sap pm presentation bmansi_ppt1
TRANSCRIPT
What’s Your SAP EAM Roadmap?p
B j i J M i PEBenjamin J. Mansi, PEVesta Partners, LLC
A il 22 2010April 22, 2010
Session Overview
Takeaways
1. We can use SAP EAM as our tool implement basic to
advanced maintenance management strategies and g g
solutions
2 H I t ti i l t ti h2. Hmmm – Interesting implementation approaches
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 recognize4. We are pretty good at how we use SAP EAM but recognize
there are more opportunities
Agenda
Roadmap to SAP EAM and Maintenance Excellence The SAP EAM Decision
Functional Considerations – Quick Demo
Hidden Features - Exposed
The Implementation ApproachBig bang
Phased approach
Pilot and roll-out
A l t d d lAccelerated model
SAP EAM Optimization
EAM Continuous Improvement
Why SAP EAM? – The Decision
Master Data
W k M PWork Management Process
Identify, Evaluate, Approve, Plan, Schedule, Execute,
Complete, Analyze/Report
Preventive / Predictive / Condition MaintenancePreventive / Predictive / Condition Maintenance
Hidden features
Master Data – The Basics SAP
Functional Locations – Multi level hierarchy
EquipmentEquipment
Sub-Equipment – Multi level
Bills of material – Multi level
Material Serialization
ComponentsComponents
Work centers
Structured Master Data in SAP
Functional Locations = Locations
What are they? Provide a place for Industry Applicability
ALLthings to operate Multi level hierarchy of
plant locations
ALL
Industry LimitationsNONE
pBy physical locationSpatialProduction line based,
NONE
Production line based, process based
LinearAccounting / Cost Center g /
basedArea basedSingle asset basedgSimple or complex
Functional Location = Location
Why Flocs?
Organization of Data
Roll up of costsp
Tracking “LOCATION” and “USAGE” history in addition
i hito equipment history
Free data in work managementg
One time set up and simple mass change if needed
Total security as needed
Equipment = Equipment/Asset
What is an Equipment? Physical assets Industry Applicability Physical assets Production equipment Medical equipment
Industry Applicability ALL
Industry LimitationsMedical equipment IT Equipment Buildings and grounds
Industry Limitations NONE
g g Rotables Utilities and infrastructure Fleet, Transportation Etc.
Equipment = Equipment
Wh t ?Why create? Core / fundamental reason why many companies are in
business !business !
Document physical asset details and specifications
C ll t d t k lif l t hi t Collect and track lifecycle cost history
Collect and track lifecycle technical history
k l k ( d f d ) Track capital work (modifications and improvements)
Track location and use
Track uptime (or downtime)
Coordinate preventive, predictive & condition maint.
Disposal
Bills of Material = Spare Parts List
What is a BOM? In maintenance, list of
common repair parts
Industry Applicability ALL
common repair parts
Why? Facilitate planning of
Industry Limitations NONE
Facilitate planning of repairs
Work Centers = Crafts, Equipment
What is a WC? Identifies the type of skills
and list of available resources
Industry Applicability ALL
dand list of available resources to do work
Why
Industry Limitations NONE
Why Support capacity planning,
scheduling and dispatching of resources
MRO Materials and Components; Serialization
Components Purchased
St d i i t
Serialized Components Purchased
St d i i t Stored in inventory MRP relevant Costed
Stored in inventory MRP relevant Costed Costed
Quality inspected Flexible UOM
Costed Tracked individually Warranty tracking optione b e UO
Linked to Documents Used on Bills of
a a y a g op o Lifecycle history Commonly Repairable
Materials for planning Might not be equipment Be careful – gauge level
of effort!!of effort!!
Work Management Process
1) Work Identification2) Evaluation2) Evaluation3) Approval4) Planning4) Planning5) Scheduling6) Di t hi6) Dispatching7) Completion8) k8) Rework9) Work Analysis and 10) KPI Reporting
SAP
One Page Planned Work Order
Proactive Maintenance
Preventive Maintenance
Maintenance plan
Strategy planSingle cycle plan Multiple counter plan1
Time-based Performance-basedTime based Performance based
Just about all scenarios SomeJust about all scenarios – Some exceptions like aging equipment
Hidden Features
IntegrationIntuitive natureScalabilityTraceabilityAudit trailEase of useVisibilityVisibilitySecurityOpen ArchitectureOpen ArchitectureStandard business processes
Integration – Pre-wired and real time
Integration between
COMM PS
- Cost centercontrolling
O d
Integration between modules is pre-wired,
seamless and real-time.PS-- Material master
- Inventorymanagement- Purchasing- Contractor
- Ordercontrolling -- Project structure
and controlling- Budgets
PM
*
AM-- Asset master- Depreciation- Capitalization
PP-- Availability check
for production resources
PM-- Technical objects
- Resource- Planning +
processing of tasks
HR*
QM-- Test equipment
- Calibration tasks- Calibration
MM-BD-- Documents- Archiving
- History + Analysis
HR- Qualifications
- Manpowerplanning
Calibration results
Archiving
Integration with Material Management
Work Management and Material Integration:
•BOM Selection•Material Availability
Integration with Internal Cost Controlling
Integration with Project System
Simple assignment on the work order
provides full logisticprovides full logistic integration with a simple or complex
project.
Project Report
Integration with Asset Management
Integration between maintenance
i t dequipment and financial assets a
simple synchronized master record data
point.
Integration with Production Planning
In SAP show equipment master and PP confirmation
Integration with Quality Management - Calibrations
Intuition Built in to “SAP Environment Menu” (or double click)( )In SAP show IH01
Traceability and Audit Trail – Status Changes
Traceability and Audit Trail - History
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 l Portal screens
SAP I&I (Integration and Intelligence)
GUI T S ti D i T l GUIxT screens – Synactive Designer Tool
3rd party solutions – NRX-VIP (Visual Information for Plants)
B t ti Si lif hi hBest practice – Simplify high use screens
Work Identification
W k C l ti Work Completion
One Screen Order (Plan and Schedule)
One Screen for All Master Technical Objects
Visibility and Security
d ’ lReporting and KPI’s across plants
Business objects – BOBJ
Business IntelligenceBusiness 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 optionsRoll out options Big bang
Ph d h Phased approach
Pilot and roll-out
Accelerated model
Big Bang EAM
Definition – Multi-site/plant go live at all sites at once
Considerations Data sources - >1 legacy
once
g y Data Conversion Training Security Security Support – Team bandwidth
Phased Approach – Groups of Plants/Sites
ConsiderationsSi il diff t l t Similar or different plants Size Organization Change management Training resources
Legacy systems Common across or disparate Support
Pilot site
Choosing locationChoosing location Representative plant Plant size
Legac conside ations Legacy considerations Mature in processes or in most need? How many relevant sites?
Abilit t t d diAbility to standardizeControlled roll-out with overlapping teams!!
Advantages Less time to implement Leverage project team for roll-outs
Disadvantages Longer time to go-live Larger implementation team Leverage project team for roll outs
Test the design Reduced risk – Better end user
support and coverage
Larger implementation team How many relevant sites?
More risk – thinner resource coveragesupport and coverage
Retire legacy soonercoverage
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 dataSingle legacy with full data
Standard use of SAP
Pre-configuration of best practicesPre configuration of best practices
Custom development
Project Delivery Approach Thought
Project success is rarely a result of one great idea, g ,
but many good ideas.
TEAMWORK!!!!!!!
Session Summary
Optimized? Life Cycle decisions
Specify and Decommission
What was it designed to
do?
Does Finance know that we deactivated
the equipment?Designand Disposal
doq p
Modify
Details on
Continuous Improvement
Modify and
Improve start up issues
What are the
Improve
Procure and Build
Operate and Maintain
operating conditions?
SAP EAM Health and Usage Check
I t EAM l ti
Was your system configured with best practices in mind?
Is your current EAM solution providing the expected performance?
Was your system configured with best practices in mind?Consistent is data entry: For Equipment, MaterialsComplete and detailed preventive maintenance work Co p ete a d deta ed p e e t e a te a ce oinstructionsOverhauls - pre-planned as task listsComplete and updated BOM’s Check parts issued to orders and check to see if missing on reference object BOMPerformance based PM’s instead of Time BasedPerformance based PM s instead of Time BasedCondition based instead of performance and/or time basedMaster data warranty tracking – Equipment level vs. y g q pcomponent level
SAP EAM Health and Usage Check
I t EAM l ti idi th t d
Tracking to >75% proactive <25% reactive maintenance
Is your current EAM solution providing the expected performance?
Tracking to >75% proactive <25% reactive maintenanceAbove >>>>> enables longer term planning/schedulingg p g/ g allows a leaner workforce translate into higher reliability and less downtime
M i i OEE? Maximize OEE?Completion of PM’s on timeCreation and sharing of KPI’s across all plantsCreation and sharing of KPI s across all plants
PM Optimization
Life cycle information Cost and technicalLife cycle information – Cost and technicalAble to measure and maintain reliability/equipment healthSchedule and capacityAssignments to resourcesMaterial requirements planningReporting
C l l ’ Corporate level KPI’s
Maintenance Dept level KPI’s
Optimization
Optimized? People - Schedule and capacity
Focus on the M – Management
Good schedules are very important
J b i t kill l iJob assignments, skills planning
Are you planners really properly trained in using SAP?
Did you set up good scheduling in SAP?Did you set up good scheduling in SAP?
Proper configuration?
Time to revisit?
MRS ? Multi-resource scheduling
Interface?
Optimized? Inventory - 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? 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 equipmentequipment
3000
Optimized? Symptom Coding
Symptom codeSymptom code• Usually entered by Production• Global list of choices• Global list of choices
Symptom
Optimized? Failure coding
2.1.
Object Part1. Rotary valve? 3
Object Part
ota y a e2. Motor?3. Breaker?
3.
Object Part
Optimized? Failure coding
Damageand Cause codesand Cause codes
Damage
EAM is more than just PM
Improve what you
have done
BWKPI
Reporting
HRHuman
ResourcesBasic CMMS
Basic Maintenance
Full Enterprise
AssetManagement
Asset Maintenance
MRO Procurement
and Inventory
PM ModuleMM and BasicProcurement
PSProject
Management
CO reportingCompany
Core Financials
MRPMaterials
Requirements
QMInspection(s)
and ConditionRequirements
PlanningCondition
Information
The Asset Management PyramidBenefits from Maintenance Managemente e ts o a te a ce a age e t
Benefits from Management of Information
Benefits from Management of Knowledge and Innovation
Asset Life Cycle Optimization
Return on Asset Optimization
ReliabilityAnalysis and Optimization
ProjectManagement
FinancialOptimization
Technical Automation
AdvancedMaintenance Planning MRP Integrated
ProcurementCapacity Planning Skills
SCADAIntegration
Condition Monitoring
RFID,Mobile
Optimization
Reactive Maintenance
Preventive Maintenance
Maintenance Planning
Plant Maintenance – Maintenance Plans, Task Lists
Procurement Planning
Reactive Maintenance
Session Summary
TECHNOLOGY - Continuous Improvement
dd l d lAdditional SAP Modules supporting EAMMobile Remote work execution Operator rounds
Bar CodingPortalsCounter based preventive maintenanceMII and MES shop floor integration driving condition basedRefurbishment and rotable spare trackingRefurbishment and rotable spare trackingManagement of External ContractorsReliability and Failure analysisxAPPsWorkflowBAPI’s (Get list)( )
Additional SAP Modules for EAM – Continuous ImprovementAdditional SAP Modules for EAM Continuous Improvement
WCM - Work clearance management Lock out – Tag out
EHS – Environmental Health and Safety MSDS
DMS – Document Management SystemDMS Document Management System Work instructions, Drawings, P&ID’s
Warranty Claims Management Details of warranty Details of warranty
SRM – Supplier Relationship Management Optimize and simplify MRO part purchases
BobJ Business ObjectsBobJ – Business Objects Special reporting
Rotables Management Cockpit to manager repairable spares
Enterprise Asset Management . . .
MRO Procurement & Inventory
Asset Maintenance
A complex business process
SAP EnterpriseSystems
SAPInspection & Calibration
Human Resources
3rd Party
SAPNetWeaverApplication
andIntegration
Pl tfRFID and 3rd PartySystemsPlatformRFID and
Mobile Devices
Asset Health Monitoring
Legacy Systems
MaterialsRequirements
PlanningProject
Management
Core Financials
Financial Optimization &
Reliability Reporting
Technology - Have you thought about mobile?
Link maintenance activities with asset performance and process control informationinformationMobile Access to SAP is becoming much more viable todayyUse technology to help improve wrench time of the work forceOperator Rounds - Early failure identification
Bar-coding – Orders and Operations
Reduces typing errorsSelf directed crew enablementE pedites time confi mationsExpedites time confirmations
Bar-coding Materials
Reduces typing errorsExpedites issue/return processExpedites issue/return processAccurate inventory
New Portal content - Usability
Direct Access Confirmation
Sample screens
Create your own work list selections
Personalize your work list
Print shop floor tpapers, enter
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
OrOrOrOrOrOrOrOrCredit: 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 yourDo 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?
Assets - Moving more to reliability
The basic PM functions or simplefunctions or simple preventive maintenance willmaintenance will often not stop the failuresfailures
00 Work Order Distribution for a Typical Midsize industrial Complex
00
00 Work Order Distribution for a Typical Midsize industrial Complex
00
00
00
00
00
00
00
00
Average Maintenance Cost = $3,963 Average PM Cost = $432
0Failures Preventive Mis
RCMO/SAP Process Flow
SAP EAM BW
EquipmentEquipmentMaster DataMaster Data
MaintenanceMaintenancePlanningPlanning
MaintenanceMaintenanceExecution &Execution &
DocumentationDocumentation
SAP EAM
MaintenanceMaintenanceAnalysisAnalysis
BW
RCMOOptimizeSt t gi
FMEAFMEA
SystemSystemDefinitionDefinition
StrategyStrategyDefinitionDefinition
StrategyStrategyEvaluationEvaluation
Establish
Strategies
Risk EvaluationRisk Evaluation
Condition Monitoring O tO t
EvaluationCriteriaRCMRCM
Condition Monitoring(Future Integration)
OperatorOperatorRoundsRounds
ConditionConditionMonitoringMonitoring
OperationalOperationalPerformancePerformanceEvaluationEvaluation
MonitoringMonitoring
Current xAPPS applicable to EAM
RCMO RCMO is a Powered by SAP NetWeaver solution. Through tight
integration with SAP PM, RCMO provides the framework for defining maintenance strategies based upon RCMO and Failuredefining maintenance strategies based upon RCMO and Failure Modes Effects and Criticality Analysis (FMECA) principles.
VIP Role-based Portal views that are easily configured to adapt to y g p
changing work processes. A unified workspace enables speed-of-execution and quality decision-making.
MII Manufacturing Integration and Intelligence (SAP MII) is a 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 personnelproduction personnel
Session Summary
Takeaways
1. We can use SAP EAM as our tool implement basic to
advanced maintenance management strategies and g g
solutions
2 H I t ti i l t ti h2. Hmmm – Interesting implementation approaches
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 recognize4. We are pretty good at how we use SAP EAM but recognize
there are more opportunities
