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Absoft SAP Oil & Gas Maintenance and Operations Forum May 2012

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SAP oil & gas forum to discuss best practice in maintenance and operations.

Absoft SAP Oil & Gas Maintenance and Operations Forum May 2012

  1. 1. Maintenance and Operations Forum Thursday 17th May 2012
  2. 2. AgendaIntroductionPresentation – Standard SAP PM ReportingPresentation - MobilityFuture Sessions
  3. 3. AgendaTime Item1300 Buffet Lunch Introduction to Forum Context1330 Aims Previous Forums Session Presentation1340 Using standard SAP reporting to improve maintenance processes John Meiklejohn, Senior SAP Consultant, Absoft1410 Questions1420 Coffee Break Session Presentation1430 Mobility Bjoern Harzer, SAP Solution Architect, Absoft Questions1500 Future Sessions1510 Topic Suggestions AOB1520 Coffee and Networking
  4. 4. AgendaIntroductionPresentation – Standard SAP PM ReportingPresentation – MobilityFuture Sessions
  5. 5. Health and Safety Information Fire Alarm Assembly Point Fire Exits Restrooms Mobile Phones  Please put on silent/vibrate
  6. 6. About Absoft Over 20 years in business SAP consultancy practice – Oil & Gas SAP experience since initial release of R/3 80+ permanent employees High Staff Retention / Low Staff Turnover (7.4%) Significant investment made to on-going training (12 days per annum)
  7. 7. Why Absoft? SAP Oil and Gas Partner SAP Business Objects Partner Unrivalled track record Global turnkey project capability  39 countries  Optimisation of Requirements Gathering – right people, right Absoft has deployed SAP into 39 countries worldwide… questions • EUROPE  Accelerated implementation via purpose-built Templates • MIDDLE EAST  Resource augmentation and • AMERICAS change management • AFRICA  Continuity of service beyond go- • ASIA live
  8. 8. Products and Services SAP Implementation SAP Consulting SAP Training SAP Support (Front & Back-office) SAP Infrastructure Data Migration ReadSoft Business Objects
  9. 9. Aims Informal network for Oil and Gas organisations using SAP Share best practice use of SAP in the Plant Maintenancearena Foster discussion around potential solutions for commonpain points........?
  10. 10. Context Forum not recognised or sponsored by SAP Forum is not intended to in any way compete SAP User Group  http://www.sapusers.org/members/sigs.php?sig  Calum Davidson – Calum.Davidson@subsea7.com for more info Keen to extend reach of forum: Open to all SAP using companies in Oil and Gas sector Maintenance and Operations Forum alternating with Supply Chain Absoft happy to act as co-ordinator – agenda/topics to be driven by participants
  11. 11. Questions
  12. 12. AgendaIntroductionPresentation 1 – Standard SAP PM ReportingPresentation 2 – HandheldsFuture Sessions
  13. 13. Agenda – SAP ReportingReporting in SAP - OverviewReporting on Technical Structures  Structure and Multi Level Reports  Classification searchesOperational Reports  Overview of Reports  Using Selection Variants  Setting Display Variants  Downloading reports to Excel  Reporting tipsPlant Maintenance Information System  Overview of Standard analysis  Overview of Flexible analysis  Using ExceptionsQuestions 13
  14. 14. Reporting in SAP Reference Information:  Structure of Functional Location (e.g.IH01)  Object Lists (IH06, IH08,…)  Multiple Level Lists (IL07, IE07,…)  Purposes:  Finding Location codes and equipment numbers  Verifying Technical Structure  Reviewing/identifying spares, measuring points etc. Operational reports  List of Notifications (e.g. IW28, IW29, IW65)  Lists of Work orders (IW38, IW39)  List of Work order operations (IW37N, IW49N)  Purposes:  Work lists  Status Monitoring and progression  Planning and preparation of work packs  Interactive – allow you to access other functions by double click Maintenance Information Reports  Cost Analysis (MCI3,MCI8)  Damage and Breakdown analysis (MCI5, MCI7)  Purposes  Trends  Problem monitoring  Cost analysis  Maintenance statistics (Mean time between failures, mean time to repair etc.)  Provide limited drill down (e.g. cannot directly display/access notification from output)
  15. 15. Reporting on Technical Structures
  16. 16. Reporting on Technical StructuresUsed to identify or locate technical objects in SAPCan be used to:  Locate assets to be worked on  Safety critical assets  Spare lists for assets  Other assets impacted by problems  As aid to identify where equipment is installed in technical systems……
  17. 17. Demonstration 1
  18. 18. Operational Reports
  19. 19. Operational ReportsProvide information and functionality to support day to day maintenance activitiesNotifications  IW28 - Lists of Requests for maintenance (planning & preparation)  IW65 - Lists of activities performed  IW29 - Checking Notification progress  IW28 - Approving/activating/closing notificationsWork orders  IW38 - Daily/weekly/monthly planning and scheduling  IW38 - Approving/releasing/closing work orders  IW38/IW37N - Applying changes to ranges of orders  IW39/IW49N - Work order progress  IW49N - Monitoring work order operations  O3O_MT01 Materials tracking (RLM)Others  IK17 - Measurement readings  …….
  20. 20. Using Variants Display and selection variants can be controlled by central SAP support for use by maintenance department personnel Using variants makes it easier for operator to locate records requiring their action and display the relevant information to assist in identifying when they needs to do. Typical examples include:Role Task Selection Criteria (Variant) Display Criteria (Variant)Work Present new maintenance Select all open Notifications within Display equipment and FunctionalPreparator requests for inclusion in area of responsibility Location sorted by Priority and weekly work pack meeting equipment criticality Plan materials and internal Select all work orders which have Display work orders sorted by priority, resource requirements for been approved for planning of Start date and maintenance work work orders approved for resources and materials centres actionWork Schedule work orders to be Select all work orders with status Display total work per work centre toScheduler issued to maintenance indicating work can be carried out determine is there is a potential work shifts but have not been scheduled or overload, visibility of priority will enable despatched (e.g. released and scheduling of critical work. approved) with today‟s date>= work order start date Selection criteria could be manually entered but using pre-defined and reusable selection and display criteria saves time and reduces risk in incorrect entry by operator Basic Variants can be created centrally (by system support) – local copies can be made to tailor to suit local needs
  21. 21. Demonstration 2
  22. 22. Summary of Operational ReportsUseful for providing information to support day to day maintenanceactivitiesCan be tailored to suit daily activities for a job role/individualProvide direct interaction with other PM functionsCan be downloaded readily to Excel for further analysis
  23. 23. SAP Plant Maintenance Information System
  24. 24. Plant Maintenance Information SystemSAP information system contains several reporting structures to support analysis of Keyfigures in SAP plant maintenanceEach Report consists of:  Characteristics – Objects to be reported e.g.:  Functional Location  Equipment  Document type  Key figures – values to be reported e.g.  Count of Work orders  Total Planned valueCharacteristics form the „Rows‟ of the report Key figures form the „Columns‟ Characteristic Key Value 1 Key Value 2 Xxxxxxxxxxxxx 000000.00 0Each report uses information structures updated as data is saved in the system (e.g.when a work order is saved data is summarised into relevant Info Structures)
  25. 25. Plant Maintenance Information SystemBenefits:  Readily provides summarised data for some key performance indictors  Provides periodic data analysis capability (with comparisons)  Downloads details readily into excel for detailed analysisWeaknesses  Display , although customisable is limited, can only display one characteristic at a time (e.g. if you want to see details on all equipment in functional locations, you have to drill down to equipment level for each functional location – can be resolved by downloading to excel)  Does not permit drilldown into transactional data (in all cases)
  26. 26. Plant Maintenance Information System – ContinuedTwo main types of analysis are available:  Standard Analysis  Transactions reporting on standard Info Structures  Useful function provided to tailor report output to suit business requirements  Flexible analysis  Enables analysis and reports to be specified using exiting info Structures or SAP database tables  Enables selection of characteristics to be used in analysis (Rows)  Enable selection of Key Figures to be used in analysis (Columns)  Enables inclusion of formula‟s for additional information to be evaluated (e.g. difference between Total Planned costs and actual costs)SAP provides Exceptions functionality to further highlight or report on datadepending on specific occurrences (e.g. where actual costs have exceeded athreshold value).
  27. 27. Information System – Standard AnalysisStandard Information Structures are provided to summarise records in SAP.For Plant Maintenance several Information structures are provided analysing core keyinformation on maintenance activityInformation structures are based on information summarised by:  Technical Objects provides count and cost analysis of work carried out on technical objects providing analysis by:  Object Class (MCI1)  Manufacturer on technical object (MCI2)  Location (MCI3)  Maintenance Notifications e.g. : Mean Time to Repair & Mean Time between repairs (MTTR & MTBR)  Equipment (MCJB)  Functional Location (MCJC)  Notifications per period (MCI7)  Based on use of breakdown and breakdown duration on Notifications  Damage Analysis (MCI5) – uses notification damage and cause code catalogs  Work Orders  Cost Analysis (MCI8)
  28. 28. Standard Analysis –Objects AnalysisAnalysis provided for:  MCI1 Object Class  MCI2 Manufacturer  MCI3 LocationReports on:  Counts  Notification  Work orders – planned, unplanned completed  Damages  Breakdowns  Costs  Planned, actual, Material, Internal, External etc.  Totals  Breakdown durationsUsed to identify Best/Worst performing assets in terms of:  Breakdowns  Downtime (asset unavailable)  Costs  Maintenance effort required
  29. 29. Standard Analysis – Objects StatisticsMCI6 Object Statistics Count of Functional Locations Permitting installation of multiple equipment Sum of acquisition value registered on master Count of Count of functional Functional Locations Count of record (general data_ locations in analysis permitting a single Functional Locations equipment installation Without equipment installed Count of Count of Functional Locations equipment in analysis permitting a single equipment installation
  30. 30. Standard Analysis - Notifications Breakdown Analysis – used to determine asset reliability and need for preventative maintenance routines Equipment (MCJB) Notifications (MCI7) Functional Location (MCJB) Average Breakdown Average time between duration Breakdown end and next Breakdown start Time between 1st breakdown completion and last Breakdown StartNo of breakdown notifications Total Breakdownrecorded Duration
  31. 31. Standard Analysis - CostsMCI8 Cost Analysis provides :  No. orders created  No. immediate orders  Planned orders  Unplanned orders  No. completed orders  Est. total costs  Ext. material costs  External wage costs  Internal mat. costs  Internal wage costs  Other costs  Services costs  Total actual costs  Total planned costs  Total revenues act
  32. 32. Demonstration 4
  33. 33. Information System – Flexible AnalysisFlexible analysis evaluations and Structures permit creation of InfoStructures and reports based either on existing Structures or SAPdatabase tablesDifferent structures can be defined (for example Breakdown analysisand cost analysis) by selecting common characteristics and key figuresfrom several PM based objectsEvaluations support the addition of formulas to enable additionalcalculations to be performed such as Cost Variance (calculated usingstandard key figures Total Planned costs and Total Actual costThreshold values can be set to highlight exceptions
  34. 34. Demonstration 5
  35. 35. Using ExceptionsSAP exception functionality is used to highlight „exceptional circumstances‟ on analysis reportsExceptions are created with reference to Info Structures – each standard analysis provided be SAP islinked to an info structureFor example Cost Analysis is constructed using Info Structure S115 – cost evaluation, therefore to createan exception for the cost analysis report, Info structure S115 would be references in the exception.To see what info Structure is used by a standard analysis report, click on the icon indicated below anddetails will appear as shown Click to view data structure Info Structure to be referred to when creating an exception
  36. 36. Demonstration 6
  37. 37. Summary of Information System ReportsUseful for providing information to highlight and report on maintenancehistoryExceptions can be tailored to highlight and work flow situation requiringintervention/monitoringProvide good basis for determining reliability and cost of assets overseveral periods of timeStandard reports download readily into MS excel for further analysis
  38. 38. Questions & Comments
  39. 39. AgendaIntroductionPresentation 1 – Standard SAP PM ReportingPresentation 2 – MobilityFuture Sessions
  40. 40. Mobility – applied to the Oil & Gas IndustryBjorn Harzer, Solution Architect 17th May 2012
  41. 41. AgendaMobility  Scenarios  Benefits  ChallengesApplication to Oil & Gas  Maintenance  Supply ChainInfrastructure  Connect or Unwired?Absoft activities  Past, Present & Future
  42. 42. What is mobility about?
  43. 43. Mobility changes the way you workDrivers AreasIncreased Productivity DashboardsIncreased Efficiency ContactsIncreased Accuracy Exec‟s Calendar E-MailConvenience ApprovalsEase of Use Managers RequestsMotivation Time & Expense Field servicesAdd value to Schedulingexisting Task workers Despatchinfrastructure Self Services Sales Consumers Marketing
  44. 44. Mobility – Challenges SAP products / 3rd party products Scenarios, Exposure of data Business change vs “works like the business” Mobile phones LaptopsMultiple ERP systems TabletsConnected / Unwired Handhelds Barcode RFID Responsibility IT support / business Device settings User settings IT Maintenance
  45. 45. Mobility – Mobile Scenarios in Oil&GasTagging  Use of RFID / Bar codeScenarios  Asset tracking  Equipment history  Measurement recording  Logistics & Transportation  Container tracking  Inventory Control  Accurate stock levels  Reduced out-of-stock situation  Personnel  Identification & Access control  Attendance
  46. 46. Oil & Gas – Mobile Scenarios Maintenance Alignment of Handheld solutions to maintenance processes 6 Standards 1 2 Observation Work list Routing Notification/ Confirmation Work order Master Data Planning Work Order Scheduling Execution Analytics and TECO Closure Generation Forces 4 InspectionMeasurements Workflow result Subsequent recording workAd hoc query Downtime Failure / 5 Materials 7 Damage Time writing used 3 46
  47. 47. Oil & Gas – Advantages in maintenanceMaintenance – Improve asset reliability through  Improved efficiency  Paperless processing  Routing of work list  Subsequent workflows (mitigating actions)  Ad hoc inquires (history of equipment, spare part lists …)  Improved data quality & reporting  Accurate result recording (measurements, failure/damage/cause codes)  Accurate time writing (effort, malfunction start/end, …)  Accurate usage of materials  Improved compliance  Performance standards  Health & safety standards
  48. 48. Oil & Gas – Mobile Scenarios Supply Chain Receipt Store Pick Pack Ship Receipt Demand Procure (onshore) (onshore) (onshore) (onshore) (onshore) (offshore)Maintenance Pallets / Staging / Rentals Pick list Despatch Containers Put away 1 3 4 5 Quality Un- mgmt Pack Mani- Pack list fest Reports list Inventory / (stock list) Equipments Stock Maintenance count Container Job mgmt execution Tagging Put away 2 Store (offshore) 2 Desp. Mani- Pack note fest list Despatch Pallets / Inventory / Put away Receipt Despatch note Containers Equipments 8 7 4 6 Reason for Receipt 48 Ship Pack Return return (Backload) (offshore) (offshore)
  49. 49. Oil & Gas – Advantages for maintenanceMaintenance – Improve asset reliability through  Reliable supply chain  Improved efficiency  Accurate stock levels – reliable supply of spares  Visibility of available spares in stock  Improved cost recovery  Initiation of returns process (left overs)
  50. 50. “Connected” or “unwired”? Handheld SAP Web Application Browser Mobile Application Server BAPIs Barcode reader SAP DBAdvantages  Reuse of existing hardware and infrastructure  Intrinsic backend integration, mobile application built with reusing existing knowledge of SAP support teams  „Dumb‟ devices, easy deployment and application and device management  Real time dataDisadvantages  Live connection to SAP required
  51. 51. “Connected” or “unwired”? Sybase Unwired Create Connect Platform Eclipse Databases Consume „intelligent‟ Web Application Services DB Barcode Software reader Control Applications Management ConsoleAdvantages  Consume: Multiple device types supported, „intelligent‟, work „offline‟ with up-to-date data  Connect: Synchronisation to multiple backend systems  Control: Deployment, Device management and Security  Create: Platform independent application built in JavaDisadvantages  Additional platform required
  52. 52. Mobility – Choice!Connected UnwiredA connected environment lends itself An unwired environment is useful into situations where the area of the situations where a direct connection tooperation is contained and we can SAP cannot be ensured all the time –ensure 100% wireless network or where a low bandwidth only iscoverage available  Warehouse  Maintenance operations - or - specifically  Pack & Ship  X-rated areas
  53. 53. Mobility – Strategic Decision – Rule of Three The Rule of Three A mobile platform reduces significantly TCO and accelerates deployment if you have  3 or more mobile applications - or -  3 or more integration points - or -  3 or more device types
  54. 54. Absoft – StepsWhere have we been?  Implementation of handheld solutions  Inventory Management  Work order management  SCE management  Equipment Tracking  WarehousingWhere we want to go?  Be an end-to-end partner for our customers  Deliver handheld application  End-to-end integration to SAP backend systemWhat are we doing?  Building template scenarios of Oil & Gas Operators  “Connected”: Inventory Management  Maintenance Operations  “Unwired”: (in the planning)  out-of-the-box vs.  tailor made to O&G
  55. 55. 28 available Apps – out of the boxProcess Apps Employee Productivity Apps Human ResourcesSAP CRM Sales SAP Employee Lookup SAP Leave RequestSAP Retail Execution SAP Timesheet SAP HR Approvals SAP Interview AssistantSAP Field Service SAP Manager InsightSAP EAM Work Order Procurement SAP Shopping Cart Approvals SAP ERP Quality Issue SAP Transport Notification and StatusIndustry Apps SAP Transport Tendering FinanceSAP Electronic Medical Record SAP Travel Receipt Capture SAP Travel Expense ApprovalsSAP Citizen Connect SAP Payment Approvals SAP GRC Access Approver SAP GRC Policy Survey SalesSAP Business Objects SAP Sales Order Notification SAP Material AvailabilitySAP Business Objects Mobile SAP Customers and Contacts SAP Customer Financial Factsheet SAP ERP Order StatusSAP Business Objects Explorer This presentation and SAP„s strategy and possible future developments are subject to change and may be changed by SAP at any time for any reason without notice. This document is provided without a warranty of any kind, either express or implied, including but not limited to, the implied warranties of merchantability, fitness for a particular purpose, or non-infringement
  56. 56. Work order App – scope 2/2People and roles Planner / Scheduler Technician / Worker Back officeProcesses Mobile Scenario SAP ECC SAP ECC SAP ECC SAP ECC Schedule Settlement Work Review Perform Confirm Work and and Planning Work Work Work Completion Dispatch Closure Details
  57. 57. Work order App “What is this all about?” Field technicians rely on up-to-date information to perform their jobs efficiently. SAP EAM Work Order mobile application empowers companies to gather, assess, and share the relevant information from the moment it is needed or identified. Built on Sybase Unwired Platform the application addresses the requirements for plant maintenance operations staff for Enterprise Asset Management. Key Pain Points Addressed Increase maintenance worker efficiency Minimise manufacturing or supply chain interruptions due to Facts & Figures: asset malfunction or breakdowns Enable data access and data entry anywhere, avoiding errors Role: Service Technicians and speeding up end-to-end business process•SAP Technology Stack: SUP 2.0; SAP NetWeaver DOE; SAP ERP 6.0 Get timely and accurate information from the field•Mobile Device Support: Windows 32 Tablets and Laptops Increase asset visibility and performance •Video http://youtu.be/MX3w0S8RKcE Key Product Features http://www1.sap.com/solutions/technology/ente Work Orders – Ability to view and update relevant information •More Info rprise-mobility/manufacturing- regarding tasks, operations, planned time and material apps/maintenance-app.epx Technical Objects– Ability to view and update critical information about functional location and equipments to increase asset uptime Inventory– Ability for field workers to track and manage the parts without any delay or overhead Business Partner – Ability to get a complete view of customer history and critical contact information
  58. 58. Mobility – Demo Materials ManagementInventory Management MM-IM  Goods receipt with printing of material label  From vendor (MIGO/101)  Return from work order / cost centre (MIGO 202/262)  Goods issue  Pick list based on open reservations (MB25/26/MIGO)  Manual issue to order / cost centre (MIGO 201/261)  Returns to vendor (MIGO/122)  Transfers  from bin to bin (MM02)  From storage location to storage location (MIGO/311/313/315)  Stock take  Ad hoc stock adjustment (MI10)  Continuous Count (MI04)  Inquiries  Find material by description (MM03)  Show bin for material (MM03)  Stock list for bin (MB52)  Print material label  Print bin label  User settings  User defaults (e.g. plant, storage location, cost centre, printer, decimal point/time/date formats) (SU3)  Manual replenishment  Create stock purchase requisition
  59. 59. Link to the physical world & benefitsLinkage  Understand physical world  “How do the guys work on the shop floor?”  - and - identify events in the physical world with postings in SAPResult  Mobile application works the way they work!  Compliance through enforcement of business process
  60. 60. Mobility – Questions?
  61. 61. AgendaIntroductionPresentation 1 – Standard SAP PM ReportingPresentation 2 – MobilityFuture Sessions
  62. 62. Ideas? Topic Suggestions … Contact Tim Galloway Kim Shand tgalloway@absoft.co.uk kshand@absoft.co.uk
  63. 63. Thank You