PI Internal

SAP PM PROJECT OPTIMISATION@ JAMBUSAR

SEP’18
PI Internal

Sr. Process Status Remarks

No.
1 Preventive Maintenance Process implemented, but master data not
updated, thus system not generating planned
orders.

2 Calibration Order Process implemented, but due to lack of

training and unavailability of proper master
data, process not being used.
3 Breakdown Maintenance Process implemented but not being used in
correct manner, thus system not able to
generate critical breakdown analysis.
PLANT MAINTENANCE CURRENT STATUS @ PI
4 Condition Monitoring Process implemented, but due to lack of
training and unavailability of proper master
data, process not being used

5 Shutdown Maintenance Process not implemented.

6 Permit Management Not being used.

Project
PI Internal: SAP Plant Maintenance

Key Milestones : Published Duration Baseline Start Baseline Finish Actual /Expected Responsible Status
Finish
SAP Plant Maintenance Process Streamlining 120 days 01-08-18 30-11-2018    To be started

SAP PM Kick OFF Meeting 10 01 08 2018 10 08 2018 25 July’18 JR Completed

Scope:
Streamlining of SAP Plant Maintenance
Level One training for Core Team process and implementation of additional
10 01 08 2018 10 08 2018 03 Aiug’18 JR Completed
members
processes which are not being used
      Business requirement document preparation 20 13 08 2018 31 08 2018 To be started currently.
      Business Blue print document Preparation
and signoff
20 01 09 2018 20 09 2018 To be started

   Master data collection (Parallel activity) 60 01 08 2018 31 09 2018    To be started

Project Team
      Realization 30 21 09 2018 20 10 2018    To be started Project sponsor   : VS
      20 % Master Data upload 10 22 10 2018 31 10 2018    To be started Project Owner     : RT
      UAT & Signoff 10 01 11 2018 09 11 2018    To be started IT Lead : JR
   Master Data upload 100 % (PRD) 10 12 11 2018 20 11 2018    To be started Project Team :
      End User training 7 21 11 2018 27 11 2018    To be started
CoreLevel
High TeamScope BRD :
Mr. Hardik Bhatt (Utility dept.)
      Go-live 3 28 11 2018 30 11 2018    To be started
Mr. Nimesh Patel (Utility dept.)
      Post Go-live support    
Mr. Pritam Patel (Electrical dept.)
Mr. Aman Joshi (Mechanical dept.)
Recent Updates Upcoming Key Activities
Mr. Chintan Anadkat (Inst. Dept.)
 Formal kick-off meeting for Plant Maintenance improvement  Session two for PM improvement project, on PM critical
Mr. Vasant Sojitra
project done. Master data.
Mr. Rohitpratap Singh
 Identification of core team and Power users done for Jambusar  Discussion with Core team and Power user’s for As-Is and To-
Mr. Amit D Saraswat
Plant. Be documentation.
Mr. Ajay Kumar Dubey <
 Session One for PM improvement project done.
 Level one training for Core team member's done.

Key Risks and Issues Required Decisions & Support

 Master data collection & Standardizations  Incorporation of Project into SLAs of Biz Owners.
 Availability of Core Team .
PI Internal
Under-utilization of the system due
to lack of Training
Reactive Mode of Working
Incomplete equipment/asset
structures
Manual Process and Reporting
Online Visibility on Costs/Planning
Current SAP does provide the kinds
of data needed to make better
decisions.
Determine where we are
AS-IS
SAP PM PROJECT METHODOLOGY
SAP PM Reconfiguration to meet TO-BE Process
SAP PM Core Team Fully Trained in Jambusar Unit
Standardised Master Data and Equipment BOM
Process Documentation and Training
How We are Going to reach there
(GAP ANALYSIS) How We shall know we have arrived
(Project Deliverables)
Preventive Maintainence Through SAP
Complete Equipment Hierarchy
Paperless System
Where we want to go Easy data Retrivation for Audit
TO-BE Online permit system with auto Notification
Desire for more proactive vs. reactive environment
Proactive Planning for Daily, Weekly. Monthly
Uptime/Availability with Improved OEE
Basis
Expense Monitoring
Planning & Budgeting
Complete Visibility of Maintainence Operations
Failure Analysis
Reduced Downtime MTTR and MTBR through SAP
Budget and Inventory Control 5 Why and 8D Analysis through SAP
Improved Service to User Departments
Better Collaboration within and Outside Departments Online Legal compliance (Form No 9,10,11 IBR)
Online Approval of Gate Pass
Spares Inventory Control with Maint. SLOC
Online Reporting for Expenses
PM BOM with Critical Spares List
PI Internal Project : SAP Plant Maintenance

S.NO. Main Process

1 S.NO. Support Process
Breakdown Maintenance
2 1 Gate pass creation
Preventive Maintenance
3 2 Water Tanker Process
Corrective Maintenance
4 3 Reporting & MIS
Condition monitoring
5 3 Spares Inventory Management
Shutdown Maintenance
6 4 PR and PO Tracking
Calibration Process
7 5 Legal compliance (Form No 9,10,11 IBR)
Modification/CAPEX Order
6 Waste lube oil generation (life cycle)

7 Budgeting and Expenses Reporting

PI Internal

Maintenance Work Order Process Flow

10 Maintenance Required 1
Close Work Order
Cost Object

9 Settle Order Costs Create Notification 2

Scheduled
Scheduled
(Planned)
(Planned)
8 Enter Part and Work Order Maintenance Maintenance
Maintenance
Work Order
Damage Code Cycle Create Work Order 3

7 Time Confirmations
Plan Work Order 4

6 Perform Work Release Work 5

Order
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ROOT CAUSE ANALYSIS
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HOW THIS IS DONE IN SAP

8
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HOW ACTIVITIES ARE ENTERED

9
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BREAKDOWN ANALYSIS REPORT

10
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BREAKDOWN MAINTENANCE CRITICAL REPORTS
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COST ANALYSIS REPORT SAMPLE SNAPSHOTS