Drakenstein s Maintenance and Asset Management Approach

Transcription

1 Drakenstein s Maintenance and Asset Management Approach Bouke Spoelstra February 2013 Customer for life through the delivery of excellence

2 Drakenstein s Requirement Requirement Definition Current Asset Register (constant verification and updating) Optimisation of their Operational Resources Unified Process of Managing Assets and Work Integrate Data Sources: Spatial, SCADA and Financial

3 Process Impact on Asset Register CAPEX Supply Chain Maintenance Asset Disposal Asset Register Service Strategy Financial Accounting Condition Assessment Operations

4 Unified Business Process for all Work Drakenstein s Flow Trough Business Process Work Initiators: Help Desk: Service Request CAPEX Planned Maintenance Unplanned Maintenance Work Planning Scheduling Assigning & Dispatching Field Force Management Closeout Feedback Analysis

5 Service Management Process Client Call Create Service Request Classify Request Work Planning Create Work Order Customer for life through the delivery of excellence

6 Helpdesk: Client Calls Other Feeds: Self Service Application

7 Location Identification Search Hierarchies/ Map Drill down Filter for correct street or ERF

8 Verify duplicate Service Requests

9 Work Order reference SR for Auto status updates

10 CAPEX Process Functions: CAPEX Cost Centre Budgeting GIS Integration Compatible Unit Estimator Standard Job Plans Standard Project Templates Supply Chain Integration Outages Planning Maximo Scheduler Customer Notifications Crew Management Workflow signoffs Master Plan Notifications Work Planning Project Definition Work Package Development Field Estimating Office Estimating Customer for life through the delivery of excellence

11 Preventive Maintenance Functions: Meters (SCADA) Calendar Standard Job Plans Master PM s PM Sequencing Supply Chain Integration Outages Planning Maximo Scheduler Customer Notifications Crew Management Workflow signoffs Preventive Maintenance Launching Conditions Notifications Preventive Maintenance Generation Job Plans & Procedures PM Predictions Work Planning Customer for life through the delivery of excellence

12 Corrective & Emergency Maintenance Functions: DMS Integration SCADA Integration Condition Monitoring Infrared Cameras Online Monitoring High/Low Alarm Levels High/Low Action Levels Colour conditions GIS Integration Incident Classification Work Prioritisation Standard Work Templates Smart Feeds Actions Launching Prioritisation Incident Reporting Trending Work Planning Customer for life through the delivery of excellence

13 Planning to Execution Functions: Job Plans Resource selection Material Labour Tool Services Planning Tools Dispatching Tools Mobility Tools CAPEX, Preventive Maintenance, Service Requests, Incidents Work Planning Dispatching Material, Resource Planning Assignment Approve Work Crew Scheduling Field Force Management Customer for life through the delivery of excellence

14 P&S Optimization Achievement on Productivity 13% 10% Personal Clerical 15% Waiting for Jobs 22% Travel Time and Stores 10% Waiting for Instructions 30% Productive Work Reduce from 70 % to 50% Before P&S Optimization 50% Productive Work 60% Increase in Productivity After P&S Optimization

15 Planning & Scheduling Optimization ROI Impact of Improvement Reduce time to complete jobs by 33 % Increase Productivity (Labor wrench time) by 60 % Effect Of Improvement 3 techs at 30% = 90 % total productivity 2 techs at 50% + 1 0% = 100% total productivity A planner can plan work for technicians depending on industry and complexity of maintenance work. Average ratio is 1-20 One planner /scheduler for 20 technicians (21 employees) will yield the same output as 30 technicians without planners Visual Planner allows Planners, Schedulers and Supervisors achieving a 20% time saving (One full day per week)

16 Work Management Focus Areas Capacity Planning Resource Optimization Assignment Dispatching Real-time Communication Forecast Work Identify Resource Gaps Availability: Assets Location Material Tools Labor/Crews Resource Leveling Graphical UI Labor and Crews Graphical UI Public Map Control Route Optimization Labor and Crews Assign Emergency Work Communication To Field Technicians Schedule Compliance

17 Roles in Managing Work Scheduler/Planner Defines and adjusts labor/crew availability along with resource leveling Capacity Planning Assigns work orders to resources Continuously optimizes the schedule as the operational environment changes Sequence and route work assignments based on geography Dispatcher Monitor field resources and work order progress and status Monitor the location of field resources compared to open orders Enter status and complete work orders on behalf of technicians who don't have mobile devices Sequence and route ongoing work assignments based on geography and optimization Field Technician Supervisor approves and assigns work on mobile devices Receive work orders in the field and provide real time status updates to dispatch Complete, edit and approve work orders on mobile devices along with viewing work on a map with optimal driving directions Notify dispatch of potentially dangerous situations, incomplete work

18 Scheduling: Resource Load and Availability

19 Planning: Resource Optimisation 19

20 Dispatching: Real-time monitoring

21 Mobile Interface

22 2 x Clicks

23 Location Direction Speed

24 Mobile Supported Devices

25 Service Request feedback Completing the work order a message will appear notifying you that the Service Request will be Resolved

26 Prepare for: Meter Management Lifecycle ASN File Vendor Marriage and Test Files Meter Receipt Location: Meter Shop Meter Marriage Meter Shop Meter Random Sample Test Meter Shop Storeroom or Staging Area Truck (Rolling Storeroom) Meter Shipment A Status: Not Ready Quarantined Stock Stock Stock Meter Installation Service Order Storeroom Meter Meter Shop Meter Meter Inspection/Test Meter Shop Storeroom Truck (Rolling Storeroom) Meter Removal Premise Stock Shipment Stock Passes Test Needs Test Needs Test Needs Test Service Order Active Left in Open Meter Fails Test, Lost or Obsolete Sync Meter End of Lifecycle A Storeroom or Metershop Retired Lost Obsolete

27 The Value to Drakenstein Unified solution for: Service Management Work Management Asset Management Supply Chain Management For all asset groups Infrastructure Plant Facilities Transportation IT assets Visualisation GIS integration Map Integration Dashboards BI Cognos Customer WEB UI Service Management Supply Chain Management Work Management Asset Management

28 Questions?

29 IBM Maximo: The Operational Solution Organisation

30 IBM Maximo Detail Functions Asset Management Locations Asset Failure Codes Conditioning Monitoring Meters Meter Groups Classifications / Specifications Linear Assets Maximo Spatial Depreciation Work Management Job Plans Routes Work Order Tracking Failure Reporting Safety Quick Reporting Labor Qualifications Lock-Out / Tag-Out Tools / Crafts / Companies Preventive Maintenance Master PM Compatible Unit Estimating Resource Scheduling Materials Management Item Master Storerooms Inventory Lot Management Kitting Issues & Transfers Condition Codes Stocked Tools Service Items Classifications / Specifications Purchasing Request for Quotation Receiving Receiving Inspections Purchase Requisitions Invoices Purchase Orders Desktop Requisitions Enhanced Workflow in SLAs and Escalation Manager Configuration UI, Database Fields, and Applications Maximo Integration Framework (MIF) Native Integration Capabilities KPIs / Reporting / Analysis Security & Administration Contract Management Purchase Contracts Master Contracts Warranty Contracts Lease / Rental Contracts Labor Rate Contracts Payment Schedules Service Management Service Catalogs SLA Management Service Requests Incidents Problems Changes Releases Solutions Ticket Templates