Digital Enterprise Asset Management Increase Productivity, Visibility and Efficiency Fast!

Transcription

1 Digital Enterprise Asset Management Increase Productivity, Visibility and Efficiency Fast! Raj Singh - Director EMEA South Center of Excellence IoT & Digital Supply Chain Digital Operations

2 SAP's Vision for Asset Management Provide best-in-class user experience seamlessly on all devices. UI harmonization Roadmap for mobile apps EAM and EH&S in S4/HANA Geospatial Enablement Framework Multi Resource Scheduling Customer Connection Help ensure accuracy of master data and allow for sharing master data alongside the value chain. Data Services and Information Steward Master Data Governance EAM extension Visual Enterprise EAM workbench in development Establish a business network for OEMs, service providers, operators, and other contributors. Make operational data available for comprehensive analytics and insight-toaction, leveraging the IoT. Asset Intelligence Network Predictive Maintenance and Service on-premise and in the cloud 2

3 Current Best Practices?

4 Excessive Paperwork Work orders can be 100 pages or more! Forms are completed manually The keyed in by the technician at a PC Doubles the administration Reduces productivity 4

5 Excessive Paperwork Paper based manuals, diagrams and parts listings Parts consumption is all paper based Part numbers look the same Components often look the same could lead to significant negative consequences 5

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7 Paper Safety Systems Safety checklist on paper Doesn t enforce the process Analysis in hindsight No real time situational context 7

8 Manual Time Sheets Time sheets filled in at the end of the day. or even at the end of the week! Time is rounded up to the nearest hour or half hour No accuracy = no optimisation Planners and supervisors can t track progress of in progress maintenance and service requests 8

9 Sophisticated Planning Systems Planning process are often manual Spreadsheets Spreadsheet + magnifying glasses Paper based planning Even maintenance files in crates being moved as the status changes! 9

10 Hand Written Labels No Barcodes for Tracking 10

11 Spare Parts and Inventory Maintenance engineers lose time walking to the stores to pick up parts Lose more time returning unused parts Stop work to go to the stores to pick up unplanned parts Inside the stores: Spare parts are all barcoded No barcode scanning implemented Poor stock accuracy Operational as well as P&L impact 11

12 Context Enterprise Asset Management

13 SAP Line of Business Asset Management Supporting Asset Management processes end-to-end Portfolio and Project Management Asset Operations and Maintenance Environment, Health, and Safety Asset Performance and Intelligence Idea Management Asset Information Governance Incident Management Asset Strategy and Performance Portfolio Management Maintenance Planning and Scheduling Health and Safety Management Asset Network and Collaboration Project Management Maintenance Execution Environment Management Asset Prediction and Optimization Resource Management Mobile Asset Management Management of Change Project Connectivity Maintenance Safety and Permit to Work 13

14 The E2E SAP EAM Architecture Asset Manufacturer AIN 3D VE Service Provider Central hub for linking equipment in a collaboration ecosystem Resource Allocation / Scheduling WO Scheduling PdMS 3D VE ERP Preventive Planning Maintenance Notification Maintenance Order Creation Measuring Point linked with MII MRS/ClickSoftware LAM Predictive Maintenance Asset Health Monitoring Vibration Analysis Virtualization Assets Maintained in PM EHS WCM Relevant Risks Safety Measures Work Clearance MII 3D VE Real time Asset Performance KPIs Condition-Based Maintenance Automatic Actions upon events Virtualization Measuring Point linked from PM Energy Monitoring Work Manager 3D VE Device Integration IoT Client PCo Machine / Asset Integration Assets in the Field (External Scenarios) Assets in Shop Floor / Operations (Industrial Scenarios) Maintenance Order Execution Visual work instructions

15 User Interface

16 UX and User Interface Evolution 16

17 Launchpad features: Tiles based on role(s) that can be adapted List views Maintenance request Information centers Favorites Comprehensive list of EAM transactions available Fiori Launchpad Navigation Overview

18 Strategies for Asset Maintenance

19 Maintenance Journey & Asset Optimization Organizations are maturing their maintenance strategies Reactive Preventive Conditionbased Predictive Wait until a machine fails and then undertake maintenance. Perform maintenance activities based on regular intervals (time or counter based) Continuously observe the status of assets and react to predefined conditions and events. Apply advanced analytics of operational and business data to help determine the condition of specific equipment and predict when to perform maintenance. Digital Twin Companies are moving from a reactive to a proactive approach, leveraging machine data for better insights. 19

20 Processes in Asset Management

21 The maintenance process Initiate Plan Schedule Execute Close & analyze 21

22 Initiate How is Maintenance Work Generated? Maintenance Notification Manual order creation Direct Order Creation Inspection/Rounds Scheduled PM Time/Counter Strategy Condition Based Inspection/Rounds Machine Integration Real Time Predictive Forecasts and Failure Patterns 22

23 S4HANA OP 1610 Request Maintenance APP Creates Maintenance Notification

24 Plan How can we proactively manage work packages? Comprehensively manage master data for technical objects Build preventive maintenance plans, review past execution, and account for the requirements of the work package Gain real-time visibility into current performance of assets Safety Equipment Tasks & Operations Tools Locations Spare Parts/BOM Time/Labor Skills/Craft 24

25 Order and Notification List Webdynpro (ECC 6.0 Eph 6/7) & S4HANA OP (no side panel)* You can create your own queries, worklists, and backlog. You can user personalize and export to excel

26 Asset Viewer (ECC 6.0 Eph 6/7) & S4HANA OP/Cloud

27 I can add based on the BOM for the equipment and automatically have insight into if I have material availability or not!

28 Schedule How do we build and dispatch the work package? Manual Planning Manual assignment creation in the Planning Board (via drag & drop) Manage potential resource conflicts with contextual alerts Further features like Qualification Matching, Tool Planning, Travel Times, Clocking Data, Capacitive Planning Resource Selection Identical to manual planning but with pre-selection of resources based on different criteria Automatic Planning Automatic Scheduling based on availabilities and qualifications Utilization based automatic scheduling Intelligent shifting Optimization An optimization engine proposes an optimized schedule (travel times, SLA dates, etc.) 28

29 MRS 10 Planning Board This is webdynpro and available for ECC and S4HANA OP 29

30 New Fiori apps for MRS - S4HANA OP 30

31 Execute and Confirm Perform the work quickly, correctly, and safely? Access to prioritization, asset location, repair history, work order details, documentation, notes, and required materials Create additional notifications or sub-work orders SAP 3D Visual Enterprise Viewer embedded for work instructions Inspection rounds data capturing Issuance and consumption of materials, including material search Timesheet data entry with e-signature Complete work orders and capture all relevant data 31

32 Close & Analyze How is the work tracked and managed? How can we continue to improve? Optimization can be reached by changing the maintenance strategy to a more agile approach. Condition data allows for a ranking of assets according to a health score. For healthier assets the service interval can be prolonged while it can be shortened for others. This results in less failures while reducing maintenance cost. 32

33 Asset Centric Mobility SAP Work Manager Complete work orders and capture all relevant data Access to asset location, repair history, work order details, materials needed Create notifications or work orders Master data integration Create, update, display equipment and functional locations unrelated to work orders and notifications Install and uninstall of equipment Edit equipment and functional location characteristics View equipment and functional related data Upload and download of attachments Linear asset management Inspection rounds 33

34 SAP standard solutions Inspect, maintain, and repair assets SAP Work Manager SAP Inventory Manager SAP Rounds Manager Asset Management Complete work orders and capture all relevant data Access to asset location, repair history, work order details, materials needed Create notifications or work orders Linear asset management Integration with GIS (Esri) Integration with ERP Customer Service SAP 3D Visual Enterprise Viewer embedded Crew management Inspection rounds SAP Multiresource Scheduling integration (MRS) SAP CATS integration for time and attendance Augmented reality component Material Management Speed receipt / back-order reporting to-and-from shipping/receiving Perform physical and cycle counts quickly Check availability of materials while on-the-job Accept and distribute incoming materials by purchase order Warehouse management processes Condition Monitoring Take measurements and readings Conduct operator rounds Perform inspections such as for maintenance, compliance, and Environmental, Health and Safety Get automatic alerts for measurements outside the safe range Quickly create notifications based on current location and equipment 34

35 Typical Asset Intensive Workforce Mobilization Crew Management Manage crews & vehicles Reassign jobs Automated Debriefing CATS time tracking Parts & materials GIS Locate jobs/assets on maps Find best route Locate other crews and points of interest View geo-fences to avoid unauthorized areas Attachments Photographs Documents Location Based Services Track crews in real-time via GPS Capture geo-tags Track job and work status and progress Safety & Communications Automated distress calls Real-time permits/tag-outs Multi-party messaging Intelligent Scripting Perform multi-point inspections Perform branched diagnostics Perform complex work orders Measurements & Readings Capture with barcode, Bluetooth and peripherals Machine to machine Interactive 3D Schematics View part and asset assemblies Initiate tasks and transactions from therein 35

36 SAP 3D Visual Enterprise Viewer Android & ipad 3D Work Instructions Assembly Installation Maintenance Repair / Service Training Analytics Integrated SDK 36

37 SAP Enterprise Asset Management 3D Visual Enterprise Viewer Now 2D support and 2D tagging possible Interactive 2D CGM support Connecting 2D Graphics to SAP Business Data CGM is an Open International Standard File Format for 2D Acceptance of CGM across SAP's asset-intensive industries and international standards such as the Commercial Airlines, Auto and Trucking, Aerospace & DoD, Railroad Industry, Petroleum Industry 37

38 Solutions Asset Intelligence Network

39 The asset intelligence network will bring together the manufacturers, service providers, and operators of the world s assets to collaborate around shared equipment information to maximize availability, improve efficiency, and create new business models.

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41 SAP Asset Intelligence Network Cloud-based platform for asset information exchange Nameplate info Maintenance strategy 3D parts # / BOM Service bulletins & revs Failure modes Recalls Safety controls Process controls Service bulletin Designs and drawings Design improvements Sensor definition Licensing Operating instructions Maint instructions Safety instructions Product training Service bulletin receipt Service bulletin processed Usage information Installation information Failure / incident data Design recommendations Risks and controls Measurement documents Telemetry Manufacturer Service provider Operator 41

42 SAP Asset Intelligence Network Sharing Model and Equipment Information Information Model Information Model Attributes Equipment Attributes Installation Information Life Cycle Information Structure and Parts Structure Spare Parts Documentation Model Documents Equipment Documents Instructions Announcements Monitoring Measuring Points Error Codes Improvement Cases Time Line 42

43 Solutions Predictive Maintenance

44 SAP Predictive Maintenance and Service From Sensor to Insight to Outcome Sensor Data Insight Action Outcome Connected assets IT/OT Convergence Data analysis Maintenance activities Business Value Onboarding Connectivity Device management Security Big Data ingestion Big Data infrastructure Merging sensor data with business information Root cause analysis Asset health monitoring Machine learning Anomaly detection Triggering of corrective actions Prioritized maintenance and service activities Optimized warranty and spare parts management Prescriptive Maintenance Quality improvements Customer experience Increased quality Lower costs Operational efficiency R&D effectiveness Material procurement 44

45 Solutions Asset Strategy and Performance Management

46 SAP Asset Strategy and Performance Management Planned innovations Support the asset management organization in defining, planning and monitoring the optimal maintenance strategy for physical assets by providing the required level of collaboration and integration as well as the needed data and analytics This is the current state of planning and may be changed by SAP at any time. 46

47 Vision: optimizing the maintenance strategy portfolio Planned innovations Current Maintenance Strategy 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Mantainance Strategy Portfolio CM PM CBM / PdM Collaboration IoT Integration Analytics SAP Asset Strategy and Performance Management Optimal Maintenance Strategy 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% Mantainance Strategy Portfolio CM PM CBM / PdM! Maximize asset productivity and availability Drive safe operations Minimize costs This is the current state of planning and may be changed by SAP at any time. 47

48 Business Case ROI

49 Process Apps Drive Value in Multiple Areas Value source Realized or expected improvement from Syclo Apps Benefit Range Syclo App Increase Revenue Improve First-Time Fix Rates 15% - 20% Reduce Unplanned Downtime 20% - 30% Service Manager Work Manager Value of Syclo Apps Reduce Costs Eliminate Admin Time of Manual Paper Orders 90% - 100% Increase Work Order Capacity 20% - 30% Minimize Overtime Costs 40% 60% Work Manager Inventory Manager Service Manager Reduce Inventory Carrying Costs 5% - 10% Eliminate Manual Data Entry into ERP/CRM 90% - 100% Optimize the Balance Sheet Accelerate Days Sales Outstanding Reduce Spare Parts Inventory 10% - 15% Reduce Pick Errors Service Manager Inventory Manager 49

50 Thank you! More information: