SAP Preventive Maintenance The Core and More. Len Harms - Vesta

Transcription

1 SAP Preventive Maintenance The Core and More Len Harms - Vesta

2 Agenda The Core Preventive Maintenance The Core Light CBM and More

3 The Core PM

4 Preventive Maintenance: Forms Preventive maintenance Time-based Performance-based Condition-based Druck Temperature Pressure Thickness

5 Preventive Maintenance: Plan Types Maintenance plan Single cycle plan Strategy plan Time-based Service Procurement Performance-based Multiple counter plan

6 Building Blocks 1. When Cycle or strategy that determines when a PM should be done 2. Where Equipment or Functional Location The asset, assets, or location where the work is to take place 3. What Task List Define tasks, materials and tools that are required

7 Tip - Add the Default to the user settings

8 Maintenance Plans with single Asset You can create several maintenance plans. Each maintenance plan contains a maintenance item that describes the object to be maintained. The system generates a separate order for each object on a due date.

9 Maintenance Plan Item with Linear

10 Maintenance Plans with Asset list You create one maintenance plan. You assign an object list to the maintenance plan in which all object to be maintained are listed. The system generates an order for all objects on a due date. Supports inspection routes, lubrication routes

11 Enhance- Asset List in Ehp4 For operations in a task list, technical objects can be maintained SAP 2009 / 11

12 Leverage LAM, OAA, GEO.e with Plan Linear Assets can be represented in plans Use Geo.e to add spatial data Operational Account Assignment provides cost of inspection at the exact position of the work

13 Report on Inspection plans and results

14 Inspection results support long term planning Use results to feed the long term asset planning Leverage PPM to support the long term plan Create long term plan 4 3 Analyze results Create Inspection plans 1 2 Gather results

15 Maintenance Plans with Strategy You create one maintenance plan. You assign an object list or a single asset. The system generates an order for all objects on the due dates with the tasks that match the strategy. Supports a single plan with different tasks per call date Can be performance or time The strategy unit must be consistent

16 Maintenance Plan with Notification Made possible once multiple Notifications could be added To a single order. Also possible to add task list in a notification as of ERP2005

17 Other Items Move/Skip/Release in graphic simulation Change documents in the maintenance plan Scheduling parameters

18 Preventive maintenance in most organizations today Transformer Work order Technician is executing work SAP ERP Work orders are created in regular Intervals

19 Agenda The Core Preventive Maintenance The Core Light CBM and More

20 The Core PM and More

21 Create a new development project TC:CMOD ENHANCEMENT IS IMRC0001

22 Sample Program

23 Measurement Point Set an upper and/or lower limit

24 Enter reading and valuation code

25 Condition based maintenance (using mobility) Transformer Current Voltage Temperature Technician feed rounds information Into SAP to populate measurement documents Transformer SAP ERP Current Voltage Temperature Transformer Current SAP determines whether Work order should be created Voltage Temperature Technician is executing work

26 Agenda The Core Preventive Maintenance The Core Light CBM and More

27 Condition Based Maintenance The Goal Easily accessible dashboards allow asset managers and staff to monitor asset health in real time via measurement points Real-time alerts via dashboards give instant updates on equipment status and allow rapid reaction V.P. Trend analysis identifies problem areas for immediate investigation Asset health Continuous improvement Best practice Links to ERP data to trigger maintenance workflow to reduce unplanned downtime and improve reliability.

28 Current Situation Quite a few of equipment delivered today have built in sensors New sensors (temperature, leakage, etc.) are very affordable Collection, analysis and integration into SAP can be setup in a few weeks Transformer Current Voltage Temperature SAP ERP

29 Challenges The historian collect lots of data but provides little information to SAP Investments in the historian data has been made that is not leveraged EAM groups does not have visibility to condition data in SAP to make/optimize their decisions

30 Integrated condition based maintenance Determine whether or not to create notification or work order Transformer Current Voltage APPs Temperature Transformer Current Voltage Temperature OSI PI SAP MII SAP ERP Data Historian Transformer Work order is made available to the Technician Current Voltage Temperature Technician is executing work

31 Integration and Intelligence Intelligence: Real-time analytics engine that aggregates and delivers unified visualization of events, alerts, KPIs and decision support to personnel thru role-based dashboards Integration: A single layer enabling SAP ERP connectivity into real-time systems to drive equipment-to-enterprise business process interoperability

32 Condition Based Maintenance - Detail Tag Name AB323DS DS PUMP3223.TP Threshold Temp: Rule Name (MII Transaction) Description DailyRunHourUpda te This rule updates the run hours per equipment based on a summarized, binary IsRunning Tag. Parametera are the tag name and the Measurement Point name NotificationOnExc eedthreshold This rule creates a notification once a tag value has exceeded the Threshold value. The Threshold value can be a tag or static value. Select Asset Select Rule Associate Tags and/or fixed values Select Frequency Submit to database 121 MII DB

33 Enter inspection data Manual Entry of Inspection Data Provide maintenance staff with a means to manually input measurement readings Easy-to-use Web-based interface allows untrained staff to enter inspection results Easily delete or modify an erroneous entry

34 Asset Health Alerts Visual indicators and 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 react appropriately and make informed decisions quickly Maintenance staff can trigger a maintenance request if warranted Prioritized asset management enables a consolidated alert view

35 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

36 What s in each solution? SAP Rapid Deployment solutions Software Quickly address the most urgent business processes Content SAP-supported best practices, templates, and tools make solution adoption easier Enablement Guides and educational material speed enduser adoption Service Fixed scope and price provide maximum predictability and lower risk

37 Get started with condition-based maintenance quickly and affordably Business challenges Critical asset failures which can have serious environmental and enterprise level consequences as demonstrated by recent high-profile industrial catastrophes Finding a CBM solution that has low entry, low TCO, and leverages existing SAP investments Traditional time or counter-based maintenance strategies missing a dynamic component leading to higher maintenance cost Other RDS available is Asset Health Visualization There is a solution SAP Condition-Based Maintenance rapiddeployment solution enables your organization to perform maintenance only when necessary by arming maintenance teams with sophisticated intelligence and comprehensive asset health dashboards. The solution also enables manual and automatic triggering of maintenance workflow leveraging through native integration with the SAP Enterprise Asset Management (SAP EAM) solution.

38 Key deliverables What does SAP deliver? Perform installation check Lead workshop to confirm predefined requirements Set up MII connectivity with shop floor system via connector in SAP Plant Connectivity Set up the plant database schema for storing shop floor aggregate data Configure the asset health index to meet customerspecific dashboard requirements Activate and test solution Enable knowledge transfer to key users Enable support for go-live What do you have to do? Provide IT infrastructure (server) Install SAP MII, version 12.2, on the development and production environments Install SAP BusinessObjects Dashboards software to make optional changes to predefined health index dashboards Provide asset hierarchy structure from existing SAP ECC and SAP EAM applications and information on tag thresholds Provide access to existing shop floor system with connector from SAP Plant Connectivity Provide appropriate contacts in the business and IT departments Conduct end-user training and change management Conduct performance and integration testing Perform data migration and cleansing Transport to production

39 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, the standard service offering supports a single plant implementation.

40 In the system Link CBM monitoring system to Historians to gather real-time data perform manual inspection and then enter results into CBM monitoring system Evaluate data to trigger automated maintenance notification via CBM rules and logic Perform maintenance jobs with visual support using SAP 3D Visual Enterprise Perform trend analysis by viewing historical plant data

41 Conclusion - Benefits Minimize risks and stay in compliance via alerts of imminent catastrophic asset failures Manage investment risk by starting with a baseline scope and then scale it gradually Reduce maintenance due to fewer reactive repairs of broken equipment Support effort to stay within regulatory compliance Reduce maintenance rework and mean-time-to-repair (MTTR) Operate equipment in an economically and environmentally sustainable 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

42 Summary - Support Asset Life Cycle

43 Contact: Len Harms

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45 THANK YOU FOR PARTICIPATING Please provide feedback on this session by completing a short survey via the event mobile application. SESSION CODE: 8595 For ongoing education on this area of focus, visit