Plant Maintenance User Group meeting November 10 - 13 2002 Banff, Canada Using SAP PM for Reliability Analysis Using SAP PM for Reliability Analysis Vince Flynn Vince Flynn E. I. DuPont deNemours & Co. Inc. E. I. DuPont deNemours & Co. Inc. Joel Barger Joel Barger Meridium Inc. Meridium Inc.
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Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Using SAP PM for Reliability AnalysisUsing SAP PM for Reliability Analysis
Vince FlynnVince FlynnE. I. DuPont deNemours & Co. Inc.E. I. DuPont deNemours & Co. Inc.
Joel BargerJoel BargerMeridium Inc.Meridium Inc.
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
Outline
• Background DuPont and SAP• The Business Problem• A Reliability Process Model• Sources of Reliability Data in SAP• Meridium and Reliability Tools• Concluding remarks - Importance of deriving value from the data
already being collected• Questions and Answers
Global operations, science based corporation• Based in Wilmington, Delaware • Consists of 14 strategic business units
plus joint ventures• 2001 Sales were $27,726 (million)• Total Assets are $40,319 (million)• 79,000 Employees• 200 years young
• 50+ Manufacturing Sites• $1,200 (million) in annual maintenance costs
Plant Maintenance User Group meeting November 10 - 13 2002
Banff, Canada
DuPont SAP Update
• Began using SAP in the early 1990s− PM used in Europe, Asia and Canada – R/2− US sites remained on Legacy Business and CMMS systems
• Now implementing a multi-year program to move North America onto SAP R/3 − Projects within the program are Business driven− “Go-Lives” are sequenced from 2002 thru 2004+− Multiple cluster architecture with leveraged configuration− Utilizing most R/3 Modules, including PM (no HR)− Bolt-on applications being used to augment SAP functionality,
including Meridium
The Business Problem
• Maintenance optimization requires:− Efficiency – Planning & Scheduling, Materials Procurement, etc…− Effectiveness – Doing the right work− Reliability Improvement - to eliminate failures and optimize
maintenance strategies.− The Stake for Reliability Improvement is BIG− The potential Uptime gain is worth 5X the maintenance cost
savings
• Identified a need for a Reliability Analysis Tool Set that would enhance the value of the data being collected in SAP PM
The Stable Domains of MaintenanceA
sset
Eff
ecti
vene
ss
ReactiveReactive
PlannedPlanned
RegressiveRegressive
Reliability Focused
Reliability Focused
Manage to the budget, Let
facilities deteriorate
Fix it when it fails, no facilities
deterioration
Fix before failure, no facilities
deterioration
UPtime and defect elimination focus,
improve the facilities
Source – Winston Ledet & DuPont CMLT
Reliability
Reliability is "the probability that a device will perform its intended function for a specified length of time when operated within the environment for which it was designed.“
Nachlas (1995)
What is reliability?
• Elimination of failures?
• Reduction in frequency & cost of repairs?
• Predictableavailability?
• Avoidanceof incidents?
…All of these
A Reliability Model – with a Systems View
DefectElimination
Operate/Maintain
FacilitiesDesign & Build
Analysis &DecisionSupport
SAP PM Business Process
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Work ID
Prioritize
Plan
Schedule
Execute
Confirm &Document
Work ID
Prioritize
Plan
Schedule
Execute
Confirm &Document
Operate/Maintain
Operate
TransactionalData
(Events &History)
Reliability Data from SAP• Notification Data
− Functional Location− Equipment Number
and Class− Breakdown Indicator− Catalog Codes
• Work Order Data− Cost – Labor &
Materials− Duration
PM with Defect Elimination - Reactive Reliability
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Operate/Maintain
Operate
TransactionalData
(Events &History)
DataAnalysis for
Stake
Prioritize Basedon Business
Impact
SelectWhat toWork on
Root CauseFailure
Analysis
EliminateSystemDefect
LeverageLearnings
Defect Elimination
• Analysis done in SAP PMIS, Excel or other tools
• Impact of lost downtime not tracked in SAP
• Maintenance Plans and Strategy changes not easily referenced to Root Cause Studies
• Data is not well organized
PM with Analysis & Decision Support
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
LeverageLearnings
Defect Elimination
Operate/Maintain
Operate
TransactionalData
(Events &History)
PM with Analysis & Decision Support
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
LeverageLearnings
Defect Elimination
Operate/Maintain
Operate
TransactionalData
(Events &History)
• Analysis tools linked to a common database in Meridium− Utilizes the SAP data structures
- F/L, Equipment, Class, Catalog Codes etc…
− Provides Analysis Tools not in SAP− Weibull Analysis− Risk Based Inspection− Reliability Centered
Maintenance− System Reliability, etc…
− SAP interfaced to Meridium
• Maintenance Plan and Strategy changes linked to F/L and Equipment− Recommendations are sent to
SAP as an M4 Notification Task− Replace, change inspection
interval, etc..
Reliability for New Facilities
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Defect Elimination
Design Procure
ComissionConstruct
Operate/MaintainFacilities Design & Build
Operate
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
Reliability for New Facilities
RoutineMaint
TurnaroundMaint
SpecificEquipment
Plans
Defect Elimination
Design Procure
ComissionConstruct
Operate/MaintainFacilities Design & Build
Operate
Analysis & Decision SupportStrategies
MaintenanceTurnaroundSpare Parts
TrainingOperations
AnalysisFunctional/Criticality
and/orRisk BasedInspection
Equipment Analysis Data
• Closing the Loop on New and Upgraded Facilities
− Project Engineers can look at performance data to make Life Cycle Cost Evaluations
− Mean Time Between Failures− Reliability Centered Maintenance− System Reliability, etc…
A Reliability Model – A Systems View
DefectElimination
Operate/Maintain
FacilitiesDesign & Build
Analysis &DecisionSupport
Data Requirements for Reliability
PM data enables analysis!
Available Data
What and Where?
SAP Fields Used
Functional Location, Eq Class
Failure Times Malfunction Start and End Date
Failure Modes Damage Code
Failure Costs Total Work Order Cost
Failure Effects Failure Effects
Failure Causes Cause Code
Equipment Classes, Characteristics and Catalog Codes
• The PM Equipment Class is a structured catalog of Equipment based on:− Legacy equipment types− Benchmarking
What does it cost to maintain a specific class of equipment
− ISA, ISO and other Standards
• For DuPont over 400 Classes have been defined− Characteristics have been defined for each Class
• Catalog Codes (Failure Codes) are related to an Equipment Class− Used ISO Standard 14224 as a basis for coding
Plant Maintenance User Group meeting November 10 - 13 2002