planning for reliability - asset management · pdf filesap pm module • is a multi-purpose...
TRANSCRIPT
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PLANNING FOR RELIABILITY
IT’S SAP THAT BRINGS IT ALL TOGETHER
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PRESENTATION
• Introduction
• Fundamentals
• Planning & Scheduling
• Reliability Engineering
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Qenos Overview
• As Australia’s sole manufacturer and leading supplier of polyethylene (PE)
• Manufacturing facilities at Altona (Vic) and Botany (NSW)
• Ownership change to China National Chemical Corporation (100%) – “ChemChina” effective February 2006
• Directly employs ~800 people
• Annual turnover A$700M-A$900M
• Have used SAP since 1995
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EVOLUTION OF QENOSAPC
(Esso)
Hoechst (1997)
ASR (Esso)
Compol (Mobil) Kemcor
Orica (1998)
This mixed parentage has lead to problems in agreeing best SAP implementation
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SAP AT QENOS
• SAP has been used as an ERP system since 1995 integrating materials management, maintenance and financials
• Commenced with SAP R2 in 1995 and upgraded to SAP R3 later the same year
• Upgrade to SAP ECC 6.0 Mar 2008
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SAP PM MODULE• IS A MULTI-PURPOSE TOOL
• WILL SUPPORT WORLD’S BEST MAINTENANCE AND RELIABILITY PRACTICE …
• JUST AS WELL AS IT WILL SUPPORT WORLD’S WORST MAINTENANCE AND RELIABILITY PRACTICE
IT DOES NOT DISCRIMINATE
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SAP PROCESSES
• SAP does not dictate what your process should be.
• Know what your processes are.
• Understand how SAP supports and can enhance these processes.
• Deliver training in the process not just in SAP
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FUNDAMENTALS
Technical Objects
Work Centers
Failure Codes
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TECHNICAL OBJECTS• FUNCTIONAL LOCATIONS
- Structures the maintenance objects of a company.
- A functional location represents the place at which a maintenance task is performed.
• EQUIPMENT- An individual, physical object that is
maintained as an autonomous unit.• MATERIALS / ASSEMBLIES
- The goods that are the subject of business activity.
- A technical object can be divided into assemblies to separate it into more clearly defined units.
- Assemblies are used for maintenance bills of material and maintenance task lists.
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WORK CENTER - DEFINITION• Work centers can be:
- Machines
- People
- Production lines
- Groups of craftsmen
• The activities performed at or by the work center are valuated by charge rates, which are determined by cost centers and activity types.
• The work center has an available capacity.
QENOS
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WORK CENTER - CAPACITY HEADER
We target 100% utilisation for scheduling
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INTERVAL AVAILABLE CAPACITY
Intervals created to reflect the actual available capacity available for the period
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WORK CENTER -HIERARCHY
Available capacity is entered for work centers at lowest level.
SAP sums this up to the higher level which is then used in Capacity Planning
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FAILURE CODES
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FAILURE CODES
Codes used should be consistent throughout the organisation to enable easy comparison
Guidance on code selection and use is available in ISO 14224 Second Edition – 2006; Petroleum, petrochemical and natural gas industries — Collection and exchange of reliability and maintenance data for equipment
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CATALOGS
• Catalogs can be assigned to
- Notification Types
- Technical Objects
• Functional Locations
• Equipment
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CODING• Failure Mode as observed by operator
• Not currently used at Qenos
• = RCM Functional Failure
• See ISO 14224 Tables B.6 – B.12
• Examples:
- Low Output
- No Output
- Vibration
- External Leakage – process medium
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SAP – ISO 14224
Maintainable Item; Annex AObjectParts
Maintenance Activity; Table B.5Activities
Cause; Table B.3Causes
Condition; Table B.2Problems
Failure Mode; Tables B.6 – B.12
(Failure Mode as observed by operator –RCM Functional Failure)
Coding
ISO 14224SAP Catalog
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OBJECT PARTS(MAINTAINABLE ITEMS)
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DAMAGE CODES
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CAUSES
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ACTIVITIES
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PLANNING & SCHEDULING
NOTIFICATIONS
ORDERS
SCHEDULING
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PLANNED WORK LIFE CYCLEANYONE
BUDGET OWNER
MTCE PLANNER
WORK CENTER
Create Notification
Review Notification
Create & Scope Order
Detail Plan
Approve Order
Schedule
Perform Work
Confirm & History
Review Order
Complete Order
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NOTIFICATIONS
• Used to request maintenance work• Record as a minimum
- Short description of task- Location (to equipment level preferred)- Priority
• All SAP PM users can create notifications• Note: SAP does not enforce the use of notifications for
work requests. You may choose to create work orders directly or notifications and orders in the one transaction – Choose one option and stick to it.
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ORDERS
• Contain data for planning and executing tasks
• Functions in orders integrate with other modules
- Materials Management (MM)
- Project System (PS)
- Controlling (CO)
- …
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ORDER HEADER DATA
REVISION
COST ESTIMATE
JOB OWNER
LOCATION INFORMATION
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PLANNED ORDER - BASIC
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PLANNED ORDER – MULTIPLE OPERATIONS
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MULTIPLE ORDERS NETWORKED
ORDER PLANNING
COMPLEX
Networked orders must be scheduled as a total network using
transaction IW70
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COMPONENTS
Components can be easily added from Bills of Materials
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IMPROVEMENT CYCLE
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Task Lists
• Set-up operations data in task lists for re-use later
• Reduce planning effort• Capture learning• Three Types
- Functional Location- Equipment- General - Assembly
• Hierarchical Task Lists - task lists can reference other task lists
NEW
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Planner should always ask is there a task list for this job (or similar). If yes then use it.
If not, then consider whether a new task list should be created.
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SCHEDULING
• SAP Planning Board is used for scheduling
• If the work order hasn’t been planned then it cannot be scheduled.
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Scheduling Overview
W00W00 W01W01
W02W02
WR1WR1
WR2WR2
WR3WR3
WR4WR4
WR5WR5
W..W..
W..W..
W..W..W51W51
W52W52
STANDING ORDERS –CONSIDER FOR ALL SCHEDULES
MUST DO JOBS IN
INDICATED PERIOD
RANKED JOBS
SORT ORDERS BY ASSIGNING APPROPRIATE REVISION
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W00W00 W01W01
W02W02WR1WR1
WR2WR2
WR3WR3
WR4WR4
WR5WR5
W..W..
W..W..
W..W..
W51W51
W52W52
PLANNING BOARD
SCAF
Work Center Capacity determines size of bucket
WELDMECH ELEC LAGG
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•Review backlog of ready orders and assign to appropriate revision
•Check material availability: Go To –List of Available Material
•Select orders to take to planning board
•Go to – Planning Board
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CAPACITY
REQUIREMENTS
Remaining Available Capacity
- Hours
% Available Capacity
Dispatched
Planning board is configured to match the Qenos scheduling process
Dispatch sequence by Revision
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Confirmations Distribution & Schedule Completion
0%
20%
40%
60%
80%
100%
WK04
WK08
WK12
W16
W20
W24
W28
W32
W36
W40
W44
W50
W04
W08
W12
W16
W20
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
P1/P2 CNF
Other CNF(Bull Bar!)
CNF onPlan Tasks
ScheduleCompletion
RESULTS
AIM TO ELIMINATE/MINIMISE
“BULL-BAR” WORK
IT’S OK TO BREAK SCHEDULE WITH THIS
PRIORITY 1 OR 2 WORK-RELIABILITY
OPPORTUNITY
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SOMETIMES OLD WAYS ARE STILL THE BEST
LABELS PRINTED FROM SAP USING WORD MERGE
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RELIABILITY ENGINEERING
•Notifications
•Work Order History
•Analysis
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Notification Header
WHERE?
WHAT?
WHEN?
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Malfunction Data
Used in MTBF calculations
Used in MTTR calculations
Failure counted in MTBF and MTTR calculations
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What happened?
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Why did it happen?
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What was done?
Object Services can be used to attach/link to documents, photos etc.
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WORK ORDER HISTORY
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ANALYSIS
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Example of Information System Report
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Tip
SAP Report MS Excel File
MS Access MS Excel Report/Chart
• For regular reports can use combined functionality of MS Excel and MS Access to minimise set-up effort
MS Access tables linked to MS Excel file
MS Excel worksheets linked to MS Access tables
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IN SUMMARY• Fundamentals
- Technical Objects- Work Centers- Failure Codes
• Planning & Scheduling- Notifications- Orders incl. Task Lists- Planning Board
• Reliability Engineering- Notifications- Work Order History- Analysis
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Conclusion• SAP has all the features needed to support a world class
maintenance and reliability program
• Take time to understand SAP – On-line help documentation is very comprehensive
• Read SAP release notes
• Most problems I have seen relate to poor process definition and implementation rather than SAP inadequacies