MAINTENANCE STANDARD GUIDELINE BASE …extportal.vale.com/maint/Sud/pdf/MGUID-15002-1.pdf · PLANT MAINTENANCE Scheduling Capacity Planning VALE # MGUID-15002 PAGE ... SAP Interval

MAINTENANCE STANDARD GUIDELINE BASE METALS

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PLANT MAINTENANCE Scheduling Capacity Planning

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Training Code (If applicable):

Document Owner: Name: Denis Deschamps Position: Business Process Specialist Department: Base Metals

Table of Contents

1.0 PURPOSE....................................................................................................................................................................... 2

2.0 SCOPE ........................................................................................................................................................................... 2

2.1. EXCEPTIONS .................................................................................................................................................................... 2

3.0 REFERENCES .................................................................................................................................................................. 3

4.0 DEFINITIONS ................................................................................................................................................................. 3

5.0 SETTING WORK CENTER DATA ...................................................................................................................................... 4

5.1. WORK CENTER BASIC DATA ............................................................................................................................................... 4 5.2. WORK CENTER DEFAULT VALUES ........................................................................................................................................ 5 5.3. WORK CENTER CAPACITIES ................................................................................................................................................ 6 5.4. WORK CENTER SCHEDULING .............................................................................................................................................. 7 5.5. THE WORK CENTER COSTING ............................................................................................................................................. 8 5.6. WORK CENTER TECHNOLOGY TAB ....................................................................................................................................... 9

6.0 CAPACITY DETAILED SETUP ........................................................................................................................................... 9

6.1. STANDARD AVAILABLE CAPACITY ........................................................................................................................................ 10 6.2. PLANNING DETAILS ......................................................................................................................................................... 11 6.3. SHIFT SCHEDULES AND HOURS OF WORK FOR THE WORK CENTER .............................................................................................. 12 6.4. INTERVALS AND SHIFTS .................................................................................................................................................... 13 6.5. ADDING PERSONNEL TO WORK CENTERS ............................................................................................................................ 14 6.6. PROMETHEUS GROUP GS SHIFT UPDATER .......................................................................................................................... 16

7.0 VIEWING THE CAPACITIES ON THE GWOS BOARD ....................................................................................................... 16

7.1. SETTINGS TO PULL CAPACITIES FROM CR12 ......................................................................................................................... 16 7.2. SETTING TO PULL CAPACITIES FROM PGPNL/SHIFT ............................................................................................................. 17 7.3. SETTINGS TO VIEW TOTAL CAPACITY OF WORK CENTER FROM PGPNL/SHIFT ............................................................................ 18

8.0 REPORTING ................................................................................................................................................................. 18

8.1. REPORTING FROM BUSINESS OBJECTS ................................................................................................................................ 18

9.0 APPENDICES ................................................................................................................................................................ 19


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1.0 PURPOSE

The purpose of this document is to outline the process to perform capacity planning in SAP. The intent is to have a standardized process for all sites to use within Base Metals to set up the resource capacity within SAP, and as an additional subset Prometheus, such that scheduling can be executed in as precise as practical view. In all discussions relating to the Asset Management Framework, the term scheduling is used to describe the process of defining the start time, sequence of execution and resource allocation (including workplace, labour, equipment, etc.) for Tasks. The objectives of scheduling are firstly to ensure that all Tasks are completed at the right time and secondly to make the most efficient use of resources while doing this.

2.0 SCOPE

This document pertains to the following objects:

IR01, IR02, IR03 – Work Center Create, Change and Review

CR12 – Change Work Center Capacities, Intervals and Shifts

PGPNL/SHIFT – Prometheus Group GS Shift Updater

PROGROUP/ZGWOS – Graphical Work Order Scheduler

2.1. EXCEPTIONS

There are no exceptions


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3.0 REFERENCES

The following references were used in the development of this document. They shall be used in their most recent revision.

VPS – Vale Production System

One Vale Business Process documents (BP310) o Maintain Assets

Plan and Schedule Maintenance Activities

AMF – Asset Management Framework o TA 10.0 Scheduling

TA 10.07 Is labour and downtime next week fully loaded TA 10.05 Identify work synergies and conflicts

4.0 DEFINITIONS

Work Center – Used to assign work, perform capacity planning, and for scheduling; may represent employees, machines, production lines or assembly work centers

Activity Type – Identifies the type of resource represented and together with the Cost Center contains the cost of the resource


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5.0 SETTING WORK CENTER DATA

5.1. WORK CENTER BASIC DATA

The first step in setting up a Work Center’s capacity is to understand the basic requirements of SAP, specifically the One Vale design. Here is the standard set up for Basic Data. Since work centers are used throughout SAP modules there are several fields that are not used in PM.

The initial set up of the Work center would typically be done by a Maintenance Divisional Support resource on the creation of the Work Center. There are several layers of Work Centers in the Work Center Hierachy. Scheduling is done at the lowest level or the resource level commonly known as Level 6.

Therefore, as part of this guidline, no changes would be done to this Tab of Work Center Data.


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5.2. WORK CENTER DEFAULT VALUES

The default values have to be entered for the Work Center.

The only variation on the Default Values would be the Control Key; Internal (PM01) or External (PM02). These would typically be done at the creation of the Work Center by the Maintenance Divisional Support resource.


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5.3. WORK CENTER CAPACITIES

The Capacities information for the Work Center needs to be populated.

The majority of the Time the Capacity Category will be 002 - Person with the Other Formula being SAP008. In some cases the Capacity Category will be 001 – Machines in the case of the shops or production scheduling (Divisional Shops in Ontario or Central Shops in Manitoba at time of writing of this document).

These would typically be done at the creation of the Work Center by the Maintenance Divisional Support resource.


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5.4. WORK CENTER SCHEDULING

The Work Center Scheduling Tab needs to be populated

Under Execution time the Other Formula should be populated with SAP004.

Under Dimension and Unit of measure of work, populate Work Dimension with TIME and Work Unit with H for Hours.

Basic Capacity information is also set up during work center creation.



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5.5. THE WORK CENTER COSTING

The costing tab information must be populated.

Validity Date is the start date as of when the work center can be used. Recommended to be a date in the past such as 2011.01.01 and end date in the future such as 2999.12.31.

Controlling area for Base Metals is ACBR.

Cost center is the home cost center for the Work Center in question. It is important to use the correct cost center to ensure budgets are consumed appropriately and management can manage costs.

Activity Type int.Proc must be polulated with the appropriate Activity type for the resource identified in the Work Center. During this step, the budget for the Resources must be reviewed and a standard rate identified to ensure costing flows through the Work Order appropriately. The Formula SAP008 must be populated.

If the correct Cost Center/Activity Type combination does not exist, contact your cost analyst to have this created with the appropriate Standard Rate (based on the Guideline to set Activity Rates).


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5.6. WORK CENTER TECHNOLOGY TAB

The Technology tab is not used in our current SAP configuration

6.0 CAPACITY DETAILED SETUP

The next step is to set up the capacities for the Work Center. This is done from CR12 typically by the scheduler. Enter your Plant, Work Center and Capacity Category (always 002 for Person).

This will bring you to the Detailed Capacity screen for the Work Center.


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6.1. STANDARD AVAILABLE CAPACITY

Set Capacity Planner group to PLN

In Available Capacity, the

Factory Calendar should be set to Z5

Active Version to 1

Base unit of Measure to H

Since most site Work Centers operate 24 hours a day (with some variation of individual resources at 10.5 or 8) the Standard Available Capacities should be set as shown in the screen shot below. To facilitate the capacity planning at a more granular level, we consider breaks to be 0 and the day to be a full 24 hours. This eliminates the risk of work extending into another day due to conflicting strategies in capacity planning set up. Therefore, this will give you an operating time of 24:00 hours. The unavailable times will be managed later in this document.

Set the Capacity Utilization at 100%.

When assigning your Work Center capacities (no. of indiv. Cap.) you need to know the total number of resources that are available in the Work Center. This is typically found in the HR application (PeopleSoft, VIP or Safe EMS). The Work Center resources should include all resources assigned to the Department(s) in the time management systems since there is not always a one to one relationship between the time management applications and SAP.


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6.2. PLANNING DETAILS

“Relevant to finite scheduling”, “Can be used by several operations” and “Long-term planning” should all be checked.

Overload % should be blank.


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6.3. SHIFT SCHEDULES AND HOURS OF WORK FOR THE WORK CENTER

If there are more than one schedule i.e. 24-7 and an 8 hours a day you would use the longest day as your starting point. Remember to map out your shift schedules prior to starting since SAP Interval and Shifts is based on the resources during that time period and not the crew shift. Use calendar time as opposed to shift time.

Example:. A crew with 10 resources working 8 hours steady days Monday to Friday and 16 resources working 12 hours 24/7 or 4 per shift would look like this

Start Time End Time

Length of Break

Cap. Util. Number

Operating Time Capacity

Unit of Measure

Monday 0:00:00 7:00:00 0:00:00 100 4 7.00 28 H 7:00:00 15:00:00 0:00:00 100 14 8.00 112 H 15:00:00 0:00:00 0:00:00 100 4 9.00 36 H Tuesday 0:00:00 7:00:00 0:00:00 100 4 7.00 28 H 7:00:00 15:00:00 0:00:00 100 14 8.00 112 H 15:00:00 0:00:00 0:00:00 100 4 9.00 36 H Wednesday 0:00:00 7:00:00 0:00:00 100 4 7.00 28 H 7:00:00 15:00:00 0:00:00 100 14 8.00 112 H 15:00:00 0:00:00 0:00:00 100 4 9.00 36 H Thursday 0:00:00 7:00:00 0:00:00 100 4 7.00 28 H 7:00:00 15:00:00 0:00:00 100 14 8.00 112 H 15:00:00 0:00:00 0:00:00 100 4 9.00 36 H Friday 0:00:00 7:00:00 0:00:00 100 4 7.00 28 H 7:00:00 15:00:00 0:00:00 100 14 8.00 112 H 15:00:00 0:00:00 0:00:00 100 4 9.00 36 H Saturday 0:00:00 0:00:00 0:00:00 100 4 24.00 96 H Sunday 0:00:00 0:00:00 0:00:00 100 4 24.00 96 H

The key is the number of resources working during the period of time, not the actual workers shift schedule.


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6.4. INTERVALS AND SHIFTS

The Work Center capacities can be built directly in CR12 using the Cheat sheet for “Work Center – Maintain Work Center Capacities – CR12”. Included in the Cheat sheet is the setup for Intervals and Shifts based on the information gathered above.

Some additional information to consider when setting up your Work Center Capacities:

Valid From - to

Enter the date range from the start of the scheduling period for your Work Center until 12-31-9999 Intervals can be entered for specific events (shutdowns)

Length of cycle 7

Week Days For each day where there will be resources present. (Mon to Fri crew would not have any hours assigned on Sat or Sun (Zero hours do not delete the lines)

Shift Shift(s) added to represent when resources will be on site (Note: this is calendar based so the next day starts at 12:00am) A crew working an 8 hour night shift that begins at 11pm and finishes at 7am would have a shift entry that runs from 23:00 to 24:00 and 00:00 to 07:00

Start Time and End Time

Start of calendar shift (see shift above) End of calendar shift

Length of Break Leave at 00:00:00. If break duration is added the duration of the break will be averaged across the remaining working hours

Capacity Utilization Leave at 100. Any other value will be calculated across the working hours and affects the scheduled execution time displayed

Number Budgeted resources for the day/shift depending on work center


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6.5. ADDING PERSONNEL TO WORK CENTERS

Once the capacities are set up, add the individual resources into the work center using cheat sheet “Work Center – Adding Individuals to a Work Center – CR12”. This is done to facilitate the creating of the shift schedules in Prometheus PGPNL\Shifts and will help in the time confirmation process. Whenever there is a change in resources to the Work Center, this assignment must be updated.


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6.6. PROMETHEUS GROUP GS SHIFT UPDATER

Now you are prepared to populate the detailed crew shift schedule. When creating it, you should use and end date of 01-01-9999 such that you never have to update it again and only required updating based on the personnel changes in the work center and their shift schedules. Using the Cheat Sheets for “Prometheus - Work Center – PGPNL.SHIFT” and “Prometheus – Work Center Instruction for PGPNL Shift” set your work center personnel schedules and times including planned time off. This will provide you with a detailed view of your available capacity in the GWOS board

7.0 VIEWING THE CAPACITIES ON THE GWOS BOARD

7.1. SETTINGS TO PULL CAPACITIES FROM CR12 Standard setting to view capacities are read from CR12. Intervals and Shifts capacity will be displayed if populated and Header capacity will be displayed if intervals and shifts have not been updated. Note: in this example the work center is showing 192 hours available on each day of the week and is being pulled from CR12


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7.2. SETTING TO PULL CAPACITIES FROM PGPNL/SHIFT Note: for the same date and work center the available capacity for the work center for the week now varies and the individuals work schedules are now visible.


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7.3. SETTINGS TO VIEW TOTAL CAPACITY OF WORK CENTER FROM PGPNL/SHIFT Note: In this example for the same dates and work centers the Hierarchy is now collapsed and is showing the same hours available for each day of the week

8.0 REPORTING

None.

8.1. REPORTING FROM BUSINESS OBJECTS None


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9.0 APPENDICES

APPENDIX A: Revision Notes and Approvals


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9.1. Appendix A: Revision Notes and Approvals The Revision Notes and Approvals table only displays the latest revision number and a list of the last revisions made to the document. For details on previous revisions contact the document owner.

Rev Revision Notes

1

New Base Metals Maintenance Standard

Approvals

Name and Position

Date

Document Owner

Denis Deschamps Base Metals Business Process Specialist

April 17, 2018

Canada/UK Base Metals

Heiko Leers Base Metals Maintenance Focal Point

Documents

MAINTENANCE STANDARD GUIDELINE BASE …extportal.vale.com/maint/Sud/pdf/MGUID-15002-1.pdf · PLANT MAINTENANCE Scheduling Capacity Planning VALE # MGUID-15002 PAGE ... SAP Interval