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SAP Condition Based Maintenance solution

Taking your preventive maintenance program to the next level


Idea to Performance
Operational Excellence Value Map

Capital Portfolio Asset Visibility and Asset Operations Environment, Health Energy and Quality Management
and Project Performance and Maintenance and Safety (aka Environmental and Compliance
Management ORM) Resource
Management
Energy
Asset Portfolio Asset Performance Asset Planning and Incident Transparency and
Corporate Quality
Management Management Scheduling Management Performance
Management
Energy and
Capital Project Asset Improvement Operations and EHS Risk Environmental Quality Planning
Management Programs Maintenance Assessment Initiatives and Control
Management

Optimized
Monitoring Capital Service Management Emission
Maintenance and Quality Operations
Investments Procurement of Change Management
Plant Operations

Environmental
Prepare and deploy Spare Parts Maintenance Worker
Regulatory
asset information Management Safety Management
Compliance

Monitor and
Mobile Asset Work Permit
maintain
Management Management
asset information

Technology Enabler 3D Visual Enterprise M2M Connectivity Enterprise Mobility

© 2013 SAP AG. All rights reserved. Customer 2


EAM Benchmarking Analysis

Metric
Overall Companies
(n = 130) Maintenance Approach Breakdown
Average Q1
15.7%
Weekly Maintenance Schedule Attainment
Rate 64.3 90.5
(in %)
46.3%
38.0%
Asset Utilization (in %) 81.0 97.6

Unplanned Downtime or Outages (in %) 13.0 4.0

Wrench Time (in %) 47.8 75.0


Reactive Maintenance Preventive Maintenance
Overtime Hours (% of total hours) 13.8 5.0
Predictive Maintenance
MRO Inventory Obsolescence
8.4 0.7
(as a % of Total MRO Inventory)

Rework Time (in %) 12.2 5.0

© 2013 SAP AG. All rights reserved. Customer 3


Maintenance in most organizations today?

Time-based or reactive practices are common


 Spare parts and resource planning difficult
 Can’t identify problems between scheduled
inspections
 Equipment may or may not be running
 No account taken of actual run time
 Not cost effective for asset reliability

Work Execution
Work orders are
Equipment time-based or reactive

© 2013 SAP AG. All rights reserved. Customer 4


The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 5


The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 6


Reactive (Breakdown) Maintenance in SAP

Call / create Create Order


notification order and
release

0010 Inspect pumps


Production Supervisor/ Maintenance Planner 0020 Replace seals

Confirm and
complete order
Fix problem

Maintenance workcenter
Technician / Backoffice
Technician
© 2013 SAP AG. All rights reserved. Customer 7
The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 8


Preventive Maintenance Considerations

 Legal / Statutory regulations e.g. 2 yearly pressure test of pressure


vessels
 Quality assurance e.g. customer quality requirements
 Reduction of breakdown frequency of assets, thereby:
 Lowering costs of restarting
 Prolonging the lifecycle of assets
 Environmental considerations
 Manufacturers’ requirements
 Lowering of maintenance costs

© 2013 SAP AG. All rights reserved. Customer 9


Preventive Maintenance

 Focuses on the basics - designed to improve the reliability of


equipment.

 Performed on a specified scheduled basis / interval e.g. Run


Time, Time interval, Number of Cycles etc.

 Corrective action identified during PM activities / inspections

 Tasks are often performed before the asset has operated for its
entire life expectancy or too late – asset has failed.

© 2013 SAP AG. All rights reserved. Customer 10


Preventive Maintenance in SAP

WHEN? WHAT?
Time or counter-based Task lists
strategies
Maintenance
plan
- Single cycle
- Strategy
- Multiple counters

Order/
Notification
Order/
Notification
Order/
Notification

Schedule plan

WHERE?

© 2013 SAP AG. All rights reserved. Customer 12


Complete cycle for Work Order Processing

1 Notification Technical object Date


Description Malfunction

2 Operations Material
Planning Internal/external ressources Tools

3 Scheduling Order release Capacity leveling


Shop Papers Availability check

4 Execution Planned/unplanned material withdrawal


External procurement

5 Completion
Time confirmation Order settlement
Technical completion Technical
confirmation

History
Material usage, orders, notifications, PM-IS, usage list
© 2013 SAP AG. All rights reserved. Customer 13
The basic problem with preventive maintenance

 Failures don’t happen at fixed times

 Failure patterns are random based on a distribution

 When is the failure going to occur?

 How do I detect a failure before it impacts the business?

 Why do I perform maintenance activities with the same intervals on equipment


that are not running as frequently?
Probability Distribution
Function f(t)

Working age t
© 2013 SAP AG. All rights reserved. Customer 14
The basic problem with preventive maintenance

4% 1 “Bathtub Curve” – High infant mortality,


age related then a low level of random failure, then a
2% wear out zone.
11%
5%
2 “Traditional View” - Random failure
7% then a wear out zone.

“Slow Aging” – Steady increase in


14% 3
the probability of failure

not 4 “Best New” – Sharp increase in the


age related probability of failure then random failure
89%
5 “Constant Random Failure” – Random,
68% no age related failure pattern

6 “Worst New” – High infant mortality then


random failure

Information by Nowlan and Heap RCM report - Graphic courtesy of MRG Inc. www.mrginc.net

© 2013 SAP AG. All rights reserved. Customer 15


The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 16


Inspection Rounds in SAP

• Technical
• Times
Objects • Maintenance
Plan and • Work order • Materials
Define • Measuring plan Execute Confirm
Schedule • Documents • Measurment
Points • Schedule
readings
• Task List

Define Inspection Rounds Plan and Schedule Execute Inspection Round Confirm Inspection
Inspection Rounds rounds
Inspection rounds are lists of Craftsman executing inspection
simpler smaller tasks sorted in a Inspection rounds are performed rounds are supported through During or after work execution
predefined sequence a on regular basis either the predefined already planned actual information like effective
craftsman work off periodically or initiated by an and scheduled job instructions work time, used materials or
Locations, machines, devices event containing description of work, measurement readings are
are subject of work can be linked Inspection rounds are planed the location, necessary tools, confirmed
to a task and scheduled in SAP EAM materials or documents Actual information is used to
Measurement reading task can using Maintenance plans In SAP EAM the operational adapt operation or maintenance
be performed and documented inspection round document are activities, keep operations and
on predefined measurement maintenance work orders asset history and settle the
points inspection work
Inspection rounds are defined in
SAP EAM with General
Maintenance Task Lists utilizing
Functional Locations and Pieces
of Equipments and assigned
measurement points

© 2013 SAP AG. All rights reserved. Customer 17


Inspection Rounds - Enhancement

New Production Resources Tool (PRT) type: Measuring point

Header (task list / work order) Assignments to operations

Operation 10 Description Work center Functional location Equipment …


Document …

Description …
Measuring point A
Measuring point A
Measuring point B
Measuring point C

Measuring point C

Operation 20 Description Work center Functional location Equipment …


Document …

Description …

Measuring point X Measuring point X


Remark: The measuring point assigned as
PRT has to be defined as measuring point Measuring point Y Measuring point Y

for the technical object of the operation


Measuring point Z

© 2013 SAP AG. All rights reserved. Customer 18


Record the Results of the Inspection:
Overall Completion Confirmation

– With the confirmation of the inspection round work order measurement readings can be entered
– The entered measurement readings will be saved as measurement documents for the
corresponding measurement point
– Create (and change) notification from confirmation screen as part of the feedback (from EHP5)
– New BAdI IMRC_CHECK_RDGS and an example implementation. This shows how an error
message is issued when the tolerance limits for measurement readings are exceeded (from
EHP5)

© 2013 SAP AG. All rights reserved. Customer 19


SAP Work & Rounds Manager

SAP Work Manager SAP Rounds Manager

 Access to asset location,  Take measurements


repair history, work order and readings
details, materials needed  Historic standards and
 Complete Work Orders and safe ranges
capture all relevant data  Generate notifications
 Create Notifications or on-the-spot
Work Orders on the spot  Trend readings, points
 CATS - time & attendance and sequences
 Guided workflow to avoid emergencies
and outages
 Capture all touches in
SAP® ERP  Download rounds by
equipment, FLOC, or
Entry List
 Automatic calculation of
readings, limits, and
alerts

© 2013 SAP AG. All rights reserved. Customer 20


SAP Work Manager

© 2013 SAP AG. All rights reserved. Customer 21


The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 22


Condition Based Maintenance

 A subset of Predictive Maintenance (PdM)


 Equipment state observed & condition monitored continually / real time
 Deviations from standard / tolerance cause alarm
 Event driven, identifying need for maintenance intervention when it is actually
necessary

Equipment
Proactive planning

Work Execution

Condition

© 2013 SAP AG. All rights reserved. Customer 23


Data recording depends on the type, designed capability
and limits at which assets and its parts are used.

Stationary systems Rotating systems Electrical systems

 Pressure vessels  Prime movers  Transformers


 Pipelines  Pumps  HT Cables
 Pipes  Motors  Switch gear
 Containers and  Gears  Tap changers
Tanks  Oscillators  Insulators
 Civil structure  Motors/generators

 Leakage detection  Vibration


 Corrosion  Oil analysis  Heat map

 Wall thickness  Debris analysis  Leakage currents

 Cracks  Bearing temperature  Corona detection

 Physical check for  Noise  Acoustic and


electrical noise
deformation  Heat/thermal map
 Visual and Smell
 Visual and smell

© 2013 SAP AG. All rights reserved. Customer 24


SAP Condition Based Maintenance rapid deployment
solution

Integration
 The condition-based maintenance process is automated by
leveraging seamless and real-time integration between a shop floor
monitoring system and SAP Enterprise Asset Management (SAP
Plant Maintenance).

Dashboards
 Intuitive dashboards allow your maintenance team to
easily access and visualize information related to condition-
based maintenance that shows the health of your enterprise
assets.

Charts
 Equipment operators can view asset performance and
multivariable charts to better understand performance
history and the relationship between measurement points to
drive maintenance decisions

© 2013 SAP AG. All rights reserved. Customer 26


SAP Condition-Based Maintenance

What’s included Business benefits


SAP Condition-Based Maintenance provides native  Leverage existing infrastructure quickly with native
integration which allows you to automate and optimize integration
your organization's maintenance processes.  Provide an end-to-end solution from problem
detection to resolution
 SAP Plant Connectivity integration with a shop floor  Deploy predefined and tested integration points
prevents imminent equipment failures by alerting your
and data mapping between plant systems and
maintenance team to out-of-threshold measurements
SAP ERP back end
 Real-time data enables your maintenance team to
schedule and perform maintenance or repair when it  Visualize the overall health of your enterprise
is least disruptive assets via tighter integration across the landscape
 Native (BAPI) integration with SAP ERP enables the
retrieval of measurement documents for SAP MII as
well as automated maintenance workflow triggers
 Integration with traditional or SAP HANA databases
 Optional integration to SAP 3D Visual Enterprise can
provide visual aid to maintenance workers on their
jobs
 Support for automated, manual, and mobile
integration

© 2013 SAP AG. All rights reserved. Customer 27


What’s in each rapid deployment solution?

SAP Rapid Software


Deployment Quickly address the most urgent business
processes
solutions
Content
SAP-supported best practices, templates,
and tools make solution adoption easier
Enablement
Guides and educational material speed
end-user adoption
Service
Fixed scope and price provide maximum
predictability and lower risk

© 2013 SAP AG. All rights reserved. Customer 28


Rapid-Deployment Solution Implementation Methodology

Shorter time to start, deploy, and run through well defined scope and best practices

0 10 20 30 40 50 60 70 80 90 100

Traditional Business
Preparation Realization Testing Go-live
Project blueprint

Savings up to… 95% 50% 30%


Rapid- At least 40% time and effort
Deployment reduction compared to similar
Solution scope of traditional project
Discover Start Deploy Run

© 2013 SAP AG. All rights reserved. Customer 29


Process Flow for Condition Based Maintenance

Visual
HANA SAP ERP - Plant Maintenance*
Enterprise

Condition Based Maintenance RDS


Mobile Inspection rounds
(Content)

SAP Manufacturing Integration &


Intelligence

System within a plant- 1


Plant Connectivity

DCS SCADA Historian

*requires EHP4

© 2013 SAP AG. All rights reserved. Updated:Customer


5 May 2012 30
SAP Manufacturing Integration and Intelligence (SAP MII)

Supplier/Contract Distributor /
Manufacturer Customers
ERP SCM PLM

PLAN MAKE DELIVER

INTEGRATION

Manufacturing Integration & Intelligence


Business Logic Services
Visualization Composition
Environment
Quality Engine
KPIs / Metrics / Alerts
Data Services
Performance Worker UI‘s
Management Plant Historian
DCS /
PLC via
OPC Plant Connectivity

SCADA / HMI
MES

LIMS/ Inspection /
Equipment Testing Wireless
Environmental Plant Data Integration
Plant DB
Building Management Collection

Manufacturing ERP Business Process


Analytics Simplification

© 2013 SAP AG. All rights reserved. Customer 32


SAP MII delivers shop floor integration

SAP MII extracts data SAP MII’s ability to


from SAP Business ERP SCM PLM perform transaction
Suite provides execution into
real-time visibility and PLAN MAKE DELIVER SAP also enables
distribution to Plant automated, plant-
Floor Systems of: level creation of:
INTEGRATION

Planned Orders Manufacturing Integration & Intelligence


Bills of Material
Production & Process Business Logic Services
Orders Visualization Composition
Material Inventory Levels Environment Production Confirmations
Inspection Lots Data
Quality Engine
Process Messages
Master Recipes KPIs / Metrics / Alerts Material Receipts
Material Details Material Consumptions
Batch Details
Data Services
Material transfers
Resources & Functional Inspection results
Locations recording
Plant Historian
Maintenance Work Order DCS / Quality Notifications
& Notification details PLC via Batch Characteristic
OPC
Material & Order Costs recording
Work Orders & results
SCADA / HMI recording
MES
Maintenance Notifications
LIMS/ Inspection /
Equipment Testing Wireless
Environmental Plant Data Integration
Plant DB
Building Management Collection

© 2013 SAP AG. All rights reserved. Customer 33


Plant Connectivity:
Example of System Landscape (PCo/MII/ERP)

© 2013 SAP AG. All rights reserved. Customer 35


Asset Health Indication

Shop Floor Data

© 2013 SAP AG. All rights reserved. Customer 39


SAP Condition-Based Maintenance - In the system

Asset Health Alerts

 Visual indicators and e-mail


notifications alert maintenance staff
to the assets in the most critical
status
 Data-driven notifications alert users
to changes in asset health status so
that they can react appropriately and
make informed decisions quickly
 Maintenance staff can trigger a
maintenance request if warranted
 Prioritized asset management
enables a consolidated alert view

© 2013 SAP AG. All rights reserved. Customer 40


Individual Measurement point / Tag information with alerts

Measurement Point Detail

Measurement Point: Oil Viscosity


Type: Equipment
Asset Name: Equipment 2-1

Lower Range Limit: 10


Low Control Limit: 25
Target: 50
High Control Limit: 75
Upper Range Limit: 90

© 2013 SAP AG. All rights reserved. Customer 41


SAP Condition-Based Maintenance - In the system

Asset Health History

 View asset performance data from


multiple measurement points
simultaneously (up to 10 concurrent
measurement points)
 Highlight potential problem area with
normalized data
 Zoom in and out of a cluster via the
slider-based based UI
 Change the scope of data for
analysis by minute, hour, day, and
week

© 2013 SAP AG. All rights reserved. Customer 42


SAP Condition-Based Maintenance – Manual
Measurement Reading

Manual Entry of Inspection


Data
 Provides maintenance staff with a
means to manually input
measurement readings
 Easy-to-use Web-based interface
allows untrained staff to enter
inspection results
 Easily delete or modify an erroneous
entry

© 2013 SAP AG. All rights reserved. Customer 43


The maintenance evolution

Sensors
Mobile Rounds feeding
Sensors
Functionality Rule engine to
Preventive/ populating
No preventive populating make
Scheduled Measurement
Maintenance Measurement decisions
Maintenance documents
documents about
maintenance
necessary

© 2013 SAP AG. All rights reserved. Customer 44


Predictive Maintenance (PdM)

 Process of monitoring the condition of an asset and taking an action to


avoid the consequences of a failure.

 Utilizes some form of technology to detect equipment problems as they


are developing & predict future condition

 Accomplished through trending & analysis of condition parameters

 Common tools & techniques:


 vibration, temperature, pressure, flow, speed, voltage/current, thermography, sonics,
particulate count, oil, etc.

© 2013 SAP AG. All rights reserved. Customer 45


Business Objects - Predictive Analysis

 Intuitively design complex predictive models


 Read and write from data stored in HANA
 Visualize, discover, and share hidden insights
 Drag-and-drop visual interface for data
 Predictive library (with R integration)
 Visualize, discover, and share hidden insights

INSIGHT INTO PARTS

INSIGHT INTO LOCATION Forecast Planed and Unplanned


Cost
INSIGHT INTO FAILURES
Forecast Planed and Unplanned
INSIGHT INTO TECHNICAL Resources
OBJECTS
INSIGHT INTO BREAKDOWNS Forecast Planed and Unplanned
Parts
INSIGHT INTO MAINTENANCE
ORDERS Forecast Planed and Unplanned
Services
INSIGHT FROM ASSET BusinessObject Predictive Analysis
ANALYTICS
Business Object Visual Intelligence

© 2013 SAP AG. All rights reserved. Customer 46


SAP Predictive Analysis - for generating forecasts on
asset management information

Combine technical and


business data

Derive decisive
knowledge optimizing
cost, risk, and
performance

Repair or inspect
before you experience
an unplanned
downtime

Analyze your spending

Operate your assets in


windows of integrity

© 2013 SAP AG. All rights reserved. Customer 47


Thank you

Contact information:

Dean Fitt
Solution Manager EAM, Industry Business Solutions
dean.fitt@sap.com
Appendix
MII 14.0 Innovations
Manufacturing Integration & Intelligence
Key Needs Key Innovations
• Centralized/Decentralized hierarchy to categorize and define plant data.
• Plant Information
• Provide a searchable global tag namespace and taxonomy that provides
enterprise context to the plant sensor networks. Catalog
• Support for Contextual Messaging from the Bottom-up (ie: OEE, CBM)
• KPI configuration and KPI Monitoring • Plant Performance
• Alert Configuration and Alert Monitoring Management

• Co-location of ME and MII into one NW Instance


• API calls between the applications, one common solution • Co-Location with ME

• Improve productivity of plant app development teams


• Easy to use tools for end users to build analytical apps for plant operations • Productivity and

MII through Business Objects integration with Crystal Reports and SAP
Dashboards
Usability
Enhancements
• OData (www.odata.org) interface to support both SUP and HTML 5
• Quality of Service Support(QoS) for RFC and IDoc Messages sent to MII
(EO only) • Messaging Services
• EO and EOIO Support for MII WS Message Listener Enhancements

• MDO Enhancements to support Design Time and Run Time Joins


• Transport of MII Configurations using CTS+ Services • Continuous
Improvement
• Monitoring changes to MII Configurations centrally using Solution Manager

© 2013 SAP AG. All rights reserved. Customer 50


Asset Performance Measurement and Improvement
Management
 Performance  Improvement  Condition Based
Management Management  Criticality Maintenance
Analysis

RCM/ FMEA
Analysis

 Predictive
 Maintenance
Analytics
Management

 Time Based  Performance  Run to  CBM


PM Based PM Failure

 Automatic  Mobile
 Asset Data
Analytics Collection
 Planning & Scheduling
 Manual

 Correction  Repair  Replace  Refurbish


 Asset Health Monitor

© 2013 SAP AG. All rights reserved. Customer 51