MEB

Turnaround / Shutdown Management with SAP Enterprise Asset Management Dean Fitt

SAP AG

A collaboration of:

What I’ll Cover

SAP Enterprise Asset Management can be used to manage the whole lifecycle of a Shutdown.

Integration and ease of use based on ERP components plant maintenance (PM) and project system (PS) enabled through the use of Maintenance Event Builder (MEB).

Portfolio and Project Management (PPM) and Multi Resource Scheduling (MRS) that support the process.

Highlight enhancements and new functionality.

Key points to Take Home

Questions

Contents Introduction & Overview

SAP Solution for Shutdown Management

Wrap Up

Why are Shutdowns so important?

Most critical periodical event during the plant life cycle.

Single most influential contributor to the total cost of maintenance.

Safety, Health, and Environment regulations must be adhered to.

Ensures future plant performance and safe-guards the investment.

Compliance with Statutory Regulations

Complex event - time of increased activity, with numerous vendors, contractors, and heavy equipment engaged in multiple tasks in close quarters.

Involves strong interaction between Maintenance and Operations.

Definition

Initial Planning

Scoping

Work Lists

Plan Cost

Resource Plan

High Level Schedule

Evaluation

Demobilization

Post Mortem

Cost Reconciliation

Financial Report

Scheduling

Critical Path

Resource Leveling

Daily Schedules

Planning

EH&S Plan

Work Packages

Pre-shutdown preparation

Align Capital Work

Cost Plan (Budget)

Typical Phases of a Shutdown

Execution

Execute Work

Packages

Time, Material Confirmations

Manage Break-in Work

Progress Reporting

Equipment Testing

Work Permits

H 1 H 2 H 3 H 4

Definition Planning Execution Evaluation

Timeline

Scheduling

Contents Introduction & Overview

SAP Solution for Shutdown Management

Wrap Up

Planning, Building, and Commissioning Assets

Asset Visibility and Performance

Operational Risk Management

Optimized Asset Operations and Maintenance

Real Estate Lifecycle Management

Plan & Design

Procure & Build

Com- mission

Operate Maintain Decom- mission

SAP Solution for Enterprise Asset Management

MRO Procurement & Inventory

Asset Maintenance

Financial Optimization Reliab. Reporting

Inspection & Calibration

Human Resources

RFID and Mobile Devices

Asset Health Monitoring

Materials Requirements Planning Project Management

Core Financials

Design & Specify

Procure & Build

Decom- mission & Dispose

Operate & Maintain

Enterprise Asset

Management

SAP supports organizations to efficiently and sustainably manage the whole lifecycle of physical assets in terms of

performance, risks, and expenditures to achieve and maintain the stated business objectives. Integrated asset management processes to collaborate across all related activities such as finance, HR, risk, and compliance – easily deployable

in modular implementable steps

Asset intelligence and a holistic view of performance, risks and expenditures throughout an asset’s lifecycle to ensure efficient utilization of assets

Continuous and proactive operational risk management to support instant decisions and minimize disruption

Leverages the SAP Business Suite

* According to PAS 55, the BSI standard for good practice in asset management

Definition

Portfolio and

Project Management (PPM)

Plant Maintenance (PM)

Project System (PS)

Maintenance Event Builder (MEB)

Materials Management (MM)

Maintenance Cost Budgeting (MCB)

Evaluation

Portfolio and Project

Management (PPM)

Plant Maintenance (PM)

Project System (PS)

Financial (FI) / Controlling (CO)

Materials Management (MM)

Business Intelligence (BI)

Scheduling

Plant Maintenance

(PM)

Project System (PS)

Multi Resource Scheduling (MRS)

Enterprise Project Connection (EPC)

Planning

Plant Maintenance

(PM)

Project System (PS)

Maintenance Event Builder (MEB)

Document Management System (DMS)

SAP Solutions Supporting Shutdown

Execution

Plant Maintenance

(PM)

Project System (PS)

Cross Application Time Sheet (CATS)

Mobile EAM Work Order

Materials Management (MM)

Multi Resource Scheduling (MRS)

High Level Architectural View – Shutdown Management

SAP ERP Plant Maintenance

SAP Portfolio and Project Management

SAP ERP Project System

Ass

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Portfolio Initiative (Program) Portfolio Item (Project / Proposal)

Portfolio / Strategic Buckets

optional: Project, Phases, Tasks, Checklist Items...

Network Activities

Project

WBS

PM Order

Notification

Technical object Maintenance Plan

Maintenance Cost Budget

Base Planning Object

Costing Model

Maintenance Event Builder

Task List

PM Order

Multi Resource Scheduler

Definition

Definition

Evaluation Scheduling

Planning

Execution

Portfolio & Project Management (PPM)

Project System + PM Orders

+ Maintenance Event Builder

Multi Resource Scheduler (MRS)

Job Control and Analytics

Time

Pla

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Planning Bucket Quarterly Daily shift Hours Monthly

Asset Details Plant/ Group Floc Floc/Equip Equip Subsection

Resource Role level Trade Team

Individual Individual Team

Work details Project level Orders operation

Operation Operation Phases & task

Strategic Planning

Tactical Planning

Execution Planning

Detailed Schedules

Execution Controlling

The Planning and Scheduling Life Cycle

Definition

Evaluation Scheduling

Planning

Execution

SAP Portfolio and Project Management

Portfolio Planning & Monitoring

Long Term Investment & Portfolio Planning

Risk Assessment, Prioritization

High Level Cost Planning

High Level Resource Planning

Capital Pre-Approval

SAP Portfolio and Project Management 5.0

Project Management & Execution

Project Scheduling

Detailed Resource Planning

Detailed Cost Planning & Approval

Scheduling & Dispatching

Regulatory Reporting

Document Management

SAP Project System (PS)

Core Processes / Activities

- Developing Work Lists and Packages

- Cost Planning

- Processing of work orders

- Update of technical assets

SAP ERP for Maintenance,

Logistics Financials, HR

Maintenance Event Builder (MEB) – A Workbench for Shutdowns

t

Prod. Line / Asset 1 Prod. Line / Asset 2

Prod. Line / Asset 3

Prod. Line / Asset 4

General Task Lists Standard Network / WBS

Notifications

Maintenance Event Builder

Orders Project

Revisions

Maintenance Opportunities /

Events

Facilitates Maintenance Planning and Scheduling

Helps eliminate redundant tasks within a work package

Sequences maintenance tasks by assigning them to appropriate time frames

Planning project based maintenance events

PS - Project Builder

MEB - Workbench

PM - Developing Work Lists

PM - Maintenance Plans

MCB - Data Flow

Extractor Maintenance Orders

Maintenance Orders

0PM_DS04

Maintenance Plans

Maintenance Task list (Notifications)

Extractor 0PM_DS07

0PM_PRM_PLCS_1

Cost planning and budgeting

Forecast of resources like parts, service and internal resources

Estimated Unplanned demands

0PM_C05

0PM_C01

0PM_C06 0PM_OPA_1

Planning

Definition

Evaluation Scheduling

Planning

Execution

MEB - Review Backlog

The planner reviews all open maintenance requests that need action.

The planner can group these task based on priority, location and resources needed

MEB - Review Maintenance Opportunity Planner meets with operations team to plan shutdown

Planner enters these opportunities as revisions in MEB

Based on the dates of the shutdown and priority, the planner assigns maintenance requirements (notification or WO) to the event.

MEB – Creating Work Packages for the Shutdown

Once the work load is evaluated by operations and maintenance, the planner generates orders or assigns generated orders to the work package

MEB - Generate Orders for a Revision

Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical objects are deleted

MEB – Optimizing the Work Package

Notification

Chk1

T2

T1

ST1

ST2

ST3

ST4

ST5

SB1

ST1

ST6

ST3

Order

ST1

Order

ST3

Elimination

Revision

Order

ST3

Order

ST2

Order

ST4

Order

ST5

Order

ST1

Order

ST6

Insert video clip here: -Overview Radiation Shaft

Scheduling

Definition

Evaluation Scheduling

Planning

Execution

MEB - Assigning Orders to a Project Automatically

PM/PS - Assigning Orders to a Project Network

Orders can be assigned manually using drag and drop or automatically based on the Reference PM/PS Element field. Transaction ADPMPS (does not require MEB)

• Network Scheduling: – schedule activities of one network only

• Overall Network Scheduling

(CN24) – schedule all connected networks/subnetworks (and PM/CS

orders) simultaneously

• Overall Network Scheduling with Selection Options (CN24N)

– schedule selected networks/subnetworks simultaneously – analyze dates of subnetworks (and PM/CS orders) using the

Subnetwork Monitor

PS - Network and Overall Network Scheduling

PS - Project Editor • The Project Editor is enhanced with

• Additional Data Sets for example PM/CS Order Dates

• Date Planning and Scheduling (new)

• Advanced Date Overviews and Comparison

• Usability Improvements

Display PM/CS order in hierarchy

Activity Dates Overview

Date Planning and Scheduling Overall Dates Overview

In the Gantt Chart, you can:

Display dates of project objects (Tabular area, Graphical area)

Change dates and durations (Drag time bars for WBS elements, Specify dates in tabular area)

Define user-specific settings and manage variants (for example, time bar labels)

Choose different timescales (for example, monthly)

Print and print preview Gantt chart

PS - Project Editor Gantt Chart

Multi Resource Scheduling (MRS)

Work Center Capacity

Alert Monitor

Demand Gantt

Work Center Gantt

MRS - Scheduler Workplace

SAP Enterprise Project Connection (EPC)

Execution

Definition

Evaluation Scheduling

Planning

Execution

Operations and activities can automatically be defaulted for users in CATS

Additional data such as remaining work can be entered via mouse click.

Time Confirmation Using Cross Application Time Sheets (CATS)

SAP EAM Work Order Mobile Application

• Notification Management

■ Create, view, and edit notifications and related objects (activities, items, tasks)

• Work Order Management

■ Create, view, and edit work orders

■ Display related business partners and historical data

■ Record working time and material consumption

■ List, calendar, and map view

Technical Object Management

■ View equipments and functional locations

■ Display technical object on a map

■ Display associated documents

■ Display history and characteristics

Business Partner

■ Display business partner header and contacts

■ List and map view

Inventory Management

■ Track and manage inventory

■ Material consumption booked on orders updates inventory

Standard solution for mobilizing SAP Enterprise Asset Management

Built on industry leading Sybase Unwired Platform

Online & Offline

Work Permit Management (WPM) Project with Statoil and ConocoPhillips to develop an Oil&Gas specific permit to work

solution.

Existing functionality in SAP Work Clearance Management (WCM) has been enhanced, so that industry specific work processes for work permits can be configured in customizing.

WPM - Work Preparation Create Operational Valve & Blind List

Evaluation

Definition

Evaluation Scheduling

Planning

Execution

KPI Framework Reports within

BCV Dashboards Crystal reports

integrated

Reporting and Analytics Options

Contents Introduction & Overview

SAP Solution for Shutdown Management

Wrap Up

High Level Architectural View – Shutdown Management

SAP ERP Plant Maintenance

SAP Portfolio and Project Management

SAP ERP Project System

Ass

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Portfolio Initiative (Program) Portfolio Item (Project / Proposal)

Portfolio / Strategic Buckets

optional: Project, Phases, Tasks, Checklist Items...

Network Activities

Project

WBS

PM Order

Notification

Technical object Maintenance Plan

Maintenance Cost Budget

Base Planning Object

Costing Model

Maintenance Event Builder

Task List

PM Order

Multi Resource Scheduler

Best Practice Stage 1 - Developing

Planning of Effort

90% of Planned Work

Completed

Within Budget <5% Over

All Equipment inspected

Stage 2 - Maturing

Tight control of scope

Manage resource

constraints

Daily status update of

progress

95% of planned work

completed

Estimates of work based on

industry norms

Equipment available for

maintenance

Delays in equipment start-

up as a result of integrity

issues

Stage 3 – Best Practice

Portfolio management

process in place

Issues rectified early

Quality of work to ensure

on-time start-up

Materials and Resources

managed to ensure

availability at right time

Work Permit process

streamlined

Early planning

Shutdown and start-up on

time

Dean Fitt SAP AG

[email protected]