Turnaround / Shutdown Management with SAP Enterprise Asset Management Dean Fitt

Transcription

1 Turnaround / Shutdown Management with SAP Enterprise Asset Management Dean Fitt SAP AG A collaboration of:

2 What I ll Cover SAP Enterprise Asset Management can be used to manage the whole lifecycle of a Shutdown. Integration and ease of use based on ERP components plant maintenance (PM) and project system (PS) enabled through the use of Maintenance Event Builder (MEB). Portfolio and Project Management (PPM) and Multi Resource Scheduling (MRS) that support the process. Highlight enhancements and new functionality. Key points to Take Home Questions

3 Contents Introduction & Overview SAP Solution for Shutdown Management Wrap Up

4 Why are Shutdowns so important? Most critical periodical event during the plant life cycle. Single most influential contributor to the total cost of maintenance. Safety, Health, and Environment regulations must be adhered to. Ensures future plant performance and safe-guards the investment. Compliance with Statutory Regulations Complex event - time of increased activity, with numerous vendors, contractors, and heavy equipment engaged in multiple tasks in close quarters. Involves strong interaction between Maintenance and Operations.

5 Typical Phases of a Shutdown Definition Planning Scheduling Execution Evaluation Initial Planning Scoping Work Lists Plan Cost Resource Plan High Level Schedule EH&S Plan Work Packages Pre-shutdown preparation Align Capital Work Cost Plan (Budget) Critical Path Resource Leveling Daily Schedules Execute Work Packages Time, Material Confirmations Manage Break-in Work Progress Reporting Demobilization Post Mortem Cost Reconciliation Financial Report Equipment Testing Work Permits Timeline H 1 H 2 H 3 H 4 Definition Planning Scheduling Execution Evaluation

6 Contents Introduction & Overview SAP Solution for Shutdown Management Wrap Up

7 SAP Solution for Enterprise Asset Management Asset Maintenance MRO Procurement & Inventory Plan & Design Procure & Build Planning, Building, and Commissioning Assets Commission Operate Maintain Decommission Human Resources Asset Health Monitoring Project Management Inspection & Calibration RFID and Mobile Devices Materials Requirements Planning Design & Specify Enterprise Asset Management Decommission & Dispose Procure & Build Operate & Maintain Asset Visibility and Performance Operational Risk Management Optimized Asset Operations and Maintenance Core Financials Financial Optimization Reliab. Reporting Real Estate Lifecycle Management SAP supports organizations to efficiently and sustainably manage the whole lifecycle of physical assets in terms of performance, risks, and expenditures to achieve and maintain the stated business objectives. Integrated asset management processes to collaborate across all related activities such as finance, HR, risk, and compliance easily deployable in modular implementable steps Asset intelligence and a holistic view of performance, risks and expenditures throughout an asset s lifecycle to ensure efficient utilization of assets Continuous and proactive operational risk management to support instant decisions and minimize disruption Leverages the SAP Business Suite * According to PAS 55, the BSI standard for good practice in asset management

8 SAP Solutions Supporting Shutdown Definition Planning Scheduling Execution Evaluation Portfolio and Project Management (PPM) Plant Maintenance (PM) Project System (PS) Maintenance Event Builder (MEB) Materials Management (MM) Maintenance Cost Budgeting (MCB) Plant Maintenance (PM) Project System (PS) Maintenance Event Builder (MEB) Document Management System (DMS) Plant Maintenance (PM) Project System (PS) Multi Resource Scheduling (MRS) Enterprise Project Connection (EPC) Plant Maintenance (PM) Project System (PS) Cross Application Time Sheet (CATS) Mobile EAM Work Order Materials Management (MM) Multi Resource Scheduling (MRS) Portfolio and Project Management (PPM) Plant Maintenance (PM) Project System (PS) Financial (FI) / Controlling (CO) Materials Management (MM) Business Intelligence (BI)

9 Asset Planning & Operations Project Planning & Execution Long Term Planning & Monitoring High Level Architectural View Shutdown Management Portfolio / Strategic Buckets Portfolio Initiative (Program) Portfolio Item (Project / Proposal) SAP Portfolio and Project Management optional: Project, Phases, Tasks, Checklist Items... Project Costing Model Base Planning Object WBS Network Activities SAP ERP Project System Maintenance Event Builder Multi Resource Scheduler Maintenance Cost Budget PM Order Notification Maintenance Plan Task List Technical object PM Order SAP ERP Plant Maintenance

10 Definition Definition Planning Scheduling Execution Evaluation

11 Planning Granularity The Planning and Scheduling Life Cycle Definition Planning Scheduling Execution Evaluation Strategic Planning Tactical Planning Execution Planning Detailed Schedules Execution Controlling Planning Bucket Quarterly Monthly Daily shift Hours Asset Details Plant/ Group Subsection Floc Floc/Equip Equip Resource Role level Team Trade Team Individual Individual Work details Project level Phases & task Orders operation Operation Operation Portfolio & Project Management (PPM) Project System + PM Orders + Maintenance Event Builder Multi Resource Scheduler (MRS) Job Control and Analytics Time

12 SAP Portfolio and Project Management SAP Portfolio and Project Management 5.0 Portfolio Planning & Monitoring Long Term Investment & Portfolio Planning Risk Assessment, Prioritization High Level Cost Planning High Level Resource Planning SAP Project System (PS) Capital Pre-Approval Project Management & Execution Project Scheduling Detailed Resource Planning Detailed Cost Planning & Approval Scheduling & Dispatching Regulatory Reporting Document Management SAP ERP for Maintenance, Logistics Financials, HR Core Processes / Activities - Developing Work Lists and Packages - Cost Planning - Processing of work orders - Update of technical assets

13 Maintenance Event Builder (MEB) A Workbench for Shutdowns Prod. Line / Asset 1 Prod. Line / Asset 2 Prod. Line / Asset 3 Prod. Line / Asset 4 Maintenance Event Builder Notifications Maintenance Opportunities / Events Revisions t Facilitates Maintenance Planning and Scheduling Helps eliminate redundant tasks within a work package Sequences maintenance tasks by assigning them to appropriate time frames Planning project based maintenance events Orders Project General Task Lists Standard Network / WBS

14 PS - Project Builder

15 MEB - Workbench

16 PM - Developing Work Lists

17 PM - Maintenance Plans

18 MCB - Data Flow Maintenance Plans 0PM_PRM_PLCS_1 Extractor 0PM_DS07 Forecast of resources like parts, service and internal resources Maintenance Task list (Notifications) 0PM_C05 Cost planning and budgeting 0PM_OPA_1 0PM_C06 Maintenance Maintenance Orders Orders Extractor 0PM_DS04 0PM_C01 Estimated Unplanned demands

19 Planning Definition Planning Scheduling Execution Evaluation

20 MEB - Review Backlog The planner reviews all open maintenance requests that need action. The planner can group these task based on priority, location and resources needed

21 MEB - Review Maintenance Opportunity Planner meets with operations team to plan shutdown Planner enters these opportunities as revisions in MEB

22 MEB Creating Work Packages for the Shutdown Based on the dates of the shutdown and priority, the planner assigns maintenance requirements (notification or WO) to the event.

23 MEB - Generate Orders for a Revision Once the work load is evaluated by operations and maintenance, the planner generates orders or assigns generated orders to the work package

24 MEB Optimizing the Work Package Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical objects are deleted Revision Notification Chk1 T1 SB1 ST1 ST2 ST1 ST6 ST3 ST3 T2 Elimination ST4 ST5 ST1 Order ST3 Order Order Order Order Order Order Order ST1 ST2 ST3 ST4 ST5 ST6

25 Insert video clip here: -Overview Radiation Shaft

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27 Scheduling Definition Planning Scheduling Execution Evaluation

28 MEB - Assigning Orders to a Project Automatically

29 PM/PS - Assigning Orders to a Project Network Orders can be assigned manually using drag and drop or automatically based on the Reference PM/PS Element field. Transaction ADPMPS (does not require MEB)

30 PS - Network and Overall Network Scheduling Network Scheduling: schedule activities of one network only Overall Network Scheduling (CN24) schedule all connected networks/subnetworks (and PM/CS orders) simultaneously Overall Network Scheduling with Selection Options (CN24N) schedule selected networks/subnetworks simultaneously analyze dates of subnetworks (and PM/CS orders) using the Subnetwork Monitor

31 PS - Project Editor The Project Editor is enhanced with Additional Data Sets for example PM/CS Order Dates Date Planning and Scheduling (new) Advanced Date Overviews and Comparison Usability Improvements Date Planning and Scheduling Overall Dates Overview Display PM/CS order in hierarchy Activity Dates Overview

32 PS - Project Editor Gantt Chart In the Gantt Chart, you can: Display dates of project objects (Tabular area, Graphical area) Change dates and durations (Drag time bars for WBS elements, Specify dates in tabular area) Define user-specific settings and manage variants (for example, time bar labels) Choose different timescales (for example, monthly) Print and print preview Gantt chart

33 Multi Resource Scheduling (MRS) Demand Gantt Work Center Gantt Work Center Capacity Alert Monitor

34 MRS - Scheduler Workplace

35 SAP Enterprise Project Connection (EPC)

36 Execution Definition Planning Scheduling Execution Evaluation

37 Time Confirmation Using Cross Application Time Sheets (CATS) Operations and activities can automatically be defaulted for users in CATS Additional data such as remaining work can be entered via mouse click.

38 SAP EAM Work Order Mobile Application Standard solution for mobilizing SAP Enterprise Asset Management Notification Management Create, view, and edit notifications and related objects (activities, items, tasks) Work Order Management Create, view, and edit work orders Display related business partners and historical data Record working time and material consumption List, calendar, and map view Online & Offline Technical Object Management View equipments and functional locations Display technical object on a map Display associated documents Display history and characteristics Business Partner Display business partner header and contacts List and map view Inventory Management Track and manage inventory Material consumption booked on orders updates inventory Built on industry leading Sybase Unwired Platform

39 Work Permit Management (WPM) Project with Statoil and ConocoPhillips to develop an Oil&Gas specific permit to work solution. Existing functionality in SAP Work Clearance Management (WCM) has been enhanced, so that industry specific work processes for work permits can be configured in customizing.

40 WPM - Work Preparation Create Operational Valve & Blind List

41 Evaluation Definition Planning Scheduling Execution Evaluation

42 Reporting and Analytics Options KPI Framework Reports within BCV Dashboards Crystal reports integrated

43 Contents Introduction & Overview SAP Solution for Shutdown Management Wrap Up

44 Asset Planning & Operations Project Planning & Execution Long Term Planning & Monitoring High Level Architectural View Shutdown Management Portfolio / Strategic Buckets Portfolio Initiative (Program) Portfolio Item (Project / Proposal) SAP Portfolio and Project Management optional: Project, Phases, Tasks, Checklist Items... Project Costing Model Base Planning Object WBS Network Activities SAP ERP Project System Maintenance Event Builder Multi Resource Scheduler Maintenance Cost Budget PM Order Notification Maintenance Plan Task List Technical object PM Order SAP ERP Plant Maintenance

45 Stage 1 - Developing Planning of Effort 90% of Planned Work Completed Within Budget <5% Over All Equipment inspected Best Practice Stage 2 - Maturing Tight control of scope Manage resource constraints Daily status update of progress 95% of planned work completed Estimates of work based on industry norms Equipment available for maintenance Delays in equipment startup as a result of integrity issues Stage 3 Best Practice Portfolio management process in place Issues rectified early Quality of work to ensure on-time start-up Materials and Resources managed to ensure availability at right time Work Permit process streamlined Early planning Shutdown and start-up on time

46 Dean Fitt SAP AG