spare parts identification · transformation to correct master data record structure yet...
TRANSCRIPT
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15th INTERNATIONAL OPERATIONS & MAINTENANCE CONFERENCE IN THE ARAB
COUNTRIESUNDER THE THEME: “SMART MAINTENANCE” CONICIDE WITH THE 15TH ARAB MAINTENANCE
EXHIBITION
TOMAS HLADIK, ONDREJ STEJSKAL
Logio, Prague
SPARE PARTS IDENTIFICATIONA CASE STUDY FROM A PETROCHEMICAL PLANT
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EUROPEAN PETROCHEMICAL AND RAFINERY PLANT
MULTINATIONAL HOLDING – GROUP OF COMPANIES
AREA OF 10 SQUARE KM
MORE THAN 1000 BUILDINGS
THOUSANDS OF KM OF ELECTRICAL WIRING,
TELECOMMUNICATIONS WIRING, PIPES, PIPE BRIDGES
ROAD, RAIL AND PIPES
INTRODUCTION TO CASE – SITUATION
CASE STUDY – AGENDA
1) SITUATION
2) METHODOLOGY
3) PHYSICAL IDENTIFICATION USING SMARTPHONES
4) MATCHING – FINDING DUPLICATE ITEMS AND FIRST BENEFITS
5) PROJECT PITFALLS
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PRODUCTION FACILITIES
REACTORS, TANKS, COLUMNS, HEAT
EXCHANGERS, SILOS, FURNACES,
FLARE STACKS, PIPING, ENERGETICS,
AND OTHERS
MORE THAN 50 000 ACTIVE ITEMS
WORTH OF 100sM EUR
FASTENERS, FITTINGS, POWER
EQUIPMENT, CHEMICAL EQUIPMENT,
CABLES, LOADERS, CONVEYORS,
FEEDERS, COUPLINGS, ROTATING
MACHINES, DCS SYSTEMS, BEARINGS,
ELECTRICAL EQUIPMENT, SEALS,
MEASUREMENT AND CONTROL, FILTERS
AND OTHER SPECIAL DEVICES
INTRODUCTION TO CASE
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INTRODUCTION TO CASE – SPARE PARTS EXAMPLES
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PHYSICAL IDENTIFICATION ON SITE
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SQUIRREL WAREHOUSES
CREATED HISTORICALLY FROM UNCONSUMED ITEMS AND ITEMS
UNDERGOING RENOVATIONS
SPARE PARTS MANAGEMENT – INITIAL SITUATION
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SQUIRREL WAREHOUSES
SPARE PARTS MANAGEMENT – INITIAL SITUATION
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IMPERFECTIONS IN MASTER DATA
INCOMPLETE INFORMATION IN MASTER DATA (LACK OF LINKS TO
DOCUMENTATION AND NORMS, LACK OF BOMs OF DEVICES
DUPLICATES - IDENTICAL ITEM UNDER SEVERAL ID NUMBERS
NO UNIFIED METHODOLOGY OF IDENTIFICATION (NAMING) OF SPARE PARTS
DIFFERENT NAMES FOR IDENTICAL ITEMS
NO COMMON REQUIREMENTS ON TECHNICAL PARAMETERS
INCOMPLIANCE WITH METHODOLOGY OF OTHER COMPANIES IN HOLDING
NO DIVISION TO GENERIC ITEMS AND SPECIFIC SPARE PARTS
ENTIRE STOCK MANAGED BY SAME STRATEGY
SPARE PARTS MANAGEMENT – INITIAL SITUATION
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1. TO CREATE COMMON METHODOLOGY OF IDENTIFICATION FOR
MAINTENANCE MATERIAL
TO REACH COMPATIBILITY AMONG EXISTING METHODOLOGIES WITHIN THE
HOLDING
2. TO PERFORM PHYSICAL IDENTIFICATION
TO CONDUCT PHYSICAL IDENTIFICATION OF ITEMS IN SQUIRELL WHS AND IN
SAP MANAGED WHS ACCORDING TO CREATED METHODOLOGY
3. TO ELIMINATE SQUIRREL WAREHOUSES
TO MATCH SQUIRREL ITEMS WITH SAP MANAGED ITEMS AND UNIFY THEIR
STOCK, OR TO CREATE NEW MASTER DATA FOR UNMATCHED ITEMS
4. TO SET SAFETY STOCK LEVELS FOR GENERIC ITEMS
TO CALCULATE ONE COMMON SAFETY STOCK LEVEL FOR EACH ITEM,
BASED ON JOINT NEEDS OF ALL CONSUMERS IN PLANT
PROJECT OF MAINTENANCE MATERIAL IDENTIFICATION – GOALS
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PROJECT OF MAINTENANCE MATERIAL IDENTIFICATION – STRUCTURE
Develop standards to unify identification of Spare parts and Generic items
• One identification standard - Identical names for identical spares and Identical categories for Spare parts and Generic items
• Development of database, parsing of current SAP master data and reshaping to master data record according to new identification standard
• Development of software (App) for collection and processing ofdata for physical identification on site
• Fixing Master data structure in SAP
• Definition of responsibilities and approval processes
Physical identification of spare parts in warehouses and fix SAP data in the system
• Physical identification/inspection of maintenance materiál in warehouses
• Summarization and correction of data in SAP (master data clean-up)
• Elimination of temporary warehouses without SAP management
Preparation Stage
Identification Stage
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SHORT NAME OF MATERIALPLANT AND WAREHOUSE NUMBER
UNITS OF MEASURMENTMATERIAL GROUP NAMEDIVISION ON SP AND GI
CATEGORY OF STOCK (CRITICAL ITEM, STRATEGIC ITEM)
By parsing and cleaning of data strings we can prepare correct master data form
Current SAP master
data record
Purchasing orders
Transformation to correctmaster data record structure
Yet incomplete, but correct form of CZ/EN short text (subject to
complete by physical identification)
VUZA PRIR V. 111 PN??/DN65.0 Flanged globe valve DN65 PN?? 422643
PARSING OF CURRENT SAP MASTER DATA
LINKS TO STANDARDSATEST NUMBERS, SPECIFICATIONS
(DIMENSIONS, TEMPERATURES, PRESSURE, SURFACE
ADJUSTMENTS)
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Each item is identified in the following steps:
Step Description Output
1 SELECTION OF MATERIAL CATEGORY Fasteners
2 SELECTION OF KEY WORD (ITEM NAME) Stud screw with bolt
3 SELECTION OF MATERIAL GROUPPIP_FAS
Screws, bolts, washers – general, not atested
4 FILLING INDD REQUIRED INFORMATION
CZ: Svorník s maticí 40x200xW ¾“ NEREZEng: Stud with nut 40x200xW ¾“ Stainless
SHORTCUT: SVOR+M 12050.6 100MM W ¾“
5FILLING IN MAXIMUM OF OTHER REQUESTED
ATTRIBUTESMaterial of bolt: 12050.6; Logistic dimensions:
30x15x15; Norm: ČSN 2515.2
6 ASSESMENT OF TECHNICAL CONDITION NEW/OLD/REPAIRED
STEPS OF IDENTIFICATION
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Identification tree – example
Rotary machinesPumps
Whole pumps
Spares for pumpsPlunger pumps
Plunger crank systemHousing set
Pump housingHousing lidExcenter
Crankshaft setCrankshaftCrankshaft bushingOil flinger ring
Plunger pumpCentrifugal pumpScrew pumpGear pump
Centrifugal pumpsImpeller
Centrifugal pump…
…
……
……
CategorySubcategory
Keyword
Keyword EU
Keyword ENG
Keyword CRC
Keyword N16
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How the name is created?
Added to name according to defined syntax
Categories and key words as selected by identificator Basic name
Key Identification attributes Přivařovací koncentrická [DN1]/[DN2] [various text]
Redukce
Redukce přivařovací koncentrická nerez DN80/50 40/VII
Přechod přivařovací koncentrický DN80/DN50 Z 17248.4
Welding-neck concentric reduction SS DN80/50 40/VII
RED PRIV KON 17248.4 3/3 DN80/50
Name example CZ:
Name example N16:
Name example ENG:
Name example CRC:
Redukce přivařovací koncentrická [material] DN[DN1]/[DN2] [various text]
Přechod přivařovací koncentrický DN[DN1]/DN[DN2] [type] [material]
Welding-neck concentric reduction [material] DN[DN1]/[DN2] [var text]
RED PRIV KON [material] [thicknes1]/[thicknes2] DN[DN1/DN2]
Syntax example CZ:
Syntax example N16:
Syntax example ENG:
Syntax example CRC: All identification data stored in database.
The syntax can bechanged EX POST, ifneeded, all created
names will be updated
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Android Application IND
PHYSICAL IDENTIFICATION ON MOBILE DEVICE
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Add item
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Plan of Identification – Warehouses
Building Description Unit Progress
0515 + oplocený venkovní sklad na jižní straně budovy 0515 POX Physical identification completed, validation in progress
bez označení odkrytá plocha na severní straně budovy 1510, jižne od ulice E a mostu Za POX
1431 POX Physical identification completed, validation in progress
bez označeníodkrytá plocha přilehlá k severní straně boduvy 1431, průsečík ulice 5a a železnice
93a, (volbě ložené armatury a potrubí)POX Physical identification completed, validation in progress
bez označeníodkrytá plocha SV od budovy 1442, mezi železnicemi 99 a 93a, (volně ložené
armatury a potrubí)POX Physical identification completed, validation in progress
bez označeníodkrytá plocha přilehlá k západní straně budovy 1421, ulice 5a (volbě ložené
armatury a potrubí)POX Physical identification completed, validation in progress
bez označení oplocená plocha severně od budovy 1442, jižně od ulice E (armatury a potrubí) POX Physical identification completed, validation in progress
1443 POX no materials to identify
1443/1 POX no materials to identify
1424 pouze volné plochy POX Physical identification completed, validation in progress
1523 pouze sklad v jižní části budovy Močovina Physical identification in progress
3630 překladiště 3630, západní strana budovy 3607 (volně ložená zařízení) NH3 Physical identification completed, validation in progress
3610 volná plocha NH3 no materials to identify
3609 NH3 Physical identification completed, validation in progress
3612 NH3 Physical identification completed, validation in progress
0623 Haly A,B,C Hlavní sklad Physical identification to be started DEC2016
0625 Haly 4,5,6,7 Hlavní skladBlind physical stock counting completed,
Physical identification to be started JAN2017
2515 Hlavní sklad Physical identification to be started 2Q2017
0621 Hlavní sklad Physical identification to be started FEB2017
0512 venkovní plocha Hlavní sklad Physical identification to be started MAR2017
1111 Haly A,B Hlavní sklad Physical identification in progress
1139 Jeseník u kolejiště (Fanta) JESL Physical identification to be started NOV2016
1130 Plechová samostatně stojící budova (jeseník) (Kašpar) JESL Physical identification to be started NOV2016
1131Budova dílen údržby T700 sklad oddělený oplocením v jihovýchodní části budovy
(Kašpar)JESL Physical identification to be started NOV2016
1143 Sklad olejů a těsnění (dobře evidovanej - štítky); Fanta JESL Physical identification to be started NOV2016
6655 sklad VH (Šiška, Mrišo) VH Physical identification to be started JAN2017
6822 VH Physical identification to be started JAN2017
2225 VH Physical identification to be started JAN2017
1132 VH Physical identification to be started JAN2017
0315 sklad VH Kopisty (Šiška, Mrišo) VH Physical identification to be started FEB2017
0213 VH Physical identification to be started FEB2017
4829 VH Physical identification to be started FEB2017
3313 VH Physical identification to be started FEB2017
3333 VH Physical identification to be started FEB2017
0425 VH Physical identification to be started FEB2017
6627 sklad VH (Pavel Kepl) VH Physical identification to be started JAN2017
6596 VH Physical identification to be started JAN2017
4804 VH Physical identification to be started JAN2017
9602 VH Physical identification to be started JAN2017
No. Building Description Unit Progress Pozn.
; 0515 + oplocený venkovní sklad na jižní straně budovy 0515 POX Physical identification completed
2 0515 VNR Physical identification completed
3 bez označení odkrytá plocha na severní straně budovy 1510, jižne od ulice E a mostu Za POX Physical identification completed
4 1431 POX Physical identification completed
5 bez označeníodkrytá plocha přilehlá k severní straně boduvy 1431, průsečík ulice 5a a železnice 93a,
(volbě ložené armatury a potrubí)POX Physical identification completed
6 bez označeníodkrytá plocha SV od budovy 1442, mezi železnicemi 99 a 93a, (volně ložené armatury
a potrubí)POX Physical identification completed
7 bez označeníodkrytá plocha přilehlá k západní straně budovy 1421, ulice 5a (volbě ložené armatury
a potrubí)POX Physical identification completed
8 bez označení oplocená plocha severně od budovy 1442, jižně od ulice E (armatury a potrubí) POX Physical identification completed
9 1443 POX no materials to identify
10 1443/1 POX no materials to identify
11 1424 pouze volné plochy POX Physical identification completed
12 1523 pouze sklad v jižní části budovy Močovina Physical identification completed
13 3630 překladiště 3630, západní strana budovy 3607 (volně ložená zařízení) NH3 Physical identification completed
14 3610 volná plocha NH3 no materials to identify
15 3609 NH3 Physical identification completed, validation in progress
16 3612 NH3 Physical identification completed, validation in progress
17 0623 Haly A,B,C Hlavní sklad Physical identification in progress
18 0625 Haly 4,5,6,7 Hlavní skladBlind physical stock counting completed, warehouse
removed to another location
19 2515 Hlavní sklad Physical identification to be started
20 0621 Hlavní sklad Warehouse removed
21 0512 venkovní plocha Hlavní sklad Physical identification to be started
22 1111 Haly A,B Hlavní sklad Physical identification completed, validation in progress
23 1139 Jeseník u kolejiště (Fanta) JESL Physical identification completed, validation in progress
24 1130 Plechová samostatně stojící budova (jeseník) (Kašpar) JESL Physical identification completed, validation in progress
25 1131 Budova dílen údržby T700 sklad oddělený oplocením v jihovýchodní části budovy JESL Physical identification completed, validation in progress
26 1143 Sklad olejů a těsnění (dobrá evidence - štítky); Svoboda - pod Fantou JESL Physical identification completed, validation in progress sklad olejů
27 6655 sklad VH (Šiška, Mrišo) VH Physical identification cancelled strojní
28 6822 VH Physical identification cancelled strojní
29 2225 VH Physical identification cancelled strojní
30 1132 VH Physical identification cancelled strojní
31 0315 sklad VH Kopisty (Šiška, Mrišo) VH Physical identification cancelled strojní
32 0213 VH Physical identification cancelled strojní
33 4829 VH Physical identification cancelled strojní
34 3313 VH Physical identification cancelled strojní
35 3333 VH Physical identification cancelled elektro a mar
36 0425 VH Physical identification cancelled elektro a mar
37 6627 sklad VH (Pavel Kepl) VH Physical identification cancelled elektro a mar
38 6596 VH Physical identification cancelled elektro a mar
39 4804 VH Physical identification cancelled elektro a mar
40 9602 VH Physical identification cancelled elektro a mar
41 0524 Technip Physical identification completed elektro a mar
42 7211 Sklad MaR vedle vrátnice PCH Physical identification in progress MaR
43 8401 Sklad Elektro Rozvodna EJ (volné plochy + zamykatelné sklady) 1. patro + přízemí PCH Physical identification to be started before at 2017 elektro a mar
44 7522 Sklad Elektro a MaR Rozvodna Farrel v patře PCH Physical identification in progress before at 2017 elektro a mar
45 7512 Sklad Strojních ND - Peletizace PCH Physical identification to be started strojní
46 7723 Sklad Stroní + Elektro Farrel 2 PCH Physical identification to be started Strojní, Elektro
46 98 Plocha mezi blokem 98 a plotem PCH Physical identification to be started Strojní
47 0524 Elektrodíly pro PCH, správce Inelsev (Velké motory 5M Kč bez temperace) PCH Physical identification to be started before at 2017 elektro
48 1718 Velký sklad AGRO Physical identification to be started before at 2017 MaR
49 8411 Velín EJ - dílna strojní údržby PCH Physical identification to be started Strojní
50 7411 Energoblok - strojovna PCH Physical identification to be started Strojní
51 7521 PE1 granulace - bude zrušeno s nájezdem PE3 PCH Physical identification to be started
52 7512 PP Farrel1 PCH Physical identification to be started
53 7723 PP Farrel2 PCH Physical identification to be started
54 7511 Velín S+E - dílna strojní údržby PCH Physical identification to be started Strojní
55 7301 PCH Physical identification to be started
56 1433 Rozvodna POX AGRO Physical identification to be started before at 2017 Elektro
57 1423 POX AGRO Physical identification to be started before at 2017 Elektro
58 3612 Elektro 1.p AGRO Physical identification to be started
09/08/201728/02/2017
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1717
NH3
POX
CENTRAL WAREHOUS
E
CW
JESL
CW VNR
CWPOX
VH
VH
VH
VH
VH
Investment
s
PHYSICAL IDENTIFICATION COMPLETED, VALIDATION IN PROGRESS
IDENTIFICATION NOT STARTED YET
IDENTIFICATION IN PROGRESS
POSTPONED
Project plan:NH3 – validation readyPOX – validation readyCW – started NOV2016JESL – started NOV2016VH – start in 2017PCH+EJ postponed by UniRPAINVESTMENTS – started DEC2016
DECISION PENDING
POX 1319
Started28. 8. 2017
PCH + EJ
Started20. 9. 2017
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WEB-BASED IND – DETAIL OF IDENTIFICATIONApplication for Validation and Administration of created records
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WEB-BASED INDApplication
for Validation
and Administration
of created records
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Progress of Identification
Centralwarehouse
„Black“ warehouses
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Key numbers – progress
Since the project started, 36 827 materials were identified,
out of them 27 878 on central warehouses and 8 949 in temporary warehouses.
In central warehouse, 19 551 items were stock counted.
Validation of Hi-pressure parts in Ammonia unit was accomplished.
1820 items validated in Ammonia unit in total (validation 1).
Matching of hi-pressure parts in Ammonia unit finished (coupling black materials with SAP items
in Central warehouse). Validation 2 of matched pairs to be started.
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Validated by master data admin
Validated by responsiblemaintenancetechnician
VALIDATION OF IDENTIFICATION
Name + attributes
VALIDATION OF DUPLICATES
SQUIRREL – CentralWH
VALIDATION OF DUPLICATES IN CENTRAL WH
VALIDATION OF MRP CONTROL LEVELS
REVISION AND VALIDATION OF IDENTIFICATION METHODOLOGY Keywords, identifikation trees, translations
Validated by responsiblemaintenancetechnician
Validated by master data admin
Validated by Maintenance Engineer nominated for particular material category
1 2 3 4
0
VALIDATION LEVELS
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0
200
400
600
800
1000
1200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
V1 V3 V4 V5 V6
Progress of validation states of items in Ammonia unit
For validation
Rejected
Corrected
Validated
Risk: Validation
of identifieditems takes
time!
Weeks
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Progress of validations Ammonia – activity of maintenanceengineers responsible for validation(states Rejected and Validated)
0
200
400
600
800
1000
1200
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
V1 V4 V6
Rejected
Validated
Risk: Validation
of identifieditems takes
time!
Weeks24
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WEB-BASED IND – VALIDATOR ACCOUNT
Application for Validation and Administration of created records
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Matching of black spares with central warehouse
UNIRPA COOPERATION
844 N16 items in black warehouses ofNH3 unit
Lxxxxx
377 N16 items on Central warehousein Planning group
210
Objectives:
1 Joining duplicates2 Estimate of value
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844 items
in black warehouses
Matching of black inventories – Searching for duplicates
Paired black items 844
100% match (similarity = 1) 172
No match (max similarity = 0) 641
Partial match (similarity between 0 and 1) 31
377 items
in Central warehouse
Perfectmatch
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Black items paired so far 844
100% match (similarity = 1) 172
No match (max similarity = 0) 641
Partial match 31
Estimate of nominal value of black items 3 500 000 EUR
Estimate of scrap value of black items 20 000 EUR
Matching of black spares with central warehouse
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Transfer of black inventories into SAP
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ACTIVITY CONTRACTOR CUSTOMER
To provide App for identification and to service App during identification x
To provide initial and operational trainings to explain identification procedure x
To register handling and consumption of items in WHS during identification x
To provide personnel and equipment for material handling for purposes of identification
x
To ensure security during identification x
To validate correctness of master data records x
To provide sufficient human resources according to scope of items to be identified x
To accomplish minimum volume of data records agreed in contract x
To prepare and hand over all documentation related to identified parts x
PREREQUISITES FOR IDENTIFICATION
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Kategorie CCT
Kategorie CRC
Comparison of material groups of different methodologies
Some annexes are not finished yet
Some categories can not be simply linked
PROJECT PITFALLS
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REVISIONS AND CUSTOMIZATION OF IDENTIFICATION METHODOLOGY
MUST BE DONE BEFORE PHYSICAL IDENTIFICATION STARTS
TIME OF PERMANENT EMPLOYEES IS LIMITED, THUS THERE IS NEED
TO PLAN TIME OF TECHNICIANS AND IT ADMINS, AND
OUTPUT QUALITY CONTROL OF PERFORMED IDENTIFICATIONS PRIOR
TO VALIDATION HAS TO BE INTRODUCED
WHEN USING SUB-SONTRACTORS FOR IDENTIFICATION, NEED TO SET
MONITORING AND REPORTING ACCORDING TO DEFINED INDICATORS
OF PERFORMANCE
PROJECT PITFALLS
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THANK YOU
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