Engineering Data Lifecycle Management Overview

Transcription

1 Lifecycle Management Overview Ron Brennan, Chemicals and Petroleum Industry Consultant, IBM NRSC Perth 13/10/2011

2 Handover Overview The Handover Dilemma The Case for Smarter Management Scope of Lifecycle Management Management Business Processes Management Supporting Applications Integrated Management Architecture What are Leading Companies Doing Differently? Learning From Other Industries Top 3 To-Dos

3 The Handover Dilemma data handover is not easy - Variety of data in a variety of formats High volume of data - Diverse source systems - EPC / Owner-operator systems not compatible Who is responsible for data handover- MCP or operations? Lack of handover/management of change business processes What about operations systems? Typical engineering data handover behaviours - File away documents in document management system (or file cabinet) - Render drawings in PDFs to store as documents - One-time loading of operations systems Typical Information Equipment Sheets Hierarchy, Register Tag numbers Maintenance Strategies Criticality Rankings Reliability Centered Maintenance FMEAs Maintenance Activities Lists Maintenance Job Routines Corrosion Inspection Job Routines Consolidated Bill of Materials Spare Parts & MRO Lists Operations Procedures Commissioning, Startup Strategy, Plan, Procedures Training Manuals Maintenance Manuals As-Built Drawings Equipment Baselines

4 The Case for Smarter Management The case for change is to avoid the hidden costs of additional activities - handover format conversions - QA equipment lists, material numbers, etc. - QA tag naming nomenclature - Plant hierarchy configuration - Document management classification taxonomy And to prepare the data for use - User access - Operations systems use These issues should be treated as related and should be addressed in an integrated manner Lifecycle Management Handover? How hard can it be?

5 Scope of Lifecycle Management EPCs Owner-Operator Management EPC Access Portal / / Doc Control / Workflow Status User Query Transmittal Workflow Handover Transmittal Review / Transmittal Review / Approval Process Approval Workflow Process Handover Operational Systems Load Management of Change Transmittal Workflow Changes Management System EPC Sub EPC Sub EPC Sub Document Control Document Management System Warehouse Changes ERP FA FA Major Capital Project Lifecycle FID FEED BOD Detail Design and Construction Handover Startup Production Steady-State Operations ENGINEERING DATA LIFECYCLE BUSINESS PROCESSES Lifecycle Creation and Handover Management of Change Design Documents Review and Approval Handover Operational Systems Load Management of Change

6 Lifecycle Management Business Processes Integrated Lifecycle Business Process 3.0 Enrichment Handover Enriched EPC Work Package 1.0 Transmittal/Work Package Review/Approval Approved Work Package 2.0 Handover Load Signal 4.0 Load Application Change Transaction 5.0 Maintain System of Record Change Work Order Returned Work Package ERP FA MM AMS Document Control Track transmittal and workflow status Review workflows Log exceptions / interfaces Handover Efficient receiving / loading / QA of data Access to engineering data in native formats Linkage of engineering data components Enrichment Full equipment descriptions Complete AMS spare parts catalogue Load Applications Load of operations application with engineering data Update of operational systems from engineering and maintenance activities Maintenance of Change Maintain accurate system of record for engineering data Accurate company records

7 Lifecycle Management Supporting Applications Warehouse () - info cross references - Access - rendering & collation - Integration - Load/QA workflows Document Management System () - Repository for (native format) - Repository for related documents e.g. equip data sheets, SoP s, manuals Document Control (DC) - work package mgmt Integration to Operational Systems key for efficient start-up and ongoing operations - ERP FA/MM - AMS - Other Operational Systems Management Document Control Integration layer Operational Systems ERP FA FA Access Portal & workflow Warehouse Management System Document Management System

8 Integrated Management Architecture Search Document Controllers Document Editors Maintenance Doc Edit Document Viewer PDF, 2D/3D Drawings Portal / Portal Search Casual Users / Portal Viewer Bulk Load Check IN Document Control Approvals Check OUT Warehouse Published Documents (PDF format) TBD R/T Repository Register Architecture Capabilities Document control capabilities with repository for storage and access data management with repository for storage and access Storage of documents and drawings in corporate repository Publication of documents, drawings, and engineering data with role-based access Maintains engineering data system of record

9 What Do Leading Companies Do Differently? EPCs EPC Sub EPC 1. EPC data handover specifications EPC Sub defined in ITTs EPC Sub Transmittal Workflow Management Integration Services Integrated Lifecycle Business Process QA Access Portal / / Models / Workflow Status 3. integration services among systems defined 3.0 Transmittal Review / Transmittal Review / Approval Process Approval Workflow Process Models Enrichment Enriched Operational Systems Load and Management of Change Workflow Process Document Management System 4. Handover as packages are approved 2. Repeatable data management processes implemented Warehouse User Query Changes Owner-Operator Transmittal Workflow Changes 5. Maintain engineering data System of Record(s) ERP FA FA Management System 6. data lifecycle management implemented EPC Work Package Returned Work Package 1.0 Transmittal/Work Package Review/Approval Approved Work Package 2.0 Handover Load Signal 4.0 Load Application Change Transaction 5.0 Maintain System of Record Change Work Order ERP FA MM AMS

10 Learning From PLM From Other Industries A&D and Automotive Design for Maintainability PLM/MRO integration Operate & Maintain End of Life Decommission 3D MBD: from design to production to certification Commissioning Certify Operate & Maintain Manage Multi-discipline simulation IP Produce Virtual Production Mockup As Planned-As Built collaboration Source: Dassault Systems Construction Validation Testing Manage, Collaborate FEED Design Allow virtual product multidiscipline IP management Pre-FEED Architecture Validation Studies Validate Airframe and Systems Architecture in a single environment Feasibility

11 Lifecycle Management - Top 3 To-Dos 1. Define Management processes for the full data lifecycle, including responsible parties Document Control data handover EPC to capital project team Capital project team to Operations Document Management (repository) Management of Change access methods 2. Define these as integrated engineering data lifecycle processes 3. Define engineering data systems of record and processes to maintain

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