ConAgra Foods leveraged SAP to support reliability analytics across its consumer plants. It created a Reliability Center of Excellence to optimize SAP configuration for reliability, including developing a taxonomy, criticality analysis, and workflows. Key aspects included linking failure mode and effect analysis to technical object catalogs, developing granular criticality ratings, and optimizing maintenance workflows. The presentation provided examples of how these reliability tools and processes were implemented in SAP.

1. Produced by:Platinum SponsorPremier Sponsor
Leveraging SAP to Support Reliability
Analytics
Chris Zawislak & Mike Poland
ConAgra Foods, Inc Life Cycle Engineering, Inc.

2. • ConAgra Overview
• Taxonomy
• Criticality
• Workflows
• Key points to take home
• Questions
What I’ll Cover

3. ConAgra Foods overview
Slide 3
ConAgra Foods started in 1919 as Nebraska Consolidated Mills. In 1971 it was renamed
ConAgra, Inc., and the company became ConAgra Foods in 2000.
ConAgra Foods is a Fortune 500 company with more than 24,000 employees, with the
company’s world headquarters located in Omaha, Neb.
ConAgra Foods is one of North America’s leading food companies, with brands in 97 percent
of America’s households.
In fiscal year 2010, ConAgra Foods brought in $12+ billion in net sales.

4. “From the earth” to food you love

5. ConAgra Foods Brands

6. Introduction & Overview
Executive Vision
• Leverage CPS to
improve performance
• Leverage SAP to drive
cost down

7. Situation
• 2007 PM Pillar established
• Working to establish foundation (PM Step 1)
• Implemented SAP across consumer plants
• Currently working to develop reliability competencies
• SAP configuration was adequate to support foundation
but requires optimization to support reliability analytics
and other continuous improvement activities

8. SAP PM
Risk Analysis
Failure Mode and
Effect Analysis
Severity of
Failure
Likelihood of
Occurrence
Delectability of
Failure
Risk Ranking Control Plans
Reliability
Analysis
Asset Module of
EAM
Continuous Improvement
Functional
Hierarchy
Criticality
Analysis
Reliability Maturity

9. Action
Create a Reliability Center of Excellence
• Reliability Action Team
• Reliability Focus Team
• Reliability Engineering function and resource
development
• Reliability Infrastructure – SAP Configuration
 Taxonomy
 Criticality
 Workflows

10. •Learning to See
Process Flow Diagram
Value Stream Mapping
Relationship Models
Equipment Criticality
Failure Analysis
Risk Analysis
Risk Ranking
Standard Work
Operating Procedures
Preventive
Predictive
Condition Monitoring
Remote Monitoring
Operator Care
Critical Spares
OEE
TCO
Asset Utilization
MTBF
MTTR
OPERATIONAL STABILITY
MeasureControlAnalyzeClassify
Continuous Improvement
Plan Do Check Act
Reliability Infrastructure

11. Slide 11
Taxonomy
“Systematic classification of items into generic groups
based on factors possibly common to several of the
items”
ISO 14224, Petroleum and natural gas industries — Collection and
exchange of reliability and maintenance data for equipment

12. Slide 12
Hierarchy
(1)
Business
Category
(2)
Installation/
Business Unit
(3)
Cost Center/ Op Unit
(4)
Function
(5)
System/ Process Line
(6)
Sub system/Asset/Equipment
(7)
Component/Maintainable Item
(8)
Part/ BOM
Use/LocationDataEquipmentSubdivision
Taxonomy per ISO 14224:2006

13. Functional Block Diagram
In Feed Assembly Out feed AssemblyFill Table
Shaker
VFD
Drive Unit
PLC
Rotary Filler – Technical Object
Objects

14. FMEA to SAP
Slide 14
FAILURE MODE
(FUNCTIONAL FAILURE) POTENTIAL CAUSE(S) CURRENT CONTROL(S)
SEVERITY
PROBABILITY
DETECTION
RISK PRIORITY NUMBER
STRATEGY:
CM ‐ Corrective
(RTF)
PM ‐ Time Based
CBM ‐ Condition
Based
MOD ‐
Modification
THERMOGRAPHY
VIBRATION ANALYSIS
ULTRASOUND
OIL ANALYSIS
MOTOR CIRCUIT ANALYSIS
TEMPERATURE READING
INSPECTION
LUBRICATION
SCHEDULED REBUILD
SCHEDULED REPLACEMENT
ROUTINE CLEANING
AMD CLEANING
AMD INSPECTION
AMD LUBRICATION
CSD VALIDATION
RUN TO FAILURE
DINNER OUT OF POSITION AND OR DOES NOT TRANSFER LUG MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM D
CHAIN STRETCH DAILY PM INSPECTION, AUTO LUBE 8 2 1 16 CBM D
RAIL MISALIGNMENT DAILY PM INSPECTION 3 2 2 12 CBM D
SERVO MOTOR FAILURE 1W PM INSPECTION (VISUAL) 5 4 9 180 CBM 1M 1W
PHOTO EYE FAILURE (2) NONE 3 5 7 105 PM 1M
DRIVE CHAIN FAILURE 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1W
DRIVE SPROCKET WORN 1W PM INSPECTION (VISUAL) 4 2 3 24 CBM 1W
LUG CHAIN CONTAMINATION (PRODUCT FALLING) NONE 2 5 9 90 MOD
DINNER NOT IN 4 X 5 MATRIX RAIL MISALIGNMENT INFORMAL PM DAILY INSPECTION 3 2 4 24 MOD
BELT CONTAMINATION NONE 3 8 8 192 MOD
SERVO MOTOR FAILURE NONE 5 4 9 180 CM, POSSIBLE MOD
BELT DRIVE GEAR(2) FAILURE (ONE PLASTIC, ONE METAL) DAILY PM INSPECTION 4 2 2 16 CBM D
BELT TORN OR EXCESSIVELY WORN INFORMAL PM DAILY INSPECTION 3 3 3 27 CBM D
Damage Codes Cause Codes
Task Codes

15. Rotary Filler Catalog Profile
Code
Component
Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC
1001 Rail Misalignment X X
1002 Failed Bearing X X
1003 Worn Gear X X X X
1004 Air Leak X
1005 Failed Electrical Circuit X X X
1006 Failed Belt X X
1007 Programming Error
1008 Failed Belt X
1009 Failed Chain X
1010 Failed eye X X
Cause Code Catalog
Code
Component
Description In feed Fill Table Out Feed Shaker Drive Unit VFD PLC
2001 Process Stopped X X X X X X
2002 Process Slow X X X X X X
2003 Process Fast X X
2004 Over fill X X X X X
2005 Under fill X X
Damage Code Catalog
Rotary Filler Cause Code Group
Rotary Filler Task Code Group
Rotary Filler Damage Code Group
Maintenance Plan

16. Finding: ABC Indicator does provide adequate granularity for
equipment criticality
Result: Insufficient indicators provide requisite separation of assets for
prioritizing the application of corporate resources
Recommendation: Develop a criticality business process and RACI to
at least Base-10
There are 36 characters available in ABC Indicator which provide
considerable granularity but often only 3 are used….
Criticality Analysis
Slide 16

17. Criticality Analysis
• Single point failure
• Impact to value stream
• Impact to corporate objectives
• Replacement asset value
• Impact on reputation
• Impact on EHS

18. Criticality Analysis
Slide 18

19. RIME Index
Slide 19
Work Order Type
EquipmentCriticality
10 9 8 7 6 5 4 3 2 1
10 100 90 80 70 60 50 40 30 20 10
9 90 81 72 63 54 45 36 27 18 9
8 80 72 64 56 48 40 32 24 16 8
7 70 63 56 49 42 35 28 21 14 7
6 60 54 48 42 36 30 24 18 12 6
5 50 45 40 35 30 25 20 15 10 5
4 40 36 32 28 24 20 16 12 8 4
3 30 27 24 21 18 15 12 9 6 3
2 20 18 16 14 12 10 8 6 4 2
1 10 9 8 7 6 5 4 3 2 1

20. Workflow Optimization
Slide 20

21. Key Points to Take Home
• SAP configuration needs to mature along with your organization
• Collaboration between reliability, maintenance, and IT professionals is key
• Control strategy performance indicators should depend on work order accuracy
• Leverage FMEA for development of technical object catalogs as well as overall
control strategy
• FMEA and technical object catalogs are living documents and should be updated
when appropriate
• Criticality needs to be granular enough to support reliability analytics and backlog
management
• Task, damage, and cause codes are linked to equipment class for ease of
replication across the enterprise

22. Build or Migrate
Database
Risk Analysis
Failure Mode and
Effect Analysis
Severity of
Failure
Likelihood of
Occurrence
Detectability of
Failure
Risk Ranking Control Plans
Reliability
Analysis
Asset Module of
EAM
Continuous Improvement
Functional
Hierarchy
Criticality
Analysis
Close the Loop

23. Produced by:Platinum SponsorPremier Sponsor
Chris Zawislak, CMRP
ConAgra Foods, Inc.
Christopher.Zawislak@conagrafoods.com
Mike Poland, CMRP
Life Cycle Engineering, Inc.
MPoland@LCE.com

24. Produced by:Platinum SponsorPremier Sponsor
March 27 – 30, 2011
Hyatt Regency Huntington Beach Resort and Spa
Huntington Beach, California