MRO MM and Basic Procurement Procurement and Inventory PMAsset Module Maintenance HR Human Resources Full Enterprise Asset Management CO reporting Company Core Financials PS Project Management MRP Materials Requirements Planning QM Inspection(s) and Condition Information .
Task Lists .The Asset Management Pyramid Benefits from Maintenance Management e e ts o a te a ce a age e t Benefits from Management of Information Benefits from Management of Knowledge and Innovation Return on Asset Optimization Asset Life Cycle Optimization Technical Automation Advanced Maintenance Planning Preventive Maintenance Reactive Maintenance Financial Optimization Reliability Project Analysis and Management Optimization SCADA Integration MRP Condition Monitoring RFID. Mobile Skills Integrated Procurement Capacity Planning Plant Maintenance – Maintenance Plans.
Session Summary .
Continuous Improvement dd l d l Additional SAP Modules supporting EAM Mobile Remote work execution Operator rounds Bar Coding Portals Counter based preventive maintenance MII and MES shop floor integration driving condition based Refurbishment and rotable spare tracking Management of External Contractors Reliability and Failure analysis xAPPs Workflow BAPI’s (Get list) ( ) .TECHNOLOGY .
P&ID’s Warranty Claims Management Details of warranty SRM – Supplier Relationship Management Optimize and simplify MRO part purchases BobJ – Business Objects Special reporting Rotables Management Cockpit to manager repairable spares .Additional SAP Modules for EAM – Continuous Improvement WCM . Drawings.Work clearance management Lock out – Tag out EHS – Environmental Health and Safety MSDS DMS – Document Management System Work instructions.
. .Enterprise Asset Management . A complex business process Asset Maintenance MRO Procurement & Inventory SAP Enterprise Systems Human Resources Inspection & Calibration Asset Health Monitoring RFID and Mobile Devices SAP NetWeaver Application and Integration Platform Pl tf 3rd Party Systems Project Management Materials Requirements Planning Legacy Systems Core Financials Financial Optimization & Reliability Reporting .
Have you thought about mobile? Link maintenance activities with asset performance and process control information Mobile Access to SAP is becoming much more viable today y Use technology to help improve wrench time of the work force Operator Rounds .Early failure identification .Technology .
Bar-coding – Orders and Operations Reduces typing errors Self directed crew enablement Expedites E pedites time confirmations confi mations .
Bar-coding Materials Reduces typing errors Expedites issue/return process Accurate inventory .
Usability Direct Access Confirmation .New Portal content .
Sample screens Create your own work list selections Personalize your work list Print shop floor papers. enter t confirmations. change and display work list items .
Process Which is your organization? Has the company really settled into the use of SAP? Often a need for some follow up training Or Credit: Rusty Jarrett/Getty Images .
Business Information .BI Do you have well developed and agreed on KPIs that can be traced back to the corporate KPIs? Do you have agreed coding for FMEA type information and are your people trained in how to use these codes? Are you really getting the reports you need? .
Moving more to reliability The basic PM functions or simple preventive maintenance will often not stop the failures .Assets .
00 00 00 00 00 00 00 00 0 Work Order Distribution for a Typical Midsize industrial Complex Average Maintenance Cost = $3.963 Average PM Cost = $432 Failures Preventive Mis .
RCMO/SAP Process Flow SAP EAM Equipment Master Data Maintenance Planning Maintenance Execution & Documentation BW Maintenance Analysis RCMO FMEA Strategy Definition Optimize Strategies St t gi System Definition Risk Evaluation Strategy Evaluation Establish Evaluation Criteria RCM Condition Monitoring (Future Integration) Operator O t Rounds Condition Monitoring Operational Performance Evaluation .
Through tight integration with SAP PM.Current xAPPS applicable to EAM RCMO RCMO is a Powered by SAP NetWeaver solution. RCMO provides the framework for defining maintenance strategies based upon RCMO and Failure Modes Effects and Criticality Analysis (FMECA) principles. A unified workspace enables speed-ofexecution and quality decision-making. VIP Role-based Portal views that are easily configured to adapt to y g p changing work processes. MII Manufacturing Integration and Intelligence (SAP MII) is a composite application that helps organizations to become more adaptive by connecting the mySAP™ EAM solution to the plant floor in realtime and delivering actionable intelligence to production personnel .
Session Summary .
Takeaways 1. We can use SAP EAM better than we have in the past – there is room to improve and optimize 4. We can use SAP EAM as our tool implement basic to g g advanced maintenance management strategies and solutions 2. We are pretty good at how we use SAP EAM but recognize there are more opportunities . Hmmm – I t 2 H Interesting i l ti implementation approaches t ti h 3.
com .Thanks for Attending! Questions? Ben Mansi – Vesta Partners 610-420-1891 bmansi@vestapartners.
This action might not be possible to undo. Are you sure you want to continue?