Adopting Risk-Based Maintenance: Enabled By SAP Asset . PDF Free Download

2y ago

76 Views

1 Downloads

3.43 MB

51 Pages

Report/dmca

Download PDF

Transcription

Adopting Risk-Based Maintenance: Enabled bySAP Asset Strategy and Performance ManagementDean Fitt, Solution Manager, SAP SESession ID # ASUG82661May 7 – 9, 2019

About the SpeakersDean Fitt Solution Manager, SAP SE Dean is a member of SAP’s global Enterprise Asset Management(EAM) solutions team. Dean is based at SAP GlobalHeadquarters in Walldorf, Germany. Dean joined SAP in 1998 asa Plant Maintenance (PM) Consultant with SAP Africa, beforemoving to Germany in 2001. Fun fact: Rode the Cape Argus cycle tour 26 consecutive times

Key Outcomes/Objectives1. A risk-based maintenance approach enablesbetter decision-making for maintenanceplanning and reduces the probability of assetfailure2. Minimize environmental and safety risks3. Enhance asset reliability and availability

Agenda SAP Intelligent Asset ManagementBusiness Background and DriversSolution OverviewSummaryQ&A

DisclaimerThe information in this presentation is confidential and proprietary to SAP and may not be disclosed without the permission of SAP.Except for your obligation to protect confidential information, this presentation is not subject to your license agreement or any other serviceor subscription agreement with SAP. SAP has no obligation to pursue any course of business outlined in this presentation or any relateddocument, or to develop or release any functionality mentioned therein.This presentation, or any related document and SAP's strategy and possible future developments, products and or platforms directions andfunctionality are all subject to change and may be changed by SAP at any time for any reason without notice. The information in thispresentation is not a commitment, promise or legal obligation to deliver any material, code or functionality. This presentation is providedwithout a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for aparticular purpose, or non-infringement. This presentation is for informational purposes and may not be incorporated into a contract. SAPassumes no responsibility for errors or omissions in this presentation, except if such damages were caused by SAP’s intentional or grossnegligence.All forward-looking statements are subject to various risks and uncertainties that could cause actual results to differ materially fromexpectations. Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only as of their dates,and they should not be relied upon in making purchasing decisions. 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC5

SAP Enterprise Asset Management Portfolio – Business CapabilitiesState-of-the-art business processesLeverage new technologies to enable new assetmanagement business processes anywhere and anytime.Asset Strategy andPerformanceReal-time insightsBring together information from operational and businesssystems using IoT for scalable transparencyRisk-based asset strategiesAdopt risk based approach to determine critical assetsdriving optimal asset strategiesThe power of prediction, optimization andsimulationDrive smarter decisions, improve reliability, and P S/4HANASAP Leonardo IoTCollaboration throughout the asset lifecycleShare asset information, access one version of the truth,and collaborate on a cloud-based business network withintegrated processes 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC6

SAP Asset Strategy and Performance ManagementMonitor and ImproveDefine Systems & Assets to AnalyzeContinuously monitor the performance and effectiveness ofthe maintenance strategiesAsset Central Foundation enables asset information to be modelledutilizing templates based on ISO standards e.g. ISO14224. Models,equipment, locations, systems, groups, spare parts, documents,instructions, failure modes are all included in Asset CentralFoundation.Implement MaintenanceStrategiesImplement the recommended actions/tasks in themaintenance management system.Develop RecommendedActionsThe result of the RCM/FMEA will recommend preventiveand/or corrective tasks. These tasks can use existinginstructions or can trigger a new instruction to be created.Identify Critical AssetsThe Risk and Criticality assessment ranks assets byrisk and criticality which can then be used as thebasis for further analysis. This is achieved by settingup a matrix of consequence of failure vs probability offailure.Perform AnalysisUse proven methodologies like Reliability CentredMaintenance (RCM), Failure Modes and Effects Analysis(FMEA), Preventive Maintenance Review* (PMR), RiskBased Inspection** (RBI), Root Cause Analysis* (RCA) orChecklists to identify the optimal maintenance strategies foryour assets.*planned** partner planned 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC7

Business Background and Drivers

Good Asset ManagementLeads to Improved Business Outcomes Reduction in safety incidents Reduction in EnvironmentalIncidents Adherence to Statutory Regulations Reduced Annual service andmaintenance cost Adherence to Plannedmaintenance budget vs. actualcost Reduced energy and inputcosts 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLICDriveSafe operations Increased Overall EquipmentEffectiveness Increased Return on assets Reduction in UnplannedoutagesReduceCostsMaximizeAsset Productivity9

Technology is changing our approach to maintenance*Use of Maintenance Strategy – TodayReactivePreventivePredictive*Use of Maintenance Strategy – FutureReactivePreventivePredictiveAlthough still relevant, preventivemaintenance can result in overmaintaining assets and highercostsThe Internet of Things is leading toincreased use of predictivemaintenanceThe goal is to enable more ITdriven (data science & rulesdriven) approaches to predictivemaintenance in order to reduceunplanned failures and the numberof overall maintenance actions*Proportion of maintenance strategies are for illustration purposes only and will vary based on many factors 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC10

Determining the Correct Maintenance StrategyApply industry standard methodologies to determine optimal asset strategiesPreventiveRisk & Criticality AnalysisRCOn-ConditionRCMAsset StrategiesPredictiveFailure FindingMethodologiesRun to FailureRCAReliability CenteredMaintenanceFMEAFailure Modes &Effects AnalysisPMR*PreventiveMaintenanceReview*RootCause AnalysisRBIModification 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC*Risk Based Inspection*Planned11

Solution overview

SAP Asset Strategy and Performance ManagementMonitor and ImproveImplement MaintenanceStrategiesDevelop RecommendedActions 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLICDefine Systems & Assets to AnalyzeSAP AssetStrategy andPerformanceManagementIdentify Critical AssetsPerform Analysis13

SAP Asset Central FoundationNext-Generation Master Data LayerAsset ClassificationMaster Data LayerClassesSubclassesAsset onsGroupsAnnouncementsSpare PartsAsset ilureAsset InformationInstructionsAlert Types WorkOrdersFailureModesOrganization RepresentationCompanyProfileIAM 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC14

Models and EquipmentTemplate SystemTopCLASS:TransformerModel TemplateFamily ACLASS:MotorSUBCLASS:PowerSUBCLASS:InstrumentModel TemplateFamily BModel TemplateFamily ECLASS:PumpCLASS:SwitchgearMODEL TemplateModel TemplateClass Type:E-23E-23MODELE-23-8384EQUIPMENTE-23-8384Ser No: 981 4981Model TemplateClass Type:E-24MODELModel TemplateClass Type:E-25E-23-9547MODEL TemplateE-24MODELE-24-7487MODELE-24-8748 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLICEQUIPMENTE-23-9547Ser No. 978 2547EQUIPMENTE-24-7487Ser No: 898 8742EQUIPMENTE-24-8748Ser No: 257 688415

Systems:Define the boundaries and function of the systems that contain the selected equipment A system is an overview with a logical structure throughoutcomplex assets or asset structuresExamples are fluid systems, braking systems or pipingsystems.Systems can be nested.In parallel the topology of a system can be visualized usingthe functionality of our Hilscher Net IoT partnership.Power GenerationSystemEquipmentEquipmentCooling WaterSystemEquipmentEquipmentEquipment 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC17

GroupsModels, Equipment and Locations There are different types of groups e.g. assignequipment into different groups based on riskand criticality assessment. Objects that are grouped can be analyzed bypopulation or age. You can filter by all kinds ofobjects (Equipment, Model, Subclass,Manufacturer etc.) An FMEA Assessment can be performed on agroup 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC18

LocationAsset Hierarchies 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC Flexible configuration ofnaming conventions formaster datastandardization Parent/childrelationships for masterdata inheritance19

Failure Modes A failure mode is aprobable failure that couldoccur to piece ofequipment Failure Modes can beassigned to Models,Equipment, Locations,Spare Parts and Groups. They are based on asubclass and havedifferent categories andtypes. RAMS Figures (Reliability,availability, maintainabilityand safety) and KPIs(MTTF, MTTR, MTBF). 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC21

InstructionsInstructions describe how to execute maintenance There are different types ofInstructions e.g. Breakdown,Installation, Operations, PlannedMaintenance Instructions can be assigned toModels, Equipment and Groups Failure Modes can only be assignedto Breakdown Instructions. You can define the number of steps,duration, criticality, safety rules, toolsand required spare parts. Additionally you can definepreconditions, the steps themselvesand post checks. You can add different documents. Ifyou added an animated 3D file (.vds)the end user can view thesequences. 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC22

FunctionFunctions are used to definehow the assigned objects areintended to operate. You canassign functions to equipment,models, locations and systems.You can currently use thisfeature in the Reliability CentredMaintenance (RCM)assessment. 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC23

Asset Central FoundationERP IntegrationCheckout the new integration guide! Integration scenario ensures asset information is kept current betweenAsset Central (ACF) and Enterprise Asset Management (EAM).Cloudsolutions Integration between AC & EAM, covers both data & user experienceimprovements. AINPdMSASPMAsset CentralIntegration provides Bi-directional synchronization of asset informationfor technical objects –oEquipmentoFunctional LocationoDocumentsoNotificationsoWork ordersOn-PremisesolutionsS4HANA/ECCSupported Releases – S/4 HANA On Premise 1709 & above, ERP Enhancement package 6 & above. 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC25

SAP Asset Strategy and Performance ManagementRisk and Criticality AssessmentAssess which are the critical assets to determine which assets are likely to benefit most from application ofRCM, FMEA or PM ReviewDescription: Assessment of asset(s) (equipment, location, group or system) criticality based on risk score. Calculation of risk score based on different dimensions and scales and for different impact categories. Supporting the selection of the most appropriate analytical process (i.e. RCM/FMEA, PM review, CM) basedon the result of the criticality assessment Informed assessment based on historical maintenance data and relevant KPIs (EAM/PdMS integration). 2019 SAP SE or an SAP affiliate company. All rights reserved. ǀ PUBLIC27

Reliability Centered Maintenance (RCM)The purpose of the standard SAE JA1011, published in 1999, is to set out the criteria that any process must comply with in order to be called “RCM.” Thetwelve pages’ document,

Dean joined SAP in 1998 as a Plant Maintenance (PM) Consultant with SAP Africa, before moving to Germany in 2001. Fun fact: Rode the Cape Argus cycle tour 26 consecutive times. Key Outcomes/Objectives 1. A risk-based maintenance approach enables better decision-making for maintenance planning and reduces the probability of asset failure 2. Minimize environmental and