sap cbm
TRANSCRIPT
SAP Preventive Maintenance – The Coreand More
Len Harms - Vesta
Agenda
The Core – Preventive Maintenance
The Core – “Light” CBM
“and More”
The Core PM
Preventive Maintenance: Forms
Time-based Performance-based Condition-based
Preventivemaintenance
Temperature
Thickness
Druck
10
2030 40 50
60
70
80
Pressure
2001
Preventive Maintenance: Plan Types
Time-based
Maintenance plan
Single cycle plan Multiple counter planStrategy plan
Performance-based
Service Procurement
Building Blocks
1. When
Cycle or strategy that determines when a PM shouldbe done
2. Where – Equipment or Functional Location
The asset, assets, or location where the work is totake place
3. What – Task List
Define tasks, materials and tools that are required
Tip - Add the Default to the user settings
Maintenance Plans with single Asset
• You can create several maintenance plans.
• Each maintenance plan contains a maintenance item that describes the object to bemaintained.
• The system generates a separate order for each object on a due date.
Maintenance Plan Item with Linear
Maintenance Plans with Asset list
• You create one maintenance plan.
• You assign an object list to themaintenance plan in which all objectto be maintained are listed.
• The system generates an order for allobjects on a due date.
• Supports inspection routes,lubrication routes
For operations in a task list, technicalobjects can be maintained
© SAP 2009 / 11
Enhance- Asset List in Ehp4
Leverage – LAM, OAA, GEO.e with Plan
Linear Assets can berepresented in plans
Use Geo.e to add spatialdata
Operational AccountAssignment provides costof inspection at the exactposition of the work
Report on Inspection plans and results
Inspection results support long term planning
Use results to feedthe long termasset planning
Leverage PPM tosupport the longterm plan
1
23
Create Inspectionplans
Gather results
Create long termplan
4
Analyze results
Maintenance Plans with Strategy
• You create one maintenance plan.
• You assign an object list or a singleasset.
• The system generates an order for allobjects on the due dates with the tasksthat match the strategy.
• Supports a single plan with differenttasks per call date
• Can be performance or time
• The strategy unit must be consistent
Maintenance Plan with Notification
Made possible once multipleNotifications could be addedTo a single order.
Also possible to add task listin a notification as ofERP2005
Move/Skip/Release in graphicsimulation
Change documents in themaintenance plan
Scheduling parameters
Other Items
Preventive maintenance – in mostorganizations today
SAP ERP
Transformer
Work orders arecreated in regular
Intervals
Technician is executing work
Workorder
Agenda
The Core – Preventive Maintenance
The Core – “Light” CBM
“and More”
The Core PM and More
Create a new development project TC:CMOD
ENHANCEMENT IS IMRC0001
Sample Program
Measurement PointSet an upper and/or lower limit
Enter reading and valuation code
Condition based maintenance (using mobility)
SAP ERP
Current
Temperature
Voltage
Transformer
SAP determines whetherWork order should be created
Technician is executing work
Technician feed rounds informationInto SAP to populate
measurement documents
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
Agenda
The Core – Preventive Maintenance
The Core – “Light” CBM
“and More”
Condition Based Maintenance The Goal
Easily accessible dashboardsallow asset managers and staff tomonitor asset health in real timevia measurement points
Real-time alerts viadashboards give instantupdates on equipment statusand allow rapid reaction
Links to ERP data to triggermaintenance workflow toreduce unplanned downtimeand improve reliability.
Asset health
Continuous improvement
Best practice
Trend analysis identifiesproblem areas forimmediate investigation
V.P.
• Quite a few of equipment delivered today have built insensors
• New sensors (temperature, leakage, etc.) are very affordable
• Collection, analysis and integration into SAP can be setup in afew weeks
Current Situation
SAP ERP
Current
Temperature
Voltage
Transformer
• The historian collect lots of data but provides littleinformation to SAP
• Investments in the historian data has been made that is notleveraged
• EAM groups does not have visibility to condition data in SAPto make/optimize their decisions
Challenges
Integrated condition based maintenance
SAP ERP
Current
Temperature
Voltage
Transformer
DataHistorian
SAP MII
Determine whetheror not to create notification
or work order
Work order is madeavailable to the
Technician
Technician is executing work
OSI PI
APPs
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
Integration and Intelligence
Integration: A single layer enabling SAP ERPconnectivity into real-time systems to driveequipment-to-enterprise business processinteroperability
Intelligence: Real-time analytics engine thataggregates and delivers unified visualization ofevents, alerts, KPIs and decision support topersonnel thru role-based dashboards
Rule Name (MIITransaction)
Description
DailyRunHourUpdate
This rule updates the run hours per equipment basedon a summarized, binary IsRunning Tag. Parametera arethe tag name and the Measurement Point name
NotificationOnExceedThreshold
This rule creates a notification once a tag value hasexceeded the Threshold value. The Threshold value canbe a tag or static value
… ….
Condition Based Maintenance - Detail
Tag Name
AB323DS
DS.32.1231
PUMP3223.TP
1. Select Asset2. Select Rule3. Associate Tags and/or fixed values4. Select Frequency5. Submit to database
Threshold Temp: 121
MII DB
Enter inspection data
• Provide maintenance staff witha means to manually inputmeasurement readings
• Easy-to-use Web-basedinterface allows untrained staffto enter inspection results
• Easily delete or modify anerroneous entry
Manual Entry of InspectionData
Asset Health Alerts
• Visual indicators and e-mail notifications alert maintenance staff to the assets in the most critical status
• Data-driven notifications alert users to changes in asset health status so that they can reactappropriately and make informed decisions quickly
• Maintenance staff can trigger a maintenance request if warranted
• Prioritized asset management enables a consolidated alert view
Asset Health History
• Communicate real-time asset health status, monitor and adjust maintenance plan• Clear data layout and status indicators allow you to quickly compare current with target asset output.• Aggregate health status• Gauges visualize the criticality of current asset health• Search by specific asset domain for monitoring• Option:• SAP 3D Visual Enterprise provides a 3D visual image of the asset being monitored
What’s in each solution?
Software
Quickly address the most urgent businessprocesses
Content
SAP-supported best practices, templates,and tools make solution adoption easier
Enablement
Guides and educational material speed end-user adoption
Service
Fixed scope and price provide maximumpredictability and lower risk
SAP RapidDeploymentsolutions
Business challenges There is a solution
SAP Condition-Based Maintenance rapid-deployment solution enables your organization toperform maintenance only when necessary byarming maintenance teams with sophisticatedintelligence and comprehensive asset healthdashboards. The solution also enables manual andautomatic triggering of maintenance workflowleveraging through native integration with the SAPEnterprise Asset Management (SAP EAM) solution.
Get started with condition-basedmaintenance quickly and affordably
Critical asset failures which can have seriousenvironmental and enterprise level consequences asdemonstrated by recent high-profile industrialcatastrophes
Finding a CBM solution that has low entry, low TCO,and leverages existing SAP investments
Traditional time or counter-based maintenancestrategies missing a dynamic component leading tohigher maintenance cost
Other RDS available is Asset Health Visualization
What does SAP deliver? What do you have to do?
Provide IT infrastructure (server)
Install SAP MII, version 12.2, on the developmentand production environments
Install SAP BusinessObjects Dashboards software tomake optional changes to predefined health indexdashboards
Provide asset hierarchy structure from existing SAPECC and SAP EAM applications and information ontag thresholds
Provide access to existing shop floor system withconnector from SAP Plant Connectivity
Provide appropriate contacts in the business and ITdepartments
Conduct end-user training and change management
Conduct performance and integration testing
Perform data migration and cleansing
Transport to production
Key deliverables
Perform installation check
Lead workshop to confirm predefined requirements
Set up MII connectivity with shop floor system viaconnector in SAP Plant Connectivity
Set up the plant database schema for storing shopfloor aggregate data
Configure the asset health index to meet customer-specific dashboard requirements
Activate and test solution
Enable knowledge transfer to key users
Enable support for go-live
System requirements
SOFTWARE• SAP ECC 6.0 EHP4 or above• SAP Manufacturing Integration & Intelligence (SAP MII) on SAP NetWeaver® CE 7.3
version 12.2, SP4 or above• SAP Plant Connectivity 2.2, SP3 or above• SAP BusinessObjects Dashboards 4.0 SP4 or above*• SAP 3D Visual Enterprise application (optional)
DATABASE• SAP HANA® 1.0 SP5 or above (optional) **
* required only for customizing dashboards** SAP HANA® content supporting cross-plant implementation is provided. However, thestandard service offering supports a single plant implementation.
In the system
• Link CBM monitoring system toHistorians to gather real-time data
• perform manual inspection andthen enter results into CBMmonitoring system
• Evaluate data to trigger automatedmaintenance notification via CBMrules and logic
• Perform maintenance jobs withvisual support using SAP 3D VisualEnterprise
• Perform trend analysis by viewinghistorical plant data
Conclusion - Benefits
– Minimize risks and stay incompliance via alerts of imminentcatastrophic asset failures
– Manage investment risk by startingwith a baseline scope and thenscale it gradually
– Reduce maintenance due to fewerreactive repairs of brokenequipment
– Support effort to stay withinregulatory compliance
– Reduce maintenance rework andmean-time-to-repair (MTTR)
– Operate equipment in aneconomically and environmentallysustainable way
– Increased return on assets (ROA)
– Maximized asset utilization
– Improved overall equipment effectiveness (OEE)
– Reduced operational risk in asset management
– Reduced maintenance cost as a percentage of revenue
Summary - Support Asset Life Cycle
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SESSION CODE: 8595
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