NBCL PLANT MAINTENANCE MODULE

NYANZA BOTTLING CO .LTD

Business Requirements Document

(BRD)

Prepared by: ICST- NBCL

Prepared for: Management -NBCL
Date Submitted:

Document Number: 1/ PLANT MAINTENANCE /BRD

Version: 0.1

Last Updated: July 16, 2015

Creation Date: July 16, 2015

COMPILED BY: ICST /16.07.15

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VERSION UPDATED

Version Prepared Submitted Approved Approval Description of

Number By Date By Date Change
0.1 SANGAM BADAJENA

COMPILED BY: ICST /17.06.14

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TABLE OF CONTENTS

INTRODUCTION ................................
.....................................................................................................................
..................... 4
Purpose of a Requirements Analysis .................................................................................. .................. 4
Audience ................................
..............................................................................................................................
.............................. 4
Stakeholder Identification................................
................................................................................................
..................................... 4
Purpose of BRD ................................
...................................................................................................................
................... 5
Business Goal ................................
......................................................................................................................
...................... 5
Benefits of BRD ................................
...................................................................................................................
................... 5

BUSINESS OVERVIEW ................................

................................................................................................
.......................................... 6
Flow Chart ................................
...............................................................................................................................
............................... 7
Suggested ERP flow......................................................................
flow...................................................................................................
.............................7
OEE Report Calculation...........................................................................
Calculation.............................................................................................
..................13

APPENDIX A: REQUIREMENTS
ENTS ANALYSIS APPROV
APPROVAL .................................................
................. 15

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1 INTRODUCTION

1.1 PURPOSE OF A REQUIREMENT ANALYSIS

A requirement analysis document encompasses activities conducted to determine the needs or conditions
for a new or altered PLANT MAINTENANCE process.. It commonly takes place after a request is received. It
is the process of gathering information about business and technical requirements supporting a request,
consolidating this information into a cohesive document.

1.2 AUDIENCE
The audience for this document includes:
includes:-

1. NBCL Management
2. Maintenance Department.
3. ICST-NBCL
4. ESS- Service Provider [i.e., developers who may participate in the requirements at later stage for
Implementation of ERP Module]

1.3 STAKEHOLDER IDENTIFICATION

CATION

Stakeholder Number of Critical Success Factors

Name Individuals

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1.4 PURPOSE OF BUSINESS

USINESS REQUIREMENT DOCUMENT

The main purpose of the BRD is to Implement ERP for PLANT MAINTENANCE & to incorporate all
current process in System.

1.5 BUSINESS GOALS / OBJECTIVES TO BE ACH ACHEIVED

• Planned / preventive, repair, emergency and other user
user-defined
defined maintenance tasks details.
• Ensure all materials, supplies and parts are available and accessible to maintain and service
equipment.
• Access existing or create new maintenance work orders from system to enhance communication
and reporting
• Complete maintenance history and audit trail
• Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg
Spare inventory are consum
consumed
• Generate work orders and schedule material inventory and required labor (with associated skill
level) for planned maintenance

1.6 BENEFITS OF BRD

Through this BRD, one can analyze all process
process. This document will help Management,
anagement,
ICST & Maintenance Team m to switch all system in ERP with required Reports.

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2. BUSINESS OVERVIEW

In NBCL & NDL Maintenance team is following 4 kinds of maintenance process

process--

1. Annual Maintenance (Through OEM) OEM)- In this process a service person will come to analyze the
equipments & will submit a report to Management with complete details of service need to be done
(Spare part details, Time to resolve problem, Cost for resolving issue's). Maintenance team will send this
reports to Management and after required approvals maintenance team will make Purchase request for
spare parts if it is not available in Stores. After receiving Spare parts ,OEM person will come and resolve
the issue.

2. Preventive Maintenance- In this type of maintenance maintenance time /Date is fixed. Team will plan
accordingly.

3. Predictive Maintenance- In this type of maintenance ,team have to plan as per to working condition of
machines.

4. Break Down Maintenance- This is a situation where team have to give support (Maintenance ) on
immediately.

All the above maintenance process are captured in manual sheets and then goes to management for
preparing different reports. Only if OEM service person is comi
coming
ng for service then only a service PO is
being raised. Rest all are in manual sheets.

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2.3 FLOW CHART OF PLANT MAINTENANCE

MAINTENANCE-NBCL

MAINTENANCE

PREVENTIVE
MAINTENANCE
Spare part
availability
PREDECTIVE check at store
MAINTENANCE

STORE
BREAK DOWN
MAINTENANCE
If No If
Yes
ANNUAL
MAINTENANCE
PURCHASE
REQUEST

PO

MATERIAL SERVICE PO TO
REVEIVED / GRN OEM

SERVICE PO
WORK ORDER CLOSE

Work Order In
Process
In
Annual Maintenance process
WORK ORDER
service PO need to close after CLOSE
Work Order close.

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SUGGESTED FLOW IN ERP

STEP 1. ISSUE LOG (ANNUAL / PREVENTIVE / PREDECTIVE / BREAKDOWN

DOWN - MAINTENANCE)

Whenever there will be some maintenance required , Maintenance team will have to create an Issue Log
in system. This may be Annual maintenance / Preventive Maintenance / Predective Maintenance /
Breakdown Maintenance. This is a sample format to log problem details with Machine.

Abbreviations

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COMMON PROCESS FOR APPLICATION

User can perform following task.
a. Add: It is used to add new record.
b. Edit: It is used to modify existing record.
c. View: It is used to view in details.
d. Close: It is used to close the screen/form
e. Delete: It is used to delete existing record.
f. Save: This button updates the modified entries.
g. Cancel: It helps in cancelling the ongoing process.
h. Print: It prints the report.

CANCELLING THE EXISTING ISSUE LOG FROM SYSTEM / EDITING DETAILS FROM SAVED LOG DATA

There may be some scenario where modification required on loged data or cancelling the log , user need
to login from their id & can make changes as per to requirement ( Approval Required-
Required Management -
Mandatory).
atory). To make any changes department have to take approval from Management ( Auto alert to
Supervisor login / request for change ) through ERP Only . This process will capture all history of making
Plan , Editing , Cancelling & Closing details.

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STEP 2: JOB ORDER/ CLOSING JO

After Making Maintenance Log for Machines , User need to make JO ( Job order) where they will
allocate the work in actual. User need to fill all details of Shift / Machine / Spare Part Required Qty to
complete the Order.
*Once the JO is assigned to a supervisor through Work Order, System will show JO status as WIP &
Once Work order is completed , system will show JO status as Completed.

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STEP 3: (MRS) MATERIAL REQUISITION SLIP

In this form User can request for materials required for Maintenance process.. Material will be received &
after Maintenance / Repairing the balance materials will be issued back to warehouse. For all Spare parts
user need to select codes for the same
same.

Abbreviations

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STEP 4: MATERIAL RECEIVE NOTE

After getting materials from stores , user need to make " stock in" in Maintenance warehouse .
Maintenance team have to count all materials & cross check before making inward entry against MRS
raised. Here they can enter the details like short fall in Qty while receiving materials from Stores /
warehouse.. This is very important for recording movements of each item through system. QC is
mandatory here.

STEP 5: WORK ORDER / CLOSING WORK ORDER

Here user need to allocate the work to respective supervisor along with the shift / Time required to
complete the JO. All spare parts will be handed over to supervisor to complete this work.

After completing
leting Work Order , User need to change the status of WO to Close. This format will also be
used for closing Work Order in system. When User will close the WO , the linked JO will be closed and
all will be recorded in Machine Repair Logs. One can see in re
reports - All history of the machines like No .

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of time it has been repaired / Day Wise / Supervisor Allocated / Time taken to repair / Type of
maintenance etc.
Over All Equipment Efficiency Report

There will be a report to calculate OEE (Over all Equipment efficiency ) during a shift.
The table below contains hypothetical shift data, to be used for a complete OEE calculation, starting with
the calculation of the OEE Factors of Availability, Performance and Quality.. Note that the same units
of measurement (in this case minutes and Bottles)) are consistently used throughout the calculations.
Example-

Calculation steps-
As per to above example , system will calculate Planned Production Time, Good Bottles,
Bottles Operating Time,
Availability & finally Quality. Below formula defined for each steps.

Result-

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APPENDIX A: REQUIREMENTS ANALYSI

ANALYSIS APPROVAL

The undersigned acknowledge that they have reviewed this requirements analysis document and agree
with its information. Changes to this version will be coordinated with, and approved by, the undersigned,
or their designated representatives.

Signature: Date:
Print Name:
Title:
Role:

Signature: Date:
Print Name:
Title:
Role:

Signature: Date:
Print Name:
Title:
Role:

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DOCUMENT No. NBCL/1/ PLANT MAINTENANCE