Gentile Consulting Scheduling Solutions for the Utility Industry
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Gentile ConsultingScheduling Solutions for the
Utility Industry
Gentile Consulting
SAP Highlights
Professional Highlights
• 11 Years SAP PS & PM
• Expert: Capacity Planning & Scheduling in PS
• PS Integration to Plant Maintenance
• Development of Plant shutdown scheduling
• Engineering Work Management
• Plant Daily work scheduling
• Prior Business: 22 Years in Power Industry managing resource planning and work management
• Extensive Supervision Experience in the Nuclear resource planning area
• SRO license certification from the Nuclear Regulatory Commission (NRC)
• Outage & Daily Scheduling Manager
Clients• Nebraska Public Power District-
• PSE&G
• Dominion Resources
• Lockheed Martin
• Nova Chemicals
• Coors
• King Pharmaceuticals
Industry / Process
• Nuclear Utilities
• Fossil Utilities
• Chemical Industry
• Pharmaceuticals
• Defense
• Brewing
C O N F IG U R A T IO N T R A IN IN GO N -S IT E
S U P P O R T
R E P O R T IN G
T E S T IN G
Gentile Consulting
““Technology can enhance but never substitute Technology can enhance but never substitute for processes”for processes”
Agenda
• Basic PrinciplesBasic Principles• Benefits of Scheduling in SAPBenefits of Scheduling in SAP• PS/PM Integration PS/PM Integration • Network ApplicationsNetwork Applications• Scheduling Business ProcessScheduling Business Process• Case StudyCase Study
Scheduled Dates are the only common factor throught the
Enterprise
Gentile Consulting
R/3Client / Server
FI
COAM
PS
WF
IS
MM
HR
SD
PP
QMPM
Applies to any Enterprise weather or not they Applies to any Enterprise weather or not they use SAP!use SAP!
Inability to maintain a schedule or working without a schedule disrupts
every level of the Enterprise.
Gentile Consulting
R/3Client / Server
FI
COAM
PS
WF
IS
MM
HR
SD
PP
QMPM
Applies to any Enterprise weather or not they Applies to any Enterprise weather or not they use SAP!use SAP!
Basic Principles
Maintenance Plans --- Operations Maintenance Plans --- Operations SchedulesSchedules
Maintenance Performs PlanningPlanning is the creation of the actual Planning is the creation of the actual
instructions of what task to perform instructions of what task to perform and how to perform the task.and how to perform the task.
It includes:
•The reservation of material and tools
•Identification of required resources
•Identification of any supporting activities (permits, scaffolds, plant or system conditions etc.).
•The sequencing of the tasks to be performed in a logical order.
Operations Schedules
Scheduling involves taking the output of Scheduling involves taking the output of the planning function and defining the the planning function and defining the time frame for performance of the time frame for performance of the operation or activity with consideration operation or activity with consideration of the operational impact of the of the operational impact of the maintenance.maintenance.
It involves sequencing the task in It involves sequencing the task in relation to other tasks, which may or relation to other tasks, which may or may not be related, in such a manner as may not be related, in such a manner as to optimize resources, production to optimize resources, production schedules and business requirements.schedules and business requirements.
Schedule Accuracy
The accuracy of the schedule The accuracy of the schedule produced is directly proportional produced is directly proportional to the quality of the individual to the quality of the individual work plans.work plans.
The accuracy of the schedule The accuracy of the schedule executed is proportional to the executed is proportional to the frequency of which it is updated.frequency of which it is updated.
Scheduling Process
• Scheduling must be integrated Scheduling must be integrated into your work management into your work management process beginning at the work process beginning at the work identification phase.identification phase.
• Scheduling process must include Scheduling process must include all support organizations in all support organizations in schedule developmentschedule development
Schedule Adherence
• If the schedule truly reflects the If the schedule truly reflects the needs and the priorities of the needs and the priorities of the Enterprise then schedule Enterprise then schedule adherence should be the goal of adherence should be the goal of every organization in the every organization in the Enterprise.Enterprise.
Schedule Adherence
S chedu le A dhearence
B ack logR esourceU tiliza tion100%
Critical Factors
• If you accept the importance of If you accept the importance of scheduling to the Enterprise you must scheduling to the Enterprise you must commit the best people to the job.commit the best people to the job.
• Scheduling must begin at the work Scheduling must begin at the work identification phase of a defined identification phase of a defined maintenance process.maintenance process.
• Schedule support must be the primary Schedule support must be the primary function of every organization.function of every organization.
• All work must enter the system and be All work must enter the system and be performed and monitored in one system.performed and monitored in one system.
Benefits of using SAP Scheduling
A single transaction that will provide access A single transaction that will provide access to:to:
• Custom schedules for all work groupsCustom schedules for all work groups• Resource reportsResource reports• Material requirements for any work periodMaterial requirements for any work period• Live POC reports for all work groupsLive POC reports for all work groups• Planned VS. Actual reports (work, Planned VS. Actual reports (work,
planning , costs etc)planning , costs etc)• Schedule multiple orders via a single Schedule multiple orders via a single
transactiontransaction
Benefits of using SAP Scheduling
A single transaction that will provide A single transaction that will provide access to:access to:
• Any cost report currently in your systemAny cost report currently in your system• Graphics (Gant and Pert charts)Graphics (Gant and Pert charts)• Earned Value AnalysisEarned Value Analysis• Change DocumentsChange Documents• All purchasing documents that pertain to All purchasing documents that pertain to
your scheduleyour schedule• Ability to distribute schedules Ability to distribute schedules
automaticallyautomatically
BASICS OF PS/PM INTERGRATION
R/3Client / Server
FI
COAM
PS
WF
IS
MM
HR
SD
PP
QMPM
PROJECT
WBS StructureWBS Structure
Operative NetworkOperative Network
Sub NetworksSub Networks
PM OrdersPM Orders
Build
Structure
Build
Structure
PROJECT
WBS StructureWBS Structure
Operation NetworkOperation Network
Sub NetworksSub Networks
PM OrdersPM Orders
WBS StructureWBS Structure
Operative NetworkOperative Network
PLAN MATERIALSPLAN MATERIALS
PLAN RESOURCESPLAN RESOURCES
PROJECT
PROJECT
Plan CostsPlan CostsPS
Plan MilestonesPlan Milestones
PROJECT PSPlan DatesPlan Dates
S F
S
S
S
S
S
F
F
F
F
F
Schedule Planning
Schedule Planning
Whiteboard Examples
Scheduling Business Process
UNIVERSAL PROBLEM
SCHEDULE ADHEARANCESCHEDULE ADHEARANCE
• INCONSISTENT PRIORITIESINCONSISTENT PRIORITIES
• COORDINATION OF SUPPORT ACTIVITIESCOORDINATION OF SUPPORT ACTIVITIES
• EMERGENT WORKEMERGENT WORK
• MATERIAL COORIDINATIONMATERIAL COORIDINATION
• MANAGEING INDICATORS VERSUS WORKMANAGEING INDICATORS VERSUS WORK
SCHEDULE ADHEARANCE
INCONSISTENT PRIORITIESINCONSISTENT PRIORITIES
““If I identified the problem it has to be the If I identified the problem it has to be the most important thing we have to do.”most important thing we have to do.”
““Lets work on this now so I won’t have to Lets work on this now so I won’t have to listen to them complain”.listen to them complain”.
SCHEDULE ADHEARANCE
COORDINATION OF ACTIVITIESCOORDINATION OF ACTIVITIES
““Operations doesn't have the permit Operations doesn't have the permit ready”.ready”.
““The scaffold is in the wrong place”.The scaffold is in the wrong place”.
““Engineering does not have the package Engineering does not have the package ready”.ready”.
““We are waiting for the crane”.We are waiting for the crane”.
““The only qualified engineer is on The only qualified engineer is on vacation”.vacation”.
SCHEDULE ADHEARANCE
EMERGENT WORKEMERGENT WORK
“ “ The compressor broke down and I had to The compressor broke down and I had to pull resources from our scheduled pull resources from our scheduled activities”activities”
Emergent Work can be planned on and Emergent Work can be planned on and compensated for!compensated for!
SCHEDULE ADHEARANCE
MATERIAL COORIDINATIONMATERIAL COORIDINATION
Materials Management is the most directly Materials Management is the most directly effected organization when a schedule is effected organization when a schedule is
not followed.not followed.
Has the most impact on the “Bottom Line”Has the most impact on the “Bottom Line”
• Inventory ManagementInventory Management
• Expediting FeesExpediting Fees
• Consolidating RequirementsConsolidating Requirements
• Shopping TimeShopping Time
5 Weeks Out
All ZRBM’s have been loaded into the Network.
All Corrective maintenance is assigned to the bucket
of the Network
3 Weeks Out
Weekly Scheduling Meeting –the forecast schedule is reviewed for
acceptance by maintenance, operations, planning, engineering and
materials
3 Weeks Out
Orders from the “bucket” aremoved to specific work days.
Current WeekExecution
Management Approval requiredto break the schedule.
1 Week Out
Schedule is communicated and distributed to all parties.
1 Week Out
Final review and schedule lockdown.The schedule is reviewed for final
acceptance by maintenance, operations,planning, engineering and materials
Work Week Schedule Development Process Overview
Weekly Scheduling AgendaMONDAY SCHEDULE REVIEW
MEETING• WORK STARTING ON MONDAY EXCEPTIONS ONLY• UPCOMING WORK FOR TUESDAY• REVIEW OUTSTANDING FOLLOW-UPS IN ACTION LOG.
TUESDAY SCHEDULE REVIEW
MEETING •EXCEPTIONS FROM BEGINNING OF WEEK TO DATE •UPCOMMING WORK FOR WEDNESDAY•LESSONS LEARNED FROM WEEKLY KPI’S
WEDNESDAY SCHEDULE REVIEW MEETING
•EXCEPTIONS FROM BEGINNING OF WEEK TO DATE•UPCOMMING WORK FOR THURSDAY•DETAIL SCHEDULE REVIEW FOR NEXT WEEK
THURSDAY SCHEDULE MEETING•EXCEPTIONS FROM THE BEGINNING OF WEEK TO DATE•UPCOMMING WORK FOR FRIDAY•REVIEW UNSCHEDULED WORK BUCKET PMC’S ONLY•STATUS NEXT SHUTDOWN NETWORKS (ARE THEY READY TO GO?) PMC’S ONLY•QUICK CHARGE QUE STATUS
FRIDAY SCHEDULE MEETING•INCOMPLETE WORK FROM BEGINNING OF WEEK•ITEMS REQUIRED TO BE CARRIED OVER TO NEXT WEEK•FINAL SCHEDULE COMMENTS FOR NEXT WEEK
Daily Scheduling Action Log
Case Study