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Turnaround / Shutdown Management with SAP

Enterprise Asset Management
Dean Fitt
SAP AG
A collaboration of:

What I’ll Cover
 SAP Enterprise Asset Management can be used to manage the whole lifecycle of a
Shutdown.
 Integration and ease of use based on ERP components plant maintenance (PM) and
project system (PS) enabled through the use of Maintenance Event Builder (MEB).

 Portfolio and Project Management (PPM) and Multi Resource Scheduling (MRS) that
support the process.
 Highlight enhancements and new functionality.

 Key points to Take Home
 Questions

Contents
 Introduction & Overview

 SAP Solution for Shutdown Management
 Wrap Up

Why are Shutdowns so important?





Most critical periodical event during the plant life cycle.
Single most influential contributor to the total cost of maintenance.
Safety, Health, and Environment regulations must be adhered to.
Ensures future plant performance and safe-guards the investment.
Compliance with Statutory Regulations
Complex event - time of increased activity, with numerous vendors, contractors, and
heavy equipment engaged in multiple tasks in close quarters.
 Involves strong interaction between Maintenance and Operations.

Typical Phases of a Shutdown Definition Planning Scheduling  Initial Planning  EH&S Plan  Critical Path  Scoping  Work Packages  Resource Leveling  Work Lists  Plan Cost  Pre-shutdown preparation  Daily Schedules  Resource Plan  Align Capital Work  High Level Schedule  Cost Plan (Budget) Execution Evaluation  Execute Work Packages  Demobilization  Time. Material Confirmations  Cost Reconciliation  Manage Break-in Work  Post Mortem  Financial Report  Progress Reporting  Equipment Testing  Work Permits Timeline H1 Definition H2 Planning H3 H4 Scheduling Execution Evaluation .

Contents  Introduction & Overview  SAP Solution for Shutdown Management  Wrap Up .

and expenditures to achieve and maintain the stated business objectives. risk.SAP Solution for Enterprise Asset Management Asset Maintenance Plan & Design MRO Procurement & Inventory Procure & Build Commission Operate Maintain Decommission Planning. risks and expenditures throughout an asset’s lifecycle to ensure efficient utilization of assets  Continuous and proactive operational risk management to support instant decisions and minimize disruption  Leverages the SAP Business Suite * According to PAS 55. Reporting Design & Specify Procure & Build Enterprise Asset Management Decommission & Dispose Asset Visibility and Performance Optimized Asset Operations and Maintenance Operate & Maintain Operational Risk Management Real Estate Lifecycle Management SAP supports organizations to efficiently and sustainably manage the whole lifecycle of physical assets in terms of performance. Building. the BSI standard for good practice in asset management . and Commissioning Assets Human Resources Inspection & Calibration Asset Health Monitoring RFID and Mobile Devices Project Management Materials Requirements Planning Core Financials Financial Optimization Reliab.  Integrated asset management processes to collaborate across all related activities such as finance. HR. and compliance – easily deployable in modular implementable steps  Asset intelligence and a holistic view of performance. risks.

SAP Solutions Supporting Shutdown Definition Planning Scheduling Execution Evaluation  Portfolio and Project Management (PPM)  Plant Maintenance (PM)  Plant Maintenance (PM)  Plant Maintenance (PM)  Portfolio and Project Management (PPM)  Project System (PS)  Project System (PS)  Plant Maintenance (PM)  Project System (PS)  Maintenance Event Builder (MEB)  Multi Resource Scheduling (MRS)  Project System (PS)  Cross Application Time Sheet (CATS)  Plant Maintenance (PM)  Document Management System (DMS)  Enterprise Project Connection (EPC)  Mobile EAM Work Order  Financial (FI) / Controlling (CO)  Materials Management (MM)  Materials Management (MM)  Multi Resource Scheduling (MRS)  Business Intelligence (BI)  Maintenance Event Builder (MEB)  Materials Management (MM)  Maintenance Cost Budgeting (MCB)  Project System (PS) .

Tasks..Long Term Planning & Monitoring High Level Architectural View – Shutdown Management Portfolio / Strategic Buckets Portfolio Initiative (Program) Portfolio Item (Project / Proposal) Asset Planning & Operations Project Planning & Execution SAP Portfolio and Project Management optional: Project. Phases. Checklist Items. Project Costing Model Base Planning Object WBS Network Activities SAP ERP Project System Maintenance Cost Budget PM Order Notification Maintenance Plan Task List Technical object PM Order SAP ERP Plant Maintenance Maintenance Event Builder Multi Resource Scheduler ..

Definition Definition Planning Scheduling Execution Evaluation .

The Planning and Scheduling Life Cycle Planning Strategic Planning Planning Bucket Asset Details Resource Work details Quarterly Tactical Planning Scheduling Execution Planning Execution Detailed Schedules Execution Controlling Monthly Daily Plant/ Group Subsection Floc Floc/Equip Equip Role level Team Trade Team Individual Individual Project level Phases & task Orders operation Operation Operation Portfolio & Project Management (PPM) Project System + PM Orders + Maintenance Event Builder shift Evaluation Multi Resource Scheduler (MRS) Hours Planning Granularity Definition Time Job Control and Analytics .

Prioritization High Level Cost Planning High Level Resource Planning SAP Project System (PS) Capital Pre-Approval Project Management & Execution Project Scheduling Detailed Resource Planning Detailed Cost Planning & Approval Scheduling & Dispatching Regulatory Reporting Document Management SAP ERP for Maintenance.0 Portfolio Planning & Monitoring Long Term Investment & Portfolio Planning Risk Assessment.SAP Portfolio and Project Management SAP Portfolio and Project Management 5. HR Core Processes / Activities - - Developing Work Lists and Packages Cost Planning Processing of work orders Update of technical assets . Logistics Financials.

Line / Asset 3 Prod. Line / Asset 4 t Maintenance Event Builder Maintenance Opportunities / Events Notifications Revisions Orders General Task Lists Project Standard Network / WBS  Facilitates Maintenance Planning and Scheduling  Helps eliminate redundant tasks within a work package  Sequences maintenance tasks by assigning them to appropriate time frames  Planning project based maintenance events .Maintenance Event Builder (MEB) – A Workbench for Shutdowns Prod. Line / Asset 1 Prod. Line / Asset 2 Prod.

Project Builder .PS .

Workbench .MEB .

Developing Work Lists .PM .

Maintenance Plans .PM .

service and internal resources 0PM_DS07 0PM_C05 Maintenance Task list (Notifications) Cost planning and budgeting 0PM_C06 0PM_OPA_1 Maintenance Maintenance Orders Orders Extractor 0PM_DS04 0PM_C01 Estimated Unplanned demands .MCB .Data Flow Maintenance Plans 0PM_PRM_PLCS_1 Extractor Forecast of resources like parts.

Planning Definition Planning Scheduling Execution Evaluation .

 The planner can group these task based on priority.Review Backlog  The planner reviews all open maintenance requests that need action.MEB . location and resources needed .

MEB .Review Maintenance Opportunity  Planner meets with operations team to plan shutdown  Planner enters these opportunities as revisions in MEB .

.MEB – Creating Work Packages for the Shutdown Based on the dates of the shutdown and priority. the planner assigns maintenance requirements (notification or WO) to the event.

Generate Orders for a Revision Once the work load is evaluated by operations and maintenance. the planner generates orders or assigns generated orders to the work package .MEB .

MEB – Optimizing the Work Package Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical objects are deleted Revision Notification Chk1 SB1 T1 ST1 ST1 ST6 ST2 ST3 ST3 T2 Elimination ST4 Order Order ST5 ST3 ST1 Order Order Order Order Order Order ST1 ST2 ST3 ST4 ST5 ST6 .

Insert video clip here: -Overview Radiation Shaft .

.

Scheduling Definition Planning Scheduling Execution Evaluation .

Assigning Orders to a Project Automatically .MEB .

Assigning Orders to a Project Network Orders can be assigned manually using drag and drop or automatically based on the Reference PM/PS Element field.PM/PS . Transaction ADPMPS (does not require MEB) .

PS .Network and Overall Network Scheduling • Network Scheduling: – schedule activities of one network only • Overall Network Scheduling (CN24) – schedule all connected networks/subnetworks (and PM/CS orders) simultaneously • Overall Network Scheduling with Selection Options (CN24N) – schedule selected networks/subnetworks simultaneously – analyze dates of subnetworks (and PM/CS orders) using the Subnetwork Monitor .

PS .Project Editor • The Project Editor is enhanced with • • • • Additional Data Sets for example PM/CS Order Dates Date Planning and Scheduling (new) Advanced Date Overviews and Comparison Usability Improvements Date Planning and Scheduling Overall Dates Overview Display PM/CS order in hierarchy Activity Dates Overview .

time bar labels) Choose different timescales (for example. you can:      Display dates of project objects (Tabular area. Specify dates in tabular area) Define user-specific settings and manage variants (for example. monthly) Print and print preview Gantt chart . Graphical area) Change dates and durations (Drag time bars for WBS elements.PS .Project Editor Gantt Chart In the Gantt Chart.

Multi Resource Scheduling (MRS) Demand Gantt Work Center Gantt Work Center Capacity Alert Monitor .

MRS .Scheduler Workplace .

SAP Enterprise Project Connection (EPC) .

Execution Definition Planning Scheduling Execution Evaluation .

Time Confirmation Using Cross Application Time Sheets (CATS) Operations and activities can automatically be defaulted for users in CATS Additional data such as remaining work can be entered via mouse click. .

and edit notifications and related objects (activities. view. and map view ■ View equipments and functional locations ■ Display technical object on a map ■ Display associated documents ■ Display history and characteristics Business Partner ■ Display business partner header and contacts ■ List and map view Inventory Management Online & Offline ■ Track and manage inventory ■ Material consumption booked on orders updates inventory Built on industry leading Sybase Unwired Platform . view. and edit work orders Display related business partners and historical data Record working time and material consumption List. calendar. tasks) • ■ ■ ■ ■ Work Order Management Create.SAP EAM Work Order Mobile Application Standard solution for mobilizing SAP Enterprise Asset Management • Technical Object Management Notification Management ■ Create. items.

 Existing functionality in SAP Work Clearance Management (WCM) has been enhanced. so that industry specific work processes for work permits can be configured in customizing.Work Permit Management (WPM)  Project with Statoil and ConocoPhillips to develop an Oil&Gas specific permit to work solution. .

Work Preparation Create Operational Valve & Blind List .WPM .

Evaluation Definition Planning Scheduling Execution Evaluation .

Reporting and Analytics Options KPI Framework Reports within BCV Dashboards Crystal reports integrated .

Contents  Introduction & Overview  SAP Solution for Shutdown Management  Wrap Up .

Phases.Long Term Planning & Monitoring High Level Architectural View – Shutdown Management Portfolio / Strategic Buckets Portfolio Initiative (Program) Portfolio Item (Project / Proposal) Asset Planning & Operations Project Planning & Execution SAP Portfolio and Project Management optional: Project. Tasks.. Checklist Items. Project Costing Model Base Planning Object WBS Network Activities SAP ERP Project System Maintenance Cost Budget PM Order Notification Maintenance Plan Task List Technical object PM Order SAP ERP Plant Maintenance Maintenance Event Builder Multi Resource Scheduler ..

Developing  Planning of Effort  90% of Planned Work Completed  Within Budget <5% Over  All Equipment inspected Stage 2 .Maturing  Tight control of scope  Manage resource constraints  Daily status update of progress  95% of planned work completed  Estimates of work based on industry norms  Equipment available for maintenance  Delays in equipment startup as a result of integrity issues Stage 3 – Best Practice  Portfolio management process in place  Issues rectified early  Quality of work to ensure on-time start-up  Materials and Resources managed to ensure availability at right time  Work Permit process streamlined  Early planning  Shutdown and start-up on time .Best Practice Stage 1 .

fitt@sap.com .Dean Fitt SAP AG dean.