A Fully Integrated Global EAM Service Provider
Table of Contents Strategy & Process Services Overview... p. 3 Asset Reliability Services Overview... p. 4 Systems & Technology Services Overview... p. 7 Page 2 of 9
Strategy & Process Services Overview Business Process Review The objective of the business process review is to define business workflows and procedures that will allow customer to operate at an optimum level throughout the maintenance organization. Effective management of an organizations maintenance program encapsulates almost every department within an organization and ties heavily into EAM system utilization. The five primary areas related to EAM business process include asset management, work management, purchasing, storeroom management, and receiving. The developed workflows encapsulate both the computerized maintenance management system ( CMMS ) data management activities as well as the integration into the organizations overall maintenance strategy and execution process. EAM Assessment Accurately identify your organization s Current State on the EAM Maturity Continuum by comparing your existing operation to Best Practice, identifying areas for improvement and opportunities for return on investment. The assessment focuses on the following key areas: EAM System Functionality & Utilization, Instrument Calibration, MRO Inventory Management, Metrics & Performance Improvement, Maintenance & Reliability Strategy, Planning & Scheduling, and Work Management. EAM Master Planning Once an EAM Assessment is completed, a gap analysis is performed and a comprehensive project outline is developed providing detailed steps for each improvement action and the subsequent tasks that need to be executed, including content such as: required man hours for completion, a priority defining the target rate (hours of execution per week), an execution schedule, and associated milestones for the purposes of delineating the scope of work to be integrated. This master plan is the prioritized actions required to improve overall asset management and progress up the EAM Maturity Continuum towards the Enterprise state. EAM System Gap Analysis An EAM system gap analysis evaluates the current system utilization of an organization s current CMMS. These findings are base lined against predetermined deliverables. The initiative can be focused on new or improved functionality in updated versions of the customer s CMMS application or other best of breed CMMS. The point of focus may also be to evaluate current configuration, data quality, and usage as related to current customer business needs and industry Best Practices. Page 3 of 9
Asset Reliability Services Overview Asset Setup Services Asset Information Data Collection, Standardization, and EAM System Population The collection, standardization, and EAM System population of all required asset data for optimized management. This is the development of your Master Asset List ( MAL ) which will include identification of assets that may not be registered in the EAM System and therefore are currently not managed effectively. Asset Hierarchy Development Establishing an effective asset hierarchy to provide EAM System cost roll up and ensure the correct asset can be located within the EAM System in a timely manner. Reliability Engineering Services Failure Code Development The development of failure codes for utilization within the EAM System in order to properly classify asset work order failure history for future analysis and improvement efforts. Asset Criticality Ranking The prioritization of all assets based on critical factors such as: safety, quality, environmental impact, operational throughput, operation cost, and/or current reliability. The MAL will be the data set used for Asset Criticality Ranking ( ACR ). This ACR will be populated into the EAM System and combined with Work Order Priority to calculate a Work Order Criticality for prioritization of all planning and scheduling activities. Preventive Maintenance Optimization Review of the current PM strategies for assets (with the execution prioritized by ACR) to optimize each strategy based on a predetermined approach such as: OEM requirements, industry Best Practices, subject matter expertise, predictive maintenance application, and/or Failure Modes and Effects Analysis. Failure Modes and Effects Analysis Utilizing a proven failure mitigation methodology to analyze the potential failure modes and effects of assets in order to develop the most proactive maintenance strategy. Bad Actor Analysis The analysis of predetermined assets that are not performing as expected or are currently bottlenecking the operational process to develop corrective actions in order to optimize their performance. Root Cause Failure Analysis The analysis of predetermined recurring failures in order to identify their root cause and develop corrective actions to eliminate or reduce future failures. Lubrication Program Development The development of a formal lubrication program utilizing Best Practices such as: lubrication selection, lubrication storage, lubrication identification, lubrication routes, lubrication point tagging, lubrication task documentation, lubrication program training, and used lubrication analysis. Critical Spare Part Identification The identification and EAM System population of critical spare parts for assets (with the execution prioritized by ACR) to ensure the right parts are on hand for the right assets. Page 4 of 9
Asset Reliability Services Overview Maintenance Engineering Services Safety Critical Element Management Review of equipment and locations, identification of relevant Safety Critical Elements, development of performance standards, and alignment of maintenance assurance within the CMMS. Mechanical Integrity Services Mechanical Integrity Program Development Assess and audit the current Mechanical Integrity ( MI ) program, including a gap analyses versus industry practices, codes, and standards. Assist in equipment selection or boundary definitions to be covered by an MI program. Develop written management systems for MI programs, including identifying pertinent recognized and generally accepted good engineering practices ( RAGAGEP ). Develop inspection, testing, and preventive maintenance ( ITPM ) plans. Identify and write maintenance procedures. Integrate MI programs or ITPM plans into the CMMS. Identifying MI training and competency needs. Develop programs for quality assurance ( QA ) and management deficiencies. Assist with OSHA's National Emphasis Program ( NEP ) inspection. Planning and Scheduling Services Planning and Scheduling Optimization The development of planning and scheduling Best Practices such as: weekly planning meetings, effective job plan creation, EAM System work order planning (standardized job plan creation), material kitting and staging, weekly scheduling meetings, EAM System work order scheduling (utilization of bolt-on scheduling software), and/or establishing operational calendars for scheduling. Outage Planning and Execution Comprehensive coordination of all outage planning activities to include key activities such as: operational personnel interfacing, work order planning, material planning and procurement, material kitting and staging, effective scheduling (to include Gantt charting), and the identification of milestone activities. Management of all outage work execution to ensure daily schedules are met and effective communication exists throughout the outage with focus on milestone activities. MRO Inventory Management Services MRO Inventory Information Data Collection, Standardization, and EAM System Population The collection, standardization, and EAM System population of all required inventory data for optimized management. This is the development of your Item Master List which will include identification of inventory that may not be registered in the EAM System and therefore are currently not managed effectively. Asset Bill of Materials Development The identification and EAM System population of bill of materials ( BOMs ) for assets (with the execution prioritized by ACR) to allow for effective work order planning as materials have been identified in advance of the planning process. MRO Inventory Management Optimization The development of inventory management Best Practices such as: cycle count program, inventory turns analysis, material kitting and staging program, effective storeroom layout and organization, inventory classification, point of use storage, inventory reordering process, and/or inventory issuing process. Page 5 of 9
Asset Reliability Services Overview Instrument Calibration Services Instrument Calibration Management Optimization The development of instrument calibration management Best Practices such as: master instrument list development, instrument classification, calibration sheet development, calibration labeling, test equipment and standards, calibration program administration, and calibration performance trending. Management Reporting Services Key Performance Indicator Development The identification of the appropriate key performance indicators ( KPI ) at each level within the organization required for effective asset management. This includes standardized calculation for consistent KPI generation and tracking. FDA Compliance Services Compliance Focused EAM Assessment Utilizing the same EAM Assessment framework with emphasis on the recommended Standard Operating Procedures ( SOPs ) that should be in place for effective asset management. The assessment focuses on existence of the recommended SOPs and conformance that they are being followed. FDA 483 Remediation Our team has the prerequisite cgmp experience to respond to any FDA 483, Warning letter, or Consent Decree. Our approach includes remediation protocols, SOPs, and a remediation plan that defines the rationale for any program enhancements as well as the milestones and key performance indicators to ensure sustainability. As part of our implementation process we document workflow and approval processes as part of the change management process. Training and Workshop Services Asset Criticality Ranking Failure Modes and Effects Analysis MRO Inventory Management Planning and Scheduling Preventive Maintenance Optimization Reliability Engineering Root Cause Failure Analysis Staff Augmentation Services Procurement and MRO Inventory Manager Electrical/Instrumentation Engineers Instrument Calibration Manager Maintenance Manager Maintenance Planner Maintenance Project Manager Mechanical Engineers Mechanical Integrity Engineers Pipeline Engineers Reliability Engineer Verification Engineers Page 6 of 9
Systems & Technology Services Overview CMMS / EAM System Implementations and Upgrades CMMS Source Selection Evaluation of current maintenance management needs for an organization are evaluated and primary EAM system requirements are developed and reviewed to determine key functionality to maximize the efficiency of maintenance management processes for a specific organization / industry vertical. These requirements are utilized to evaluate each best of breed CMMs application provider to determine which applications functionality is best designed to meet the organizations needs in an out of the box format. While all major EAM systems are configurable to meet maintenance needs, each application has specific functionality that may be more standardized for a specific deployment. System Implementation / Upgrade Project Management CMMS implementation leadership to manage the implementation process. Genesis project managers have significant experience in deploying EAM systems to manage organizational maintenance activities. Based on PMBOK principals, Genesis has its own project management methodology developed specifically for CMMS implementations and upgrades. Application Installation & Preliminary Configuration Installation and initial configuration of the CMMS application. This includes the installation of the CMMS core applications and web servers necessary to deploy and run the CMMS applications. Genesis has experience installing stand along and clustered application servers. Installation does not include the installation of core operating systems or core database installation and setup. System Implementation / Module Implementation Experienced resources configure, test, train, and deploy CMMS applications to manage defined workflows for all major application modules including asset management, work management, inventory management, purchasing, calibration, safety, budgeting, scheduling, and add on specialty modules for each best of breed application. Data Migration Services Data migration services include evaluating the current state and quality of existing data for proper analysis prior to selecting data migration standards and developing mappings. All data sources are identified and the scope is determined for migration / upgrade into the defined CMMS application. Genesis uses standard methodologies and tools applied based on the data to be migrated such as master data, transactional history, combining multiple external applications, etc. Tools range from import / upload utilities and migration managers to script development and execution. Validated System Implementation Genesis will lead / assist in the CMMS validation process for pharmaceuticals and other regulated industries including the document creation, testing, and deployment of validation applications. Services include requirements development, installation verification or qualification, design specification development, output qualifications, performance qualifications, and reverse traceability matrix development. Genesis can also assist with the validation plan and other documentation as needed. Handheld Technologies Develop requirements for handheld functionality and determine best handheld solution for identified CMMS application. Genesis will perform installation and setup of mobile application and assist with application configuration to meet business processes for identified areas including work management, inventory management, and calibration. Page 7 of 9
Systems & Technology Services Overview System Integration Genesis will develop integration system requirements for necessary activity between the CMMS application and other external systems. An integration data mapping will be completed to determine necessary data to be transferred to or from the external systems. The primary CMMS application will be configured to transfer specified data to the developed output file for import into the external application. Incoming integrations will be developed to allow the proper import of necessary data into the proper tables and configuration of the CMMS application. Support Services CMMS Application Support Genesis provides CMMS application support services for ongoing customer assistance. A variety of topics are available for support with different support plan options based on the amount of assistance needed to support daily customer CMMS activities. Support topics include functional support, data updates, integration support, architectural support, workflow assistance, technical troubleshooting, issue resolution, and report support. Training and Workshop Services Maximo / Infor EAM - Work Management System This training provides users with an understanding of how to create, manage, and execute work orders in best of breed EAM applications. This training is based on system features required for effective work management including work order creation and execution, preventive maintenance setup and scheduling, work order, job planning, cost tracking, work permits, safety, and metric measurement. Maximo / Infor EAM - Inventory Management System This training provides users with understanding of how to create, and manage stock items in best of breed EAM applications. This training is based on system features required for cost-efficient effective stock and non-stock management including item master creation and standardization, stock-outs, bin management, reorder functionality and principles, cycle counting, staging, and returns and transfers. Maximo / Infor EAM - Purchasing Management System This training provides users with an understanding of how to create and manage the requisition and purchase of items in best of breed EAM applications. This training is based on system features required for an effective procure to pay process for stock items, non-stock items, and services. Topics include quotations, requisitions, purchase orders, receiving, returns, contract management, invoices, and price adjustments. Maximo / Infor EAM - Calibration Management System This training provides users with understanding of how to create, and manage instruments, standards, and perform calibrations in best of breed EAM applications. This training is based on system features required for an effective calibration management process and includes creating and managing instruments, standards, test points (data sheets), calibration schedules, calibration execution, and traceability reporting. Maximo / Infor EAM - System Administration This training provides IT and power users with understanding of how to configure and manage CMMS functionality and access. This training supplies information and training concerning system settings and options that control the manner in which the CMMS operates and controls data. Topics include application base settings, screen modifications, security, workflow design, base data entry and management, electronic signatures, audit controls, GL setup, dashboard configuration, and application specific configuration abilities. Page 8 of 9
Systems & Technology Services Overview Maximo / Infor EAM - System Workflow This training provides IT and power users with understanding of how to configure and manage Maximo workflow. Users will be taught the process of developing specific workflow based on data related conditions to route and manage the flow of data and maintenance through utilization of the Maximo workflow module. Topics include workflow creation, routing, approvals, escalations, cron tasks, and node functionality. BIRT / Actuate - Report Development This class is designed to provide hands on BIRT / Actuate report development experience. Users will be taught all basic report development requirements relating to Maximo report development. Topics include creating new reports, adding fields and logos, developing parameters, hyperlinking from list reports to detailed reports, header and footer development, calculations and totals, report localization, and Maximo report registration. Page 9 of 9