Plant Maintenance
EBM Work Identification training
1
Training Summary
• Description:
Understand the Work Identification process for Maintenance
Management and EBM variants
• Duration:
3 hours
• Target group:
Preventive Maintenance Manager, Mechanical Maintenance
Manager, Electrical Maintenance Manager, Planner, Maintenance
Requester, Maintenance worker
• Topics:
Maintenance Management (Processes and Tool)
» Work Identification
• Tools: SAP PM, TIS
FOR INTERNAL USE ONLY © LafargeHolcim 2015 *
EITS Evacuation plan
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Training Rules
• Be punctual
• Turn off your mobile phone
4 In case you need to attend a call, please go out training room
or use coffee breaks
• Participate actively
4 In case of questions ask
er ? ?
Oth
Any
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Objectives of the Training
● Understand concepts and reasons why
notifications are created in Plant Maintenance
Management
● Knows what information must be on notifications
● Understand the 4 ways of creating notifications in
SAP
● Understand the lifecycle of a notification
● Knows what reports can be used for notifications
analysis
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
EBM Scope
Cement Manufacturing Scenarios (Level 1) EBM
Maintenance
MAN- 1 Capex Management
MAN-2 Production Planning MAN-3 Production Execution
MAN-4 Maintenance Management
MAN-5 Inventory Management
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8
Cement Manufacturing Business Processes (Level 2)
MAN- 4 Maintenance Management
Major Shutdown
Preventive Work
Work Planning Work Scheduling
Maintenance Identification
RCFA, FMEA,RCM History Analysis History Recording Work Execution
Master Data Update: Technical Structure (Functional Locations, Equipment, BOM)
(*)
RCFA: Root Cause Failure Analysis
FMEA: Failure Mode and Effect Analysis
RCM: Reliability-Centered Maintenance
Short title, Department, Name/Function or Event/Creator, Date yymmdd, FOR INTERNAL USE ONLY © LafargeHolcim 2015
Classification 9
EBM Work Identification Process
FOR INTERNAL USE ONLY © LafargeHolcim 2015
EBM Work Identification Process
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Plant Maintenance, EBM Work Identification, 2014-06-06
EBM Work Identification Process
Process The purpose of the work order system is to plan, schedule, control and monitor maintenance
Objectives activities and to maintain the equipment with an optimum maintenance cost while increasing
availability. It also provides an auditable trail for all the jobs.
The Work identification, planning and scheduling process intends to establish a homogeneous
standard system in LafargeHolcim to assess and evaluate the Work order flow.
The main elements of the assessment are:
• Notifications: identification of the problems or potential problems and malfunctions that may
directly affect the performance of an equipment or system.
• Work Orders: object that shows in detail how a particular maintenance activity is to be executed.
• Total Backlog: list of all the work that has been identified and not yet completed.
• Work Centers: groups of personnel responsible to perform and supervise the maintenance
activities
• Weekly/Daily Plan: definition of the maintenance requirements for the week to be broken down
into daily plans indicating skills needed and hours required.
Key Inputs • Maintenance Work requirements
Key Outputs • Weekly/Daily Maintenance Plan
Process • KPI: Schedule Compliance (K6) and Planning Accuracy (K7)
Indicators • SPI: Aging work request (S7), Scheduled ratio (S4), Overdue (S3), Outstanding work (S2),
Material reservation usage (S9), Call out (S1)
Process Owner • LHGRS Cement Manufacturing Services – Maintenance and Equipment Reliability
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Plant Maintenance, EBM Work Identification, 2014-06-06
EBM Work Identification Process
# Step Name Input Description of Step Output
1 Create • Walk by inspections (Wbi) • Creation of a notification concerning an activity that needs to be performed by • Notification MR
Maintenance • Preventive Maintenance Routines (PMRs) the maintenance department due to a result of a preventive maintenance
Request • Condition Monitoring (CM) activity, a malfunction or failure of an equipment or an exceptional situation.
• Equipment failures
• Requests from all departments
• Root Cause Failure Analyses
2 Shall it break • Maintenance request • Address to maintenance the level of urgency for the requested activity by • Daily meeting review
weekly setting the priority within the MR (Urgent, To plan, no activity)
schedule? • The maintenance department will then know if it is requested to change
daily/weekly plan, to plan the activity and include it in the standard process or
just an information.
3 Daily Meeting • MR with priority • Review all new MR addressed to maintenance and decide how to treat them • Request additional information from
Review (change daily/weekly schedule, include in normal planning process, further the requester
analyze potential issue, request more information or reject the MR) • Reject the MR as non relevant
• Accept the MR
4 Close the MR • Reject MR • Close the MR • Inform the requester
5 Requester • Close MR • Informed the requester on the reasons why the MR was rejected or on the • MR
informed • Request more information need to receive more information / details on the request (initial MR has to be
updated by the requester)
6 Work Order • MR accepted • Check if any work order already in the backlog concern the same request • Close the MR with comments if
Exist? duplicates or assign the MR to the
existing WO
7 Assign to a WO • MR accepted • Assign the MR to the WO • Review Backlog
• WO already existing
8 During • MR accepted • Assess the need to perform the activity during major shutdown • Assign revision number linked to
Shutdown? • No WO already created the shutdown
• Create directly WO
9 Create WO • MR accepted • Create the WO for the activity to be performed. Identification and planning of • Impact on reliability
• Revision assigned required skills, materials, work force, tools and PPEs.
• Major Shutdown Process
10 Assign revision • Activity to be performed during the major • Assign the relevant revision number to the notification • Major Shutdown Process
shutdown FOR INTERNAL USE ONLY © LafargeHolcim 2015
Plant Maintenance, EBM Work Identification, 2014-06-06
EBM Work Identification Process
Preventive Mechanical Electrical
Maintenance
# Step Name Requester Maintenance Maintenance Maintenance Planner
Manager
Manager Supervisor Supervisor
1 Create Maintenance R A
Request
2 Shall it break R A
weekly schedule?
3 Daily Meeting I, C A R R R R
Review
4 Close the MR I, C A R R R R
5 Requester informed I, C A R R R R
6 Work Order Exist? A I I R
7 Assign to a WO I A I I R
8 During Shutdown? C, I A C C R
9 Create WO A C C R
10 Assign revision I A I I R
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Plant Maintenance, EBM Work Identification, 2014-06-06
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Maintenance Notification
The notification contains all important information about the problem
and triggers the maintenance process
What information has
to be on the notification
to be able to execute
the work with full
satisfaction?
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Maintenance Notification
Notification must answer the questions WHAT, WHEN, WHERE, HOW MUCH about the
problem and give the due date
Meaningful Title Notification Title
Location Func. Loc. / Equipment
Object Part
Detailed Description
Subject (Long Text)
Cause Cause Code
Cause Text
Receiver
Planner Group
Requester
Main Work Center
Due Date
Reported By
Required Start / Priority
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Notification Screen
Notification Title
Func. Loc. / Equipment
Object Part
Required Start / Priority
Subject (Long Text)
Planner Group
Main Work Center
Reported By
Cause Code
Cause Text
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP (4 scenarios)
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Four Scenarios to create Notification in SAP
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SCENARIO 1
Creation of a Notification manually in SAP
Easiest way to create a notification is out of Technical Structure
Transaction
IH01
Select Equipment
(or Functional Location)
GOTO
→ Create notification
→ General
Functional Location and
Equipment automatically
entered in Notification
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SCENARIO 2
Creation of a Notification manually in SAP
Specific Transaction to create Notifications Transaction IW21
Use a Proper Title that describes the problem or request very well
Enter title
Do NOT write an ACTION
(Like: Align belt)
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SCENARIO 2
Creation of a Notification manually in SAP
Use the long text to give all relevant information to the planner
Use the long text to enter all information that could be helpful for the
receiver of the notification to understand the problem.
Use a common structure to write the text
It should be clear who wrote what and when!
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SCENARIO 2
Creation of a Notification manually in SAP
Functional location and equipment gives the location of the problem
As the notification was created
out of the technical structure
nothing has to be added here
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SCENARIO 2
Creation of a Notification manually in SAP
Give the planner the required information to be able to schedule the work and
address it to the right planner
Choose the Required
Start Date according
your priority
Priority U → start date is today!
If the notification is the result of a stoppage of Priority P → normal planning process
the equipment mark the Breakdown check box. Priority 9 → just for information for maint
Enter the Username of the Select the right Planner Group and
requester mainFOR
work center
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SCENARIO 2
Creation of a Notification manually in SAP
Choosing the right Object Part and Cause Code make the analysis of
failures very comfortable
Mandatory at notification’s closure
Choose the correct
object part from the list
Enter a supporting text
Choose the cause code Enter a supporting text
from the list
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SCENARIO 3
Create notification from TIS
TIS allows a direct creation of Notification from the Downtime Log
Indicate if a
Notification needs
to be open
automatically in
SAP ECC6
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SCENARIO 4
Create Notification from Preventive Orders
Create notifications from PM02 work orders Transaction ZPM001
Select the PM02 order(s) from
which notifications should be
created
Click on the work order number
to create a notification from the
work order
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SCENARIO 4
Create Notification from Preventive Orders
Create notifications from PM02 work orders Transaction ZPM001
Fill out all the fields like in any
other notifications then save
Indicate if you want to create a
new notification from the same
inspection
List of notifications create out of
the PM02 work order
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Notification User Status
User status on the notification: CPM and CALL
CPM is automatically
indicated if you generate the
notification from the PM02
CALL is manually set in the
status screen.
CALL means that the notification
result from offshift work
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Livecycle of a Notification
At every step during the lifecycle of the notification the document gets
another system status
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports in SAP
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Notification Reports in SAP
Selection Criteria used for for Notification list
Transaction IW28 There are several
selection criteria you
can use when listing
in SAP.
For Notification the
highlighted fields are
the ones usually
used.
You can use any field
available in the list
criteria.
Most utilized are
Maintenance Plant,
Notification Date
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Notification Reports in SAP
Executing the List Transaction
When you completed
entering your selection click
the ‘Execute’ button and
your list will come out based
on your selected layout
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Notification Reports in SAP
Other specific report: Prometheus Notification History
● Transaction
Transaction: /PROGROUP/NHR
/PROGROUP/NHR
○ Select from the “Navigator” or include in your “favorites”
Transaction IW33
● Into the work order
○ in the “Enhancement” tab – activate the notification
history report
This will call the report from the
reference functional location in
the work order
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Notification Reports in SAP
Notification history
Transaction IW69
Report with Work Order information Order cost
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Summary
Scenarios to create a Notification
Notification MUST
contains all important
information about the
problem and triggers
the maintenance
process
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*
Summary
Questions / Doubts
Comments
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Summary
CONGRATULATIONS
THANK YOU FOR YOUR ATTENTION
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Annex - SAP LAYOUTS
Changing Layout for your list Valid for all SAP list
Click the ‘Get’ to
change the entire
lay out
The current Layout is the one with
the icon
Select a new layout by clicking on
the Layout Name. The system will
bring you back to your list with the
new Layout FOR INTERNAL USE ONLY © LafargeHolcim 2015
Annex - SAP LAYOUTS
Changing the content of your Current Layout 1. Click ‘Current’
2. Click Column
Name to arrange
alphabetically
3. Select the Column
you want to add
4. Click this button to
move the selection
to the Displayed
Column
5. Click this button to
proceed and show
your list with the
added column
6. This is optional, if
you want to save the
changes, click this
FOR INTERNAL USE ONLY
button
© LafargeHolcim 2015
Annex - SAP LAYOUTS
Saving the Layout Changes
7. Do not overwrite
the ‘Default Name’,
put in your preferred
name for this layout
in the ‘Save Layout’
Field. Type in the
description of this
Layout in the ‘Name’
Field. Check the
User Specific and
uncheck the Default
Setting unless you
want it to be your
default
8. Click the ‘Transfer’ button to
save the layout you selected
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Annex - SAP LAYOUTS
Selecting a Default Layout for yourself
To make this as a default
Layout for yourself, click
‘Back’ to get back to the
‘Selection Criteria’ screen
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Annex - SAP LAYOUTS
Selecting a Default Layout for yourself
1. Click the ‘Save’ button
2. Encode:
U_yourusername
in the ‘Variant
Name’ and the
description of the
layout in the
‘Meaning’ field.
Every time you use this
transaction your layout
will be the default layout
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Annex - SAP SELECTION ENTRY
Selecting Multiple Entries that are not in Range
To select multiple selection that
are not in range, click the
‘Multiple Selection’ button
FOR INTERNAL USE ONLY © LafargeHolcim 2015
Agenda
Objectives
EBM Overview of Work Identification
Maintenance Request and Notification concepts
Notification creation in SAP
Lifecycle of Notifications
Reports
Annex
Background
Plant Maintenance, EBM Manufacturing, EBM Preventive Maintenance FOR INTERNAL USE ONLY © LafargeHolcim 2015
training, 2014-06-04 *
Background
New cause code catalogue reduced number of codes by object
part for Maintenance Reliability Analysis
i Indicate the object part and the cause code in
maintenance request
Simplify
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Background
Each object type has its own Object part catalogue
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Background
Cause Code Catalogues and Object Part Codes
• Combine three existing catalogues
1 Object Type
− Code defined in LHAC 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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Background
Cause Code : Electrical & Instrumentation Group
MTBF 2010 Wear / Tear / Fatigue
2020 Modification / new installation
2030 Lubrication Application/Procedures
2040 Out of operational limits
Idle time
2050 Incorrect Design
2060 Fabrication / Overhaul defect
2070 Planned Maintenance (Prev/Shutdown) ONLY TIS
2320 Corrosion
2330 Misalignment
2340 Improper Installation/Spare/Material
2360 Loose / Missing parts
2380 Negligence
2300 Natural Disaster (Maint. required)
2350 Inappropriate process control settings
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Plant Maintenance, EBM Work Identification, 2014-06-06
Background
Cause Code : Mechanical Group
MTBF 2010 Wear / Tear / Fatigue
2020 Modification / new installation
2030 Lubrication Application/Procedures
2040 Out of operational limits
Idle time
2050 Incorrect Design
2060 Fabrication / Overhaul defect
2070 Planned Maintenance (Prev/Shutdown) ONLY TIS
2320 Corrosion
2330 Misalignment
2340 Improper Installation/Spare/Material
2360 Loose / Missing parts
2380 Negligence
2300 Natural Disaster (Maint. required)
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Plant Maintenance, EBM Work Identification, 2014-06-06
Background
Cause Code : Production and process Group
MTBF
2020 Modification / new installation
2040 Out of operational limits
2070 Planned Maintenance (Prev/Shutdown) ONLY TIS
Idle time 2320 Corrosion
2340 Improper Installation/Spare/Material
2360 Loose / Missing parts
2380 Negligence
2300 Natural Disaster (Maint. required)
2370 Internal Captive Power Plant failure ONLY TIS
2110 Product -Raw Material Quality ONLY TIS
2140 AFR usage ONLY TIS
2150 Refractory / Casting Installation
2310 Lack of Raw Material for Operation ONLY TIS
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Plant Maintenance, EBM Work Identification, 2014-06-06
Background
Cause Code : Others
MTBF 2160 Occupational, Health and Safety
2170 Accident
Idle time 2180 Environment Standards
2200 Sabotage or Theft
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Plant Maintenance, EBM Work Identification, 2014-06-06
Background
Cause Code : Idle time Group – NOT FOR MR
2190 Failure of external Power or Gas Supply
Idle time
2210 Peak Power Non Utiliz. - No Maint.
2230 Natural Disaster - No Maint. required
2240 Lack of Demand
MTBF
2290 External logistical Constraints
2250 Planned Prod. Stop - No Maint.
2260 Change Produced Mat. - No Maint.
2270 Strike
None of these cause codes must be assigned to
a MR notification
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Plant Maintenance, EBM Work Identification, 2014-06-06
FOR INTERNAL USE ONLY © LafargeHolcim 2015
