Absoft SAP Oil & Gas Maintenance and Operations Forum May 2012
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Transcript of Absoft SAP Oil & Gas Maintenance and Operations Forum May 2012
Maintenance and Operations Forum
Thursday 17th May 2012
Agenda
Introduction
Presentation – Standard SAP PM Reporting
Presentation - Mobility
Future Sessions
Agenda
Time Item
1300 Buffet Lunch
1330
Introduction to ForumContextAimsPrevious Forums
1340Session Presentation
Using standard SAP reporting to improve maintenance processes John Meiklejohn, Senior SAP Consultant, Absoft
1410 Questions
1420 Coffee Break
1430Session Presentation
Mobility Bjoern Harzer, SAP Solution Architect, Absoft
1500 Questions
1510Future Sessions
Topic SuggestionsAOB
1520 Coffee and Networking
Agenda
Introduction
Presentation – Standard SAP PM Reporting
Presentation – Mobility
Future Sessions
Health and Safety Information
Fire Alarm
Assembly Point
Fire Exits
Restrooms
Mobile Phones
Please put on silent/vibrate
About Absoft
Over 20 years in business
SAP consultancy practice – Oil & Gas
SAP experience since initial release of R/3
80+ permanent employees
High Staff Retention / Low Staff Turnover (7.4%)
Significant investment made to on-going training (12 days per annum)
Why Absoft?
SAP Oil and Gas Partner
SAP Business Objects Partner
Unrivalled track record
Global turnkey project capability
39 countries
Optimisation of Requirements Gathering – right people, right questions
Accelerated implementation via purpose-built Templates
Resource augmentation and change management
Continuity of service beyond go-live
Absoft has deployed SAP into 39 countries worldwide…
• EUROPE
• MIDDLE EAST
• AMERICAS
• AFRICA
• ASIA
Products and Services
SAP Implementation
SAP Consulting
SAP Training
SAP Support (Front & Back-office)
SAP Infrastructure
Data Migration
ReadSoft
Business Objects
Aims
Informal network for Oil and Gas organisations using SAP
Share best practice use of SAP in the Plant Maintenance arena
Foster discussion around potential solutions for common pain points
........?
Context
Forum not recognised or sponsored by SAP
Forum is not intended to in any way compete SAP User Group
http://www.sapusers.org/members/sigs.php?sig
Calum Davidson – [email protected] for more info
Keen to extend reach of forum: Open to all SAP using companies in Oil and Gas sector
Maintenance and Operations Forum alternating with Supply Chain
Absoft happy to act as co-ordinator – agenda/topics to be driven by participants
Questions
Agenda
Introduction
Presentation 1 – Standard SAP PM Reporting
Presentation 2 – Handhelds
Future Sessions
Agenda – SAP Reporting
Reporting in SAP - Overview
Reporting on Technical Structures Structure and Multi Level Reports Classification searches
Operational Reports Overview of Reports Using Selection Variants Setting Display Variants Downloading reports to Excel Reporting tips
Plant Maintenance Information System Overview of Standard analysis Overview of Flexible analysis Using Exceptions
Questions
13
Reporting in SAP
Reference Information: Structure of Functional Location (e.g.IH01) Object Lists (IH06, IH08,…) Multiple Level Lists (IL07, IE07,…) Purposes:
Finding Location codes and equipment numbers Verifying Technical Structure Reviewing/identifying spares, measuring points etc.
Operational reports List of Notifications (e.g. IW28, IW29, IW65) Lists of Work orders (IW38, IW39) List of Work order operations (IW37N, IW49N) Purposes:
Work lists Status Monitoring and progression Planning and preparation of work packs Interactive – allow you to access other functions by double click
Maintenance Information Reports Cost Analysis (MCI3,MCI8) Damage and Breakdown analysis (MCI5, MCI7) Purposes
Trends Problem monitoring Cost analysis Maintenance statistics (Mean time between failures, mean time to repair etc.) Provide limited drill down (e.g. cannot directly display/access notification from output)
Reporting on Technical Structures
Reporting on Technical Structures
Used to identify or locate technical objects in SAP
Can be used to: Locate assets to be worked on Safety critical assets Spare lists for assets Other assets impacted by problems As aid to identify where equipment is installed in technical systems
……
Demonstration 1
Operational Reports
Operational Reports
Provide information and functionality to support day to day maintenance activities
Notifications IW28 - Lists of Requests for maintenance (planning & preparation) IW65 - Lists of activities performed IW29 - Checking Notification progress IW28 - Approving/activating/closing notifications
Work orders IW38 - Daily/weekly/monthly planning and scheduling IW38 - Approving/releasing/closing work orders IW38/IW37N - Applying changes to ranges of orders IW39/IW49N - Work order progress IW49N - Monitoring work order operations O3O_MT01 Materials tracking (RLM)
Others IK17 - Measurement readings …….
Using Variants
Display and selection variants can be controlled by central SAP support for use by maintenance department personnel
Using variants makes it easier for operator to locate records requiring their action and display the relevant information to assist in identifying when they needs to do. Typical examples include:
Role Task Selection Criteria (Variant) Display Criteria (Variant)
Work Preparator
Present new maintenance requests for inclusion in weekly work pack meeting
Select all open Notifications within area of responsibility
Display equipment and Functional Location sorted by Priority and equipment criticality
Plan materials and internal resource requirements for work orders approved for action
Select all work orders which have been approved for planning of resources and materials
Display work orders sorted by priority, Start date and maintenance work centres
Work Scheduler
Schedule work orders to be issued to maintenance shifts
Select all work orders with status indicating work can be carried out but have not been scheduled or despatched (e.g. released and approved) with today’s date>= work order start date
Display total work per work centre to determine is there is a potential work overload, visibility of priority will enable scheduling of critical work.
Selection criteria could be manually entered but using pre-defined and reusable selection and display criteria saves time and reduces risk in incorrect entry by operator
Basic Variants can be created centrally (by system support) – local copies can be made to tailor to suit local needs
Demonstration 2
Summary of Operational Reports
Useful for providing information to support day to day maintenance activities
Can be tailored to suit daily activities for a job role/individual
Provide direct interaction with other PM functions
Can be downloaded readily to Excel for further analysis
SAP Plant Maintenance Information System
Plant Maintenance Information System
SAP information system contains several reporting structures to support analysis of Key figures in SAP plant maintenance
Each Report consists of: Characteristics – Objects to be reported e.g.:
Functional Location Equipment Document type
Key figures – values to be reported e.g. Count of Work orders Total Planned value
Characteristics form the ‘Rows’ of the report Key figures form the ‘Columns’
Each report uses information structures updated as data is saved in the system (e.g. when a work order is saved data is summarised into relevant Info Structures)
Characteristic Key Value 1 Key Value 2
Xxxxxxxxxxxxx 000000.00 0
Plant Maintenance Information System
Benefits: Readily provides summarised data for some key performance
indictors Provides periodic data analysis capability (with comparisons) Downloads details readily into excel for detailed analysis
Weaknesses Display , although customisable is limited, can only display one
characteristic at a time (e.g. if you want to see details on all equipment in functional locations, you have to drill down to equipment level for each functional location – can be resolved by downloading to excel)
Does not permit drilldown into transactional data (in all cases)
Plant Maintenance Information System – Continued
Two main types of analysis are available: Standard Analysis
Transactions reporting on standard Info Structures Useful function provided to tailor report output to suit business
requirements Flexible analysis
Enables analysis and reports to be specified using exiting info Structures or SAP database tables
Enables selection of characteristics to be used in analysis (Rows) Enable selection of Key Figures to be used in analysis (Columns) Enables inclusion of formula’s for additional information to be evaluated
(e.g. difference between Total Planned costs and actual costs)
SAP provides Exceptions functionality to further highlight or report on data depending on specific occurrences (e.g. where actual costs have exceeded a threshold value).
Information System – Standard Analysis
Standard Information Structures are provided to summarise records in SAP.
For Plant Maintenance several Information structures are provided analysing core key information on maintenance activity
Information structures are based on information summarised by: Technical Objects provides count and cost analysis of work carried out on technical objects
providing analysis by: Object Class (MCI1) Manufacturer on technical object (MCI2) Location (MCI3)
Maintenance Notifications e.g. :Mean Time to Repair & Mean Time between repairs (MTTR & MTBR)
Equipment (MCJB)Functional Location (MCJC)Notifications per period (MCI7)Based on use of breakdown and breakdown duration on Notifications
Damage Analysis (MCI5) – uses notification damage and cause code catalogs
Work Orders Cost Analysis (MCI8)
Standard Analysis –Objects AnalysisAnalysis provided for: MCI1 Object Class MCI2 Manufacturer MCI3 Location
Reports on: Counts
Notification Work orders – planned, unplanned completed Damages Breakdowns
Costs Planned, actual, Material, Internal, External etc.
Totals Breakdown durations
Used to identify Best/Worst performing assets in terms of: Breakdowns Downtime (asset unavailable) Costs Maintenance effort required
Standard Analysis – Objects Statistics
MCI6 Object Statistics
Count of functional locations in analysis
Count ofequipment in analysis
Sum of acquisition value registered on master record (general data_
Count ofFunctional Locations permitting a single equipment installation
Count ofFunctional Locations permitting a single equipment installation
Count ofFunctional Locations Without equipment installed
Count ofFunctional Locations Permitting installation of multiple equipment
Standard Analysis - Notifications
Breakdown Analysis – used to determine asset reliability and need for preventative maintenance routines
Equipment (MCJB)
Functional Location (MCJB)
Notifications (MCI7)
No of breakdown notificationsrecorded
Average Breakdown duration Average time between
Breakdown end and next Breakdown start
Time between 1st breakdown completion and last Breakdown Start
Total BreakdownDuration
Standard Analysis - CostsMCI8 Cost Analysis provides : No. orders created No. immediate orders Planned orders Unplanned orders No. completed orders Est. total costs Ext. material costs External wage costs Internal mat. costs Internal wage costs Other costs Services costs Total actual costs Total planned costs Total revenues act
Demonstration 4
Information System – Flexible Analysis
Flexible analysis evaluations and Structures permit creation of Info Structures and reports based either on existing Structures or SAP database tables
Different structures can be defined (for example Breakdown analysis and cost analysis) by selecting common characteristics and key figures from several PM based objects
Evaluations support the addition of formulas to enable additional calculations to be performed such as Cost Variance (calculated using standard key figures Total Planned costs and Total Actual cost
Threshold values can be set to highlight exceptions
Demonstration 5
Using Exceptions
SAP exception functionality is used to highlight ‘exceptional circumstances’ on analysis reports
Exceptions are created with reference to Info Structures – each standard analysis provided be SAP is linked to an info structure
For example Cost Analysis is constructed using Info Structure S115 – cost evaluation, therefore to create an exception for the cost analysis report, Info structure S115 would be references in the exception.
To see what info Structure is used by a standard analysis report, click on the icon indicated below and details will appear as shown
Info Structure to be referred to when creating an exception
Click to view data structure
Demonstration 6
Summary of Information System Reports
Useful for providing information to highlight and report on maintenance history
Exceptions can be tailored to highlight and work flow situation requiring intervention/monitoring
Provide good basis for determining reliability and cost of assets over several periods of time
Standard reports download readily into MS excel for further analysis
Questions & Comments
Agenda
Introduction
Presentation 1 – Standard SAP PM Reporting
Presentation 2 – Mobility
Future Sessions
Bjorn Harzer, Solution Architect17th May 2012
Mobility – applied to the Oil & Gas Industry
Agenda
Mobility Scenarios Benefits Challenges
Application to Oil & Gas Maintenance Supply Chain
Infrastructure Connect or Unwired?
Absoft activities Past, Present & Future
What is mobility about?
Mobility changes the way you work
Exec’s
Managers
Task workers
Consumers
Areas
DashboardsContactsCalendar
E-MailApprovalsRequests
Time & ExpenseField services
SchedulingDespatch
Self ServicesSales
Marketing
Drivers
Increased ProductivityIncreased EfficiencyIncreased Accuracy
ConvenienceEase of UseMotivation
Add value toexistinginfrastructure
Mobility – Challenges
Mobile Strategy
Security
Devices Diversity
ConfigurationApplication
Deployment
Monitoring & Backup
Backend Integration
Standards & Development
Multiple ERP systemsConnected / Unwired
Mobile phonesLaptopsTablets
Handhelds Barcode
RFID
SAP products / 3rd party products
IT Maintenance
Device settingsUser settings
Scenarios,Business change vs
“works like the business”
ResponsibilityIT support / business
Exposure of data
Mobility – Mobile Scenarios in Oil&Gas
Tagging Use of RFID / Bar code
Scenarios Asset tracking
Equipment history Measurement recording
Logistics & Transportation Container tracking
Inventory Control Accurate stock levels Reduced out-of-stock situation
Personnel Identification & Access control Attendance
46
Master
Data
Planning
Notification/ Work
Order Generati
on
Schedulin
g
Executio
n
Confirmation and TECO
Work order Closur
e
Analytics
Oil & Gas – Mobile Scenarios Maintenance
Alignment of Handheld solutions to maintenance processes
Subsequentwork
MeasurementsInspection
result recording
Workflow
Forces
1 2
5
Observation Work list Routing
Standards
3
4
6
7Ad hoc queryFailure / Damage
Downtime Time writingMaterials
used
Oil & Gas – Advantages in maintenance
Maintenance – Improve asset reliability through Improved efficiency
Paperless processing Routing of work list Subsequent workflows (mitigating actions) Ad hoc inquires (history of equipment, spare part lists …)
Improved data quality & reporting Accurate result recording (measurements, failure/damage/cause codes) Accurate time writing (effort, malfunction start/end, …) Accurate usage of materials
Improved compliance Performance standards Health & safety standards
48
Staging / Put away
Demand
Procure
Receipt (onshor
e)
Store (onshor
e)
Pick (onshor
e)
Pack (onshor
e)
Ship (onshor
e)
Receipt (offshor
e)
Oil & Gas – Mobile Scenarios Supply Chain
Rentals
Qualitymgmt
Inventory / Equipments
Tagging Put away
2
Pick list
3
Pallets /Containers
41 5
Return
Pack (offshore
)
Ship (offshore
)
Receipt (Backloa
d)
Reason for
return
Inventory / Equipments
Pallets / Containers
ReceiptDespatch
notePut away
6
Job execution
Container mgmt
Despatch
Despatch
478
Pack list
Mani-fest
Un-Packlist
Pack list
Mani-fest
Desp.note
Stock count
Reports(stock list)
Store(offshore)
2
Maintenance
Maintenance
Oil & Gas – Advantages for maintenance
Maintenance – Improve asset reliability through Reliable supply chain Improved efficiency
Accurate stock levels – reliable supply of spares Visibility of available spares in stock
Improved cost recovery Initiation of returns process (left overs)
“Connected” or “unwired”?
Web Application
Server
Handheld
Browser
SAP
SAPDB
MobileApplication
BAPIs
Barcode reader
Advantages Reuse of existing hardware and infrastructure Intrinsic backend integration, mobile application built with reusing existing knowledge
of SAP support teams ‘Dumb’ devices, easy deployment and application and device management Real time data
Disadvantages Live connection to SAP required
Connect
“Connected” or “unwired”?
Consume
‘intelligent’Application
Barcode reader
Advantages Consume: Multiple device types supported, ‘intelligent’, work ‘offline’ with up-to-date data Connect: Synchronisation to multiple backend systems Control: Deployment, Device management and Security Create: Platform independent application built in Java
Disadvantages Additional platform required
DB
Create
Eclipse
ControlManagement
Console
Sybase Unwired Platform
Web Services
Software Applications
Databases
Mobility – Choice!
Connected
A connected environment lends itself to situations where the area of the operation is contained and we can ensure 100% wireless network coverage
Warehouse- or -
Pack & Ship
Unwired
An unwired environment is useful in situations where a direct connection to SAP cannot be ensured all the time – or where a low bandwidth only is available
Maintenance operationsspecifically X-rated areas
Mobility – Strategic Decision – Rule of Three
The Rule of Three
A mobile platform reduces significantly TCO and accelerates deployment if you have
3 or more mobile applications
- or -
3 or more integration points
- or -
3 or more device types
Absoft – Steps
Where have we been? Implementation of handheld solutions
Inventory Management Work order management SCE management Equipment Tracking Warehousing
Where we want to go? Be an end-to-end partner for our customers
Deliver handheld application End-to-end integration to SAP backend system
What are we doing? Building template scenarios of Oil & Gas Operators
“Connected”: Inventory Management Maintenance Operations “Unwired”: (in the planning) out-of-the-box vs. tailor made to O&G
28 available Apps – out of the box
Industry Apps
SAP Electronic Medical Record
SAP Citizen Connect
Process Apps
SAP CRM Sales
SAP Retail Execution
SAP Field Service
SAP EAM Work Order
Employee Productivity Apps
Human ResourcesSAP Employee Lookup SAP Leave RequestSAP TimesheetSAP HR ApprovalsSAP Interview AssistantSAP Manager Insight
ProcurementSAP Shopping Cart ApprovalsSAP ERP Quality IssueSAP Transport Notification and StatusSAP Transport Tendering
FinanceSAP Travel Receipt CaptureSAP Travel Expense ApprovalsSAP Payment ApprovalsSAP GRC Access ApproverSAP GRC Policy Survey
SalesSAP Sales Order NotificationSAP Material AvailabilitySAP Customers and ContactsSAP Customer Financial FactsheetSAP ERP Order Status
This presentation and SAP‘s strategy and possible future developments are subject to change and may be changed by SAP at any time for any reason without notice. This document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or non-infringement
SAP Business Objects
SAP Business Objects Mobile
SAP Business Objects Explorer
Work order App – scope
Processes
2/2
People and roles
Technician / Worker Planner / Scheduler Back office
Schedule
and Dispatch
Review Work
Details
PerformWork
ConfirmWork
SAP ECC
Mobile Scenario
WorkPlanning
SAP ECCSAP ECC
Settlement and
Closure
SAP ECC
WorkCompletion
Work order App
“What is this all about?”
Field technicians rely on up-to-date information to perform their jobs efficiently. SAP EAM Work Order mobile application
empowers companies to gather, assess, and share the relevant information from the moment it is needed or identified. Built on
Sybase Unwired Platform the application addresses the requirements for plant maintenance operations staff for
Enterprise Asset Management.
Key Pain Points Addressed
Increase maintenance worker efficiency
Minimise manufacturing or supply chain interruptions due to asset malfunction or breakdowns
Enable data access and data entry anywhere, avoiding errors and speeding up end-to-end business process
Get timely and accurate information from the field
Increase asset visibility and performance
Key Product Features
Work Orders – Ability to view and update relevant information regarding tasks, operations, planned time and material
Technical Objects– Ability to view and update critical information about functional location and equipments to increase asset
uptime
Inventory– Ability for field workers to track and manage the parts without any delay or overhead
Business Partner – Ability to get a complete view of customer history and critical contact information
Facts & Figures:
Role: Service Technicians
•SAP Technology Stack: SUP 2.0; SAP NetWeaver DOE; SAP ERP 6.0
•Mobile Device Support: Windows 32 Tablets and Laptops
•Video http://youtu.be/MX3w0S8RKcE
•More Infohttp://www1.sap.com/solutions/technology/enterprise-mobility/manufacturing-apps/maintenance-app.epx
Mobility – Demo Materials ManagementInventory Management MM-IM
Goods receipt with printing of material label From vendor (MIGO/101) Return from work order / cost centre (MIGO 202/262)
Goods issue Pick list based on open reservations (MB25/26/MIGO) Manual issue to order / cost centre (MIGO 201/261) Returns to vendor (MIGO/122)
Transfers from bin to bin (MM02) From storage location to storage location (MIGO/311/313/315)
Stock take Ad hoc stock adjustment (MI10) Continuous Count (MI04)
Inquiries Find material by description (MM03) Show bin for material (MM03) Stock list for bin (MB52) Print material label Print bin label
User settings User defaults (e.g. plant, storage location, cost centre, printer, decimal point/time/date formats)
(SU3)
Manual replenishment Create stock purchase requisition
Link to the physical world & benefits
Linkage Understand physical world “How do the guys work on the shop floor?” - and - identify events in the physical world with postings in SAP
Result Mobile application works the way they work! Compliance through enforcement of business process
Mobility – Questions?
Agenda
Introduction
Presentation 1 – Standard SAP PM Reporting
Presentation 2 – Mobility
Future Sessions
Thank You