ispm warranty
TRANSCRIPT
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Reliability Dynamics LLC
Tony Ciliberti, PEPrincipal Engineer, Reliability Dynamics LLC
ISPM Equipment Warranty Solution for SAP
mailto:[email protected]:[email protected]:[email protected]:[email protected] -
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2Integrated Failure Reporting and Warranty Processes
Failure reporting process based on standard practices:
ISO 14224: Collection and exchange of reliability and maintenance data for equipment
Reliability-Centered Maintenance (RCM)
Standard data collection, merging, and analysis processes
Customers and primary suppliers can use the same process, in essence a common
reliability language between them
Failure reports double as warranty claim forms, if warranty applies
Warranty details explicitly given on both equipment records and failure reports
Return Material Authorization (RMA) master records
One or more devices assigned to an RMA
RMA data visible on equipment master records
Complete lifecycle warranty tracking with rigor that eliminates claim duplicity
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3Warranty Process Overview
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4Warranty Master Records
Should contain one or more
provisions
Each provision can be generic or
material master record specific
Warranty provision documents can be
integrated with material master records
with document info records (DIR)
Each provision has a counter and
duration based on counter units
Provisions have a link operator (and/or
specification) that can be used to
specify when a subset of conditions
pertain to the overall warranty validity
Can be classified for additional
attribute data
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5Warranty Master Records
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6Equipment Master Record
Warranty Tab
Shows warranty master records,
provisions, and overall status
Positive result
Warranty master level: all provisions of
the warranty are valid based on the link
operator (and/or specification)
Provision level: the individual provision isvalid
Negative result
Warranty master level: one or more
provisions of the warranty are invalid
with an and link operator
Provision level: the individual provision is
invalid
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7Equipment Master Record
RMA Tab
Shows the last RMA master record
assignment
Details include other equipment items
that are also assigned to the RMA
Equipment serializationGives equipment a unique identity in
the field (PM) and the warehouse (MM)
EQ# = MM# + Serial#
Gives complete lifecycle tracking of
equipment
Facilitates goods transfers of equipment
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8Equipment Master Record
User Status
Equipment user status is set to RMA
RMA processing when assigned to
an RMA master record
The status controls/restricts business
processes not allowed while the
equipment is out of service
Once received back from the vendor,
the status is reset to the appropriate
setting
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9Notification: Equipment Failure Report
Failure reporting process based on
ISO 14224 and Reliability-Centered
Maintenance (RCM) methodologies
The notification doubles as a failure
reporting mechanism and warranty
claim formWarranty statuses are explicitly shown
on the first tab
ISO 14224:2006 Petroleum, petrochemical and natural gas industries -- Collection and
exchange of reliability and maintenance data for equipment
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10Notification: Failure Report User Status
Usage:
Administer RMA process
Designate warranty claims
Administer warranty disputes
A notification cannot be closed if a
warranty dispute is unresolved
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11Notification: Level 1 Failure Assessment
Catalog coding is used to specify
functional failures:
Multiple reporting parties can input their
findings, including the vendor
One or more entries possible per
reporting party
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12Notification: Level 2 Failure Assessment
Use coding to specify:
Component failure mechanism
Root cause
Error codes
Reporting party
Codes 100% consistent with vendor
reliability coding process (common
reliability language)
Customer and vendor failure findings
can be compared (and disputed)
programmatically
Level 2 coding can be maintained in
SAP front-end via characteristic
maintenance (CT04)
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13Notification: Failure Disposition Coding
Actions taken by customer and
vendor
Used to document what was done to
address:
The failure (corrective actions)
Warranty (if applicable)
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14RMA Master Record
Installed Base (IBase) functionality
used to create RMA master records
RMA is the vendor Return Materials
Authorization
Used to administer equipment returns for
warranty and/or evaluation by vendor
Change effectivity gives completelifecycle tracking of all changes and
updates to RMA records including
equipment assignments and removals
Materials serialization allows complete
integration with material managementprocesses
Tracking via goods movements
Quality management processes
Unique specification on SD orders
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15RMA Master Record: Temporal Limitation
Only one equipment can be assigned to
one RMA record at one time
If you assign an equipment that is
already part of another IBase, you will
get the system message shown at right
Effectivity gives you complete reporting
and details for every equipment IBase
assignment, E.g.:
Equipment P101 may be assigned to RMA
record 001 from time A to time B, and then to
RMA record 002 from time C to time D
Complete records for both RMA records and
assignments to those RMA records are
maintained by the system
Ensures no duplicate submittals to
vendor
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16RMA Master Record: User Status
Used to administer RMA process
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17Onsite Repairs with Vendor Warranty Credits and
Core Credits
Warranty repair costs should be reimbursed by the vendor
The PM repair order is the mechanism used to confirm proper vendor credit
All material transactions must be booked against the respective repair orders
Goods issues of spare parts
Goods return of remanufactured cores
Credits must be reconciled against actual credits
Failed components (if required by vendor)
Replacement parts from vendor returned to inventory with credit to respective orders
Credits for labor must be booked against the respective repair orders
The order balance:
Should be appoximately zero for warranty repairs (depending on terms)
Should reflect core credits when using Caterpillars remanufactured parts Reman
Program (or equivalent program by other vendors)
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18PM Repair Orders List Report:
Confirm Vendor Credits