Evoluzione delle soluzioni SAP per la manutenzione dei mezzi e delle infrastrutture
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Transcript of Evoluzione delle soluzioni SAP per la manutenzione dei mezzi e delle infrastrutture
Evoluzione delle soluzioni SAP per la manutenzione dei
mezzi e delle infrastrutture
Verona, 5 ottobre 2012
© 2011 SAP AG. All rights reserved. 2
Una soluzione completa dalla progettazione di un nuovo
impianto alla messa in esercizio e gestione
Progettazione e
Pianificazione
Asset portfolio
management
Enterprise Asset Management
Analisi su Indici
Manutentivi e
Prestazioni
Impianti
Gestione
Manutenzione
Gestione rischi
operativi degli
impianti
Patrimonio
immobiliare
Capital project
management
Asset Information
management
Incident management
EHS risk assessment
EHS program
management
Management of
change
Maintenance worker
safety mgmt
Audit management
Set up plant
dashboards and act
on alerts
Conduct improvement
programs
Optimize
maintenance and
plant operations
Asset planning and
scheduling
Operations and
maintenance
Service procurement
Spare parts
management
Investment and
construction
Sales and marketing
Lease and space
management
Maintenance and
repair
© 2011 SAP AG. All rights reserved. 3
Manutenzione integrata con altri processi aziendali
Reporting
Richieste
Acquisto
Budget costi
Manutenzione
Scarico
Costi
Notifiche
Avvisi
Contratti
Cicli di
lavoro
Pianificazione
basata sui
consumi
Rotables
Mana-
gement
Chiusura
Ordine
Parti di ricambio
Acquisti di servizi
Manutenzione ed
esecuzione
Pianificazione
Cataloghi
elettronici
ricambi
Ordini
acquisto
Gestione
collaborativa
offerte fornitori
Portale
Fornitori
Prestazioni
di
servizio
Fatturazione
Operations
Engineering
Maintenance
Procurement
Fornitore di Servizi
Gestione
documentale
Sedi tecniche
Equipment
Distinte di
Manutenzione
Gestione
fermate
Classification
Manutenzione
Preventiva
Conferma
attività
Schedulazio
ne
Esecuzione
Ordine
Manutenzio
ne
© 2011 SAP AG. All rights reserved. 4
© 2011 SAP AG. All rights reserved. 5
Semplicità di utilizzo tramite NWBC
Job List with Jobs
Information Center
Asset Viewer
Confirmation List with
assigned Jobs
e.g. Solution Database,
Online Help
EAM Launch Pad
© 2011 SAP AG. All rights reserved. 6
Un esempio
Linear Asset Management
© 2011 SAP AG. All rights reserved. 8
Peculiarità per la gestione degli Asset Lineari
La necessità di rappresentare e modellare gli asset che si estendono per vari chilometri
con una variabilità di caratteristiche e condizioni richiede uno tool adatto a modellare e
gestire le specificità di questi asset.
La dimensione “lineare” di questo tipo di asset si riflette costantemente su tutti i processi:
• Manutenzione e Riparazione
• Ispezioni
• Condizioni (dell’asset e dell’ambiente circostante)
La gestione degli “Asset Lineari” richiede inoltre una continua segmentazione dinamica
dell’asset o delle condizioni
© 2011 SAP AG. All rights reserved. 9
Linear Asset Management – Overall Concept
0,00km 529,8km
Func. Loc. A-A9
Equip. S02519
Equip. S02656
Char: surface concrete (calcestruzzo)
Char: surface bitumen (asfalto)
Char: speed limit 120 km/h
Work order: 901961
Operation 0010
Operation 0020
Work order: 901989
Notification 1007423
Item 001 : onsite inspection
Item 002: surface damaged
Meas. Point: roughness
Meas. Doc: 1 µmm
Meas. Doc: 0,87µmm
Operation 0020
Operation 0020
© 2011 SAP AG. All rights reserved. 10
Tipicità dei “Linear Asset”
Un “Linear Asset” è un particolare tipo di asset che si basa sulla dimensione “lunghezzza”;
questa dimensione è rappresentata per mezzo di un punto di partenza e di uno di fine o
specificandone la lunghezza dell’asset.
La configurazione di un “Linear Asset” ha la complessità che i componenti (o caratteristiche)
possono cambiare frequentemente sullo sviluppo della sua lunghezza:
I “Linear Assets” sono spesso connessi con altri asset lineari e costituiscono una rete
infrastrutturale (infrastructure network).
I “Linear Assets” sono soggetti a “Dynamic Segmentation”. Vari set di attributi possono essere
associati a ciascuna porzione lineare (segmento) indipendentemente dal punto di inizio e di fine
dell’asset.
I “Linear Assets” richiedono un Linear Referencing Method (LRM) come modalità per
descrivere e localizzare la posizione sullo sviluppo della sua lunghezza
Si possono usare dei punti permanente di riferimento (Markers or Referencing Locations) in
aggiunta alla distanza (offsets) da essi per individuare una posizione lungo il “Linear Asset”.
Entità puntuali (point assets) possono essere localizzati in ogni punto lungo il “Linear Asset”.
© 2011 SAP AG. All rights reserved. 11
Linear Data Fields in Functional Location
and Equipment
Single platform to address entire enterprise needs – reducing complexity and costs
Linear Asset Management è una nuova funzionalità all’interno del modulo PM disegnata
per soddisfare i requisiti per la gestione degli asset lineari.
© 2011 SAP AG. All rights reserved. 12
Linear Data Fields – Screen Layout
© 2011 SAP AG. All rights reserved. 14
Linear Data – Offsets
4,75m
2,15m
4,62m
4,60 km
0,80 km
Offsets are used to define
an exact location
© 2011 SAP AG. All rights reserved. 15
© 2011 SAP AG. All rights reserved. 16
Linear Referencing Pattern (LRP)
4 Types of Markers
Classic Marker (e.g. Milepost)
Functional Location (e.g. Bridge)
Equipment (e.g. Sign Gantry)
Well Known Location (e.g.
Service Station)
MP1
MP4
MP5
MP6
MP7
MP8
MP9
MP3
MP2
Per referenziare i punti di riferimento (marker) viene assegnato un LRP al “linear asset”.
I Patterns sono usati per indicare la distanza del “marker” a partire dallo “starting point” da cui
si inizia la misurazione (lungo il pattern).
© 2011 SAP AG. All rights reserved. 17
Linear Reference Patter (LRP) Table
© 2011 SAP AG. All rights reserved. 18
Linear Data in Maintenance Order
© 2011 SAP AG. All rights reserved. 19
Reports Enhanced with Linear Data Information Functional Location List
© 2011 SAP AG. All rights reserved. 20
Reports Enhanced with Linear Data Information Stucture List
© 2011 SAP AG. All rights reserved. 21
Reports Enhanced with Linear Data Information Multi-Level List
© 2011 SAP AG. All rights reserved. 22
Multi-Level List Report in Graphical Layout Selectable from List Output Display
Demo
Integrazione GIS
© 2011 SAP AG. All rights reserved. 24
Varie tipologie di necessità di integrazione SAP - GIS
Utente SAP con accesso al sistema GIS (con possibilità di aggiornamento)
• Utente SAP che vuole accede ai dati GIS all’interno delle funzionalità SAP
• Necessità di poter aggiornare alcune informazioni GIS direttamente da SAP
• Utilizza come front-end le funzionalità ERP (SAPGUI) o portale
Utente SAP con visualizzazione dati del sistema GIS (read-only)
• Utente SAP che richiede una visualizzazione geo-spaziale degli asset coinvolti nel processo
di manutenzione (Functional Location, Equipments, Notifications, Work Orders)
• Utilizza come front-end il portale
Utente «Power GIS»
• Utente che lavora prevalentemente sul sistema GIS (es. ESRI ArcGIS Desktop) con
eventuali add-on tools di terze parti
• Dal sistema GIS chiede l’accesso al contenuto SAP (anagrafiche sedi tecniche, ….)
• Necessita una sincronizzazione delle informazioni fra GIS e ERP.
© 2011 SAP AG. All rights reserved. 25
© 2011 SAP AG. All rights reserved. 26
Business object in SAP EAM Map viewer all’interno della SAPgui
© 2011 SAP AG. All rights reserved. 27
Business object in SAP EAM shown on a map based on X/Y coordinates
© 2011 SAP AG. All rights reserved. 28
Business object in SAP EAM on a map in a browser Creation of notifications and work orders out of a map
© 2011 SAP AG. All rights reserved. 29
Business object in SAP EAM on a map in ArcGis.com Creation of notifications and work orders out of a map
© 2011 SAP AG. All rights reserved. 30
Integrazione GIS: visualizzazione sedi tecniche Filmato 4
© 2011 SAP AG. All rights reserved. 31
Gestione delle notifiche Filmato 3
Integrazione documentale
Visual Enterpise
Open Text
© 2011 SAP AG. All rights reserved. 33
Gestione documentale in manutenzione
Le attività manutentive dipendono
fortemente dagli impianti e dalle
informazioni tecniche degli stessi.
E’ utile condividere e distribuire
informazioni relative agli impianti da
diverse fonti (disegni,manuali, norme
di sicurezza, etc etc) per aumentare
l’efficienza degli interventi manutentivi.
Sono quindi necessari strumenti integrati nel processo manutentivo per la
gestione documentale , che prevedano anche modalità di collaborazione con
entità esterne, per garantire un’efficace processo manutentivo ad esempio
nell’ambito della gestione delle emergenze.
Alcune normative richiedono di tracciare e monitorare tutta la documentazione relativa agli impianti e alle relative attività.
© 2011 SAP AG. All rights reserved. 34
Soluzione completa e integrata
Processi di Versioning, Rilascio e Modifica
Integrazione con WEB-GUI, cFolders
Accesso via Web
Ricerca avanzata (full text retrieval via
object links)
Integrazione di Processi
Struttura prodotto
Gestione Progetti
Una soluzione Aperta
Integrazione sistemi non-SAP
Interfaccia Office
Archivi ottici, scanning e plotting
Gestione Tecnica: documenti (DMS) in SAP ERP
© 2011 SAP AG. All rights reserved. 35
Visualizzazioni 3D in ambito manutentivo
Procedure manutentive e di riparazione
Pubblicazioni tecniche
Visual learning and training
Animazioni 3D animate, istruzioni di lavoro
guidate
Ricerche visuali e interrogazioni
Riduzione tempi di intervento, riduzione fermate
Attività eseguite correttamente, miglior
produttività e formazione del personale
Scenario applicativo
Il valore
SAP Visual Enterprise
© 2011 SAP AG. All rights reserved. 36
Document Access: accesso diretto a tutte le informazioni
SAP e non SAP relative ad un’entità (pratiche elettroniche)
© 2011 SAP AG. All rights reserved. 37
© 2011 SAP AG. All rights reserved. 38
© 2011 SAP AG. All rights reserved. 39
© 2011 SAP AG. All rights reserved. 40
© 2011 SAP AG. All rights reserved. 41
© 2011 SAP AG. All rights reserved. 42
© 2011 SAP AG. All rights reserved. 43
© 2011 SAP AG. All rights reserved. 44
© 2011 SAP AG. All rights reserved. 45
© 2011 SAP AG. All rights reserved. 46
© 2011 SAP AG. All rights reserved. 47
Plant Operator
Monitor asset
condition
Create
maintenance
notification,
specifying technical
object, urgency,
and symptoms
Review downtimes
with production
shift planners
Mitigating
production impact
Review
Maintenance Work
Package
Work clearance
Field Level Risk
Assessment
Begin equipment
teardown
Assess asset
condition, issue
parts requisition
Collect data:
physical parts,
photographs,
interviews, etc.
Review associated
equipment
documentation
Correspond with
equipment
supplier/OEM
Review lab tests
Complete analysis
and make
recommendations
Record actual work
hours and parts
used
In case of
corrective action,
the notification is
updated with the
found cause
Work order
completed
technically and
commercially and
then closed
Maintenance Technician
Reliability Engineer
Maintenance Technician
Equipment is back
online
Maintenance
schedule revised
Inventory updated
Plant Operator
SAP Extended ECM for Enterprise Asset Management –
equipment failure analysis
Conduct Equipment Failure Analysis
1. Notification of Failure
2. Tear Down 3. Repair 4. Start-up
© 2011 SAP AG. All rights reserved. 48
SAP Extended ECM for Enterprise Asset Management –
equipment failure analysis
SA
P E
xte
nd
ed
EC
M
SA
P P
M
Define Scope of
Analysis Initiate Analysis Conduct Analysis
Recommend-
ations
Reliability Engineer receives
an email with links to
Maintenance Notification
and Failure Analysis
Workspaces
Determine scope
(equipment, technician,
objective, time frame, etc.)
Create analysis report with
findings
Submit report for review/
approval
Create Work
Orders Completion
Create Maintenance Work
Order to investigate the
problem and provide a
remedy
Trigger creation of Failure
Analysis Workspace in
Extended ECM
Records Management
Scheduling and Fixing
Root Cause Analysis may
require revisions to
maintenance plan
(Inspection, Service,
Calibration)
Printing Shop Papers
Assign Technician
Technician repairs the equipment
Everything gets documented in the Maintenance Work Order
Workspace
Technician uses an mobile device to access documents in
related Workspaces (Functional Locations & Equipment)
Technician uses an iPhone/BB for capturing photos directly into
the Workspace
Create Maintenance
Notification
Create Maintenance
Notification of type
“Malfunction Report”
Corresponding
Maintenance Notification
Workspace is created in
Extended ECM (including
the notification documents)
Conduct Equipment Failure Analysis
Conduct predefined analysis
(ETA, FTA, RCA)
Record analysis and testing
results
Review OEM manuals for op
limits and maintenance schedule
Inquire with OEM/supplier on
model experience
Control work progress (reporting)
Collect failure data
Review maintenance/failure
history
Upload photographs and
any interview notes
Assign responsibilities to
assessment roles
Plan tasks and resources
(tasks, WFs, follow up)
1. Notification of Failure
2. Tear Down 3. Repair 4. Start-up
© 2011 SAP AG. All rights reserved. 49
Panel Operator: Equipment Failure –
Initiate Maintenance Notification
Operator creates a Maintenance
Notification of the Equipment Failure
Notification is linked to the functional location and the failed equipment
© 2011 SAP AG. All rights reserved. 50
Finding Content Related to the Equipment
Drag & Drop
Windows Integration of
Extended ECM
Complete plant hierarchy
is available as a Windows
folder structure
© 2011 SAP AG. All rights reserved. 51
Panel Operator: Equipment Failure –
Initiate Maintenance Work Order
Functional Location and Equipment
affected by the Failure
© 2011 SAP AG. All rights reserved. 52 back
Reliability Engineer: Start Analysis
© 2011 SAP AG. All rights reserved. 53 back
Access to SAP Plant Maintenance Master Data
Via SAP Extended ECM
© 2011 SAP AG. All rights reserved. 54
Maintenance Notification Workspace in
SAP Extended ECM Is Automatically Created
Project roles and
rights predefined
for this analysis
type
Default tasks list
predefined for this
analysis type
SAP metadata
All content is managed
seamlessly by the
organizations corporate
records management program
Folders to create and
store content deliverables
according to tasks
Analysis type
© 2011 SAP AG. All rights reserved. 55
Filing of Documents Related to
Enterprise Assets and Maintenance Notifications
Technicians or Maintenance Workers can takes pictures or
notes with mobile devices and file them into
Extended ECM
© 2011 SAP AG. All rights reserved. 56
E-Mail Integration of Extended ECM
Reliability Engineer receives e-mail notification to conduct a Failure analysis for the failed
equipment
© 2011 SAP AG. All rights reserved. 57
Integration in SAP Material Management and PLM
Click on Material to get direct
access to related Material
Workspaces
Material workspace
of the pump
Bill of
materials/components
of the affected pump
© 2011 SAP AG. All rights reserved. 58
Related Vendors for Required Spare Parts
Maintenance Workers have access to important material specifications and material
vendors to prepare the purchasing of spare parts in SAP
Vendors for the “Rubber Seal” (SAP
MM)
Material Workspace with all Material Documentation
© 2011 SAP AG. All rights reserved. 59
Extended ECM Vendor Workspaces with Related Materials
Related Materials of Vendor
© 2011 SAP AG. All rights reserved. 60
Root Cause Analysis
back
© 2011 SAP AG. All rights reserved. 61
Update Root Cause Analysis Folder
back
© 2011 SAP AG. All rights reserved. 62
Reliability Engineer:
Dashboard for Analysis Status Overview
Collaboratively work on the Equipment Failure Analysis
Extended ECM provides task list capabilities to publish and
track ToDos. Tony Blake checks his action items.
© 2011 SAP AG. All rights reserved. 63
Needs
Benefits
Needs Objectives
Benefits
Needs
Benefits
Objectives Objectives
Needs
Extended ECM’s benefits to key
stakeholders in equipment failure analysis
Minimize equipment failure costs by:
Access to equipment maintenance
documentation
Tear down and repair to OEM specifications
Keep assets performing at design rates
with minimal maintenance
Minimize repair time by improving first-
time fix rate and streamlining maintenance
processes
Quick and accurate accessibility to
historical failure analysis in SAP
Prolong asset lifespan through improved
failure analysis knowledge-sharing
Operations procedures are accurate
Safe operating limits are correct
Equipment information is readily available
Why did the equipment fail?
Are the operations, procedures and safe
operating limits correct?
Ability to view historical failure analysis
reports
Return the asset to service as soon as
possible
Contribute to higher reliability of the asset
How to improve equipment reliability and
minimize maintenance
How do I leverage learning across the
enterprise?
Full equipment maintenance history
including breakdowns and causes of failure
Share failure analysis results globally
Improvements to equipment reliability,
reducing maintenance costs and
eliminating unnecessary maintenance
Leverages other breakdown analysis
reports and shares findings
Plant Operator Maintenance Technician Reliability Engineer
© 2011 SAP AG. All rights reserved. 64
Where do customers see value?
Access up-to-date technical documentation; ensuring
worker safety, procedural compliance, efficient
repairs
Failure analysis report recommendations are
immediately tied to equipment data
In-process collaboration capabilities enable
engineering, vendors, procurement and to resolve
complex reliability issues
Seamless management handling of operations and
maintenance records minimizes regulatory/legal risk
SAP Extended ECM for Enterprise Asset
Management – Equipment Failure Analysis
Pianificazione e Scheduling del
personale di manutenzione
SAP Multi Resource Scheduling (MRS)
SAP e ClickSoftware
© 2011 SAP AG. All rights reserved. 66
SAP Multiresource Scheduling (MRS)
Overview – Sintesi
Scenarios Key Functions
Field Service
Plant Maintenance
Project Staffing
Workshop Planning
Intuitive to use Graphical Planning Board
Scheduling and dispatching on work center level
Status management and execution monitoring
Powerful user interfaces
Scheduling of tool resources
Planning on team level
Optimizer for automatic planning
Integration
SAP ERP Plant Maintenance / Customer Service (PM/CS)
SAP ERP Project System (PS)
SAP CRM Service
Collaboration Projects
Solution Strengths
MRS runs fully integrated as “Add-On” to the SAP
system leveraging the existing infrastructure
Strong bi-directional integration with SAP HR and PM
Flexible resource planning scenarios from manual
planning up to automated and optimized planning
High scalability through SAP NetWeaver technology
High configurability and flexible towards customer
enhancements
© 2011 SAP AG. All rights reserved. 67
MRS – Scenari di Pianificazione
Pianificazione Manuale
Assegnazione manuale degli ordini con Drag and Drop nella tavola di pianifcazione
Alert di Pianificazione
Livelli qualifiche richieste, Pianficazione Attrezzature , Tempi di Viaggio, Clocking Data,
Pianificazione Capacità
Resource Selection
Sempre Manuale, ma alcune risorse sono preselezionate sulla base di alcuni criteri
Pianificazione Automatica
Automatic scheduling based on availabilities and qualifications
Utilization based automatic scheduling
Intelligent shifting
Ottimizzazione
An optimization engine proposes an optimized schedule (travel times, SLA dates, etc)
Low Volume
High Volume
© 2011 SAP AG. All rights reserved. 68
Example: Optimizer Results
© 2011 SAP AG. All rights reserved. 69
Fornitura di servizi e gestione della forza lavoro
manutentiva Sfide e punti di attenzione
Demand Forecast Quanto lavoro è probabile che arrivi? Quando? Dove? Quale tipo?
Capacity Planning Qual è il giusto dimensionamento e il mix di competenze della forza lavoro da
allocare nelle varie aree territoriali \ depositi
Tactical Resource Planning Chi sarà a disposizione (personale che non sia in vacanza o in formazione) per fare i
lavori quando arrivano?
Rostering Chi fa parte nel turno di mattina, nel turno pomeridiano, nel week-end ...
Scheduling In un dato giorno: chi è assegnato a fare cosa, per chi, dove, quando e con quali
strumenti di supporto.
Locate Dove sono le mie risorse (persone, veicoli, strumenti ad uno specifico istante?)
Analysis Analisi delle richieste, della schedulazione, del carico di lavoro delle squadre, per giorno o per un periodo di tempo passato e raffronto fra il pianificato ed il consuntivo
© 2011 SAP AG. All rights reserved. 70
Covering the full spectrum of decision support for service
organizations
Decision Timeframe
Seconds/
Minutes
Hours/
Days
Weeks/
Months Quarters Years
Execution
Operational
Planning
Tactical
Planning
Strategic
Planning
Business
Performance
Measurement
© 2011 SAP AG. All rights reserved. 71
SAP Click software
…Allocated to the right shift
with the right skills…
Ensure just enough resources to
meet the demand… Anticipate varying maintenance demand…
At the right place and the right time.
© 2011 SAP AG. All rights reserved. 72
ClickSchedule Client
Scheduling Monitor
Resource Gantt Chart
Task List
Navigation Tree
Interactive Maps
© 2011 SAP AG. All rights reserved. 73
ClickSchedule – Web-based User Interface
© 2011 SAP AG. All rights reserved. 74
Covering the full spectrum of decision support for service
organizations
Decision Timeframe
Seconds/
Minutes
Hours/
Days
Weeks/
Months Quarters Years
Execution
Operational
Planning
Tactical
Planning
Strategic
Planning
Business
Performance
Measurement
© 2011 SAP AG. All rights reserved. 75
ClickLocate: Maps and current location display
• Visualizzazione dei tasks sulla mappa
• Spostamenti di lavoro
• Tecnici: sede di lavoro e posizione corrente
• Azioni direttamente sulla mappa: display, schedulazione di un task, assegnazione, …
• ClickLocate fornisce in ogni momento la localizzazione delle risorse, da che parte sono diretti, quanto velocemente stanno andando ed altre informazioni.
• Con ClickLocate, i managers sono in grado «di vedere» la corrente posizione dell’intera work force in un determinato momento e possono quindi prendere decisioni basate su queste precise informazioni (es. gestire una segnalazione di pericolo)
• ClickLocate fornisce la tracciatura di tutti gli spostamenti della forza lavoro, la velocità media di spostamento, se un tecnico, ad un determinato momento, si sta spostando o è fermo. I dati possono essere rilevati tramite GPS, cell-tower ID, triangolazioni con le celle telefoniche e altri «servizi mobile» che vengono installati sui device in dotazione ai tecnici o montati sui veicoli.
© 2012 SAP AG. All rights reserved. 1
© 2012 SAP AG. All rights reserved.
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