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Enterprise Asset Management
Product Management, SAP AG
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 2
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 3
Service Management
Customer Service Management
Service Sales & Marketing
Service Planning & Forecasting
Service Parts Management
Service Procurement Management
Service Operations Management
Customer Service Management
Analytics
Enterprise Asset Management
Investment Planning & Design
Procurement & Construction
Maintenance & Operations
Decommission & Disposal
Asset Life-Cycle Analytics
Service Management Solution Map, Edition 2004
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 4
Service ManagementEnterprise Asset Management
SAP Product Available
SAP Product Available with Future Releases
Future Focus
Partner Product Available
Partner Product Available with Future Releases
Collaborative Business Map Available
Sxx, Vxx, Bxx SAP Product & ServicePxx Partner Product
For more information see: http://www.sap.com
Investment Planning & Design
Business Planning (S12)Investment Management (S12)Collaborative Specification and Design (S8, P103, S140, S141)Document Management (S8, P103)Interfacing CAD, GIS and SCADA systems (S8, P103)Project Management (S8, S141)
Procurement & Construction
Supplier Qualification and Candidate Selection (S6, S13)Bidding and Contract Management (S25, S6, S140)Procurement Process (S25, S6, S12, S120)Document Management (S8, P103)Project Management (S8, S141)Collaborative Construction (P103, S8, S140, S141)Project and Investment Controlling (S12, S8)
Maintenance & Operations
Technical Assets Management (S8)Preventive and Predictive Maintenance (S8)Work Clearance Management (S134, S8)Maintenance Execution (S8, P28)Shutdown Planning (S8)
Mobile Asset Management (S8, B35)Web-Based Processing (S8)Contractor Management (S8, S6, S25)MRO and Services Procurement (S6, S25, S120, S12)Service Parts and Inventory Management (S4)Document Management (S8)Employee Management (S8, S9)Maintenance BudgetingIntegrated Asset Accounting (S12, S8)
Decommission & Disposal
Asset Transfer and Disposal (S12, S8)Document Management (S8)Collaborative Disposal Management (S8, P103, S140)Project Management (S8, S141)Waste Management (S125)Asset Compliance (S125)Asset Remarketing (S4, S2)
Asset Life-Cycle Analytics
Asset and Maintenance Reporting (S8)Asset Performance Management (S8, S13)Reliability Centered Maintenance (S8, S13)Asset Life-Cycle Costing (S13)Damage Analytics (S13, S8)Object Statistics (S13, S8)Spend and Supplier Performance Analytics (S13, S6)
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 5
The Overall View of the Asset Life Cycle
ProcurementManufacture
Installation & Test
OperationMaintenance
Refurbishment
Modification
Replacement Selection orDesign
Asset
Requirement
MarketplacesEBP
AvailabilitySafety
Status Quality
ImplementationEfficiency
Investment Management
Project Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 6
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 7
Maintenance-Relevant Objects
Company premises Buildings Machinery Assets Resources EDP infrastructure Fleet Electrical fixtures Rails Replacement parts And many more
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 8
Technical Object Types
Equipment
Assembly
Spare Parts
Functional Location
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 9
Asset Structure
Production Plant
Production street 1
Press shop
Welding plant
Assembly area
Production street 2
Shipping area
Asset structure = multi-level, hierarchical structure, organized by ...
Criteria
Technical
Functional
Spatial
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 10
Individual physical object to be maintained as an autonomous unit
Equipment
Installation and dismantling in asset structure
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 11
Master Record of a Technical Asset
Multilingual texts
Classification
Documents /Technical drawings
Addresses / Partners
Implementation
Measuring points / Counters
Permits
General
Master Record
Location
Organization
Structure
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 12
Bill of Materials
Production street 1
Press shop
Press 1
Motor ABC
Motor casing
Functional location
Functional location
Assembly
Material
Drive shaft
Press plate XYZ
Coil
Equipment
Material
Material
Material
Spare parts configuration of a piece of equipment
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 13
Web Catalogs
Transparent structure Web interface BOMs may be superfluous
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 14
Synchronisation between Equipment and Fixed Asset
Automatic data synchronization possible
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 15
Interfaces to Non-SAP Systems
R/3-Database
Asset Life-Cycle
ManagementStandard interfaces
SCADA
CAD systems
Internet
Barcode scanner
Process Control System
Geographical Information Systems
System openness through standardized interfaces
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 16
Fleet Management with Enterprise Asset Mgmt.
Standing PM order
Equipment with fleet segment
PMIS
AssetPost depreciation to PM standing order
Measuring points
Totalcost collection
Performance analysis
Asset/Equipment synchronization
Mileage and fuel
Maintenanceprocesses
Fuel entrytransaction
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 17
Technical Assets Management: Advantages
Asset transparency Meaningful history of equipment maintenance Flexible analysis options
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 18
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 19
Preventive Maintenance: Reasons
Legal regulations (for example, technical inspection of vehicles)
Quality assurance (for example, customer demands)
Reduction of breakdown frequency of assets, thereby:
Lowering costs of restarting,Prolonging the lifecycle of assets
Environmental considerations
Manufacturers’ requirements
Lowering of maintenance costs
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 20
Reduction of Maintenance Costs?
Cost of repairs
Cost of preventive maintenance
Overall cost of maintenance
Cos
ts
Degree of intensity of preventive maintenanceM0
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 21
Preventive Maintenance: Categories
Time-Based Performance-Based Condition-Based
Preventive Maintenance
Temperature
ThicknessPressure
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 22
Order/Notification
Schedule plan
WHAT?Task listsWHEN?
Time- or counter-basedstrategies
Order/NotificationOrder/
Notification
WHERE?
Preventive Maintenance
Maintenanceplan
- Single cycle- Strategy- Multiple counters
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 23
Preventive Maintenance Processing
Order/NotificationOrder/
NotificationOrder/Notification
Maintenanceplan
Scheduling
Worklist
Dispatching
MaintenanceExecution
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 24
Preventive and Predictive Maintenance: Advantages
Increase equipment reliability Reduce maintenance inventory More effective use of all resources
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 25
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 26
Business Process: Breakdown Maintenance
Production Supervisor/Maintenance Planner
Maintenance work center
Call /Notification
Create order and release
Fix malfunctionConfirm and complete order
Order
0010 Inspect pumps
0020 Replace seals
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 27
Functional Process (Acute Maintenance)
Techn. Object Condition
description Item data Activities /
Tasks Priorities
Notifica
tion
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 28
Maintenance Notification
Catalog entries Paging function Solution database
Notification with
Configurable screen areas and tab pages
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 29
Catalogs
Catalogs can contain object parts, damages, tasks, activities...
Damagecatalog
Mechanicaldamage
Code010 Corrosion020 Broken glass030 Engine defect. .. .. .
Example:
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 30
Functional Process (Acute Maintenance)
Internal / External resource- planning
Release / Print Control /
ExecutionPM
Order
Techn. Object Condition
description Item data Activities /
Tasks Priorities
Notifica
tion
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 31
Maintenance Order
Order header:Reference object, dates, priority, description
Operations:Work center, duration, description, external services
Components:Material, services, quantity, availability check
Object list:Technical objects, notifications, material
Further information:Costs, Partners, Maintenance plan information...
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 32
Component Planning with Catalogs
Available in standard for R/3 Enterprise
Branch directly from the order to a web catalog
Copying of stock and non-stock materials into the order
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 33
External Services
Integrated service request in the maintenance order
Display of short- and long-term external services Continuous posting and tracking of costs
Service entry sheets allow later verification of services performed
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 34
Time- / Material confirmation
Technical completion
Order settlement
Comple
tion
Functional Process (Acute Maintenance)
Internal / External resource- planning
Release / Print Control /
ExecutionPM
Ord
er
Techn. Object Condition
description Item data Activities /
Tasks Priorities
Notific
ation
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 35
Completion Confirmation
Reference order Technical completion
Time confirmation
Material confirmation
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 36
Objects Orders /
Notifications Costs Downtimes
Histor
y
Functional Process (Acute Maintenance)
Time- / Material confirmation
Technical completion
Order settlement
Comple
tion
Internal / External resource- planning
Release / Print
Control / Execution
PM O
rder
Techn. Object Condition
description Item data Activities /
Tasks Priorities
Notifi
catio
n
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 37
Maintenance History
Change Documents
Action Logs
Complete history and cost tracing for technical objects
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 38
Maintenance Information System
Strategically important standard evaluations are for example Cost analyses
Site analyses
Malfunction and breakdown analyses
Manufacturer analyses
…
Drill down
Drill down
Example: Cost Analysis
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 39
Business Warehouse for Maintenance Analyses
SAP BW provides a complete data warehouse solution.
The predefined Business Content in SAP BW allows analyses of Quality-, maintenance-, and service notifications
Notification items, -causes, -tasks, -activities
Maintenance- and service orders
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 40
Breakdown Maintenance: Advantages
Increase plant availability Reduce equipment stops and downtime Minimize maintenance costs substantially
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 41
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 42
Refurbishment Process
Order
0010 Refurbish pump
0020 Settle order
Refurbish Equipment
Stock
Dismantle Equipment
Re-install Equipment
Issue Equipment
Re-stock Equipment
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 43
Refurbishment
Dismantling of faulty equipments and return to warehouse for refurbishment
Material with condition-based value linked to the equipment is used to monitoravailability of stock in inventory management
Materialcondition-based valuation
Valuation type C2 (refurbished)
$ 2500
Valuation type C3 (damaged)
$ 200
Valuation type C1 (new)$ 3000
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 44
Refurbishment Process: Advantages
Completion of the life cycle of a technical asset Uniqueness through serialization Life cycle trading of equipment
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 45
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 46
Enterprise Portals: Uniform Access to All Systems
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 47
Characteristics of a Portal
High level of integration through the latest technology
Uniform interface for various applications
Simple access and high usability
Simple adaptability and thereby simple re-design of business processes
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 48
Individual Page Construction: Example
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 49
Business Package for Assets: Contents
Information on technical objects as well as corresponding notifications and orders
Simple creation and tracking of notifications
Installation and dismantling of equipments
Time completion confirmation
Material availability check
Creation, changing and display of document
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 50
Mobile Asset Management
Suite of tools tailored to the needs of the field service & field maintenance personnel
Extends Plant Maintenance and Customer Service functionality
Offline processing using mobile engine
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 51
Mobile Asset Management - Functional Overview
Technical Object Management
SAP Backend Data update in backend
Measurement & Counter Readings
Inventory Management
Notification Management
Business Partner Management
Contract Management
Order Management
Data creation and assignment
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 52
Advantages of Mobile Asset Management
Extended mobility through location-independent work Immediate on-site data entry Improved data quality Direct access to up-to-date data Lower process costs
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 53
Integration to mySAP SRM
Catalog
OCI Compliant Cataloge.g. BugsEye
Select spare parts / services
R/3 System
PM / CS
Maintenance Order
Purchase Requisition
Purchase Order (Copy)
Goods Receipt / Service Entry
Invoice
SRM
Enterprise Buyer
Sourcing
Purchase Order
Confirmation / Service Entry
Invoice
Requirement
Replication of purchase order
Follow-ondocuments can
be created in backendor in EBP
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 54
SAP R/34.6C and below
Enterprise Buyer
Order 4711 Operation 10 Operation 20
ReservationPurchaserequisition
Order 4711 Operation 10 Operation 20
Selectorder
Order 4711 Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10
Transfercomponents
Go tocatalog
Order 4711 Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10
Transfer to shopping cart
External parts catalog
Pump P1000Gears Gx01
Washer 10-10
Component Planning with Enterprise Buyer
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 55
Integration into Investment Management
Asset under Construction
Depreciation Simulation Fixed Assets
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 56
Project Oriented Shutdown Planning
mySAP PLM Project Management
mySAP PLM Program Management
Idea & Concept
Planning & Approval
Project Execution Closing
Documents Workforce
Procurement
Schedule
Project StructureBudget Claims
Costs/Revenues
StatusProgress
Payments
Project Information System
Shutdown Project Life-Cycle
Project Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 57
Shutdown Planning with Project-Oriented Maintenance (POM)
mySAP PLM Asset Life-Cycle Management offers an interface to Primavera P3, which you can use to plan shutdowns with reduced costs and downtimes. This includes:
Shutdowns (Processing industry) Revisions (Utilities) Checks/Overhauls (Aerospace)
POM supports the following core processes: Identification and selection of the work Planning/Budgeting Optimization/Simulation Performance and support of unplanned work Evaluations/Reporting
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 58
cFolders for Enterprise Asset Management
Defined partners receive controlled access to documents and materials as well as material BOMs outside of the R/3 system
Simple call-up using Internet Explorer and user ID
Own status management allows "Mini-Workflow" and version concept
Documents and notes can be edited and selected
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 59
Example: Info Exchange with Service ProvidersOperator Service providerOrdering of services
Construction of the cFolders structure
Info call up of updated data
Call up of the cFolders structure
Technical confirmation, completion of documents, for example, on handheld devices
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 60
Example: Information Exchange with Customers
Service Provider Customer
Provision of services
Construction of thecFolders structure
Notification recording
Call up ofcFolders structure
Notifications for cFolders objects
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 61
Integration and Platforms: Advantages
User-friendly interface in Enterprise Portal
Realtime documentation of maintenance
work through Mobile Asset Management
Tailored shutdown planning
Company-wide exhange of information with cFolders
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 62
Contents
Enterprise Asset Management
Technical Assets Management
Preventive and Predictive Maintenance
Breakdown Maintenance
Refurbishment Process
Integration and Platforms
Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 63
Work Clearance Management
Comply with legal safety standards
Observe additionalcompany-specific guidelines
Maintain plant safety andhigh system availability
Adhere to health and safetyrequirements in the workplace
Follow environmentalprotection regulations
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 64
Work Clearance Management: Basic
Isolation of technical objects to ensure safe and secure working conditions for personnel during maintenance work or controlled tests
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 65
Architecture
Work Approval
Applications
Work Clearance Application (WCA) Application for Fire Protection ...
Work Clearance Documents
Work Clearance Document Template Operational Work Clearance Document
Order
Work Approval
Work Clearance Application
Operational WCD
Enhanced Model
Further Applications
Order
Work Clearance Application
Operational WCD
Standard Model
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 66
Maintenance Process
Notification
SCADA
Work ClearanceManagement
CreateOrder
ReleaseOrder
ConfirmOrder
CompleteOrder
Analyze Histories
PlanOrder
Maintenance plan
Work ClearanceManagement
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 67
Objects
Status processing and audit trail:system status and user status
Assignment of partners:different roles possible
Long text processing:several internal remarks
Assignment of documents:link to document management system
Assignment of permits:process relevant, interactive, ...
Use of catalog technique:code groups and codes
General data
Reference object
Areas of responsibility
Location data
Planning data
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 68
Work Clearance Management: Advantages
Maximize your employee's safety
Improve work efficiency
Enhance your assets' productivity
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 69
Summary
Enterprise Asset Management: Your
Benefits
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 70
Advantages for Asset Operators
Increased asset efficiency and lower TCO
Sustained optimization of asset usage
Reduced expenditure for service providers and materials
Higher production capacities
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 72
Key Customers