MASTER DATA ACQUISITION USING eotd Dr Salomon de Jager PiLog

Transcription

1 MASTER DATA ACQUISITION USING eotd Dr Salomon de Jager PiLog ECCMA 10 th Anniversary Conference 27 th to 29 th October 2009 Cataloging at Source - the last piece of the puzzle

2 Master Data Management Quadrants Public Domain Client Domain ERP 1 MM eproc OPS Area Staging Area Standards Standardized External Data Non Standardized External Data Master Data Management Data Flow Master Data Acquisition ERP 2 Other Content Refinery OPS Area Staging Area

3 MDA Integrated Model Project Procurement Spares/Materials Management Operational System Vendor Master Item Catalogue Inventory Asset Register Location Structures Bills of Materials Asset Management PiLog Master Data Acquisition

4 Level of Effort Master Data Overview From the Cradle to the Grave Master Data Acquisition / Project Phase Design Procurement Documentation Construction Configuration Data Extraction Upload to ERP Preparation 18 months Max Level of Effort Master Data Management / Operational ERP Phase Planning Inventory Feedback Requisition Procurement Receiving Issuing Maintenance Phase -Out Best Business Practice Existing Practice Plant Commissioning Time 4-5 years Handover 20 years

5 Master Data Acquisition for ERP Operation Baseline Establishment and Equipment Life Cycle Management Principles

6 Managing the Acquisition of Master Data Equipment Baseline Creation and Management Sourced from: Eng Design Specs, OEM Prescriptions, Design Drawings Equipment Configuration Definition Maintenance Significant Item Identification Maintenance Task Definition Maint & Ops Resource Requirements Document Management Material Item Master Creation Driven By Operational Requirements Data requirement statements Equipment and Operations Management Operations planning and execution Reporting & Analysis Breakdown Maintenance Long Term Maintenance Planning WIP Execution Short Term Plans (WIP) Phase Out Planning Procurement Management Inventory Management HR Management

7 Managing the Acquisition of Master Data Equipment Baseline Creation and Management Sourced from: Eng Design Specs, OEM Prescriptions, Design Drawings Equipment Configuration Definition Maintenance Significant Item Identification Maintenance Task Definition Maint & Ops Resource Requirements Document Management Material Item Master Creation Driven By Operational Requirements Data Requirement Statements Equipment and Operations Management Operations planning and execution Reporting & Analysis Breakdown Maintenanc e Long Term Maintenance Planning WIP Execution Short Term Plans (WIP) Phase Out Planning Procurement Management Inventory Management HR Management

8 Master Data Equipment Configuration Management

9 Structure Types Generic Structure Specific Structure Top SYC L1 SYC L1 SYC L1 SYC L2 SYC L2 SYC L2 SYC L2 SYC L3 SYC L3 SYC L3 SYC L4 SYC L4 SYC End Eqp No 1 End Eqp No 2 End Eqp No 3 End Eqp No 4 Top SYC Top Ser SYC No X Top Ser SYC No X Top Ser SYCNo X L1 SYC Ser No X L1 SYC L1 SYC L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null L1 Ser SYC No: null Ser No: L2 SYC null Ser No: null L2 SYC L2 SYC Ser No: L2 null SYC L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null L2 Ser SYC No: null Ser No: null Ser No: null Ser No: null Ser No: null L3 SYC L3 SYC L3 SYC L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null L3 Ser SYC No: null Ser No: L4 SYC null Ser No: L4 SYC null Ser No: null L4 Ser SYC No: null L4 Ser SYC No: null L4 Ser SYC No: null L4 Ser SYC No: null Ser No: null L4 SYC Ser No: null Ser No: null L4 SYC Ser No: null

10 Generic Structure

11 Specific Structure Available End Equipment

12 Specific Structure Selected End Equipment

13 Specific Structure Population Equipment Register Eqp No Eqp Type Part No Description CR CRANE PTNO 0123 GW AK912 Crane EQP SNO 001 CHASSIS CHASSIS ASSEMBLY EQP SNO 002 POWER PACK POWER PACK EQP SNO 003 ENGINE BASIC ENGINE EQP SNO 004 EQP SNO 005 EQP SNO 006 EQP SNO 007 EQP SNO 008 EQP SNO 009 EQP SNO 010 SOLENOI D VALVE FUEL PUMP INJ PUMP SOLENOID VALVE, HOUSING AND AIR PIPE FUEL PUMP,MECHANICAL INJECTION PUMP WITH ROLLER TAPPETS INJECTO R FUEL INJECTOR INTERFA CE POWER PACK POWER PACK ENGINE, TRANSMISSION INTERFACE EQP SNO 011 TURRET TURRET POWER PACK, FUEL SUPPLY SYSTEM POWERPACK COOLING SYSTEM Specific Structure Prod X LL Comp LL Comp LL Comp LL Comp LL Comp LL Comp LL Comp LL Comp LL Comp CR LL Comp LL Comp LL Comp LL Comp

14 Structure and CI Associated Info Physical Hardware Breakdown Structure CATALOGING PROCESS Generic Equipment Configuration Structure Valid and Preferred Part No s Alternative Part Numbers Configuration Status Codes (Mods) Material Item Master INSTALLED Serialized Equipment Specific Equipment Config Structures Actual Utilization (Meter Feedback) ASSOCIATED DOCUMENTS Ageing Parameters (Meters) Standard Maintenance Tasks

15 Master data Asset Management

16 Asset Management Equipment Types Vendors Part Numbers Mat Item Numbers Departments Personnel Asset Register Asset Status Codes Asset Waranties Asset Meters Asset Tracking Application Asset Utilisation Condition Asset Meter Update/Feedback EXT Location Change Asset Status Change INT Location Change

17 Asset Management Equipment Register

18 MDA Maintenance Management

19 Maintenance Task Definition Standard Maintenance Task Priorities Status Codes Task Types Task Instructions Associated Documents Verbs Std Task Associated Info Standard Tasks OEM Instructions Trades Special Conditions Proposed Tasks Inherent Details: Standard Task Code Verb & Description Task Schedule Type Resources Fix & Statutory Indicators Task Type Estimated Duration Support Material Frequency Equipment Schedule Type (FS, SS, ) Date From Ind Experience / Expertise RCM Facilities

20 Maintenance Task Resource Requirements Standard Maintenance Task Priorities Status Codes Task Types Verbs Standard Tasks OEM Instructions Special Conditions Proposed Tasks Experience / Expertise RCM Std Task Associated Info Task Instructions Task Resources Facilities Associated Documents Trades Material Support Equipment

21 Standard Task Associated Information - Materials

22 Standard Task Associated Information - Instructions

23 MDA Materials/Inventory Management

24 Material Item Master

25 Material Item Master System/Eqp Association

26 MDA Document Management

27 Document Management Principles Document Registration Document Number Document Revision Number Document Description Document Type Document Indexing Topic Document Date Document phrases and words Document Publishing Document Breakdown Structures Document Imaging/File Management Document Associations Document Modification

28 Document Interface

29 Conclusion

30 Master Data Overview 5 Golden Rules Never underestimate the power of quality data with integrity. Data is a company Asset, treat it as such, control it, maintain it, repair it and govern it. Let the data work for you, do not become a slave of the data. Do it right the first time. Do not bring the level of your systems and data down to the User, bring the level of the User up to the systems and the operational data.