How to extract Maximum from · 2019. 4. 15. · KNPC Maximo Oil & Gas Modules Incident Reporting...
Transcript of How to extract Maximum from · 2019. 4. 15. · KNPC Maximo Oil & Gas Modules Incident Reporting...
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KNPC Success Story
How to extract Maximum from� ���� �
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About Kuwait National Petroleum Company (KNPC)
•Established in 1960 ‐ Wholly owned subsidiary of Kuwait Petroleum Corporation.
2 Refineries ‐ Mina Al Ahmadi and Mina Abdullah
Our Products ‐ Refining Crude Oil, Gas Processing and Petroleum Goods
Markets ‐ Supplying to Local and International Markets
Employee Strength – 6000
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We Started our Journey in 2005 ..
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Control Of Work Manage
Supply Chain
Change Management
Work Management
Health Safety, Security &
Environment
Knowledge Management
ManageAssets
Compliance
Operations
Hazard Risk Matrix Risk Assessment
Work Permit Certification Work Permit
Blinding / De-blinding Plan
Inventory Purchasing
Contracts Material Certification
PrioritizationMatrix
Condition for Work Job Planning
Work Order Quick Reporting Maintenance Log
OperatorTasks
OperatorLog
OperatorProcedure Benefit & Losses
Standard Actions
RegulatoryCompliance
Qualification
Audit and Survey People
Asset List
Solutions Lessons Learned Solution Search
Certification Assets Location
Location Profile Operating Policy
KNPCMaximo
Oil & Gas Modules
Incident Reporting Investigations
Safety Performance Audits
MOC Request MOC
Plant Modification Requests
Complete Utilization
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KNPCMaximo
Cross-Platform
Integration
Piping Inspection System
Digital Operator Rounds
Laboratory Information Management System (LIMS)
IP21
e Sourcing
Asset Performance Management
HSSE and Safety Training System
Cross‐System Integration
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9,365,252
588,997
362,793
1,348,201
365,949
292,91
260, 903
7,768
ItemMaster
Permit to work
Invoices
Purchase OrderWork Order Tracking
AssetsTracking
DeskTop Requisitions (DTR)
Contracts
19,045
Global Vendors & Contractors record
KNPC Maximo Utilization
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KNPC Strategy
Moving toward pure IBM environment with Multitenancy
KNPC will provide Maximo private cloud for its subsidiaries and Cross sister companies.
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KNPC End User Experience
Jamil Hassan Alawadhi Team Leader Procurement – KNPC Commercial Department
Mohammad Khaled Almarzouq Team Leader Mechanical Maintenance ‐ KNPC Maintenance Department
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Mohammad Al-MarzouqTeam Leader Mech. Maint. – Mina Abdullah Refinery
Subject Matter Expert for Sealing and Bolting Technology
SUCCESS STORY AUTOMATE KNPC UNIFIED BUSINESS PROCESS USING
MAXIMO APPLICATIONS
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
CONTENTS
Major enhancements that have been implemented in KNPC through Maximo online are as follows:
1. Electronic Work Permit System2. Maintenance E-Log Book.3. ICR – Inspection Corrosion Report4. IAT – Inspection Advice Ticket applications5. HSSE Reporting6. E-PMR.
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Electronic Work Permit System (EWPS) has been implemented in all KNPCRefineries since 2015 to meet KNPC safety requirement .
Benefits• Reduce the paper usage and save the Environment.• Top management can check the work permits status from their desktop (DCEO
and Team Leader level )• Very useful for conducting Safety Performance Audit (SPA) & Work Permit
Audits• During unit shutdown same Work Permit could be renewed up to seven days
WORK PERMIT SYSTEM
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
WORK PERMIT SYSTEM
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
WORK PERMIT SYSTEM
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
WORK PERMIT SYSTEM
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MAINTENANCE E-LOG BOOKMaintenance E-log book system has been implemented in all KNPC Refineriesfor Maintenance division since 2016 .
Benefits• Daily report being generated in system by unit Supervisor and circulated up to
Team Leader Level through Maximo.
• Every work order status is being monitored through Maximo
• Records of all activities are available digitally in Maximo
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MAINTENANCE E-LOG BOOK
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
• ICR – Inspection Corrosion report issued by Inspection & Corrosion division upon completion of final inspection of any equipment
• These reports were earlier issued as hard copies & distributed to Maintenance Planning & Operations.
• After Maximo implementation, ICR is being circulated to respective divisions through automated system
AUTOMATION OF ICR- INSPECTION CORROSION REPORT
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Inspection Corrosion Report (ICR) Maximo application
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
• Inspection / Corrosion engineer willissue an IAT after inspection ofequipment or piping throughMaximo.
• IAT will contain observations anddetails of repairs along with therepair procedure
• IATs were circulated throughMaximo instead of distributing thehard copies to MaintenancePlanning & Operations
AUTOMATION OF INSPECTION ADVICE TICKET (IAT)
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
AUTOMATION OF INSPECTION ADVICE TICKET (IAT)
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Reporting the Near Misses, Substandard Acts /conditions , Incidents in KNPC through Maximo online and details are as follows:
Near Misses (NM)
Substandard Act (SA)
Substandard Condition (SC)
HSSE Incidents
HSSE Improvement
HSSE Investigation
HSSE Recommendation Tracing
HSSE Lesson Learned
HSSE REPORTING
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
HSSE REPORTING
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
HSSE REPORTING
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
HSSE REPORTING
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Plant Modification is Hardware or Software change to the existing Plant.
Objectives:
• To ensure that implementation ofPlant Modification does notadversely affect the integrity of theplant, inherent safety and reliability.
• To optimize the process fromproposal initiation to implementationstage
Automation of Plant Modification Request (E-PMR)through Maximo
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Automation of Plant Modification Request (E-PMR)through Maximo
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MAXIMO Middle East User Group Conference 2019
Supercharging Maximo with AI and Analytics
Jamil Al-AwadhiTeam Leader Procurement – Head Office
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
OUTLINE
MPID
New PPE Management System
RFID
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Material Photo IDentification
Objective• To take the image of all spares and critical materials
• Link image to item master in Maximo
• To inspire the imagination
• To provide additional tools to Users and UDs
MPID
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MPID - BenefitsVALUE ADDED INFORMATION
SAVING TIME & EFFORT COST SAVING
Evaluation of offersHelp Engineers to see exact materials being evaluatedUseful for new UDsFamiliarize new UDs to visualize the materials used in Refinery operationsPreservation of informationPreserve both old and new informationItems’ photos still will be available in case the materials is nil balance
Physical Stock checkWill enhance the process Material InspectionEase in inspection of materialsDetails to VendorEasy to forward information to vendorMDRReduction in clarifications
GeneralizationEasy to identify the expensive spare parts that can be generalizedDuplicate itemsEasy to identify duplicate items without physically checkingAuctionEasy to exchange information with K-companies and other vendors thus increasing the realization value.
Future integration to e-auction (Reverse Auction)
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MPID
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
MPID - Benefits
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Objective
• To standardize the process of issuance of Personal Protective Equipment (PPE)
• Tracking usage of PPE
• Budgeting of PPE requirement• Quantifying Emergency, Shutdown, Personal & Visitor PPE
issues
• Optimizing the consumption of PPE
New PPE Management
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
New PPE Management - Tracking
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
New PPE Management – Consumption & Budgeting
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
ObjectiveAutomation of Warehouse through RFID not only lead to enhancement of service but also enables the other divisions to take full benefit of the technology, connecting manufacturer to the end-user thus streamlining the data flow and visibility.
Executive alignment• Provides opportunity to process and execute company’s initiatives in alignment with
objectives• Enable business value• Optimized decisions • Streamline information
Financial benefit• Financial benefits arise from improved process and efficiency, enable transparency,
reduce of cycle time, reduction of paper work and increasing the quality and life of material
• Better usage of working capital• Reducing scrap, waste and surplus
RFID
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
RFID
PHASE -I
PILOT PROJECT
Involving various scenarios of Warehouse
operation using RFID technology
Completed
PHASE -II
IMPLEMENTATION
Preparation of scope of work and implementing on
limited items
In Progress
PHASE -III
SCALING THE APPLICATION
Maintenance, Shutdown, Assets, Space optimization,
Digital signature
Future Plan
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
Looking for below technologies
Automated re-ordering
Augmented Reality in Warehouse Operations
Identification of duplicate items
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
CONCLUSION Maximo provides Control of Work system with the right processes which not only
helps to manage risks. But, it also increases the safety of Maintenance, operationand improves productivity, cost efficiency and quality,
Paperless and Environment friendly,
Maximo system is industries best practice and gives transparency and control ofMaintenance and operations activities.
Maximo is configurable Control of Work safety software, which is designed to meetour business needs and scale up to encounter new challenges.
Maximo is industry-leading system which offers total flexibility for adopting to futurebusiness needs of KNPC.
In future, KNPC plans to provide access to Maximo system through Tablet for readyaccess anywhere & anytime.
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CONFIDENTIALPROPERTY OF KUWAIT NATIONAL PETROLEUM COMPANY
TO BE REPRODUCED, AND USED, ONLY IN ACCORDANCE WITHWRITTEN PERMISSION OF KUWAIT NATIONAL PETROLEUM COMPANY
Apr‐19
THANK YOU