maintenance management project intermediate status report pierre bonnal dg-di christophe delamare...

Maintenance Management ProjectIntermediate Status Report

Pierre Bonnal DG-DIChristophe Delamare GS-ASEMarine Gourber-Pace BE-CO

Damien Lafarge EN-HEChristophe Mugnier TE-EPC

Goran Perinić TE-CRGRegis Pilon TE-EPCIngo Ruehl EN-HE

Eric van Uytvinck EN-ELDavid Widegren GS-ASE

Zornitsa Zaharieva BE-CO

Maintenance Management Project

Intermediate Status Report16th January 2013

Agenda

• Introduction I. Rühl

• MFIO status report C. Mugnier

• MMP WGs I. Rühl

• Operational issue management• Coding, layout & integration• Equipment criticality

• CMMS status report C. Delamare

• Training, seminars, workshops G. Perinic

• Resources I. Rühl

• Conclusion I. Rühl

2

MMP status according to HERMES

MMP Roadmap

MMP Concept Report

Maintenance workshop 25.11.2011 MFIO

implementation July 2012

3

4

Steering Board

CMMS Development Team

MFI Office(Maintenance Framework Implementation )

TE Maintenance Framework

Implementation

EN Maintenance Framework

Implementation

BE Maintenance Framework

Implementation

Maintenance ManagementQuality Assurance

Maintenance Management

Project

C. Mugnier

D. LafargeM. Gourber-

Pace

I. Rühl, G. Perinic

C. Delamare

P. Bonnal,Z.

Zaharieva

Department Heads BE, EN, TE, GS

Task force members

The MFIO in the MMP project

• Support and monitoring for:• Administrative tasks and Quality Assurance • Specific IT tools development• Deployment and follow up

• Communication (between users, MMP team and existing CERN services)

C. MugnierD. Lafarge

C.Perolini (TE engineer FSU 100%)J.Ruiz Cabezas (TE fellow 100%)

R.Pilon (TE staff 60%)J.Sylvestre (EN fellow 100%)

A.Metola (GS fellow 50%)B.Vercoutter (GS staff 50%)

T.Klabi (GS staff 50%)

Working groups:

• Asset management• Work management• Planning & scheduling• Documentation management• Spare parts management• Analysis & Reporting

Other existing CERN services

I. Alonso-Canella

Maintenance Management ProjectMFIO Status Report








MFIO and Working Groups Work Process

Maintenance Management Framework

Layout DB & Naming Service

DocumentManagement

System

• EDMS - EDA• Smart-team• CDD• Agile PLM

External Systems

Users Groups & Maintenance Teams

CCC Operational

Issue Management

System

• Impact• Trec• EIS ManagementProtocols

• CCC Alarms• Accelerator Controls • Layouts

• Logbook • Issue follow-up

• Roles and Methods• Protocols of exchange with existing

systems • Informatics system and SW (CMMS)• Deployment to user Groups• QAP

• Collection of best practices and needs• Collection of documentation and parts• Promotion - information - training

7

BPDs and description reports as systematic approach to:

• Collection of needs and best practices (As-Is)• Definition of specifications with common requirements (To-Be)

• Definition of workflows and global rules for:• Installation, equipment and parts management• Files, information and data management • Maintenance activities management

Methods (1/2)

8

• Asset management & coding WG• Creation of item codes and structure integration (EDMS, CDD, SMART TEAM)

https://edms.cern.ch/document/1233516/1

• Creation of functional position codes for infrastructure/machine https://edms.cern.ch/document/1233516/1

• Creation of CMMS Data Management https://edms.cern.ch/document/1244460/1

• Information management WG• Creation of maintenance information (document recording in EDMS)

https://edms.cern.ch/document/1232755/0.0

• BPMN sub process of DATA management (To-Be GCO and CMMS support) https://edms.cern.ch/document/1244460/1

• Spare part management WG• Part metadata collection tool


• Spare Part Reservation Replenishment stock Management https://edms.cern.ch/document/1235067/1

• Equipment labelling https://edms.cern.ch/document/1239800/1

• Issue management

• Corrective process management https://edms.cern.ch/document/1259123/1

Summary of established BPDs and their associated specification reports:

Methods (2/2)

9





https://edms.cern.ch/document/1232755/0.0








• The different officer role definitions have been created(general document with missions, activities, responsibilities in the group)

• Group Maintenance Information Officerhttps://edms.cern.ch/document/1222082/1

• Group Coding Officerhttps://edms.cern.ch/document/1241700/1

• Group Spare Parts Officerhttps://edms.cern.ch/document/1245013/1

• Group Quality and Methods Officer

• The officer administration guidelines have been created(context, conventions, tools, to be applied in the groups)

• GMIOhttps://edms.cern.ch/document/1243642/1

• GCOhttps://edms.cern.ch/document/1247882/1

10

BE department EN department TE department

EN-CV EN-EL EN-HE EN-MEF EN-STI TE-ABT TE-CRG TE-EPC TE-VSC

IMPLEMENTATION &

DEPLOYMENT in Groups

Guillermo

PEON

Soren POULSE

N

Eric VAN

UYTVINCK

Damien LAFARG

E

Jean Maurice

CHEVAL

LEYSamy

CHEMLIOliver

ABERLETony

Fowler

Remy NOULIB

OS

Nicolas BONETT

I

Sigrid KNOOP

S

Ludovic Germai

n-Bonne

Marc BOMO

NTPatrice BAILLY

Régis Pilon

Alexandre

SINTUREL

Eric PAGE

Fabien ANTONI

OTTI

Jaime PEREZ

E.GCO -

Group Coding Officer

X X X

X X X

X

X X X X X

GMIO - Group Maint. Information

Officer

X

X X

X

X X

X X

GQMO - Group Quality Methods

Officer

X

X

GSPO - Group Spare Parts Officer

X

X

X

X

Roles











• Close collaboration between GS/ASE and MFIO is maintained to:

• Ensure that both sides share the same information concerning current practices and new needs of the user's groups

• Carry out for each request an analysis and prepare the BPMN as well as the specification for the informatics developments

• Manage the planning and the priorities

• Foreseen for 2013:

• Developments and upgrade of the existing workflows in INFOR and development of new user interfaces

• Definition of a strategy to:• transfer into INFOR data that has been collected via an external system• manage the transition period during which new and existing workflows co-exist

• Risk analysis of the system according to the increase in the volume of data and the number of users (architecture, performance, availability …)

Informatics system and software (CMMS)

11

• Interfaces of existing systems with the Maintenance Management Framework have been identified and well defined:

• Document management systems: EDMS, EDA, Smart-team, CDD…

• Layout data base: accelerator functional position management, alarms administration, accelerator controls

• CCC operational issue management system (To be created)

• Occupational Health & Safety and Environmental Protection: RP traceability system, EIS, safety inspections

• Accelerators facilities organisation: Impact for scheduling, coordination and follow up of the maintenance tasks

• G.I.S: equipment location

• Mandate, role and responsibility of each team in charge of an existing system could be reviewed according to the MMP needs.

• Protocols and sustainable rules to manage data exchanges, must be established and integrated into the QAP.

Protocols of exchange with existing systems

12

Work progress with MFIO clients: few examples

• EN/CV :• BPD replenishment & stock management created

- work ongoing for adapting the process to TE/CRG group• EN/HE :

• Pilot group for upload/storage of maintenance/operation documentation - about 280 docs already stored in EDMS

• EN/EL : • Analysis of the functional position coding problems linked to the cabling process• Description of a proposed implementation, in addition to BPD (work on-going)

• TE/VSC : • BPD for leak detector work order traceability created

• TE/CRG : • Pilot group for upload/storage of maintenance/operation documentation

- items created, first tests of tools performed• BPD for equipment lending process based on TE/VSC use case (WO traceability)

created

13

Creating a set of specific documentation for maintenance and operation: • A well defined perimeter:

• specific conventions, background, standards, rules …• Protocols for exchanging the documentation with other system,• Making available of documents for users

• EDMS as main system for the storage and the management of documents,• A clear life cycle of the documentation, from the design phase of the equipment to the

archiving of documents,• Documents must be up to date and perennial

Use case: Registration of operational documentation

Distribution of documents

Documentation for the

maintenance and operational

activities

Project documentation

Transition phase

Doc management

users

External doc

External systems

14

Centralized processes at group level:• Workflows for creating, updating, managing and using maintenance

documentation in BPMN format:

Involved participants:• Project engineer • Representative of the teams responsible for the maintenance• Equipment responsible• GMIO (Group Maintenance Information Officer)• MFIO representative• CMMS engineer

Registration of the documentationBusiness process modelling

15

Registration of documentation

Informatics tools

• PYRAMIDE SEMI AUTOMATIQUE• PYRAMIDE AUTOMATIQUE• PYGMALION• PYJAMA• EDMSVIEWER

3 web services provided by GS-ASE • DocumentServiceT (documents creation)• FileService (files uploading) • StructureService (elements linkages)

+

16

EN-HE doc.• 17 Workbooks• 15 Projects• 38 Items• + 230 Docs EDMS• + 200 Fichiers .pdf

Registration of the documentation

17

Parts registration: In preparation

Involved:• TE-EPC, TE-CRG and EN-CV as pilot groups,• Experts: M. Bomont, N. Bonetti and R. Ecclestone, T. Klabi• Informatics developers: I. Alonso Canella, P. Bailly, S. Mallone • GCO & equip. responsible: TBD

Strategy

• Data treatment through a local system (Collecting, sorting, cleaning and formatting metadata…)

• Refurbishing the custom fields by pilot groups experts,• Collecting process based on the EN-CV experience,• Informatics tools:

• A local user interface for collecting data on-site ( Based on the EN-CV tool)• Centralized data management system as temporary interface between local system and

Infor EAM.• Provide a labelling system (user interface, application, and dedicated printer) to allow

groups to print autonomously their labels.

18

• The MFIO has established contacts with all concerned equipment groups in the BE, EN and TE departments.With each of these groups a action plan has been agreed.

• The roles concept is starting to be adopted by the group leaders

• Outlook for 2013

• Continued documentation collection effort• Start of part/asset data collection process from April 2013• Establishment or completion of the following workflows:

• Traceability• Spare part management• Documentation management• Issue management

• Continuous risk assessment in collaboration with all concerned parties

Conclusion and perspective

by end of LS1

19

Maintenance Management ProjectCMMS Status Report








CMMS tools – An update of recent improvements and news

MMP status presentation

EDMS 1261466

Agenda• EDMS tools & integrations• TREC• EAM Light• PlanBook and IMPACT integrations• Infor EAM system news• Next steps…

EDMS tools & integrations• Several tools delivered for the MFIO document collection project

according to agreed plan and priorities.

• Some examples:• 4 new web services developed to facilitate and automate creation and

updates of documents. (Oct 2012)• Improved version of EDMS Offline viewer. (Oct 2012, additional

improvements scheduled for Jan & Feb 2013.)

EDMS tools & integrations• Extended integration between EDMS and Infor EAM

• EDMS document tab in Infor EAM now also available for Parts, Categories and Planned Maintenance Schedules. (Dec 2012)

• More functionality to be made available during Q1 2013.(Examples: Full support for Item-Parts-Asset associations & EDMS tab with consolidated view.)

EDMS tools & integrations

16 OctoberWeb Services (Used for MFIO import tools )

14 September Item catalogue (EDMS Interface)First proposal of standard context (EDMS Document)

Oct Nov Dec Jan Mar

30 OctoberOffline Viewer (Improved and upgraded version)

7 DecemberEDMS Doc tab (Parts, Categories & PM Schedules)

17 FebruaryEDMS Doc tab (Consolidated view)Offline viewer (New version)

Feb

21 JanuaryOffline viewer (Improved extraction tool)

TREC = Infor EAM• TREC is an interface – all data is stored in Infor EAM.• More installations and extended usage during 2012.

• >2600 RP measurements requested in buffer zones• Installed in LHC, SPS & ALICE buffer zones (PS & ATLAS in 2013)

• The MMP effort of promoting equipment traceability will also lead to more efficient use of TREC – avoiding duplicates etc…

EAM Light - background• An easy to use interface for Work Orders and Equipment.

• Accessible from all devices with a web browser – including tablets.• It is a simple alternative for users that do not need the full Infor EAM

functionality – for example contractors.

• In production since August 2012 with very positive feedback• Version 1.0 was released on 14 August 2012 and 5 consecutive

versions were released during the autumn based on user input. (Current version: 1.5, released 10 Dec.)

• Currently widely used and very appreciated by equipment groups. Examples of users: EN/HE, EN/CV, TE/CRG, GS/FB, GS/ASE, IT/CIS, etc.

EAM Light

15 NovemberVersion 1.4 (Inspections, IMPACT link, Access Rights correction.)

15 October Version 1.3 in full production

Nov Dec Jan Feb March

10 DecemberVersion 1.5 (New main page, Viewing Equip. data, Equip. history,

Equip. replacement, Improved error handling & Value deletion.)

21 JanuaryVersion 1.6 (Edition of Custom Fields,

Support for Std. Work Orders, Parent/Child Work Orders)

25 FebruaryVersion 1.7 (Parts used for

Work Orders.)

EAM Light – the interface

EAM Light – GS/FB example• Inspections of fire extinguishers using tablets and Bluetooth

barcode laser scanners in the field.• 1 tablet (with protection) + barcode scanner per team.

EAM Light – smartphone version

• Smartphone friendly version in test. To be released end Jan 2013. • Available for any smartphone (iOS, Android, Windows Phone, etc.)• It is an online tool requiring internet connection (GSM or WiFi)

PlanBook & IMPACT Integrations

• Prototype available for visualizing/planning Work Orders in PlanBook.• Foundation for EAM-IMPACT integration bit by bit put in place.• Some examples:

• Possible to associate Equipment with IMPACT Facilities.• Possible to update Work Order dates based on named Shutdowns/Technical

Stops as defined in IMPACT.

Infor EAM - System news • New integrations with the Service Desk and CCC using web

services heavily used for creation and update of Work Orders.• CCC/TI: ~500 Work Orders / month• Service Desk: ~900 Work Orders / month

• Increased use of Infor EAM - number of Work Orders created:• ~77k in 2010.• ~86k in 2011• ~129k in 2012

• New monitoring tools allows adetailed logging of the use of Infor EAM Licenses and theserver load.

Additional licenses & modules• Following the increased usage, GS/ASE decided to

purchase additional licenses in November 2012:• 10 additional Infor EAM licenses (60 -> 70 concurrent users)• 30 additional Web Service connector licenses (80->110 concurrent

users)

• Following user requirements and needs from the support team, 2 additional modules were also purchased;• Infor EAM Alert Manager module • Infor EAM Risk & Reliability module

• The Global Search module (Google like search for Infor EAM) is as well currently being tested.• Positive feedback (so far) from EN/CV and TE/CRG.

Next steps – some examples….• Improved access rights management by deploying the

“Department Security” option.• Strongly demanded by several groups (EN/CV, etc.)• Proposal and test implementation: Q1 2013

• Continued work on strategic system integrations ;• Generalization of integration between Infor EAM and GIS due to

strong demands for locating equipment geographically. (Q1 2013)• IMPACT – EAM integration. (Gradually Q1 & Q2 2013)

• Upgrade to version 10.1.X• New functionality asked for by several groups (new “Excel-like”

screens, hyperlinks, check lists, spare part kits, SSO, etc).• Preliminary target date (depending on tests): Early Q2

Projects outside the MMP scopeExamples of projects not directly linked to the MMP project

• DGS/RP• Study on how to re-integrate their maintenance management

processes into Infor EAM for RAMSES and other RP equipment such as radiation monitors.

• Status: Project launched. Awaiting arrival of additional resource in RP.

• IT/CF & IT/CS• Feasibility tests on how Infor EAM could be used for managing

computing equipment in the data center(s) – potentially including both servers and network equipment.

• This is a follow-up of the successful Infor EAM implementation in IT/CIS launched and completed during 2012.

• Status: Test environment being put in place based on IT input.

Maintenance Management ProjectOperational Issue Management








1254813_V1_KickOff meeting CCC 29 Novembre 2012 ChM

Common processes for first line intervention: CCC side

- CCC has a key role along the first line intervention process

Equipment group or external contractor

Cern Control Center

40

Close collaboration between CCC and equipment groups is essential to improve the various interactions involved in this process

Conclusion of kick off meeting 29 Nov. 2012• Outcome of meeting

• Confirmed interest to improve the existing issue management process• LS1 is the right moment to start this WG

• Proposal for next step• Launch a WG to analyze requirements and design a proposal

• Draw inventory of current processes for piquet call , failure follow-up, offline analysis

• Gather requirements from OP + EQP Intervention teams• Agree on a common TO-BE process MODEL

• Proposed membership • CCC Accelerators + TI operation representatives• EQP first line Intervention representatives• MMP project representative

• Organization • Under discussion : BE/OP HR as WG driving force

• OP : best knowledge, focal point of requirements, key role in the data model design

• Next meeting foreseen mid February: presentation of viewpoint / UR from EQP GP and 1st line intervention teams 41

Maintenance Management ProjectCoding, Layout & Integration




Eric van Uytvinck EN-ELZornitsa Zaharieva BE-CO



• Developed a common codes search across systems in the Naming Portal (Jan 2013)

• Covered Naming, Layout, Controls Configuration , Alarms - LASER DBs

• To be extended with input from CDD/EDMS/MTF/Infor EAM (Feb 2013)

• Extended the db model and interfaces of the Naming DB to be able to provide data for the variant for each equipment code (Nov 2012)

• Provided templates from the Naming Portal for equipment codes requests for the Group Coding Officers (Dec 2012)

• Provided a recommendation for overcoming the problem of encoding the manufacturer into the assets identifiers (Oct 2012)

• Finalized the reorganization and the new codes for TE-CRG (Jan 2013)

• Working in close collaboration with the Naming Service (S. Chemly, P. Le Roux, Z. Zaharieva) [email protected]

• Locations problematic kick-off meeting with representatives from Geosip db as well as Layout, IMPACT, OP/TI, Experiments, Radiation Protection, Alarms, Controls Configuration, EDMS/CMMS

• Triggered by: • Renovation of Geosip db and

GS/AIS renovation of Foundation db;

• Requests to have a geographical localization of the functional positions in the Layout and the assets in Infor EAM

• A series of meetings are in progress to gather all of the requirement

• On-going synchronization between the Naming DB and Layout DB

• Implementing business logic – no codes shall exist in the Layout if they do not exist in the Naming DB (Q1 2013)

• Revised the codification process for equipment types, drawings, functional positions and assets using the Naming Service as a starting point – split it into 1 main and 4 sub-processes

• The Naming and the Layout services are integral parts of the proposed Maintenance Management framework solution

Establish easy-to-use and coherent naming coding references

Establish a set of common definitions & vocabulary

Effective data management – interfaces between information systems

44

Naming Service CDD / SmarTeam Layout EDMS Infor EAM /

MTF

• Provision of dictionary under development, based on the completed review of terms used throughout different systems (e.g. EDMS, Infor EAM, Layout, Controls Configuration, etc.)

mailto:[email protected]

mailto:[email protected]

45

• Investigated into the existing process of functional positions declarations used by EN-EL

• Introduced new processes to take care of synchronization of the EN-EL functional positions and addresses in the Layout and Infor DBs thus avoiding duplication of functional positions and inconsistencies

• Pending implementation

Effective data management - Interfaces between Information Systems

Integrated Data Management – Assets Management WG

• MMP Interfaces with Layout service

• The CMMS team and the Layout responsible (Pascal Le Roux) have worked on establishing the specifications for improving the integration between Infor EAM and Layout DB• Pending implementation

• Increased load on the Layout Service due to the MMP activities and the groups starting to use the Framework• Verification, updates, new declarations of functional positions, cross-

checks with data in Infor EAM, etc.

Maintenance Management ProjectEquipment Criticality




Eric van Uytvinck EN-ELZornitsa Zaharieva BE-CO



48

Criticality AssessmentInspired from:• Risk assessment for RAMS (Reliability, Availability, Maintainability, Safety)

FME(C)A – AMDE(C) IEC 60812:2006• Corporate Risk Management Practices :• EN-EL Approach to Criticality Assessment:

CI = 8.832 × log2( 1 + Π Criteria )

• TE-CRG or EN-CV Approach to Criticality AssessmentNPR = Gravity × Occurrence × Detectability

Proposed approach:

• FME(C)A-inspired CI = S × O × D• Severity 5 perspectives: scientific objectives, financial

impact, reputation, safety impact, environmental impactS = max( SO × SF × SR × SS × SE) or S = 1.1446 × log2( Π Si ) + 1 or S = 0.2 × Σ Si

• Severity measured at functional position level• Occurrence lessons learned, failure measurement

and reliability analyses (MTTF, MTBF…)

• Occurrence measured at items/parts/asset level

Layout DB

EDMSInfor EAM

Maintenance Management ProjectResources 2013








MMP MFIO Back-officeBE EN TE GS DG BE EN TE GS Extern GS

M. Gourber-Pace 20% 20%Z. Zaharieva 20% 20%BE-OP? - OIM WG 50% 50%Fellow? - CLI 100% 100%

190%

D. Lafarge 30% 30% 60%I. Rühl 20% 20%E. van Uytvinck 30% 30%J. Sylvestre 100% 100%

210%

C. Mugnier 20% 60% 80%G. Perinic 40% 40%R. Pilon 60% 60%P. Bailly 20% 20%J. Cabezas 100% 100%I. Alonso-Canella 50% 50%

350%

C. Delamare 10% 10%D. Widegren 20% 20% 20% 40%T. Klabi 50% 50% 50%B. Vercoutter 50% 50% 50%S. Mallon Amerigo 15% 15% 15%R. Martini 40% 40%P. Martel 50% 0%L. Pater (new Staff) 50% 50% 50%EDMS Team 50% 50%A. Metola (FELL) 50% 50% 50%P. Del Castro Galan (PJAS) 50% 50% 50% BI, ReportingNew FELL (6 mo. 2013) 30% 20% 30%TECH (6 mo 2013) 50% 0% GS/SE, IT, EN/STI

405% 435%

C. Perolini 100% 100% StaffS. Goldstein 40% 40% Fellows etc.

140% Extern FSU

Budget sFr. 70,000 70,000 70,000 210,000 330,000

FSU - 4FTEs fordata collection 150,000 400,000 FSU - 1FTE fordoc scanning

50'000100’000

51

Maintenance Management ProjectTraining, Seminars, Workshops








Seminars, Training and Workshops

• Maintenance management course hosted by HR (S. Schuh-Erhard)English version given by BalticBerg - pilot session on 24th/25th JanuaryFrench version in preparation

target train 50-100 maintenance responsibles in middle management

• A&T seminar “Maintenance management” on 7th February 2013review of the project status

target all maintenance stakeholders

• Presentations in SLMsseries of presentations in SLMs given by MMP members shall continue

• CERN asset and maintenance management workshop 13th -15th November 2013

European accelerator, fusion and large scale laboratory community

• Abstract proposed for the Accelerator Reliability Workshop in Melbourne

COMMUNICATION ST

54

Maintenance Management ProjectConclusion








Conclusion 1/3• Implementing MFIO very successful thanks to a

very motivated team• General progress satisfactory• Document and parts registration process well

advanced and fully operational by LS1 start up• Infor EAM continuously develops towards a

more user friendly tool

57

Conclusion 2/3• Coding / Issue / logbook / TREC / IMPACT / planβ / planbook

context adds a new dimension (and complexity) to the project

• BE moves from an observer to an active status

• Resources for support activity (MFIO) now at a sustainable level but some ‘important effort’ is still required for some time by each equipment group

• Reaching turn point where equipment group involvement becomes a prerequisite for any further advancement regarding document and parts registration which was defined as one of the key objectives

We count on BE – Laurette, Marine, Zornitsa and Peter!!!

58

Conclusion 3/3• Resource requirements

• Appoint BE-OP link person / chairman of OIM WG – BE Dpt.

• Provide a PJAS for CLI – BE Dpt.• Provide budget for data collection FSU – TE

Dpt.• Provide budget for doc scanning service – EN

Dpt.

59

60

LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1LS1

















MERCIYOUR QUESTIONS AND COMMENTS

PLEASE?!

61

maintenance management project intermediate status report pierre bonnal dg-di christophe delamare...

Documents

pilon te staff

ruiz cabezas te fellow

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rhl2mmp status

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klabi gs staff

metola gs fellow

perolini te engineer