Matthias Wobbe Meridium - MainTech konferansen 2018 - 4 ...konferanse.maintech.no/.../Meridium_RCMO_SAP_Road_to_Reliabilty.… · 2002 – Synchronization of SAP Master Data in Meridium

© Copyright Meridium 2011

the global leader in asset performance management solutions

Matthias Wobbe Meridium

™



Road to Reliability

About Meridium

Introduction to RCM

Process Overview RCMO™ and SAP

© Copyright Meridium 2011 3

Meridium Overview

• Founded 1993 • Global presence

– Americas • Roanoke, Virginia, USA – Corp HQ • Houston, Texas, USA • London, Ontario, Canada • Sao Paulo, Brazil • Mexico City, Mexico • Barcelona, Venezuela

– Europe • Bremen • Malta

– Middle East/North Africa • Dubai, UAE

– Asia-Pacific/South Africa • Perth, Australia • Bangkok, Thailand • Pune, India • Johannesburg, South Africa • Shanghai, China

• Our focus: – Help customers achieve predictable

production at the lowest sustainable cost • Serving asset-intensive industries

– 900+ licensed locations – 70+ countries

Implementation & Integration Service

Integrated Software Applications

Strategic Partners

APM Consulting & Education


Meridium/SAP Partnership

1996 – First joint customers 2000 – Certified integration between SAP PM and Meridium APM 2002 – Synchronization of SAP Master Data in Meridium 2003 – BAPI based interface 2004 – Co-Development of RCMO to be Powered By Netweaver 2005 – Powered By NetWeaver Certification 2006 – Composite Application Certification (xAPP) 2007 – RCMO™ became a SAP Endorsed Business Solution (EBS)

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http://www.rcmo.com/faqs/index.asp



Road to Reliability

About Meridium

Introduction to RCM



What is RCM?

“Reliability Centered

Maintenance is a formal

method to determine the

maintenance requirements

of an asset in its operating

context.”

“RCM stresses a proactive

approach to maintenance. This

method attempts to match the

best maintenance practice to

mitigate a potential failure

relative to the importance of

preventing that failure.”


Key Characteristics of RCM

• RCM is a proactive approach for developing maintenance strategies.

• RCM stresses the value of maintaining or preserving of a function as opposed to maintaining an asset.

• RCM matches the best practice to reduce the probability of

a potential failure relative to the severity of its

consequence.


The 7 Questions of RCM

1. What are the desired functions and performance standards of the asset in it’s operating context?

2. In what ways does it fail to fulfil its functions?

3. What causes each functional failure?

4. What happens when each failure occurs?

5. In what way does each failure matter?

6. What can be done to predict or prevent each failure?

7. What can be done if the failure cannot be predicted or prevented?

Which assets or systems do I want to analyze?


Typical Outputs of the RCM Process

1. Preventive maintenance tasks

2. Monitoring and Inspection tasks

3. Other Recommendations

– Operating procedures

– Critical spare parts

– Training opportunities

– Physical changes to system design (redesign)


Why do some RCM Initiatives Fail to Deliver?

The challenge lies with the difficulty of implementation: Collection of the required information Time consuming process RCM tools and databases are disconnected from

SAP Loading RCM recommendations into EAM is

difficult. Once loaded, RCM task justification is lost Measuring results over time is difficult. Keeping the RCM process evergreen is nearly

impossible. The Result… most RCM initiatives are one-time exercises, not “living programs”



Road to Reliability

Introduction to RCM


About Meridium


Why use RCM with SAP EAM?

SAP EAM focuses on the efficient execution of: Maintenance Planning & Scheduling Maintenance Work Spare Parts Management

RCMO focuses on effectiveness and content and answers the question…

How do you know you’re doing the

right maintenance?


Good Maintenance Strategies Executed Well

Good Maintenance Strategies Executed Badly

Improved Maintenance Strategies

Improved Maintenance Planning & Execution

Bad Maintenance Strategies Executed Well

Maintenance Improvements

Many SAP-

Customers


RCMO – Key Capabilities

1. Structured work process to develop Maintenance Strategies • Reliability Centered Maintenance (RCM) • Failure Modes Effects and Criticality Analysis

(FMECA) 2. Tightly Integrated with SAP PM work processes

• Utilizes SAP Master Data and SAP-Work History • Maintenance Planning and Execution • Maintenance Effectiveness Analysis

3. Drives automated re-evaluation of maintenance strategies for Continuous Improvement


Maintenance Strategy Development Method

Define Systems

Criticality Assessment

System Criticality

Reliability Centered

Maintenance

Failure Modes and Effects

Analysis

Structured Review

Maintenance Strategies

Implement Strategy in SAP (Maint.Plans)

Collect Work History

High Medium Low

Evaluate Strategy and Optimize

RCMO-System

SAP- System

F.Ls. and Equipment


RCMO/SAP Process Flow

16

System Definition

Strategy Management

RCMO

Equipment Master Data

Maintenance Planning

Maintenance Execution &

Documentation

SAP EAM

Strategy Evaluation

Maintenance Analysis

Establish Evaluation

Criteria

Optimize Strategies

BW

RCM

FMEA

Risk Evaluation Recommen-

dation Management

RCMO-System

SAP- System



Road to Reliability

Introduction to RCM


About Meridium


Roadmap to Reliability

Identify business drivers and align KPIs Define asset criticality / risk Develop asset management strategies Document findings and recommendations Analyze data Reevaluate to eliminate costly defects & failures


• Define Asset Structures and Hierarchies • Profit and production targets • Define metrics • Communicate at corp., group, and individual level

Identify Business Drivers and Align KPIs

How will my assets need to perform to meet the Company goals?

SAP supports to help answering these questions using SAP-analytics • Damage and object part catalogs in notifications • Cost reporting (material, internal and external services) • Punctuality of maintenance work • Downtime reporting • Maintenance activity types


Asset Taxonomy

• Taxonomy: – “The science laws or principles of

classification.”

• In SAP, it is commonly used as: – a relational grouping of asset hierarchies – The classification of assets


Asset Taxonomy

• The asset hierarchy and classification are necessary for work identification and execution.

• They are also especially important for performance evaluation and identifying opportunities for improvement.


Asset Classification

• Classification provides a structure that will enable roll-up of performance data into categories for analysis.

• As event data is documented within the taxonomy structure, an analyst may then identify opportunities for improvement by equipment category, class and type.


Asset Taxonomy - Advice

• Start with a standard

• Don’t be overly complex or deep – Asset hierarchy should match business needs – Asset Category, Class and Type is sufficient

• Use the same taxonomy across the business


Define Asset Criticality and Risk

Which assets are the most important for reliability improvement?

SAP supports to help finding the important assets through • Damage, downtime and failure statistics in notifications • Cost reporting (material, internal and external services) • Downtime reporting • …. RCMO supports the definition of systems and the criticality assessment of systems/functional locations/equipment and update of ABC-indicator of Functional Locations and Equipment

• Structured analysis at appropriate level – System or Asset – Failure mode

• Consider failure in terms of – Probability (weekly, monthly, yearly) – Consequences (business specific criteria like safety, environment,

production) • End result should be a criticality ranking of systems or equipment


Risk Management

• Asset Criticality – Risk-based asset criticality – High-level, worst likely case analysis

• Provides – Prioritization for improvement efforts – Day-to-day work management


Definition of Risk

• Risk is best defined as the product of probability and consequence

• Risk is most practically represented by a Risk Matrix


Definition of Risk

• Typical Risk Categories – Safety – Environment – Operations – Financial


Criticality Analysis

• Prioritization for work management • Prioritization for strategy improvement • Key Factor for metrics and analysis • Provides a risk basis for Strategy

development / management


What about Failure Coding?

• Coding is important for advanced analysis

• The two most important codes are: – Maintainable Item (Object Part)

• What part failed

– Condition (Damage) • What was the as-found condition of the part


Advice on Failure Codes

• You don’t need perfect

• Leverage a standard – then modify to meet your needs

• Focus on the key data elements to metrics and analysis important to you


Condition (Damage)

• Definition – The as-found condition of the maintainable item.

For failures this indicates the type of damage found to the maintainable item.

• Typical Values – Corrosion – Fatigue – Wear

• Uses – Component analysis to determine failure pattern and

expected life (Distribution Analysis) – When used in conjunction with the Maintainable

Item can provide a link to the classic RCM Failure Mode


Develop Asset Management Strategies

Where do existing strategies come from? How have existing strategies been developed? • RCM or FMECA or just review of existing strategies? • What’s the quality of the strategies in SAP? • What are the bad actors and which strategies are not effective?

RCMO and SAP support analyzing existing strategies

• View maintenance strategies linked to Functional Location and Equipment • View existing task lists (general, Functional Location and Equipment Task Lists) • View damage and downtime statistics from RCMO • View SAP-notifications from RCMO Creation of RCM/FMECAs in RCMO following the SAE-Norm for RCM Creation of templates for types of Equipment or Functional Locations Mapping of failures identified in RCM/FMECA against failure coding in SAP Assign criticality on failure consequence level Decision logic on failure consequence level


Document Findings and Recommendations

35

What are the best maintenance activities to avoid relevant failure consequences? Which activities are cost effective? Maintenance activities can be anything

– Preventive maintenance tasks (inspections, cond.monitoring, maintenance tasks)

– One time actions – Training of workforce – Change of operating procedures – Design changes

RCMO supports the documentation of findings and the comparison of the recommendations from the RCM/FMECA with the existing situation in SAP. Mapping of recommendations to maintenance plans or task lists. Creation of RCMO notifications in SAP to drive changes in SAP-master data like maintenance plans, task lists, maintenance strategies or catalog system. Grouping and consolidation of recommendations, status management on recommendation level. Implementation of maintenance activities in SAP.


Recommendation Management

• A Recommendation is a proposal for change to improve the overall performance of an asset.

• The recommendation is typically based on the result of an analysis of data performed by an analyst or analysis team.

• Recommendations usually require some level of review and commitment by management to proceed forward.


Analyze Data

37

How did the performance of the assets change after the implementation of the new maintenance strategies? Did the project meet the company goals? Analyze

−Total maintenance cost and cost by category of maintenance work (preventive, planned, unplanned, inspection, etc). − Did the performance of assets improve (MTBF, MTTR)? − Side effects of the new maintenance strategies

Import of RCMO structures into SAP-BW. Analyze effects on Functional Locations and Equipment which were or weren’t subject of RCMs/FMECAs Analyze effects on medium- low-criticality equipment. Compare different sites, locations before and after implementation of recommendations Create reevaluation criteria, use SAP-BW automated alerts.


Reevaluate to Eliminate Defects & Failures

38

What new strategy should be implemented? What can be done to improve existing strategies? Why wasn’t the maintenance program successful? Analyze

− Which failures or defects occurred? − Perform detailed analysis of failures and compare with recommendations. − Perform Root Cause Analysis − Bad actors: Have all bad actors been analyzed with RCMs/FMECAs

Detailed analysis of SAP-notifications and work orders for bad actors or low

performing equipment. Analyze data quality in SAP. Have all recommendations been implemented. Did the RCM-project oversee critical equipment or critical failures? Adress how to prevent or be prepared for next failure event. Revisit existing strategies: Reopen RCM-analysis, reassemble evaluation team



Presentation Summary


RCMO Value Proposition

Improved system definition leads to improved analysis quality and implementation quality Ability to template analysis and reuse results Speed of implementation of RCM

recommendations Import existing analysis that have not been

implemented Automation of analysis evaluation Implement a “Living” RCM program


Presentation Key Take Away’s

• RCM has gone mainstream and provides a powerful mechanism to define asset operational and maintenance strategies.

• RCMO and SAP have removed the traditional barriers of RCM program implementation through integration of the data and work processes.

• RCMO is now being utilized by industry leaders to optimize their maintenance programs.


Thank You for Your Attention

Documents

Matthias Wobbe Meridium - MainTech konferansen 2018 - 4 ...konferanse.maintech.no/.../Meridium_RCMO_SAP_Road_to_Reliabilty.… · 2002 – Synchronization of SAP Master Data in Meridium