Equipment Master Standardization

Transcription

1 Equipment Master Standardization Claudia Hardeman Valero Energy Corporation Supported by: Produced by:

2 Agenda 1. Introduction 2. New Valero model 3. System Design 4. The Journey 5. Questions

3 Valero Energy Corporation Our Business Valero Energy Corporation is a Fortune 50 company based in San Antonio, and through its subsidiaries is the world s largest independent petroleum refiner and marketer. Valero supplies fuel and products that improve people s lives with 16 refineries and 10 ethanol plants stretching from the U.S. West and Gulf coasts to Canada, United Kingdom and the Caribbean.

4 What was Reliability looking for? Which equipment type repairs are the most expensive? Do equipment have the right equipment type assigned? Which manufacturer is more reliable? Which other refinery has the exact same equipment available? PUMP Slide 4

5 Business challenges Bad or Missing Data No enterprise taxonomy of equipment existed in Valero s SAP Plant Maintenance module, preventing the Reliability Department from having accurate KPI s for analysis Not all equipment was loaded into SAP, preventing the creation of preventive maintenance plans, accurate work orders and cost allocation Lack of data governance Higher risk of data inaccuracies and inconsistencies for reporting Too many users had access to create/change records in SAP, making it difficult to maintain clean equipment records in SAP Slide 5

6 Old Valero process Individual records Create FL Create equipment Which Object Type, TechID, Manufacturer, ABC indicator? Too many users creating/changing master data Mass creation of records I/S Department (3 to 6 months) Excel template Which Object Type, TechID, Manufacturer, ABC indicator? I/S received and manipulated data in MS Access Loaded in ECC Test LSMW Got approval from requestor Loaded in ECC Production LSMW Slide 6

7 Agenda 1. Introduction 2. New Valero model 3. System Design 4. The journey 5. Questions

8 How do we bring the goal to life? The challenges were identified. There were several approaches we could take. Slide 8

9 New Valero model Develop a new SAP MDM (Master Data Management) repository to accelerate the cleansing and standardization of refinery SAP equipment. MDM does not have a predefined business content for equipment. SAP MDM provides a single version of the master data. Allows central creation and management of master data. SAP MDM components: Data Manager o Import Manager o Syndication Manager o Console o Slide 9

10 New Valero model Develop an electronic form to create, change, and delete records through an automated workflow using BPM (Business Process Management) to help establish an equipment record governance process. SAP BPM, at a very high level, consists of enterprise applications to integrate various types of business systems in order to complete necessary operational functions. Slide 10

11 New Valero model - Taxonomy First step Design an enterprise Taxonomy Created four reliability categories: o Electrical o Fixed Equipment o Instrumentation o Rotating Reduced Reliability Object Types from 243 to 105 Category Object Type Technical ID Rotating BLOWER FORCE DRAFT BLOWER INDUCE DRAFT BLOWER CLUTCH NON-OSHA CLUTCH OSHA CLUTCH COMPRESSOR CENTRIFUGAL COMPRESSOR INTEGRALLY GEARED COMP LIQUID RING COMPRESSOR OTHER COMPRESSOR RECIPROCATING COMPRESSOR PUMP LIGHT DUTY CENTRIFUGAL HEAVY DUTY CENTRIFUGAL POSITIVE DISPLACEMENT Electrical BATTERY CAPACITOR CKT_BRKR BATTERY CHARGER CAPACITOR LV AIR CKT BRKR LV MOLDED CASE CKT BRKR MV AIR CKT BRKR MV VACUUM CKT BRKR MV/HV GAS CKT BRKR MV/HV OIL CKT BRKR Slide 11

12 New Valero model Business Process Request Approve Create Enter key data to request or change equipment or functional location (individual or mass upload) Run validations for duplicate records and mandatory fields Save and submit request Record checked out in MDM Pick task from UWL (Universal Work List) Review data Approve / Reject (3 levels) Notify requesting party Record checked in MDM Syndicate record to SAP ECC Notify requesting party Slide 12

13 New Valero model Architecture User Interface Layer Role Based UI - Plant / Approver / Administrator UI BPM Process Layer Workflow and Rules SAP MDM Data Manager Record Check out Record Check in SAP ECC Record created Notify requesting party Slide 13

14 MDM and BPM: What does it look like? Process Modeling Graphical design Integrated development environment Slide 14

15 MDM and BPM: UI for End User User Interface Web-based (Web Dynpro Java) Role Specific Single inbox (Universal Worklist UWL) MDM Integration Slide 15

16 Agenda 1. Introduction 2. New Valero model 3. System Design 4. The Journey 5. Questions

17 Cleansing and Standardization Cleanse and standardize equipment records Created two main tables Equipment and Functional Location Defined a standard equipment taxonomy Extracted, mapped, and loaded records from SAP ECC to MDM Involved Reliability SME at the refineries HQ team responsible for mass cleansing

18 Equipment taxonomy configuration Equipment Taxonomy Built Taxonomy Hierarchy Equipment Category, Object Type, and TechID form the Equipment Taxonomy Equipment taxonomy is the key field to integrate MDM and BPM Classification system Classes filtered by TechID

19 Equipment cleansing business process Mass change of records using MDM > 500 records Mass changes MDM DM Syndication ESARN (Electrical Safety and Reliability Network Download Records Modify records Import file MDM IM Mapping and Validations Records in SAP ECC Mass change of records using the UI < 500 records UI Download records Modify records Upload file UI Validations Approve Syndication Records in SAP ECC

20 How did we establish a governance process? Developed a UI Equipment Management Web-based Data Governance UI components, using Java Webdynpro Defined Approver levels (BPM) Sustained data quality: o Duplicate checks prior to records creation o Records validations

21 Governance - Approval process Multiple approval levels Three departments are involved on the approval process Trigger alerts to approve and remind users Ensures reliable master data SAP BPM Request Review Approve Search MDM Web Service calls Create and Syndicate

22 Governance Sustained Data Quality Individual creation/change Overview and Detail Mass upload creation/change Role based access Functional Location and Equipment can be create on the same request WIP requests Records validation Request tracking Recall old requests

23 Agenda 1. Introduction 2. New Valero model 3. MDM Design 4. The Journey 5. Questions

24 The journey

25 Key take away points Team members with experience in equipment master data were integral to the project Secure support from upper management MDM provides the engine to accelerate the cleansing and standardization of refinery equipment SAP does not offer a predefined business content for equipment BPM was used to automate a workflow approval process to help establish equipment governance process SME agreement on equipment taxonomy definition might be a challenge Slide 25

26 Lessons learned MDM API presented challenges developing the UI interfaces We had very aggressive dates We waited too long to communicate with key users Resistance to new model was stronger than anticipated and could have been prevented by including key users during design phase Understand SAP BPM licensing process to properly estimate project cost Slide 26

27 Thank you for your time Questions

28 Claudia Hardeman Valero Energy Corporation Supported by: Produced by: