Notifications: Processing Failure Information. John Harrison IBS Chemicals November 2013

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1 Notifications: Processing Failure Information John Harrison IBS Chemicals November 2013

3 What when on before?

4 Business case for recoding failures Increasing business support for Reliability for profitability Changing regulatory environment Industry Groups are becoming increasing active in this topic A more graphical view Social awareness 2013 SAP AG or an SAP affiliate company. All rights reserved. 4

5 Overview of Functional Locations, Equipment, Bills of Material Functional Locations Equipment + Code Lists Bills Of Material Measurement Points Work Centers Partners Serial Numbers Permits Warranties 2013 SAP AG or an SAP affiliate company. All rights reserved. 5

6 Representation: Example: Flow Loop I PID Diagram Functional Locations, Equipment, and Bill of Material Electrical Signal Flow Rate Indicating Transmitter PLC Pneumatic Signal Instrument Positioner Pneumatically Activated Control Flow Rate Valve Solenoid Valve Function Location Flow Loop 1 Flow Rate Sensor Flow Rate Control Valve Floc 2 Equipment BOM Electrical Loop PLC Sensor Flow Rate Transmitter Instrument Positioner Solenoid Valve Pro/Con Pro Pro Con Detail Reporting Capabilities functional location, equipment & assembly level Implementation history Complicated to implement Pneumatic Loop Control Flow Rate Valve 2013 SAP AG or an SAP affiliate company. All rights reserved. 6

7 Reporting: How much detail is required? Where are failures to be reported? At an piece of equipment At an assembly By area By process, sub process By Tag Are failures to be summarized? By groups of like equipment By area By process How much history is required? Do you compare failures between equipment? 2013 SAP AG or an SAP affiliate company. All rights reserved. 7

8 What are maintenance notifications?

9 Maintenance Notifications. Maintenance Notifications Describe the exceptional technical condition at an object Request the maintenance department to perform a necessary task Document work that has been performed Maintenance notifications document maintenance tasks completely, and make them available for analysis in the long term Can be used to perform preliminary planning and execution of tasks. The following notification types are predefined in the standard system: Problem notification Notification of a malfunction or problem that has occurred Maintenance request Request for tasks to be performed Activity report Documentation of activities that have been performed 2013 SAP AG or an SAP affiliate company. All rights reserved. 9

10 Problem Notification / Malfunction report Definition A malfunction report describes a malfunction at an object that affects its performance in some respect. For example, an employee from production would use a malfunction report to report that: A technical system is not functioning properly Performance has been reduced for a technical system, or that the system is not functioning at all A production system is producing goods of poor quality As a rule, a malfunction report requires the maintenance department to arrange for a specific repair task to be performed, for the ideal condition of the object to be restored (according to DIN norm 31051) SAP AG or an SAP affiliate company. All rights reserved. 10

11 Notification Life Cycle 1. Problem Reported / Notification Created 2. Transform Notification (s) to Work Order 3. Perform repair / Work Work Order Cycle 4. Update Notification with Causes, Tasks, Activities, Parts, Damages 5. Close / Complete Work Order & Notification 6. Reporting and Analysis 2013 SAP AG or an SAP affiliate company. All rights reserved. 11

12 Notification Structure Notification Header Causes General Information that applies to the Tasks complete notification Activities Item Overview Item Item Item Information that Causes applies to the specific item Notification Header Level Notification Item Level Tasks Activities 2013 SAP AG or an SAP affiliate company. All rights reserved. 12

13 Maintenance Notification Malfunction Report

Notification: Failure Reporting Initial Report, by observer, basic information about the failure Breakdown Indicator Malfunction Start & End Dates After

14 Notification: Failure Reporting Initial Report, by observer, basic information about the failure Breakdown Indicator Malfunction Start & End Dates After Investigation / repair. Detailed information about what was wrong and what was done to correct the problem 2013 SAP AG or an SAP affiliate company. All rights reserved. 14

Notification: Header Priority Priority, can influence dates

16 Notification: Header: Impact Effect of Malfunction (e.g. Critical failure, Degraded Function, Incipient Failure System Availability (Total/Partial Function Loss, Running, Start-Up, Testing, Idle, ) 2013 SAP AG or an SAP affiliate company. All rights reserved. 16

Notification: Header Items Overview Multiple Items from the malfunction Damage Code

19 Notification: Item Information (Causes, Tasks, Activities) Cause Code Group (Failure Causes) Task Code Group Activity Code Group (Maintenance Activities) 2013 SAP AG or an SAP affiliate company. All rights reserved. 19

Notification: Failure Reporting (Using Classification) By Item Classification: Allows for additional information to be collected on the Notification for each item

20 Notification: Failure Reporting (Using Classification) By Item Classification: Allows for additional information to be collected on the Notification for each item Note: Associated with catalog profile Note: Use to capture the consequence severity from ISO table C SAP AG or an SAP affiliate company. All rights reserved. 20

Notification (s) : link to Work Order 2013 SAP AG

24 Other Considerations

25 General problems in recording failures using SAP EAM Notification created against functional locations and not equipment Creating notifications at a functional level makes it hard to record and analyze information about failures on individual equipment. After all it is the equipment that usually fails, not the functional location. Notifications created against incorrect equipment Upon further investigation the correct problem is identified. Without changing the information in the notification, you are adding false failure information to your analysis Inconsistent use of the break down indicator (what is a breakdown?) Breakdown definition: ISO 14224: The termination or degradation of the ability of an item to perform its required function(s) When this indicator set then the notification information is used for maintenance calculations (e.g. MTBF, Availability, etc.). Without this being set the failure will not be recorded in the standard analysis Notifications are not updated with multiple items when multiple items / components are repaired Correct causes, items, damages Incorrect dates in the notification 2013 SAP AG or an SAP affiliate company. All rights reserved. 25

26 Using SAP & Industry Standards to report failures When establishing your codes / catalogs cross company agreement is difficult. One option is to use codes based on industry accepted standards and map the standard to SAP catalogs. SAP Catalog Standard Coding (Coding D) ISO Failure Mode: Tables B.6 B.12 (Failure Mode as observed by operator RCM Functional Failure Damage (Damage C) ISO Condition; Table B.2 ISO Failure Mode: Tables B.6 B.12 (Failure Mode as observed by operator RCM Functional Failure Causes (Causes 5) ISO Cause Table B.3 Activities (Activities PM A) ISO Maintenance Activity Table B.5 Object Parts (Object Part B) ISO Maintainable Item; Annex A 2013 SAP AG or an SAP affiliate company. All rights reserved. 26

27 Using SAP & Industry Standards to report failures When establishing your codes / catalogs cross company agreement is difficult. One option is to use codes based on industry accepted standards and map the standard to SAP catalogs. SAP Function Classification Characteristic Severity Standard ISO Table C.1 Failure Consequences Functional Locations Norsk Z-002 DP Norwegian Coding System 2013 SAP AG or an SAP affiliate company. All rights reserved. 27

28 Manual / Automated failure reporting Possible methods of manual collection: Use Adobe Forms SAP GUI / SAP NWBC (Business Client) Use Syclo Work Manager (mobile) Possible methods of automated collection: Connect to DCS, Data Historians, SCADA via SAP Manufacturing Integration & Intelligence (SAP MII) Trigger BAPI_ALM_NOTIF_CREATE from 3 rd party application 2013 SAP AG or an SAP affiliate company. All rights reserved. 28

29 Work Flow - Thoughts Does an automated created Notification have to be processed differently than a manually created one? If so, how to distinguish automated notifications from manual? Notification Type, Person reporting? Understand priorities (can automated reporting process set appropriate priorities)? Are all failures a breakdown? Central body to investigate automated failure reports? To whom does the work flow to? Person, position, department, etc SAP AG or an SAP affiliate company. All rights reserved. 29

Work Flow template WS20000317 (use as a base) In this scenario, the SAP Business Workflow component helps you to process, monitor and complete newly created maintenance notifications efficiently.

30 Work Flow template WS (use as a base) In this scenario, the SAP Business Workflow component helps you to process, monitor and complete newly created maintenance notifications efficiently. This process is represented in a workflow template, which triggers and controls the execution of the following standard tasks: Notifying a person responsible (for example, the notification coordinator) that a new maintenance notification has been created or put in process, and that tasks must be defined for the notification Notifying a person responsible that tasks, which must be processed, have been created for the maintenance notification Notifying a person responsible (for example, the notification coordinator) that all the tasks for the maintenance notification have been completed, and the maintenance notification must either be completed or additional tasks must be defined for the notification 2013 SAP AG or an SAP affiliate company. All rights reserved. 30

31 Other Considerations: One Notification to One Work Order Direct access to notification via header / change button Many Notifications to One Work Order Access to notifications via Objects tab (select notification) / change button Reducing the number of tabs on the notification do you need all the options? Adding new tabs to the notification custom development / configuration Text changes breakdown indicator to maintenance event, Item to Maintainable Item, Cause to Root Cause, Is the notification subject to approval? Use long text to further describe codes 2013 SAP AG or an SAP affiliate company. All rights reserved. 31

32 Conclusion

33 Conclusion Notifications are the reporting mechanism in SAP for reporting failures and corrections Catalogue codes should be common and understood Understand the definition of a breakdown and use the break down indicator Updating the notification with damages, causes, items, etc. enhances the analytical capabilities and should be part of the process Know the level / detail that you require to be reported. Use industry standards & groups where possible to provide guidance SAP AG or an SAP affiliate company. All rights reserved. 33

Thank you Contact information: John Harrison Senior Solution Specialist, Industry Business Solutions - Chemicals SAP Labs 4120 Yonge Street, Suite 600,

34 Thank you Contact information: John Harrison Senior Solution Specialist, Industry Business Solutions - Chemicals SAP Labs 4120 Yonge Street, Suite 600, Toronto, Ontario, Canada, M2P 2B8 T +1 (416) I M: +1 (416) E john.harrison@sap.com 2013 SAP AG or an SAP affiliate company. All rights reserved.

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2013 SAP AG. All rights reserved. Internal 1

2013 SAP AG. All rights reserved. Internal 1 SAP 3D Visual Enterprise Unlocking Engineering Information for the Visual Enterprise John McNiff SAP - Idea to Performance Solutions Slide 1 of 235 Agenda Solution