Enabling Data and Analytics for Enterprise Asset management (EAM) Devang Patel & Arun Narayanan SEAL Consulting Inc SESSION CODE: EM2098
Agenda: What is EAM? Business Challenges / Benefits Why EAM? Architecture EAM Data Collection / Practice Area(s) Input Data Set Pre-Defined Rules
Live Demo Recording
Live Demo Recording Cont
What is EAM? Enterprise asset management (EAM) is a broad term vendors use to describe software that provides managers with a way to view company-owned assets holistically. The goal is to enable managers to control and pro-actively optimize operations for quality and efficiency. In earlier years, EAM was simply called maintenance scheduling software. EAMs facilitate operations by automating requests for upgrades, regular maintenance and decommissioning or replacement. Assets in terms of EAM include all assets except financial assets like stocks or bonds, but typically refer to maintainable equipment. EAM is especially important to asset-intensive industries such as Oil & Gas, Utilities, Manufacturing and Mining.
Business Challenges / Benefits In Depth value, analysis, & insight on current EAM process. An opportunity to improve Business Processes surrounding, Standard Data Processes. Improvise Source(s) of Data by standardizing processes, from which data is collected. Opportunity for customers to Improve/Improvise Maintenance Process. Visualize Equipment Downtime at a manufacturing Plant. Output the report with downtime/shutdown for each of the Equipment during Production.
Why EAM - Solution? With proper EAM Process, it allows customers the ability to assess the true state of their organization with one common deliverable, a comprehensive report identifying improvement opportunities with asset data, maintenance processes and SAP system issues. Proper and more consistent way of managing Enterprise Data. Reduced downtime at a production plant or Manufacturing plant.
Why EAM?
Reference - Architecture SAP Data Services Source Specific Template SAP Maximo SLA Non- SAP M AP Source Specific Template Source Specific Template Source Specific Template SAP Best Practices Business Rules Filters Dynamic Reporting Tool (Xcelcius Dashboards) SAP HANA RDBMS
EAM Implementation Focus Areas Data Capture Capturing missing equipment information through the physical verification/inventory of plant equipment using handheld computers pre-loaded with equipment data. Capturing missing equipment information located in unstructured sources... Process & Instrumentation Diagrams, Process Flow Diagrams, engineering drawings, etc. Consolidating and Organizing Data Defining and implementing equipment hierarchies standards. Defining and implementing appropriate equipment in a consistent ways to name equipment, noun/modifier, equipment class, etc. Adding missing equipment attributes, for example, OEM part number, physical characteristics, etc. Adding unique identifiers to equipment using barcode and RFID technologies. Combining and standardizing multiple databases. Building Bill of Materials. Data Cleansing Completeness: Descriptions, Manufacturer, Model, Part Number, etc. Consistency: Standard abbreviations and terms, naming conventions Conformity: Checks against the data dictionary with comparison to standards Duplication: Exact matches, exact substitutions, & functional equivalents. Data Migration Data mapping between any combination of source and target: JD Edwards to SAP, Maximo to SAP, Maximo to Oracle, Legacy Mainframe to SAP, etc. Mergers & Acquisitions: Speeding business integration New Plant: Data capture, as built versus as designed, EPC document conversions, etc.
EAM Data Collection Best Practice Obtain input file of all assets including tag number. Perform Input File analysis & classify if possible. Prepare Logistics plan for physical verification. Identify Assets in location using asset tags on assets. Does Asset exist as per input file? Write Asset information on RFID tags and tag them to the asset. Does Asset Exist that s not in input? Flag off for new Asset Creation (to be done offline within SAP/any other legacy system). Identify & flag off Asset Status. Consolidate Data in the required format.
Input Data Set Data Input set will reside in SAP. EAM Related Data will be extracted from SAP. EAM PM consultant will help with SAP PM Data Extracts. Non SAP centric customer solutions are also available.
Defining Rules Rules Template Managing Assets. Notifications. Preventative Maintenance. Functional Location / Equipment. Orders Notification. Maintenance Tasks. Work Order Management. MTTR (Mean Time to Repair) Reports For Plant and Manufacturing.
Defining Rules Rules Template For each Equipment problem/defect problem Notifications are initiated. For each notification created prioritize the orders for each equipment. Preventative Maintenance evaluation. For each Equipment problem/defect problem Notifications are initiated. Notifications assigned to functional location (by notification type, plant). Records with breakdown indicator set but no malfunction start/end (by notification type, plant).
Defining Rules Rules Template Records with malfunction start/end populated, but no breakdown indicator (by notification type, plant). Notifications with/without an assigned order (by system status listed above, plant, notification type). Work Orders are initiated for maintenance activity by order type, plant and system status. Prioritize orders. Summarize Orders with or without an associated notification by Notification Type and or Order Type. Backlog Orders to evaluate Open, Created, Released, Technically Completed, or Closed Orders Year to Date.
Defining Rules Rules Template With Preventative Maintenance evaluation: Summarize Maintenance Items Per Maintenance Plan. Task List not used on any Maintenance Item or Orders. Percentage of preventive maintenance orders with cost of $0, indicating that the work was not performed. Further analysis required for the Orders with Cost of $0.00. Preventive Maintenance count of Strategy Plans Vs Single Cycle.
Demo
KEY LEARNINGS Highlight/summarize 3-5 key learning points from the presentation.
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