master data: are you set up for recording...

Master Data: Are you set up for recording failures?John Harrison IBS ChemicalsOctober 23, 2013

© 2013 SAP AG or an SAP affiliate company. All rights reserved. 2

Agenda

• Why should we care?

• What is Master Data?

• Master Data in SAP EAM

• Functional Equipment

• Equipment

• Bills of Material

• Code Lists

• Maintenance Notification: Malfunction Report

• SAP MII – Plant Catalog

• Conclusion

Why should we care?


Why should we care?

Increasing business support for Reliability for profitability

Changing regulatory environment

Industry Groups are becoming increasing active in this topic

A more graphical view

Social awareness


Value Case - Using ISA-TR84.00.04 Part 1 Appendix R for Tier 3 & 4 Data

Tier 1 & 2 events are unacceptableISA-TR84.00.04 Part 1 Appendix R for Tier 3 & 4 Data gives us greater event countsMay need to look at BPCS-IPL

How do we set up our systems / master data to facilitate reporting failures?

What is Master Data?


What is “Master Data”?

No commonly accepted definition:

Definitions include phrases like: • “important to the business”, • “shared by two or more applications”, • “with their associated metadata and attributes”.

For this presentation I would like to use :

Master Data is the data that is essential to the operation or support of one or more specific business process. One essential characteristic of master data

is that it does not change frequently.


Master Data: what is the problem?

Who “owns” the master data?

Are multiple functions responsible for the master data? If so who gets what?

Which “application system” is the system of record?

How do you ensure that all other systems are up-to-date?

Do these systems talk the same “language” semantically?

Can there be an agreed central company wide definition?

Master Data in SAP EAM (for Reporting Failures)


EAM Master Data

• Functional Locations

• Equipment

• Bills Of Material

• Measurement Points

• Work Centers

• Partners

• Serial Numbers

• Permits

• Warranties

+ Code Lists


Definitions:

SAP Definition: Functional Location• an organizational unit within logistics that structures the maintenance objects of a

company according to functional, process-related or spatial criteria. A functional location represents the place where a maintenance task is to be performed and an area where equipment can be installed.

• Functional criteria: e.g. pumping station, drive unit

• Process-related criteria: e.g. polymerization, condensing

• Spatial criteria: e.g. hall, location


Definitions:

SAP Definition: Equipment• an individual, physical object that is to be maintained independently. It can be

installed in a technical system or part of a technical system (functional location). It represents the object on which the technical tasks are performed.

SAP Definition: Maintenance Bill of Material

• a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure. The components can be stock or non-stock spares or assemblies, which in turn can be described using maintenance BOMs.


Technical Object Structuring

Choices: There are three different options for representing technical objects:• Functional structuring (only functional locations)• Object-related structuring (only equipment)• Combination (equipment at functional locations)

Structuring From a Technical Perspective• Technical objects of the system are assigned to particular object classes

(equipment, functional location and assembly classes). This type of structuring can be used in addition to structuring from a functional and/or object related perspective.

Structuring From an Accounting Perspective

• The system and its technical objects are assigned to certain cost centers or tangible assets. This type of structuring can be used in addition to structuring from a functional and/or object related perspective.


Maintenance Bills Of Equipment vs. Bill of Material

Equipment BOM’s

• are specific to one piece of equipment (1:1). Equipment BOM’s can contain material specific to that piece of equipment.

Material BOM’s

• can be linked to many equipment / functional locations (n:1) via the construction type. Material BOM’s tend to have more materials assigned as they are linked to more technical objects.


Maintenance Bills Of Material (Uses)

Materials planning (when using maintenance task lists).

• The use of maintenance BOMs is advantageous for material planning, because you can perform material planning when creating a maintenance task list. The link between the task list and the maintenance BOM is created as follows:

• Using the technical object BOM for maintenance task lists for technical objects• Using the assembly in the header for general task lists

Materials/spares planning (when using maintenance orders)

• Support planning of materials or spares by providing an overview of all materials/spare parts that could be required in the maintenance order. This enables you to assign to the order all the materials you require and makes materials/spares planning considerably easier.

Locating malfunctions (when using maintenance notifications)

• Supports locating malfunctions by providing an overview of all components that make up a technical object. From this overview the object for which you want to create a malfunction report can be easily select . This enables the malfunction in the technical object to be located more precisely.


Reporting: How much detail is required?

Where are failures to be reported?• At an piece of equipment• At an assembly• By area• By process, sub process• By Tag

Are failures to be summarized?• By groups of like equipment• By area• By process

How much history is required?• Do you compare failures between equipment?


Representation: Example: Flow Loop I – PID DiagramFunctional Location Only

PLC

Electrical Signal

Solenoid Valve

Pneumatically Activated Control Flow Rate Valve

Pneumatic Signal

Flow Rate Indicating Transmitter

Flow Rate Control Valve

Flow Rate Sensor

Instrument Positioner

Function Location

Flow Loop 1

Pro / Con

Pro Simple to implement

Con Little detail reporting capabilities

Con No equipment level reporting capabilities


Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations

PLC

Electrical Signal

Solenoid Valve


Pneumatic Signal



Flow Rate Sensor


Function Location

Flow Loop 1

Electrical Loop

Pneumatic Loop

Pro/Con

Pro Simple To Implement

Pro Some Additional Detail

Con No reporting at the relevant equipment level


Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations In Detail

PLC

Electrical Signal

Solenoid Valve


Pneumatic Signal



Flow Rate Sensor


Function Location Floc 2 Floc 3

Flow Loop 1

Electrical Loop

Flow Transmitter

PLC


Pneumatic Loop

Pro / Con

Pro Detail Reporting Capabilities atfunctional level (representing equipment)

Con Can not replace / move equipment (floc) to another location

Con Complicated to Implement

Con No Installation History Available


Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations & Equipment

PLC

Electrical Signal

Solenoid Valve


Pneumatic Signal



Flow Rate Sensor


Function Location Floc 2 Equipment

Flow Loop 1

Electrical Loop

Flow Transmitter

PLC


Pneumatic Loop

Pro/Con

Pro Installation History Available

Pro Detail Reporting Capabilities at equipment & functional location level

Con Complicated to Implement


Representation: Example: Flow Loop I – PID DiagramFunctional Location, and Bill of Material

PLC

Electrical Signal

Solenoid Valve


Pneumatic Signal



Flow Rate Sensor


Function Location Material BOM / Functional Location BOM

Flow Loop 1 Flow Rate Transmitter

PLC


Solenoid Valve


Pro/Con

Pro Simple to Implement

Pro Detail Reporting Capabilities functional location level

Con No implementation history


Representation: Example: Flow Loop I – PID DiagramFunctional Locations, Equipment, and Bill of Material

PLC

Electrical Signal

Solenoid Valve


Pneumatic Signal



Flow Rate Sensor


Pro/Con

Pro Detail Reporting Capabilities functional location, equipment & assembly level

Pro Implementation history

Con Complicated to implement

Function Location

Floc 2 Equipment BOM

Flow Loop 1

Electrical Loop PLC Sensor

Flow Rate Transmitter


Solenoid Valve

Pneumatic Loop Control Flow Rate Valve

Functional Locations


EAM Master Data: Functional Location

Note: Superior Functional Location and Equipment Installation Allowed

If only 1 piece of equipment is allowed to be installed: check Single Installation


EAM Master Data: Functional Location – Alternate Labels

When different views of functional locations structures are required, use alternate labels. No new structures are generated

E.g. Spatial & Process

Note:

The functional location label is not renamed using this method. The master record of the functional location remains unchanged. Using the alternative label, a reference to this master record in an alternative labeling system has been created

Spatial

Process


Functional Location – Alternate Labels – Use Example

The user profile defines which labeling system is to be used. Labels are converted to the indicated system


EAM Master Data: Functional Location – Structure

Note: Construction Type:

• Material number under which functional locations of the same construction are grouped (Links to Bill of Material).


EAM Master Data: Functional Location – Classification

Classification:

Additional characteristics that further describes the location.

Equipment


EAM Master Data Equipment

Note: Having a catalog profile associated with the equipment restricts the available entries when reporting failures


EAM Master Data Equipment

Note: Construction Type:

• Material number under which pieces of equipment of the same construction are grouped (Links to Bill of Material).


EAM Master Data: Equipment

Classification:

Additional technical characteristics for the equipment

Bills of Material


EAM Master Data: Functional Location BOM

This Bill of Materials is unique to the Functional Location and can not be used by any other Functional Locations or Equipment


EAM Master Data: Equipment BOM

This Bill of Materials is unique to the Functional Location and can not be used by any other Functional Locations or Equipment


EAM Master Data: Material BOM

This Bill of Materials is NOT unique and can be associated with many Functional Locations and Equipment

Catalog Codes


EAM Data: Code Lists For Reporting

EAM Catalogs• Activities “A”• Object Part “B”• Damage “C”• Cause Code “5”• Tasks “2”

How many codes to use in a code group?• Do not get too fine (7 – 20)• Based on standards? (ISO

14224, PAS 55…)


EAM Data: Catalog Profiles

Classification and catalogs presented during notification processing

Maintenance Notifications


Notification: Failure Reporting (Use of Code Groups)

Object Part Code Group (Maintainable Item)

Problem or Damage Code Group (Failure Mechanism)

Cause Code Group (Failure Cause)


Notification: Failure Reporting (codes at notification & item level

Activity Code Group

Task Code Group

Activity Code Group

Activity, Tasks repeated by Item


Notification: Failure Reporting (Using Material BOM)

From Material

BOM


Notification: Failure Reporting (Using Classification)

Classification:

• Allows for additional information to be collected on the Notification

Note: Associated with catalogue profile

SAP MII Plant Catalog


Information to the People Who Need it (MII 14.0)

SAP MII 14.0 & PCo

Plant Information Catalog

Critical Assets

Shop Floor

SAP MII 14.0

Enterprise

Plant Information Catalog

Region

Plant 1

Func Loc

Work Ctr

Equip

Meas Pt1/Tag

Plant 1

Plant 1

Enterprise

Virtual Group – Points to the hierarchy defined on another

catalog instance

The Plant Information Catalog provides business context to the tags and their data by interfacing to the tag data servers in a generic way. Because of the vendor agnostic system connectivity provided by both the MII and PCo products, levels in this hierarchy can be queried for data using standard MII Queries or Services. This is ideal for the SAP EAM solution to acquire “Measurement Point” exception data to support Condition-Based Maintenance and other various solutions.

Meas Pt2/Tag

Tags have Meta-Data assigned to them from EAM (Equip ID, Cost Center, Work

Center)

PP and PM Assets (Functional Locations, Equipment and Work Centers

ERP


Information to the People Who Need it Browse of Sensor Network, Map to Business Name

Functional Location

Tags

Conclusion


Conclusion

• Without the appropriate levels of master data it is impossible to gather and analysis the information to reduce the failure levels.

• The master data must reflect the level of detail that are required to represent the pieces of equipment or assemblies that you are interested in gathering failure data.

• Equipment vs. Functional Locations: choose carefully. There are many options each with their own benefits and challenges

• Accommodate automated data collection capabilities (Tags)

• Consider future requirements / desires when establishing your master data


Next Steps

November 12 2013• IRN Webinar: Understanding Notifications and Orders in the Failure Data Collection

Process

© 2013 SAP AG or an SAP affiliate company. All rights reserved.

Thank you

Contact information:

John HarrisonSenior Solution Specialist, Industry Business Solutions ChemicalsSAP Labs | 4120 Yonge Street, Suite 600, Toronto, Ontario, Canada, M2P 2B8T +1 (416) 226-7057 I M: +1 (416) 505-5841 E [email protected]


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