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Data Quality Taxonomy & Failure Coding
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Produced by: Supported by:
Brian Gilson CMRP Lead Reliability Project Manager
Ralph Hanneman CMRP Senior Consultant
Data Quality Taxonomy & Failure Coding
Structure at Owens Corning
Founded in 1938, an industry leader in glass fiber insulation,
roofing, asphalt, and glass fiber reinforcements
NYSE: OC
2011 sales: $5.3 billion
15,000 employees in 28 countries
FORTUNE 500 company for 58 consecutive years
Component of the Dow Jones Sustainability World Index
Three powerful businesses, three valuable franchises
Composites
Roofing
Insulation
Owens Corning - Who we are
• Global leader in APM software and services for asset-intensive
industries
• Lowers the risk of harm to people, our planet and profits
by predicting and preventing physical asset failures
• Headquartered in Roanoke, VA
• Offices in Houston, Dubai, Bangalore, Madrid, Singapore, Perth, and
Porto Alegre, Brazil
• www.meridium.com
Meridium - Who we are
• Owens Corning
o On a journey towards mature manufacturing reliability practices
o Implementing ECC 6.0 EP4 in North America
o Realized Failure Coding in SAP is vital for data driven decisions
• No one right way to develop failure coding
Find what works best for your company!
Our intent is to share our story to help others towards
increased reliability of their assets & processes
Introduction
• Multiple versions of SAP
• No standard work management process
• No asset classification data being used
• One size fits all failure coding not working well
• Taxonomy classification virtually non-existent
Standardization needed to occur
Processes needed to change
Where we were…
Makeover Opportunity
• Migration from R/3 3.1i and 4.7 to ECC 6.0
• SAP Plant Maintenance Enterprise Solutions o Owned by Owens Corning MRG (Manufacturing Reliability Group)
• Objectives: o Enterprise wide solutions
o Continuous Improvement (CI)
o Data quality and user friendliness
o Change management practices and training
o Cost effective
• Thoughts to Action
o Discovery process to develop strategy and roadmap
o Selected Meridium - failure coding
o Developed catalog profile numbering convention
o Master Library Concept
o Meridium SAP enhancement code
• Initial Coding Kickoff Workshop – Oct 2011
o Meridium and OC’s MRG team
o Utilized Meridium and industry best practices
o Modeled after ISO 14224-2006 Standard
o Brainstormed taxonomy design for RWP & SAP
The journey
• “General” Assets and Codes Identified
o Core team – site representatives from all businesses
o Kickoff workshop set process
o Asset list identified and assigned catalog profile codes
o Developed failure coding
• “Specific” Assets and Codes Being Developed
o Team formed from single business
o Kickoff workshop - same process as core team
o Assets specific to business identified - assigned catalog profiles
o Sanctions additional “General” assets & codes
The journey (cont)
• A common problem
• No methodology to simplify and segregate codes for specific asset class and types
• Matching Damage codes to the Object Part codes error potential
Failure Coding Mismatches
• Catalog Profile
o Unique numbering convention of assets
• The Master Library Concept
o Object parts (maintainable items) specific to the asset
o Damage code set specific to object part (maintainable items)
• SAP Enhancement
o Automatic matching of Object Part code and Damage code group
Failure Coding Mismatch Solution
• Numerical Design
• Enables:
o Master Library concept
o Asset classification and Meridium’s best practice
o Use of single field
o Easily searchable
Catalog Profile Code
Brainstormed during
initial workshop.
Developed by
Meridium on top of
the Master Library
Concept
Master Library & SAP Customization
• Assures data quality
• Increases craft efficiency
• Optimizes code selection
• Reduces craft input errors
• Standardizes analysis, reporting and metrics
Benefits
• Change management processes and training
• Staying evergreen
• SAP implementation schedule
• Adapting to inconsistency of master data
Challenges
• MRG ownership
• Investment in the resources
• Meridium’s training and facilitation
• Meridium’s proprietary failure coding tool & database
• Brian Gilson and Ralph Hanneman
Enablers
• Positive feedback
• User adoption
• Committed people
• Code mismatch errors eliminated
• MRG Team responsible for MOC process
• “Specific” asset code development
• Ongoing monthly transports
Seeing results
Moving Forward
Code Set
Quantity of Codes developed through
Jan 2013
Detection Method 6
Functional Failure 19
Catalog Profiles (Asset Types)
87
Unique Object Parts 139
Total Object Parts Assigned to Assets
4127
Unique Damages 35
Total Damages Assigned to Object Parts
1394
Functional Loss 4
Maintenance Activity 18
Cause Codes 19
Code Groups 236
• Invest in teams to obtain user adoption and maximize
brainstorming of ideas and codes
• Standardized asset classification for category, class & type
(catalog profile)
• Utilization of master library concept reduces code selection errors
and optimizes craft activity reporting time
• Use the methodology and processes to develop profile and failure
coding as your company requires
o Leverage existing standards – Don’t reinvent the wheel
o Do what’s best for your company
Key Lessons & Takeaways
Q&A
• Mapping table showing ISO terms to SAP terms with technical information
Appendix 1- Mapping Table
ISO 14224 Term SAP Term Data Entry Method / Options Technical
Malfunction Breakdown Indicator Checkbox Field name: MSAUS
Detection Method Not in Standard SAP Subject / Coding Field Option: Use Catalog: D - Coding
Failure Mode (Functional Failure) Not in Standard SAP Subject / Coding Field Option: Use Catalog: D - Coding
Effect Effects on Operating Function Selection List Field name: AUSWK T-code OIMW
Functional Loss (Notification) System Condition Selection List Field name: ANLZN T-code OIMZ
Maintainable Item Object Part Catalog Code Catalog B: Object Parts
Condition Damage Catalog Code Catalog C: Overview of Damages
Failure Cause Cause Code Catalog Code Catalog 5: Causes
Activity Activity Catalog Code Catalog A: Activities
Task Task Catalog Code Catalog 2: Tasks
• The Master Library Concept
• Guidelines
o Each code used, has a prefix that matched the catalog it is used in
All Maintainable Items begin with Bxxx, because the Maintainable Items in
SAP are found in Catalog B.
o Each code is used to uniquely describe the part, condition, cause, etc.
There is only one code for Bearing, not a scattering of codes that mean
bearing.
o The code group for damages is the same as the maintainable item code
that the damages are documenting.
Bearing is B001 – the code group for Damages for a Bearing is “B001”.
The actual Damage codes in code group have the prefix C.
▫ E.g. C008 – Corroded, C023 – Seized, etc.
This way a technician can more easily select the damage codes based on the
maintainable item that experienced the failure
Appendix 2- Master Library Concept
• Useful whitepapers on the topic of failure coding in SAP
o Meridium Basics Failure Event Coding
o https://www.meridium.com/knowledgecenter/members/apmadvisor/basic_failure_
event_coding.asp
o Eight Steps to Boost User Adoption of Failure Event Codes
o http://www.apmadvisor.com/archivearticle.asp?id=129&is=23&ord=2
o How to Easily Use SAP Notifications to Document Crucial Failure Related
Information
http://www.apmadvisor.com/archivearticle.asp?id=223&is=43&ord=2
Appendix 3- Whitepapers
Produced by: Supported by:
Brian Gilson, CMRP Lead Reliability Project Manager
Owens Corning Sales, LLC
Ralph Hanneman, CMRP Sr. Consultant
Meridium, Inc.
