A review of CMMS/EAM usage

05 Apr 11 Kannan Palanisamy

Todays Presentation
Background Business problem CMMS usage

Plant Maintenance module Materials Management module Spare parts Management Turnaround Management Document Management
Reliability tools and Reliability analysis Inspection and Condition Monitoring Manager Key Performance Indicators Analysis and Decision support

APM usage

Background and Introduction

Kannan Palanisamy (Head of Maintenance at Ras Gas Company Ltd)
25 years experience in Oil and Gas industry Used SAP (CMMS) for the past 12 years Certified Maintenance and Reliability Professional Certified Risk Based Inspection specialist Certified Functional Safety Engineer Interested in Travelling to historical places & scenic places Play Cricket & badminton and listen to all kinds of soothing music

Business opportunity
Maintenance optimization requires: Framework - Work notification, Work order management and information management Efficiency Planning & Scheduling, Materials Procurement, maintenance cost settlement etc Effectiveness Doing the right work Reliability Improvement to eliminate failures, optimize PM strategies, and eliminate non-value adding work when possible The Stake for Reliability Improvement is BIG The potential Uptime gain is worth 10X the maintenance cost savings Reliability Analysis Tool Set needed that would enhance the value of the data being collected through maintenance

CMMS usage - SAP

SAP was Started in 1972 five former IBM employees Top 5 software company (MS, Oracle, IBM, Google, SAP) Trades on NYSE: SAP Headquartered in Walldorf, Germany (near Heidelberg)

SAP structure
9 Basic modules Interconnected and Interdependent PLM Plant Maintenance Module MM Materials Management Module FI Financial Accounting Module
MM SD PP

R/3

FI PLM CO QM WM HR

Meridium - Asset Performance Management

Strategy Development

Work Planning

Work Scheduling

Maintenance Management Cycle

Possible/Additional Data Sources:

Engineering Inspection Condition Financial Incidents Process Historians

Continuous Improvement Loop

Analysis/Assessment

Work History

Work Execution

CMMS System: SAP

Copyright Meridium, Inc. 2004

Spare parts management through SAP

Optimal spares provisioning is a prerequisite for all maintenance tasks All spare parts required were identified from Asset register. Spare parts requirements were reviewed to identify spares holding levels. Bills of Materials for all equipment with spares identified All spare parts have been catalogued directly into SAP-MM Spare parts management system is integrated with SAP system to ensure spares required to achieve maintenance tasks are readily available at the point of need. Common strategies are established for purchase of spare parts and consumables. SAP system issues reservations, materials delivery points to the plant and purchase requisitions to be processed further by relevant departments

Spare parts Management in SAP

SAP aids Data driven analysis
What are important pieces of information for a material? SAP material master (20 different views)

Real time accounting information

Accounts Receivable Accounts Payable

wheres our cash?

Inventory which materials Accounts Receivable which customers Accounts Payable which vendors

Areas of improvement in Spares management

Currently holding huge inventory. 80% of spares holding are not-moving Strategy to develop reliability tools to study and reduce non-moving spares inventory. To develop strategy for obsolescent spares (especially electronic spares like cards, hardware etc) To develop strategy for materials returns, refurbishment process and damaged materials write-off process.

Performance measurement through KPIs derived from CMMS/EAP

You cannot manage what you cannot measure By Bill Hewitt of Hewlett Packard 3 Financial Safety Environmental Work processes Backlog
Availability Reliability Maintainability Cost

Training Competency

Areas of improvement in KPIs

More leading indicators than lagging indicators
Eg. Near misses, backlog aged and high priority workorders, schedule compliance

Leading indicators allow to take action proactively Lagging indicators are reactive indicators

Meridium Inspection and Condition Monitoring Manager

Inspection & Condition Monitoring Data Management Log of Observations Findings Recommendations Reports

Document Management system in SAP

What is a document per SAP?
Equipment datasheets, Fabrication drawings etc Maintenance & Operating manuals Job procedures, lock-outs, sketches, drawings etc Check Lists Inventory Pictures Instructional Videos

SAP provides various document linking methods Document files can be stored in a common server Gets information out of individual peoples desks No need to print (save paper) Planner can add document links to work order tasks. Areas of improvement in Document management system is to add link to 3D model views especially to aid maintenance in equipment isolations etc.

Work order resourcing/job costing

SAP PM module is robust and provides an elaborate framework for Maintenance workorder management. Planner forecasts the manpower, materials, logistics and other resource requirements into the workorder Manpower and Labour time are recorded either as manual entry or CATS (Cross Application Time sheet) after work completion Maintenance costs for spares and consumables are based on costs recorded in the SAP MM module. Settlement of these costs are done according to the Settlement rules of the company. The cumulative maintenance costs (Manpower, Labour, spares, consumables etc ) are automatically recorded in SAP Several different cost reports can be generated in SAP

Turnaround/Shutdown Management in SAP

Four phases of Shutdown Phase 1 Initiation
Steering committee establishment, Charter and budget establishment

Phase 2 Planning and Preparation

SAP provides frame work to code workorders that need a shutdown for execution Generate shutdown worklist Screen worklist and approve workorders based on Risk Develop resourcing needs for the shutdown from the worklist Manpower, logistics, spares , special vendor support needs, 3rd party contractor requirement etc are logged into the workorder Cost estimate done from the workorder planning data Develop detailed planning and schedule Prepare workpack, maintenance procedures and safety procedures

Turnaround/Shutdown Management in SAP

Phase 3 Execution
Actual work execution Field planner records the manpower time for each completed task Costs are tracked from Field planners inputs into SAP Manage discovery works with proper approvals.

Phase 4 Close-out and capture lessons learned

Capture lessons learned for continuous improvement Return all unused materials and refurbish repairable parts and return to warehouse Close workorders in SAP Reconcile costs

Reliability Manager of Meridium

SAP workorder is used to record Break down information and maintenance start and end times The Meridium Reliability Manager module uses the data recorded in SAP to identify key reliability parameters namely
MTBF (Mean Time between Failures), MTTR (Mean Time to repair), Failure counts, Downtime Availability, Failure cost

Simulation provides:
Failure Counts Downtime Availability Failure Cost

what is expected to fail next and what fails the most often. Often used to determine most cost effective re-design alternatives. The only drawback is quality of data feed by planners in SAP will lead to errors in the reliability analysis.

Conclusion

SAP and Meridium assists to provide reliable clean energy (LNG) to the world

SAP and Meridium work seamlessly to provide information for continuous Asset Performance Improvement. SAP provides the state of the art CMMS system and a fully integrated Enterprise resource planning framework. Meridium data warehousing tool from SAP provides information at finger tip to target reliability improvement and to increase uptime.

References
1. Slide 6 SAP modules diagram cited in SAMS Teach Yourself SAP R/3 in 24 hours by Daniella Larocca. 2. Slide 7 Meridium APM Architecture cited in Meridium whitepaper Improving asset performance through Meridium from www.meridium.com 3. Slide 11 Quote on KPIs from Wikipedia by Bill Hewitt of HP. 4. Slide 13 Meridium Inspection Manager cited in Meridium APM Inspection Manager module from www.meridium.com