SAP Condition Based Maintenance solution. Taking your preventive maintenance program to the next level

Transcription

1 SAP Condition Based Maintenance solution Taking your preventive maintenance program to the next level

2 Idea to Performance Operational Excellence Value Map Capital Portfolio and Project Management Asset Visibility and Performance Asset Operations and Maintenance Environment, Health and Safety (aka ORM) Energy and Environmental Resource Management Quality Management and Compliance Asset Portfolio Management Asset Performance Management Asset Planning and Scheduling Incident Management Energy Transparency and Performance Management Corporate Quality Capital Project Management Asset Improvement Programs Operations and Maintenance EHS Risk Assessment Energy and Environmental Initiatives Management Quality Planning and Control Monitoring Capital Investments Optimized Maintenance and Plant Operations Service Procurement Management of Change Emission Management Quality Operations Prepare and deploy asset information Spare Parts Management Maintenance Worker Safety Management Environmental Regulatory Compliance Monitor and maintain asset information Mobile Asset Management Work Permit Management Technology Enabler 3D Visual Enterprise M2M Connectivity Enterprise Mobility 2013 SAP AG. All rights reserved. Customer 2

3 EAM Benchmarking Analysis Metric Weekly Maintenance Schedule Attainment Rate (in %) Overall Companies (n = 130) Average Q Asset Utilization (in %) Maintenance Approach Breakdown 15.7% 46.3% 38.0% Unplanned Downtime or Outages (in %) Wrench Time (in %) Overtime Hours (% of total hours) Reactive Maintenance Predictive Maintenance Preventive Maintenance MRO Inventory Obsolescence (as a % of Total MRO Inventory) Rework Time (in %) SAP AG. All rights reserved. Customer 3

4 Maintenance in most organizations today? Time-based or reactive practices are common Spare parts and resource planning difficult Can t identify problems between scheduled inspections Equipment may or may not be running No account taken of actual run time Not cost effective for asset reliability Equipment Work Execution Work orders are time-based or reactive 2013 SAP AG. All rights reserved. Customer 4

5 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 5

6 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 6

7 Reactive (Breakdown) Maintenance in SAP Call / create notification Create order and release Order Production Supervisor/ Maintenance Planner 0010 Inspect pumps 0020 Replace seals Confirm and complete order Fix problem Technician / Backoffice Technician Maintenance workcenter 2013 SAP AG. All rights reserved. Customer 7

8 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 8

9 Preventive Maintenance Considerations Legal / Statutory regulations e.g. 2 yearly pressure test of pressure vessels Quality assurance e.g. customer quality requirements Reduction of breakdown frequency of assets, thereby: Lowering costs of restarting Prolonging the lifecycle of assets Environmental considerations Manufacturers requirements Lowering of maintenance costs 2013 SAP AG. All rights reserved. Customer 9

10 Preventive Maintenance Focuses on the basics - designed to improve the reliability of equipment. Performed on a specified scheduled basis / interval e.g. Run Time, Time interval, Number of Cycles etc. Corrective action identified during PM activities / inspections Tasks are often performed before the asset has operated for its entire life expectancy or too late asset has failed SAP AG. All rights reserved. Customer 10

11 Preventive Maintenance in SAP WHEN? Time or counter-based strategies Maintenance plan WHAT? Task lists - Single cycle - Strategy - Multiple counters Order/ Notification Order/ Notification Order/ Notification Schedule plan WHERE? 2013 SAP AG. All rights reserved. Customer 12

12 Complete cycle for Work Order Processing 1 Technical object Date Notification Description Malfunction 2 Planning Operations Internal/external ressources Material Tools 3 Scheduling Order release Shop Papers Capacity leveling Availability check 4 Execution Planned/unplanned material withdrawal External procurement 5 Completion Time confirmation Technical completion confirmation Order settlement Technical History Material usage, orders, notifications, PM-IS, usage list 2013 SAP AG. All rights reserved. Customer 13

13 Probability Distribution Function f(t) The basic problem with preventive maintenance Failures don t happen at fixed times Failure patterns are random based on a distribution When is the failure going to occur? How do I detect a failure before it impacts the business? Why do I perform maintenance activities with the same intervals on equipment that are not running as frequently? Working age t 2013 SAP AG. All rights reserved. Customer 14

14 The basic problem with preventive maintenance age related 11% 4% 2% 5% 7% 14% 1 Bathtub Curve High infant mortality, then a low level of random failure, then a wear out zone. 2 Traditional View - Random failure then a wear out zone. 3 Slow Aging Steady increase in the probability of failure not age related 89% 68% 4 Best New Sharp increase in the probability of failure then random failure 5 Constant Random Failure Random, no age related failure pattern 6 Worst New High infant mortality then random failure Information by Nowlan and Heap RCM report - Graphic courtesy of MRG Inc SAP AG. All rights reserved. Customer 15

15 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 16

16 Inspection Rounds in SAP Define Technical Objects Measuring Points Task List Plan and Schedule Maintenance plan Schedule Execute Work order Documents Confirm Times Materials Measurment readings Define Inspection Rounds Inspection rounds are lists of simpler smaller tasks sorted in a predefined sequence a craftsman work off Locations, machines, devices are subject of work can be linked to a task Measurement reading task can be performed and documented on predefined measurement points Inspection rounds are defined in SAP EAM with General Maintenance Task Lists utilizing Functional Locations and Pieces of Equipments and assigned measurement points Plan and Schedule Inspection Rounds Inspection rounds are performed on regular basis either periodically or initiated by an event Inspection rounds are planed and scheduled in SAP EAM using Maintenance plans Execute Inspection Round Craftsman executing inspection rounds are supported through the predefined already planned and scheduled job instructions containing description of work, the location, necessary tools, materials or documents In SAP EAM the operational inspection round document are maintenance work orders Confirm Inspection rounds During or after work execution actual information like effective work time, used materials or measurement readings are confirmed Actual information is used to adapt operation or maintenance activities, keep operations and asset history and settle the inspection work 2013 SAP AG. All rights reserved. Customer 17

17 Inspection Rounds - Enhancement New Production Resources Tool (PRT) type: Measuring point Header (task list / work order) Assignments to operations Operation 10 Description Work center Functional location Equipment Measuring point A Measuring point B Document Description Measuring point A Measuring point C Measuring point C Operation 20 Description Work center Functional location Equipment Document Remark: The measuring point assigned as PRT has to be defined as measuring point for the technical object of the operation Measuring point X Measuring point Y Measuring point Z Description Measuring point X Measuring point Y 2013 SAP AG. All rights reserved. Customer 18

18 Record the Results of the Inspection: Overall Completion Confirmation With the confirmation of the inspection round work order measurement readings can be entered The entered measurement readings will be saved as measurement documents for the corresponding measurement point Create (and change) notification from confirmation screen as part of the feedback (from EHP5) New BAdI IMRC_CHECK_RDGS and an example implementation. This shows how an error message is issued when the tolerance limits for measurement readings are exceeded (from EHP5) 2013 SAP AG. All rights reserved. Customer 19

19 SAP Work & Rounds Manager SAP Work Manager SAP Rounds Manager Access to asset location, repair history, work order details, materials needed Complete Work Orders and capture all relevant data Create Notifications or Work Orders on the spot CATS - time & attendance Guided workflow Capture all touches in SAP ERP Take measurements and readings Historic standards and safe ranges Generate notifications on-the-spot Trend readings, points and sequences to avoid emergencies and outages Download rounds by equipment, FLOC, or Entry List Automatic calculation of readings, limits, and alerts 2013 SAP AG. All rights reserved. Customer 20

20 SAP Work Manager 2013 SAP AG. All rights reserved. Customer 21

21 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 22

22 Condition Based Maintenance A subset of Predictive Maintenance (PdM) Equipment state observed & condition monitored continually / real time Deviations from standard / tolerance cause alarm Event driven, identifying need for maintenance intervention when it is actually necessary Equipment Proactive planning Work Execution Condition 2013 SAP AG. All rights reserved. Customer 23

23 Data recording depends on the type, designed capability and limits at which assets and its parts are used. Stationary systems Rotating systems Electrical systems Pressure vessels Pipelines Pipes Containers and Tanks Civil structure Prime movers Pumps Motors Gears Oscillators Transformers HT Cables Switch gear Tap changers Insulators Motors/generators Leakage detection Corrosion Wall thickness Cracks Physical check for deformation Vibration Oil analysis Debris analysis Bearing temperature Noise Heat/thermal map Visual and smell Heat map Leakage currents Corona detection Acoustic and electrical noise Visual and Smell 2013 SAP AG. All rights reserved. Customer 24

24 SAP Condition Based Maintenance rapid deployment solution Integration The condition-based maintenance process is automated by leveraging seamless and real-time integration between a shop floor monitoring system and SAP Enterprise Asset Management (SAP Plant Maintenance). Dashboards Intuitive dashboards allow your maintenance team to easily access and visualize information related to conditionbased maintenance that shows the health of your enterprise assets. Charts Equipment operators can view asset performance and multivariable charts to better understand performance history and the relationship between measurement points to drive maintenance decisions 2013 SAP AG. All rights reserved. Customer 26

25 SAP Condition-Based Maintenance What s included SAP Condition-Based Maintenance provides native integration which allows you to automate and optimize your organization's maintenance processes. SAP Plant Connectivity integration with a shop floor prevents imminent equipment failures by alerting your maintenance team to out-of-threshold measurements Real-time data enables your maintenance team to schedule and perform maintenance or repair when it is least disruptive Native (BAPI) integration with SAP ERP enables the retrieval of measurement documents for SAP MII as well as automated maintenance workflow triggers Integration with traditional or SAP HANA databases Optional integration to SAP 3D Visual Enterprise can provide visual aid to maintenance workers on their jobs Support for automated, manual, and mobile integration Business benefits Leverage existing infrastructure quickly with native integration Provide an end-to-end solution from problem detection to resolution Deploy predefined and tested integration points and data mapping between plant systems and SAP ERP back end Visualize the overall health of your enterprise assets via tighter integration across the landscape 2013 SAP AG. All rights reserved. Customer 27

26 What s in each rapid deployment solution? SAP Rapid Deployment solutions 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 2013 SAP AG. All rights reserved. Customer 28

27 Rapid-Deployment Solution Implementation Methodology Shorter time to start, deploy, and run through well defined scope and best practices Traditional Project Preparation Business blueprint Realization Testing Go-live Rapid- Deployment Solution Savings up to 95% 50% 30% Discover Start Deploy Run At least 40% time and effort reduction compared to similar scope of traditional project 2013 SAP AG. All rights reserved. Customer 29

28 Process Flow for Condition Based Maintenance Visual Enterprise HANA SAP ERP - Plant Maintenance* Condition Based Maintenance RDS (Content) Mobile Inspection rounds SAP Manufacturing Integration & Intelligence Plant Connectivity System within a plant- 1 DCS SCADA Historian *requires EHP SAP AG. All rights reserved. Updated: Customer 5 May

29 SAP Manufacturing Integration and Intelligence (SAP MII) Supplier/Contract Manufacturer ERP SCM PLM Distributor / Customers PLAN MAKE DELIVER INTEGRATION Manufacturing Integration & Intelligence Business Logic Services Visualization Quality Engine Composition Environment KPIs / Metrics / Alerts Performance Management DCS / PLC via OPC Data Services Plant Connectivity Plant Historian Worker UI s MES SCADA / HMI Manufacturing Analytics LIMS/ Inspection / Equipment Testing Plant DB Environmental Building Management Plant Data Collection Wireless Integration ERP Business Process Simplification 2013 SAP AG. All rights reserved. Customer 32

30 SAP MII delivers shop floor integration SAP MII extracts data from SAP Business Suite provides real-time visibility and distribution to Plant Floor Systems of: ERP SCM PLM PLAN MAKE DELIVER INTEGRATION SAP MII s ability to perform transaction execution into SAP also enables automated, plantlevel creation of: Planned Orders Bills of Material Production & Process Orders Material Inventory Levels Inspection Lots Data Master Recipes Material Details Batch Details Resources & Functional Locations Maintenance Work Order & Notification details Material & Order Costs DCS / PLC via OPC MES LIMS/ Inspection / Equipment Testing Manufacturing Integration & Intelligence Business Logic Services Visualization Quality Engine KPIs / Metrics / Alerts Data Services Plant DB Environmental Building Management Composition Environment Plant Data Collection Wireless Integration Plant Historian SCADA / HMI Production Confirmations Process Messages Material Receipts Material Consumptions Material transfers Inspection results recording Quality Notifications Batch Characteristic recording Work Orders & results recording Maintenance Notifications 2013 SAP AG. All rights reserved. Customer 33

31 Plant Connectivity: Example of System Landscape (PCo/MII/ERP) 2013 SAP AG. All rights reserved. Customer 35

32 Asset Health Indication Shop Floor Data 2013 SAP AG. All rights reserved. Customer 39

33 SAP Condition-Based Maintenance - In the system Asset Health Alerts Visual indicators and 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 2013 SAP AG. All rights reserved. Customer 40

34 Individual Measurement point / Tag information with alerts Measurement Point Detail Measurement Point: Oil Viscosity Type: Equipment Asset Name: Equipment 2-1 Lower Range Limit: 10 Low Control Limit: 25 Target: 50 High Control Limit: 75 Upper Range Limit: SAP AG. All rights reserved. Customer 41

35 SAP Condition-Based Maintenance - In the system Asset Health History View asset performance data from multiple measurement points simultaneously (up to 10 concurrent measurement points) Highlight potential problem area with normalized data Zoom in and out of a cluster via the slider-based based UI Change the scope of data for analysis by minute, hour, day, and week 2013 SAP AG. All rights reserved. Customer 42

36 SAP Condition-Based Maintenance Manual Measurement Reading Manual Entry of Inspection Data Provides 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 2013 SAP AG. All rights reserved. Customer 43

37 The maintenance evolution No preventive Maintenance Preventive/ Scheduled Maintenance Mobile Rounds Functionality populating Measurement documents Sensors populating Measurement documents Sensors feeding Rule engine to make decisions about maintenance necessary 2013 SAP AG. All rights reserved. Customer 44

38 Predictive Maintenance (PdM) Process of monitoring the condition of an asset and taking an action to avoid the consequences of a failure. Utilizes some form of technology to detect equipment problems as they are developing & predict future condition Accomplished through trending & analysis of condition parameters Common tools & techniques: vibration, temperature, pressure, flow, speed, voltage/current, thermography, sonics, particulate count, oil, etc SAP AG. All rights reserved. Customer 45

39 Business Objects - Predictive Analysis Intuitively design complex predictive models Read and write from data stored in HANA Visualize, discover, and share hidden insights Drag-and-drop visual interface for data Predictive library (with R integration) Visualize, discover, and share hidden insights INSIGHT INTO PARTS INSIGHT INTO LOCATION INSIGHT INTO FAILURES INSIGHT INTO TECHNICAL OBJECTS INSIGHT INTO BREAKDOWNS INSIGHT INTO MAINTENANCE ORDERS INSIGHT FROM ASSET ANALYTICS BusinessObject Predictive Analysis Business Object Visual Intelligence Forecast Planed and Unplanned Cost Forecast Planed and Unplanned Resources Forecast Planed and Unplanned Parts Forecast Planed and Unplanned Services 2013 SAP AG. All rights reserved. Customer 46

40 SAP Predictive Analysis - for generating forecasts on asset management information Combine technical and business data Derive decisive knowledge optimizing cost, risk, and performance Repair or inspect before you experience an unplanned downtime Analyze your spending Operate your assets in windows of integrity 2013 SAP AG. All rights reserved. Customer 47

41 Thank you Contact information: Dean Fitt Solution Manager EAM, Industry Business Solutions

42 Appendix

43 MII 14.0 Innovations Manufacturing Integration & Intelligence MII Key Needs Centralized/Decentralized hierarchy to categorize and define plant data. Provide a searchable global tag namespace and taxonomy that provides enterprise context to the plant sensor networks. Support for Contextual Messaging from the Bottom-up (ie: OEE, CBM) KPI configuration and KPI Monitoring Alert Configuration and Alert Monitoring Co-location of ME and MII into one NW Instance API calls between the applications, one common solution Improve productivity of plant app development teams Easy to use tools for end users to build analytical apps for plant operations through Business Objects integration with Crystal Reports and SAP Dashboards OData ( interface to support both SUP and HTML 5 Quality of Service Support(QoS) for RFC and IDoc Messages sent to MII (EO only) EO and EOIO Support for MII WS Message Listener MDO Enhancements to support Design Time and Run Time Joins Transport of MII Configurations using CTS+ Services Monitoring changes to MII Configurations centrally using Solution Manager Key Innovations Plant Information Catalog Plant Performance Management Co-Location with ME Productivity and Usability Enhancements Messaging Services Enhancements Continuous Improvement 2013 SAP AG. All rights reserved. Customer 50

44 Asset Performance Measurement and Improvement Management Performance Management Improvement Management Criticality Analysis Condition Based Maintenance RCM/ FMEA Analysis Predictive Analytics Maintenance Management Time Based PM Performance Based PM Run to Failure CBM Asset Analytics Planning & Scheduling Automatic Data Collection Manual Mobile Correction Repair Replace Refurbish Asset Health Monitor 2013 SAP AG. All rights reserved. Customer 51