EBM2 MAC SAP Update
EBM2 MAC SAP Update
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Elements of the current Holcim MAC/SAP Standard
• Holcim MAC/SAP standard elements within SAP PM
Functional Location Catalogs
Identification - Object Part
Equipment - Symptom
‘ABC’ Criticality - Cause
Plant Section Work Order
Type of Technical Object Maintenance Activity Type
Priority Planning Board
Notifications
Catalog Profiles
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Motivation and objectives for major upgrade proposal
on current MAC SAP Standard
• Almost 10 years of SAP PM experience in the
group
About system setup (acc. MAC SAP Standard)
About system usage, friendliness (application)
• Feedback from various operations requesting a
better usage and setup to further enhance and
optimize the system
Simplification
Reduction of administrative time
• Validate and incorporate new functionalities and
upgrades available in ECC 6
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Notification
Issue #1
Process Excessive number of Notification types (M1, M2, M3)
• Distinction of the 3 maintenance notification types is not respected and
Issue consequently does not add value to the business
• Actual definition for the notification type requests to define primary and
secondary failure for each equipment Æ inconsistent usage does not allow
review and analysis
• Due to this rather vague definition, the application and usage defers largely
from plant to plant and does not always comply with the MAC definition
Affecting MAC
SAP Standard
Benefit • Simplification for all end users. Focus is to set on the creation of notification
and not on the type (e.g. M1, M2 or M3)
• The selection screen can be eliminated, entering the transaction code will
directly lead the user to the notification screen
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #2
Notification
Process Downtime recording process (Z1 notification)
• Up to now, SAP-PM was the only standard solution to record
Issue downtime and to calculate MTBF and Availability
• The actual Z1 notification leads to many confusion for the end user
Cause Codes are a mixed between downtime records and
maintenance related failures
• Information systems like TIS allow to collect this data automatically
• SAP-PM is only used as a storage database. Records are then
transferred to SAP BW for reporting or downloads to Excel
Plants without TIS or with another system
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #2
Notification
Process Downtime recording process (Z1 notification)
Proposal • Suppress Z1 Notification type in SAP
Create a separate workflow for downtime recording
Downtime log generated by TIS and reported in BW
Affecting MAC
- Direct transfer from TIS to BW without SAP PM
SAP Standard - Master data functional location, equipment and cause catalogue upload
from SAP-PM
Plants without TIS or with another system
- Create the notification direct in SAP-BW or via file to upload to SAP-BW
- Master data functional location, equipment and cause catalogue upload
from SAP-PM
Benefit • Clear split of the downtime record process and the maintenance
request process
• Revision of cause code catalogue for maintenance purpose
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
Issue
• Current cause codes are not oriented to maintenance related
failures
The cause codes catalog defined in MAC/SAP is primarily
for downtime record analysis (Z1 process)
For maintenance purpose very few cause codes are
relevant for M1and M2 notifications
This leads to have causes defined in the open cause text
which is difficult to use for further analysis
Many requests from several OpCos are to add specified
mechanical/electrical failures to the list
No pareto possible to determine detailed reliability analysis
like: bearing failure, coupling misalignment or shaft
corrosion
ÎCause code catalogue in SAP PM to be reviewed for
maintenance purposes
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
Proposal • Combine three existing catalogues
1 Object Type
1 2
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
Proposal • Draft for a new cause catalog for maintenance notification
Affecting MAC
SAP Standard
Include in Downtime
Cause Code Group MTBF is
Downtime
Cause Description Electrical Mechanical Production
Cause Code * Cause Calculation? Idle Time?
010 Normal wear X X No No
020 Corrosion X X No No
030 Mis-use/ problem on process product X X No No
040 Lubrication problem X No No
050 Mis-Alignment X X No No
060 Improper Installation X X X No No
070 Work for amelioration / new installation X X X No No
080 Material failure X X No No
090 Vibration X X No No
100 Inadapted param. / alarm not in process X No No
110 Climatic condition X X X No No
120 Improper Design X X No No
130 Leakage (Excluding lubrication) X X No No
140 Loose/Missing parts X X X No No
150 Production Overload X No No
* Number to be adjusted to the actual numbering system of cause code
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
Proposal Draft for a new cause catalog for production downtime
record Affecting MAC
SAP Standard
Include in Downtime
Cause Code Group MTBF is
Downtime
Cause Description Electrical Mechanical Production
Cause Code Cause Calculation? Idle Time?
2040 Mechanical Failure X Yes No
2080 Electrical failure X Yes No
2300 Natural disaster with Maintenance X Yes No
2070 Planned Maintenance (Prev/Shutdown) X Yes No
2110 Product Quality X Yes No
2120 Process Operation or Parameters X Yes No
2140 AFR Usage X Yes No
2150 Brick / Casting Installation X Yes No
2310 Lack of Raw Material for Operation X Yes No
2160 Occupational, Health and Safety X Yes No
2170 Accident X Yes No
2180 Environment Standards X Yes No
2200 Sabotage or Theft X Yes No
2190 Failure of Power or Gas Supply X No Yes
2210 Peak Power Non utiliz. - No Maint. X No Yes
2220 Electr. Power limitation -No Maint. X No Yes
2230 Natural Disaster (No Maint. Required) X No Yes
2240 Lack of Demand X No Yes
2250 Planned Prod. Stop - No Maint. X No Yes
2260 Change Produced Mat. - No Maint. X No Yes
2270 Strikes X No Yes
2280 Production Blasting - No Maint. X No Yes
2290 Logistical Constraints X No Yes
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
Proposal • Object part and part of object needs to be simplified
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues and Object Part Codes
English Spanish French German
Bolt Pernos /tornillos Boulon Schraube
Bracing Reforzamiento Renforcement Verstrebung
Carriage Carro/Cargador Carosse Fahrgestell
Channel Canal Profile D'Acier en Forme C (Channel) Kanal
Component, Hydraulic Componente hidráulico Composante Hydraulique Hydraulische Komponente
Control, Hydraulic
Cover
Cylinder, Hydraulic
Deflector
Control hidráulico
Cubierta
Cilindro hidráulico
Deflector
Controle Hydraulique
Couvercle
Cylindre Hydraulique
Deflecteur
Hydraulische Steuerung/Regelung
Abdeckung
Hydraulikzylinder
Deflektor
Station could be reduced from 96 to 17
Drain Drenaje Drain Ablauf
Element, Filter Elemento filtrante Élement de Filtration Filterelement
Element, Heating Elemento de calefacción Element Chauffant Heizelement
Filter Filtro Filtre Filter
Filter, Oil Filtro de aceite Filtre a Huile Ölfilter
Filter, Particulate Filter de particulate Filtre de Particulate Partikelfilter
Fitting Adaptador / sujetador Connecteur Fitting
Fitting, Hose Adaptador de mangueras Raccord de Boyau Schlauchbinder English Spanish French German
Foundation Cimiento Fondation Fundament
Frame Marco Bati Rahmen
Frame, Roller Support Estructura / marco de rodillos de soporte Bati de Rouleau Porteur Rollenstützrahmen
Fuse Fusible Fusible Sicherung Bearing Rodamiento Roulement Lager
Gasket Junta de culata Joint Dichtung
Gauge Calibrador Jauge Messgerät Fastening Element 0 0 Befestigungselement
Guard Guardas / protectores Guarde Schutz
Guard, Safety
H-Beam
Guardas/ escudos de seguridad
Viga en forma de H
Garde de Securite
Poutre en H
Schutzvorrichtung
Doppel-T-Träger
Casing / Housing Caja/Cuerpo Casing Gehäuse
Heater
Holder, Fuse
Calentador
Soporte de fusibles
Chaufferette
Porte Fusibles
Heizgerät
Sicherungsfassung
Electrical Component Componente eléctrico Composant Electrique Elektrische Komponente
Hose
Housing
Manguera
Bastidor/ alojamiento / caja, cárter
Boyau
Boitier
Schlauch
Gehäuse
Hydraulic system Sistema hidráulico Systeme Hydraulique Hydrauliksystem
Housing, Bearing
I-Beam
Caja/ alojamiento de rodamientos
Viga en forma de I
Boitier des Roulements
Poutre en I
Lagergehäuse
I-Träger/doppelter T-Träger
Cylinder Cilindro Vérin Zylinder
Indicator, Level
Insert, Wearing
Indicador de niveles
Inserto anti- desgaste
Indicateur de Niveau
Garniture Contre L'Usure
Füllstandsindikator
Verschleisseinsatz
Heating element Elemento calefacción Element Chauffant Heizelement
Joint, Expansion Junta de expansión Joint D'Expension Dehnfuge
Lines Líneas Lignes de Tuyaux Leitungen/Linien Foundation Cimiento Fondation Fundament
Lubricant, Trunnion Lubricante del muñón Lubrificant des Tourillons Lagerschmierung
Motor Motor Moteur Motor Frame/ support Estructura/soporte met Chassis/Support Supportstruktur
Nozzle Tobera/ boquilla Buses Düse
Nuts Tuercas Ecrous Mutter Gasket/Seal Empaque/sello Joint Dichtung
Oil Aceite Hiule Öl
Pedestal Pedestal Piedestal Podest Safeguard Guardas / protectores Garde corps/Carter Schutzgitter
Pier Pilar / pilote Pilier Pfeiler
Pipe, Drain Tubería de drenaje Tuyua de Drainage Abflussrohr Lubricant Lubricante Lubrificant Schmiermittel
Pipe, Incoming Tubo de Entrada Tuyau D'Entrée Eingangsrohr
Pipe, Outlet
Pipe, Suction
Tubo/ tubería de salida
Tubería de succión
Tuyau de Sortie
Tuyau de Suction
Ausgangsrohr
Saugrohr
Pump Bomba Pompe Pumpe
Pipe/Piping
Plow
Tubo /Tubería
Ranuradora
Tuyau
Charrue
Rohr
Pflug
Roller Rodillo Galet Rolle / Walze
Pump
Pump, Hydraulic
Bomba
Bomba hidráulica
Pompe
Pompe de Hydraulique
Pumpe
Hydraulikpumpe
Instrument & Sensor 0 Instrumentation & Capteur Messinstrument & Sensorik
Pump, Lift
Pump, Oil
Bomba de ascensor
Bomba de aceite
Pompe de Levage
Pompe a L'Huile
Hubpumpe
Ölpumpe
Cooling system Sistema de enfriamiento Systeme de Refreoidissement Kühlsystem
Pump, Water
Push-button
Bomba de agua
Botón por pulsación
Pompe a Eau
Bouton Poussoir
Wasserpumpe
Drucktaste
Lubrication system Sistema de lubricación Systeme de Lubrification Schmiersystem
Radiator, Cooling
Roller, Down Thrust
Radiador de enfriamiento
Rodillo de empuje
Raditeur de Refroidissement
Rouleau de Butee du Bas
Kühlradiator
Positionshaltewalze (abwärts)
Total 17
Roller, Trunnion Rodillo del muñón Rouleau Porteur Lagerzapfen
Roller, Up Thrust Rodillo de guía axial superior Rouleau de Butee du Haut Positionshaltewalze (aufwärts)
Seal Junta / sello Joint D'Etancheite Dichtung
Seal, Graphite Plates Placas de gráfito de juntas Plaque de Graphite Joint D'Etancheite Graphitplattendichtung
Seal, Trunnion Juntas del muñón Joint D'Etancheite du Tournillon Lagergehäusedichtung
Sensor, Flow Sensor de la Fluya Détecteur de Flux Strömungssensor
Sensor, Pressure Presione sensor Détecteur de Pression Drucksensor
Sensor, Temperature Sensor de la temperatura Détecteur de Température Temperatursensor
Shaft, Trunnion Eje de muñón Arbre de Rouleau Zapfenwelle
Solenoid Solenoide Solenoide Zündspule
Steel, Structural Estructural Structure Baustahl
Sump Hole Cavidad recolectora / hoyo de sumidero Trou de Puisard Sickeranlage
Supply, Power Suministro de energía / fuente de poder Unite D'Alimentation Energiezufuhr
Switch, Flow Interruptor de fluya Commutateur de Flux Strömungschalter
Switch, Level Interruptor plano Commutateur de Niveler Niveauschalter
Switch, Pressure Interruptor de Presione Commutateur de Pression Druckschalter
Switch, Proximity Interruptor de la proximidad Commutateur de Proximité Näherungsschalter
Switch, Temperature Interruptor de la temperatura Commutateur de Température Temperaturschalter
System, Cooling Sistema de enfriamiento Systeme de Refreoidissement Kühlsystem
System, Hydraulic Sistema hidráulico Systeme Hydraulique Hydrauliksystem
System, Lubrication Sistema de lubricación Systeme de Lubrification Schmiersystem
Tray Charola Plateau Kabelpritsche/-leiter
Tray Cover Cubierta/ tapa de charola Couvercle de Plateau Kabelpritscheabdeckung/-leiterabdeckung
Trough, Overflow
Valve
Salida de sobrebordamientos
Válvula
Fosse de Trop-plein
Valve
Überlauf
Klappe/Ventil 18
Valve, Drain Válvula de drenaje/ purga Valve de Drainage Ablassventil
Washer Arandela Rondelle Unterlegscheibe
Washer, Lock Arandela de seguridad Rondelle à Ressort Sicherungsscheibe
Washer, Thrust
Wiring, Electrical Cableado eléctrico
© Holcim Group Support Ltd 2010
Lavadora de guía axial Rondelle de Butee
Cablage Electrique
Druckscheibe
Elektrische Verdrahtung
MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
Total 96
EBM2 MAC SAP Update_V31082010.ppt
Issue #3
Notification
Process Cause Code Catalogues
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #4
Notification
Process Priority of Notifications
Issue
• Current definition for ‘Priority’ in notifications:
1 – Change daily plan
2 – Change weekly plan
3 – Planned in master schedule
4 – Annual shutdown
9 – No maintenance action
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #4
Notification
Process Priority of Notifications
• Reduce to 3 notification priority types
Proposal
9 – No maintenance action
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #5
Work Order
Process Priority of Work Orders
Issue • Current definition for ‘Priority’ in work orders:
1 – Change daily plan
2 – Change weekly plan
3 – Planned in master schedule
4 – Annual shutdown
9 – No maintenance action
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #5
Work Order
Process Priority of Work Orders
• Specify and simplify priority types per work order type
Proposal
Affecting MAC
• For PM01, PM04 & PM06 SAP Standard
1 – High
2 – Medium
3 – Low
• For PM02
L – Legal
R – Regular
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #6
Work Order
Process Maintenance Activity type
Issue
• Missing split and inconsistence between preventive
maintenance level #1 and 2 from MAC
• Inadequate maintenance activity type ‘call out’
Impossible to know what was the type of maintenance
performed (safety, environment, repair…)
Inactivate and add a user status in the work order
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #6
Work Order
Process Maintenance Activity type
Proposal Work Order type
Maintenance activity type
PM01 PM02 PM04 PM06
Condition Monitoring X
Lubrication X X
Affecting MAC
SAP Standard Walk by inspection X
Preventive Maintenance Routine X
Repair/Replacement X X X
Modification/Improvement X X
Calibration X X
Fabrication X
Housekeeping X
Environment X X
Occupational Health and Safety X X
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #6
Work Order
Process Maintenance Activity type
Benefit • Clear rules and definitions of different maintenance
activity types and its usage
Allows accurate review and analysis
• Clear split between maintenance preventive level 1
and 2
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #7
Revision
number Usage of ‘Revision Number’ field
• No existing standard how to use the revision field
Issue some use it to assign WO to a specific week
others use it to group WO for major shutdown works
• The priority ‘4- annual shutdown’ will be deleted as expressed in issue #5
Proposal • Use the ‚Revision Number‘ for the shutdown management. Direct
assignation of notification and work order to revision numbers
One type managing the different shutdowns with date management, e.g.
- 11B1KL1: 1st Budgeted 2011 Kiln 1 shutdown
- 11U2KL1: 2nd Unbudgeted 2011 Kiln 1 shutdown
One type to collect notifications and work orders for unscheduled shutdown.
Create as many revision as main equipment
- Kiln01
- R_Mill01
- C_Mill01
- Crusher01…
• Improve backlog management and simplify the management of work order
Benefit and notification
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Objectives for further enhancement of current MAC
SAP Standard
• Achieve a better usage and setup to further
optimize the system
Simplification
Reduction of administrative time
Better planning and scheduling tool
More meaningful indicators and higher accuracy in
reporting
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #8
MAC SAP
enhancement Weekly & Daily scheduling
• Holcim plant generally have a low level of scheduling with
Issue
many different processes and tools (SAP Planning board,
Excel, Word, Access, MS Project)
• No indicators in place to validate the quality and efficiency and
of planning and scheduling
• The MAC scheduling process is not defined in the MAC SAP
standard for
Determination of weekly resources
Weekly assignment of work orders
Commitment of weekly plan
Process to calculate indicators. MAC SAP standard only
defines the formula
NEW in MAC
SAP Standard 30
© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #8
MAC SAP
enhancement Weekly & Daily scheduling
Benefit • Improving scheduling process will lead to
Optimization of internal labor usage
Optimization and reduction of 3rd party service
usage
Improve availability of equipment
NEWS:
HGRS together with the Höver plant has developed a simple excel-
based scheduling tool (with SAP PM downloads). It allows to plan
resources per works center, on a daily base and to calculate planning
and scheduling efficiency indicators.
This temporary tool will be used in most European plants for the
next months in order to validate and determine the final needs for an
SAP solution.
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Issue #9
MAC SAP
enhancement Effectiveness of Preventive Maintenance
• Current MAC indicator (PMR %) for preventive maintenance only
Issue measure quantity of preventive maintenance done in a plant
• No MAC indicator defined that measures the effectiveness and quality of
preventive maintenance
Proposal
• Establish a workflow to monitor the number of maintenance
notifications in relation to the preventive order, with the possibility to
convert them into corrective orders.
Benefit • Fully automated Workflow that will not require additional administration
time
• Optimize the preventive maintenance program based on its outcome
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
MAC SAP
Issue #10
enhancement Equipment Classification not part of MAC SAP standard
• Equipment class are not part of MAC SAP standard and its usage is not under
Issue control.
• This code is the same than the one used for object types, based on HAC code but
with a hierarchical structure
PM1: Mechanical asset
Benefit • Standard report for cost analysis by type of equipment can be extracted from
SAP, regardless the HAC language
• Important equipment characteristic can be stored in a structured way, like
production rate, dimension etc.
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© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt
Indicators &
Issue #11
Reporting Clarification of Maintenance Performance Indicators
• A few existing MAC indicators such as PMR%, Plan attainment etc. with a
Issue few issues, such as e.g.:
PMR% does not reflect anything about the quality of Preventive
Maintenance
Plan attainment does not refer to the effective planning, nor scheduling
• No clear definition what are ‚Key Performance Indicators‘ and regular
indicators
• No indicators to express how the system and processes are applied Æ
compliance with MAC SAP Standard
• No reporting tool (e.g. MAC SAP Dashboard) available which automatically
calculates and processes all maintenance relevant indicators in a structured
report in SAP BW