SAP Preventive Maintenance The Core

and More
Len Harms - Vesta
Agenda
The Core Preventive Maintenance
The Core Light CBM
and More
The Core PM
Preventive Maintenance: Forms
Time-based Performance-based Condition-based
Preventive
maintenance
Temperature
Thickness
Druck
10
20
30
40
50
60
70
80
Pressure
2001
Preventive Maintenance: Plan Types
Time-based
Maintenance plan
Single cycle plan
Multiple counter plan
Strategy plan
Performance-based
Service Procurement
Building Blocks
1. When
Cycle or strategy that determines when a PM should
be done
2. Where Equipment or Functional Location
The asset, assets, or location where the work is to
take place
3. What Task List
Define tasks, materials and tools that are required
Tip - Add the Default to the user settings
Maintenance Plans with single Asset
You can create several maintenance plans.
Each maintenance plan contains a maintenance item that describes the object to be
maintained.
The system generates a separate order for each object on a due date.
Maintenance Plan Item with Linear
Maintenance Plans with Asset list
You create one maintenance plan.
You assign an object list to the
maintenance plan in which all object
to be maintained are listed.
The system generates an order for all
objects on a due date.
Supports inspection routes,
lubrication routes
For operations in a task list, technical
objects can be maintained
SAP 2009 / 11
Enhance- Asset List in Ehp4
Leverage LAM, OAA, GEO.e with Plan
Linear Assets can be
represented in plans
Use Geo.e to add spatial
data
Operational Account
Assignment provides cost
of inspection at the exact
position of the work
Report on Inspection plans and results
Inspection results support long term planning
Use results to feed
the long term
asset planning
Leverage PPM to
support the long
term plan
1
2 3
Create Inspection
plans
Gather results
Create long term
plan
4
Analyze results
Maintenance Plans with Strategy
You create one maintenance plan.
You assign an object list or a single
asset.
The system generates an order for all
objects on the due dates with the tasks
that match the strategy.
Supports a single plan with different
tasks per call date
Can be performance or time
The strategy unit must be consistent
Maintenance Plan with Notification
Made possible once multiple
Notifications could be added
To a single order.
Also possible to add task list
in a notification as of
ERP2005
Move/Skip/Release in graphic
simulation
Change documents in the
maintenance plan
Scheduling parameters
Other Items
Preventive maintenance in most
organizations today
SAP ERP
Transformer
Work orders are
created in regular
Intervals
Technician is executing work
Work
order
Agenda
The Core Preventive Maintenance
The Core Light CBM
and More
The Core PM and More
Create a new development project TC:CMOD
ENHANCEMENT IS IMRC0001
Sample Program
Measurement Point
Set an upper and/or lower limit
Enter reading and valuation code
Condition based maintenance (using mobility)
SAP ERP
Current
Temperature
Voltage
Transformer
SAP determines whether
Work order should be created
Technician is executing work
Technician feed rounds information
Into SAP to populate
measurement documents
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
Agenda
The Core Preventive Maintenance
The Core Light CBM
and More
Condition Based Maintenance The Goal
Easily accessible dashboards
allow asset managers and staff to
monitor asset health in real time
via measurement points
Real-time alerts via
dashboards give instant
updates on equipment status
and allow rapid reaction
Links to ERP data to trigger
maintenance workflow to
reduce unplanned downtime
and improve reliability.
Asset health
Continuous improvement
Best practice
Trend analysis identifies
problem areas for
immediate investigation
V.P.
Quite a few of equipment delivered today have built in
sensors
New sensors (temperature, leakage, etc.) are very affordable
Collection, analysis and integration into SAP can be setup in a
few weeks
Current Situation
SAP ERP
Current
Temperature
Voltage
Transformer
The historian collect lots of data but provides little
information to SAP
Investments in the historian data has been made that is not
leveraged
EAM groups does not have visibility to condition data in SAP
to make/optimize their decisions
Challenges
Integrated condition based maintenance
SAP ERP
Current
Temperature
Voltage
Transformer
Data
Historian
SAP MII
Determine whether
or not to create notification
or work order
Work order is made
available to the
Technician
Technician is executing work
OSI PI
APPs
Current
Temperature
Voltage
Transformer
Current
Temperature
Voltage
Transformer
Integration and Intelligence
Integration: A single layer enabling SAP ERP
connectivity into real-time systems to drive
equipment-to-enterprise business process
interoperability
Intelligence: Real-time analytics engine that
aggregates and delivers unified visualization of
events, alerts, KPIs and decision support to
personnel thru role-based dashboards
Rule Name (MII
Transaction)
Description
DailyRunHourUpda
te
This rule updates the run hours per equipment based
on a summarized, binary IsRunning Tag. Parametera are
the tag name and the Measurement Point name
NotificationOnExc
eedThreshold
This rule creates a notification once a tag value has
exceeded the Threshold value. The Threshold value can
be a tag or static value
.
Condition Based Maintenance - Detail
Tag Name
AB323DS
DS.32.1231
PUMP3223.TP
1. Select Asset
2. Select Rule
3. Associate Tags and/or fixed values
4. Select Frequency
5. Submit to database
Threshold Temp: 121
MII DB
Enter inspection data
Provide maintenance staff with
a means to manually input
measurement readings
Easy-to-use Web-based
interface allows untrained staff
to enter inspection results
Easily delete or modify an
erroneous entry
Manual Entry of Inspection
Data
Asset Health Alerts
Visual indicators and e-mail notifications alert maintenance staff to the assets in the most critical status
Data-driven notifications alert users to changes in asset health status so that they can react
appropriately and make informed decisions quickly
Maintenance staff can trigger a maintenance request if warranted
Prioritized asset management enables a consolidated alert view
Asset Health History
Communicate real-time asset health status, monitor and adjust maintenance plan
Clear data layout and status indicators allow you to quickly compare current with target asset output.
Aggregate health status
Gauges visualize the criticality of current asset health
Search by specific asset domain for monitoring
Option:
SAP 3D Visual Enterprise provides a 3D visual image of the asset being monitored
Whats in each solution?
Software
Quickly address the most urgent business
processes
Content
SAP-supported best practices, templates,
and tools make solution adoption easier
Enablement
Guides and educational material speed end-
user adoption
Service
Fixed scope and price provide maximum
predictability and lower risk
SAP Rapid
Deployment
solutions
Business challenges There is a solution
SAP Condition-Based Maintenance rapid-
deployment solution enables your organization to
performmaintenance only when necessary by
arming maintenance teams with sophisticated
intelligence and comprehensive asset health
dashboards. The solution also enables manual and
automatic triggering of maintenance workflow
leveraging through native integration with the SAP
Enterprise Asset Management (SAP EAM) solution.
Get started with condition-based
maintenance quickly and affordably
Critical asset failures which can have serious
environmental and enterprise level consequences as
demonstrated by recent high-profile industrial
catastrophes
Finding a CBM solution that has low entry, low TCO,
and leverages existing SAP investments
Traditional time or counter-based maintenance
strategies missing a dynamic component leading to
higher maintenance cost
Other RDS available is Asset Health Visualization
What does SAP deliver? What do you have to do?
Provide IT infrastructure (server)
Install SAP MII, version 12.2, on the development
and production environments
Install SAP BusinessObjects Dashboards software to
make optional changes to predefined health index
dashboards
Provide asset hierarchy structure fromexisting SAP
ECC and SAP EAM applications and information on
tag thresholds
Provide access to existing shop floor system with
connector from SAP Plant Connectivity
Provide appropriate contacts in the business and IT
departments
Conduct end-user training and change management
Conduct performance and integration testing
Performdata migration and cleansing
Transport to production
Key deliverables
Performinstallation check
Lead workshop to confirm predefined requirements
Set up MII connectivity with shop floor system via
connector in SAP Plant Connectivity
Set up the plant database schema for storing shop
floor aggregate data
Configure the asset health index to meet customer-
specific dashboard requirements
Activate and test solution
Enable knowledge transfer to key users
Enable support for go-live
System requirements
SOFTWARE
SAP ECC 6.0 EHP4 or above
SAP Manufacturing Integration & Intelligence (SAP MII) on SAP NetWeaver

CE 7.3
version 12.2, SP4 or above
SAP Plant Connectivity 2.2, SP3 or above
SAP BusinessObjects Dashboards 4.0 SP4 or above*
SAP 3D Visual Enterprise application (optional)
DATABASE
SAP HANA

1.0 SP5 or above (optional) **

* required only for customizing dashboards
** SAP HANA

content supporting cross-plant implementation is provided. However, the

standard service offering supports a single plant implementation.
In the system
Link CBM monitoring system to
Historians to gather real-time data
performmanual inspection and
then enter results into CBM
monitoring system
Evaluate data to trigger automated
maintenance notification via CBM
rules and logic
Performmaintenance jobs with
visual support using SAP 3D Visual
Enterprise
Performtrend analysis by viewing
historical plant data
Conclusion - Benefits
Minimize risks and stay in
compliance via alerts of imminent
catastrophic asset failures
Manage investment risk by starting
with a baseline scope and then
scale it gradually
Reduce maintenance due to fewer
reactive repairs of broken
equipment
Support effort to stay within
regulatory compliance
Reduce maintenance rework and
mean-time-to-repair (MTTR)
Operate equipment in an
economically and environmentally
sustainable way
Increased return on assets (ROA)
Maximized asset utilization
Improved overall equipment effectiveness (OEE)
Reduced operational risk in asset management
Reduced maintenance cost as a percentage of revenue
Summary - Support Asset Life Cycle
Contact:
Len Harms
lharms@vestapartners.com
610-209-6683
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