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EBM2 MAC SAP Update

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0% found this document useful (0 votes)
71 views27 pages

EBM2 MAC SAP Update

Uploaded by

parth16915
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 27

History of MAC SAP Standard

• Official standard since 2001 that supports the MAC Business


Processes defined for Plant Maintenance
• MAC/SAP Standard defines the SAP/R3 customizing settings
for Plant Maintenance and considers existing Holcim
Standards (e.g. HAC) and builds interfaces to other tools (e.g.
TIS) where applicable
• Change in 2004 of the ,Cause Code Groups’ and ,Codes’
structure
• Minor upgrade on ‚Cause Codes‘ ‚Activity Types‘ and
inactivation of ,Symptom Code’ took place in 2007
• SAP PM roadmap exercise in all IT Service centers took place
in 2008 with a clear request to cope with the indentified
potentials in order to further simplify but also enhance the
usage of the system.

4
© 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

6
© 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

9
© 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

Proposal • To simplify to 1 Notification type ‘MR’ only with a customized and


standardized screen layout

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

10
© 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

- Manual creation of Z1 notification in SAP then transfer to BW for


reporting or extraction to Excel
 Downtime log generated by TIS and reported in BW
- SAP PM is used as an intermediate database
- Synchronization between SAP and TIS poorly maintained (functional
location and equipment list, even cause codes are not updated)

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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

12
© 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

13
© 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


- Code defined in HAC manual and part of MAC SAP standard


- Code predefined in the equipment master data
2 Object Part


- To be selected from a picking list


3 Cause Code catalog


- To be selected from a picking list, depending on the object part


selection

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

15
© 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

Up to 189 parts for the Kiln!!

17
© 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

Angle Iron Angular o angulo de hierro Corniere D'Acier a Angle Winkeleisen


Baffle Deflector Deflecteur Ablenkplatte
Base
Beams
Bearing
Bearing, Roller Support
Base
Vigas / viguetas
Rodamiento
Rodamiento de rodillos de soporte
Base
Poutres
Roulement
Coussin de Support pour Rouleau
Basis/Fuss
Balken
Lager
Rollenlauflager
• Example that has already been reviewed
Block, End Bloques terminales Taquets D'Arret Gleissperre/Sperrklotz
Block, Retaining Bloques de retención Blocs de Retenue Halteeinheit

Object parts PM102001 (Kiln) Roller


Block, Roller Graphite Bloques de grafito de rodillos Bloc de Graphite pour Tourillons Grafitschmierung der Laufrollen


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

Benefit • Analysis can be done


1. By object type of object part (i.e. bearing issue)
2. By cause code (i.e. lubrication)
3. By object part and cause (bearing lubrication issue)
• Oriented to maintenance cause only
• Downtime report focus on causes for stoppages,
calculation of MTBF and availability per equipment

19
© 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

• Current definition mislead between ‚Urgency‘‚ Importance‘ and


‚Timing‘
• Production and requester must define if it will interfere with the
weekly plan or if it shall be included in the master schedule
• Same priority for notification and work order, but meaning are
different

20
© 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

 U – Urgent Æ affects daily/weekly plan Affecting MAC


 P – To be planned Æ not affecting current daily/weekly plan SAP Standard

 9 – No maintenance action

• Configuration of the request start date:


 U Æ Today’s date
 P Æ Empty to be filed in order to define the timing.
 9 Æ This priority is used for activity report. If a notification has this priority
no work order as to be assigned. It is used like the previous M3 notification

Benefit • Simplification of definition leads to better usage and for better


analysis for all user
• Improved and consistent correlation with the MAC planning and
scheduling process
• Proposal will give two new aspects:
 Prioritization of the job for scheduling process
 Helps production to set the priority

21
© 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

• Current definition mislead between ‚Urgency‘‚ Importance‘ and ‚Timing‘


• Same priority for notification and work order, but meaning are different
• Annual shutdown is a period of the year not a priority
Æ What is the importance of work orders within the shutdown plan?
• More and more legal and mandatory request (e.g. ISO, environmental
reports…) will require a clear distinction of our processes to report and show
to authorities

22
© 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

Benefit • All preventive maintenance shall be performed. ‘Legal’ refers to preventive


maintenance that must be performed due to legal requirements (OH&S,
Environment, Quality). ‘Regular’ refers to all other preventive activities
• The priority refers to the importance of the execution of the job in the daily or
weekly schedule (incl. shutdown)
• No configuration of the basic start date based on the priority

23
© 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

• Difficult to distinguish ‘ISO’ and ‘Calibration’


 Keep only one and use priority ‘Legal’ or ‘Regular’ to define
if it is a legal requirement
• Review the assignment of maintenance activity type and work
order type
 Fabrication is only for PM04
 Housekeeping is only a corrective activity. Control and
clean a switch gear is part of a “Preventive Maintenance
Routine” activity

24
© 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

25
© 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

26
© 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

27
© 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

29
© 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

Proposal Î Develop an efficient and user friendly SAP scheduling


tool covering the completed MAC process

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.
31
© 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.

# Notification created from completed PM02 Work Orders


PMR Effectiveness =
NEW in MAC at maintenance plan # PM02 completed work orders
SAP Standard

Benefit • Fully automated Workflow that will not require additional administration
time
• Optimize the preventive maintenance program based on its outcome

32
© 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.

Proposal • Define an equipment class codification / standard

• This code is the same than the one used for object types, based on HAC code but
with a hierarchical structure
 PM1: Mechanical asset

NEW in MAC - PM114: Group of asset - Conveyor


SAP Standard PM114003: Asset type – Belt conveyor
PM114005: Asset type – Bucket elevator
• Equipment class characteristic to included in the MAC SAP Standard

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.

33
© 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

Proposal • Determine a clear set and architecture of maintenance related ‚Key


Performance Indicators‘, ‚Performance Indicators‘ and ‚System &
Process Indicators‘.
• Develop MAC SAP Dashboard in SAP BW

Benefit • Transparent definition, calculation and reporting


• Ease of target setting, reporting and comparability
35
© Holcim Group Support Ltd 2010 MAC SAP Standard upgrade Status Aug 2010 August 31, 2010
EBM2 MAC SAP Update_V31082010.ppt

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