SAP PM Assessment and Improvement Processes for Reliability

Transcription

1 SAP PM Assessment and Improvement Processes for Reliability It isn t the assessment that makes your plant money; it is the equipment reliability improvement that generates the profit! After six years of developing and using our SAP PM Assessment Tool to help our customers better understand the opportunities that SAP can provide to their reliability improvement effort, the data driven assessment effort has evolved into just a part of everything we do at RSI. We found the data rich environment of SAP allowed us to provide to our customers a reliable abundance of business information that can measure and inspire continuous improvement. We have refined the SAP PM Assessment Process into a low effort, high value proposition to our customers in hopes that our clients use their resources to drive the improvement. The offering we are introducing is a low cost alternative to expensive and time consuming assessment processes of the past, allowing our customers to focus on improvement quickly and successfully. We have combined the process of evaluation and solutions. The process is offered in 4 stages, and is summarized as follows: QuickLook Assessment Summary and Overview of SAP PM Application and Maintenance Best Practices (Cost Basis). This is a fixed format assessment that can be performed remotely. The goal of this effort is to establish gaps at the organizational level. Preventive Maintenance Assessment Utilizes Basic Elements of the QuickLook Order Assessment and Details the Design and Performance Elements of the SAP PM Preventive Maintenance Process. (Effort Basis). This assessment includes performance information at the Technical Object, Equipment Type, and Criticality Levels. This assessment is available for customer requirements. Maintenance Materials Assessment Utilizes the Basic Elements of the QuickLook Material Planning Assessment and details the Storeroom, Bills of Material, and Materials Usage Design and Performance Elements. This assessment also includes Bills of Material performance and improvement strategies. This assessment is available for customer requirements. Closing the Loop with Improvement Converting the assessment opportunities to improved performance. Each assessment criteria will be paired with an improvement focus plan that Reliability Solutions, Inc. will be prepared to support the customer through the success phase of the improvement process. Lorri Craig lorri@rsi4sap.com Page 1

2 SAP PM QuickLook Assessment We do hope that every SAP PM installation was designed around each plant s maintenance best practices and aligns with the reporting to validate the application of those best practices. We do understand that there are SAP PM Applications where that luxury does not exist. For those applications, RSI s QuickLook Assessment extracts the most basic of information from your SAP PM application, and translates that data into Maintenance Best Practices Key Performance Indicators. The QuickLook takes less than a week to complete from start to finish, and is designed to be done without an onsite visit. There is no need with the limited resources in today s economy to make travel the first expense. The process is simple, the customer provides the base data tables in an excel format, RSI provides an upload procedure for these files to be imported into the RSI Data Model, and RSI provides a summary report detailing the basic maintenance best practice performance well dones and opportunities to improve. Not all manufacturing plants want to be SAP PM Leaders; they just want to be effective at equipment reliability within the confines of their own business plan. For those who want to be the best at SAP PM, RSI does offer an SAP PM Best Practices assessment, but for many, the QuickLook is the best value. QuickLook Focus Areas The QuickLook Assessment focuses on SAP PM Best Practices. Each of the 65 points is displayed within the context of Best Practices and Customer Priorities. Most opportunities are displayed graphically, with an explanation of the measurement and implications, and a suggested course of action. Technical Object Structure SAP PM Technical Objects serve as the backbone of the reliability history and improvement effort. It is important that all of the equipment have: Characteristics that are properly documented Classification and equipment typing Proper assignment of administrative information The QuickLook Assessment displays how well the equipment application in SAP PM is poised to provide efficient Notification and Work Order management, as well as structured to provide effective reliability performance reports and information. The assessment extends to Functional Locations, Planner Groups, and Work Centers. N Lorri Craig lorri@rsi4sap.com Page 2

3 Notifications and Reliability History The Notification is the Reliability History from a Why point of view. It is important that all exceptions to reliability expectations be documented for: What are the failure symptoms? What effect is this failure having on the process? What was the damage? Why did this failure occur? The QuickLook Assessment displays the organizational discipline to capture this information that will be used to create a detailed reliability history to only focus on the significant opportunities first with an effective reporting structure. Preventive Maintenance Preventive Maintenance should be the bedrock of the reliability improvement effort. Our job as maintenance people is to Prevent failure. From a Preventive Maintenance perspective, the effort should: Reduce Downtime Reduce Corrective Maintenance Spending Balance Preventive Maintenance Effort with Return The QuickLook Assessment displays the link between reliability success and the preventive maintenance effort. Work Orders and Confirmations Work Orders are the execution portion of the Reliability History. Confirmations close the reliability loop with documentation of what was executed. Every Work Order should include: Planned Labor Resources and Materials Confirmations with Labor, Status and Feedback A Work Order Classification that will drive Opportunity The QuickLook Assessment displays the organizational discipline to take reliability opportunity, plan a solution, and measure the effectiveness of the solution. Lorri Craig lorri@rsi4sap.com Page 3

4 QuickLook Assessment Logistics The true value proposition of the RSI SAP PM QuickLook Assessment is that it is designed to be done remotely. RSI will provide each assessment a website on which all process data and reports will reside, with the ability of all participants to upload and download all files. The data that feeds the assessment engine is fed from standard SAP PM list displays, with no need to drill into tables or info sets. Once the website is in place, the customer will be issued an instructional packet that will include: A Reliability focus prioritization exercise to be completed by the customer. The Customer Reliability Success Metrics and Goals A Customer Specific Processes Sheet. This will include customer specific information on: Notification Type Functional Descriptions and intent Order Type Functional Descriptions and intent The detailed instruction documents on the report download procedures into excel spreadsheets. Once the User Table is downloaded, RSI will ask the customer to complete the User data Table with Role, Supervisor, and Functional Area assignments that are used for demographics. Once the data is input into the RSI SAP PM data engine, the basic reporting will be automatically generated and documented. The reporting will be provided to the customer within 5 working days for average size SAP PM installations. Multi facility assessments do have a certain economy of scale with the common attributes, and are scaled accordingly. The preliminary documents will be issued to the customer for review and test for alignment with a conference call set up with RSI. Once the customer review is complete, the final report will be issued to the customer along with gap closing recommendations. We are true believers of the power and flexibility of the SAP PM module and how it can support increased equipment reliability while at the same time play a key role in the financial decision-making of good business practices. Our hope is to bring the QuickLook Assessment Process to our customers and support them where needed to move forward. Lorri Craig lorri@rsi4sap.com Page 4

5 Closing the Loop with Improvement While it is important to get a broad view of the opportunity with the assessment, it is essential to close the gaps so the value proposition can be realized to the customer. Reliability Solutions has the capability to work with your team to maximize SAP PM Functionality and hopefully not make SAP PM the main event, but rather make Equipment Reliability the main event. Most services do not necessitate addressing the SAP PM configuration, but where configuration modification is needed, the item is noted. Among the services offered include: Technical Object Structure Optimization o Data Entry and Functional Design of the Technical Object Data Structure. Equipment Classifications and Statuses (Configuration may be required) Functional Location Integrity and Reporting Effectiveness Criticality Assessments Level III Maintenance Materials Detail Assessment Data Based Bills of Material Development Processes Notification and Reliability History Optimization o Implementation of Reliability Focused Notification Processes Failure Code Application (Configuration may be required) Notification Design for Data Entry (Configuration may be required) Reliability History Reporting Design Preventive Maintenance Optimization o Implementation of Effective Preventive Maintenance Processes in SAP Level II Preventive Maintenance Detail Assessment Maintenance Task List Organization and Application Maintenance Plan, Item, and Strategy Design and Application Work Order and Confirmation Optimization o Optimization of Effective Work Order Processes Planning and Scheduling with SAP PM Backlog Management and Performance Reporting Work Order Design (Configuration may be required) And of course, the best SAP PM User Training available for any and all of the processes above. Lorri Craig lorri@rsi4sap.com Page 5

6 SAP Preventive Maintenance Detail Assessment The Preventive Maintenance capability within SAP PM is powerful and flexible, but as with any application, the tool must be understood well in order to reap the value of what SAP PM can provide. The Preventive Maintenance assessment is built upon the foundation of the QuickLook assessment and drills down into the specifics of the Preventive Maintenance Application. The basic philosophy of this assessment is driven by three key points: The truest measurement of Preventive Maintenance success is the reduction of corrective maintenance. There exists a nexus of optimal Preventive Maintenance effort and reliability success. It is possible to have too much of a good thing, especially given limited resources. Effective Preventive Maintenance is a growing process, and SAP PM should be applied to suit the growth over time. The assessment uses the existing SAP PM database to measure the preventive maintenance structure application as it aligns with the plant preventive maintenance strategy to identify barriers to preventive maintenance success. With the structure understood, the bottom line of preventive maintenance success is measured with adherence and reliability successes both measured and reported. There exists 27 points of analysis with this assessment. Among the Areas of Assessment include: Preventive Maintenance application against Equipment Criticality Preventive Maintenance application against Equipment and Work Type Task List Design Detail and Continuous Improvement Maintenance Plan Scheduling Design Detail and Continuous Improvement. Application of Maintenance Plan Strategies and Maintenance Packages Preventive Maintenance Adherence by Effort. Preventive Maintenance Success by Equipment Reliability. Lorri Craig lorri@rsi4sap.com Page 6

7 An additional feature of the Preventive Maintenance Assessment is a deliverable of a user friendly MS Access database report set that provides drill down capability for the following reports: And discernable by: Preventive Maintenance Adherence Summary Preventive Maintenance Adherence Detail Technical Object Corrective / Preventive Order Ratio Technical Reliability History (all Orders and Notifications) Technical Object Corrective/Preventive Cost Trend Functional Location Equipment Criticality Catalog Profile The Home Screen for the database is shown below. The RSI SAP PM Preventive Maintenance Assessment analyzes the overall structural design of the SAP PM Preventive Maintenance Assessment, while also providing a reporting tool to narrow down the Preventive Maintenance Performance Opportunities using criteria that allows the plant to focus on the low hanging fruit in Preventive Maintenance. Lorri Craig lorri@rsi4sap.com Page 7

8 SAP Maintenance Materials Assessment A significant objective of the plant storeroom is to readily provide the materials and spare parts needed to support the equipment reliability effort. The Maintenance Materials assessment is also built upon the foundation of the QuickLook Assessment and drills down into the materials strategy as it applies to equipment reliability. The basic philosophy of this assessment focuses on: The cost of stocking repair parts is part of the maintenance costs and is important to plant profitability The Inventory Strategy should match the Reliability Goals The Equipment Bills of Material is the vital link between Reliability and Materials Management. The assessment uses the existing SAP PM database to understand the materials management strategy and the links to the equipment history. Many organizations fail to establish a true partnership between stores and maintenance in a numeric way, and also fail to establish common goals centered on equipment reliability. The storeroom will default to managing a total inventory (reduction) goal if not provided with a reliability focus, an especially unfortunate situation if the cost of stocking spare parts is a fraction of the cost of lost production downtime. While it is still important to realize that true reliability success ultimately can result in reduction of the need for spare parts stocked on site, many organizations are caught in the transition stage of stocking the correct parts while corrective maintenance is still a significant effort. To support this cause, the Maintenance Materials assessment focuses on measuring the following key areas: Equipment with Bills of Material by Criticality and Equipment Type Bills of Materials Effectiveness (Which Bills of Material Parts have been used and which materials have been used that are not listed on the Bills of Material) Storeroom Maintenance Material Valuations by Criticality and Equipment Type The communication links and manual processes between planning and stores for corrective orders (reservations), and between maintenance and stores for emergency orders. Identification of some common inventory metrics such as Dead Stock and Overstock Reports. Lorri Craig lorri@rsi4sap.com Page 8

9 An additional feature of the Maintenance Materials Assessment is a deliverable of a user friendly MS Access database report set that provides drill down capability for the following reports: And discernable by: Equipment BOM Detail Equipment BOM Summary Materials Used Not Attached to that Equipment BOM Used Materials Not Attached to any BOM Equipment with No Bills of Material Functional Location Equipment Criticality Catalog Profile The Home Screen for the database is shown below. The RSI SAP PM Maintenance Materials Assessment analyzes the strategic materials contribution to the equipment reliability effort. The database report is designed to provide a solid database basis for those plants that desire to build a Bills of Material Structure to support effective Work Order Planning, as well as providing a reliability based inventory strategy for the plant storeroom and materials purchasing teams. Lorri Craig lorri@rsi4sap.com Page 9