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Enterprise Asset Management

Product Management, SAP AG

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 2

Service Management

Service Management Solution Map, Edition 2004

Customer Service Management Enterprise Asset Management

Service Sales & Marketing

Service Planning & Forecasting

Service Parts Management

Service Procurement Management

Service Operations Management

Customer Service Management Analytics


Asset Life-Cycle Analytics

Investment Planning & Design

Procurement & Construction

Maintenance & Operations

Decommission & Disposal

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 3

Service Management
Enterprise Asset Management
Investment Planning & Design
Business Planning (S12) Investment Management (S12) Collaborative Specification and Design (S8, P103, S140, S141) Document Management (S8, P103) Interfacing CAD, GIS and SCADA systems (S8, P103) Project Management (S8, S141)

Procurement & Construction Maintenance & Operations


Supplier Qualification and Candidate Selection (S6, S13) Bidding and Contract Management (S25, S6, S140) Procurement Process (S25, S6, S12, S120) Document Management (S8, P103) Project Management (S8, S141) Collaborative Construction (P103, S8, S140, S141) Project and Investment Controlling (S12, S8) Technical Assets Management (S8) Preventive and Predictive Maintenance (S8) Work Clearance Management (S134, S8) Maintenance Execution (S8, P28) Shutdown Planning (S8) Mobile Asset Management (S8, B35) Web-Based Processing (S8) Contractor Management (S8, S6, S25) MRO and Services Procurement (S6, S25, S120, S12) Service Parts and Inventory Management (S4) Document Management (S8) Employee Management (S8, S9) Maintenance Budgeting Integrated Asset Accounting (S12, S8)

Decommission & Disposal


Asset Transfer and Disposal (S12, S8) Document Management (S8) Collaborative Disposal Management (S8, P103, S140) Project Management (S8, S141) Waste Management (S125) Asset Compliance (S125) Asset Remarketing (S4, S2)

Asset Life-Cycle Analytics


Asset and Maintenance Reporting (S8) Asset Performance Management (S8, S13) Reliability Centered Maintenance (S8, S13) Asset Life-Cycle Costing (S13) Damage Analytics (S13, S8) Object Statistics (S13, S8) Spend and Supplier Performance Analytics (S13, S6)

SAP Product Available SAP Product Available with Future Releases Future Focus

Partner Product Available Partner Product Available with Future Releases Collaborative Business Map Available

Sxx, Vxx, Bxx Pxx

SAP Product & Service Partner Product

For more information see: http://www.sap.com

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 4

The Overall View of the Asset Life Cycle


Implementation Efficiency Status Quality

Maintenance

Operation
Availability Safety

Refurbishment
Project Management

Asset

Installation & Test Procurement Manufacture

Modification
Investment Management

Replacement
Requirement

Selection or Design

Marketplaces EBP

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 5

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 6

Maintenance-Relevant Objects
Company premises Buildings

Machinery
Assets Resources EDP infrastructure Fleet Electrical fixtures Rails Replacement parts And many more

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 7

Technical Object Types

Functional Location

Equipment

Assembly

Spare Parts

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 8

Asset Structure

Asset structure = multi-level, hierarchical structure, organized by ...


Production Plant Spatial Production street 1 Press shop Technical

Welding plant
Assembly area Production street 2 Shipping area Criteria

Functional

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 9

Equipment

Individual physical object to be maintained as an autonomous unit

Installation and dismantling in asset structure

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 10

Master Record of a Technical Asset

Implementation

Master Record
General

Classification Documents / Technical drawings Multilingual texts Addresses / Partners Measuring points / Counters Permits

Location
Organization

Structure

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 11

Bill of Materials

Spare parts configuration of a piece of equipment


Production street 1 Press shop Press 1 Motor ABC Motor casing Drive shaft
Functional location

Functional location
Equipment Assembly Material Material

Coil
Press plate XYZ

Material
Material

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 12

Web Catalogs

Transparent
structure Web interface BOMs may be superfluous

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 13

Synchronisation between Equipment and Fixed Asset

Automatic data synchronization possible

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 14

Interfaces to Non-SAP Systems

System openness through standardized interfaces

CAD systems Geographical Information Systems Barcode scanner Internet Process Control System
SCADA

Standard interfaces

Asset LifeCycle Management R/3Database

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 15

Fleet Management with Enterprise Asset Mgmt.


Total cost collection
Post depreciation to PM standing order

Asset

Standing PM order

Asset/Equipment synchronization

Equipment with fleet segment

Fuel entry transaction

Measuring points

PMIS
Maintenance processes Performance analysis

Mileage and fuel

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 16

Technical Assets Management: Advantages

Asset transparency Meaningful history of equipment


maintenance Flexible analysis options

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 17

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 18

Preventive Maintenance: Reasons

Legal regulations (for example, technical inspection of vehicles) Quality assurance (for example, customer demands) Reduction of breakdown frequency of assets, thereby: Lowering costs of restarting, Prolonging the lifecycle of assets Environmental considerations Manufacturers requirements Lowering of maintenance costs

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 19

Reduction of Maintenance Costs?

Costs

Overall cost of maintenance

Cost of preventive maintenance

Cost of repairs

M0
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 20

Degree of intensity of preventive maintenance

Preventive Maintenance: Categories

Preventive Maintenance

Time-Based

Performance-Based

Condition-Based

Temperature Pressure

Thickness

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 21

Preventive Maintenance
WHAT? WHEN?
Time- or counter-based strategies Task lists

Maintenance plan
- Single cycle - Strategy - Multiple counters

Order/ Notification Order/ Notification Order/ Notification

Schedule plan

WHERE?

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 22

Preventive Maintenance Processing


Maintenance plan

Order/ Notification Order/ Notification Order/ Notification Scheduling

Dispatching

Worklist

Maintenance Execution

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 23

Preventive and Predictive Maintenance: Advantages

Increase equipment reliability Reduce maintenance inventory More effective use of all resources

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 24

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 25

Business Process: Breakdown Maintenance

Call / Notification

Create order and release

Order

Production

Supervisor/ Maintenance Planner

0010 Inspect pumps 0020 Replace seals

Maintenance work center


Confirm and complete order

Fix malfunction

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 26

Functional Process (Acute Maintenance)

Techn. Object Condition description Item data Activities / Tasks Priorities

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 27

Maintenance Notification

Notification with

Catalog entries Paging function Solution


database Configurable screen areas and tab pages

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 28

Catalogs

Catalogs can contain object parts, damages, tasks, activities...

Example:
Damage catalog Mechanical damage Code 010 020 030 . . .

Corrosion Broken glass Engine defect . . .

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 29

Functional Process (Acute Maintenance)

Techn. Object Condition description Item data Activities / Tasks Priorities

Internal / External resourceplanning Release / Print Control / Execution

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 30

Maintenance Order

Order header: Reference object, dates, priority, description

Operations: Work center, duration, description, external services Components: Material, services, quantity, availability check

Object list: Technical objects, notifications, material


Further information: Costs, Partners, Maintenance plan information...

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 31

Component Planning with Catalogs

Available in
standard for R/3 Enterprise

Branch directly
from the order to a web catalog

Copying of stock
and non-stock materials into the order

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 32

External Services

Integrated service request in the


maintenance order

Display of short- and long-term external


services

Continuous posting and tracking of costs Service entry sheets allow later verification
of services performed

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 33

Functional Process (Acute Maintenance)

Techn. Object Condition description Item data Activities / Tasks Priorities

Internal / External resourceplanning Release / Print Control / Execution

Time- / Material confirmation Technical completion Order settlement

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 34

Completion Confirmation
Reference order Technical completion

Time confirmation

Material confirmation

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 35

Functional Process (Acute Maintenance)

Techn. Object Condition description Item data Activities / Tasks Priorities

Internal / External resourceplanning Release / Print Control / Execution

Time- / Material confirmation Technical completion Order settlement

Objects Orders / Notifications Costs Downtimes

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 36

Maintenance History

Change Documents Action Logs Complete history and


cost tracing for technical objects

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 37

Maintenance Information System


Example: Cost Analysis

Drill down

Strategically important standard evaluations are for example

Cost analyses Site analyses Malfunction and breakdown


analyses

Drill down

Manufacturer analyses

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 38

Business Warehouse for Maintenance Analyses

SAP BW provides a complete data warehouse solution. The predefined Business Content in SAP BW allows analyses of
Quality-, maintenance-, and service notifications Notification items, -causes, -tasks, -activities Maintenance- and service orders

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 39

Breakdown Maintenance: Advantages

Increase plant availability Reduce equipment stops and


downtime Minimize maintenance costs substantially

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 40

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 41

Refurbishment Process

Refurbish Equipment Dismantle Equipment Re-install Equipment Order Issue Equipment Re-stock Equipment

0010 Refurbish pump 0020 Settle order

Stock
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 42

Refurbishment Dismantling of faulty equipments and return to warehouse for refurbishment

Material condition-based valuation

Valuation type C1 (new) $ 3000

Valuation type C2 (refurbished) $ 2500

Valuation type C3 (damaged) $ 200

Material with condition-based value linked to the equipment is used to monitor availability of stock in inventory management

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 43

Refurbishment Process: Advantages

Completion of the life cycle of a


technical asset Uniqueness through serialization Life cycle trading of equipment

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 44

Contents

Enterprise Asset Management

Technical Assets Management


Preventive and Predictive Maintenance

Breakdown Maintenance
Refurbishment Process

Integration and Platforms


Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 45

Enterprise Portals: Uniform Access to All Systems

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 46

Characteristics of a Portal

High level of integration through the


latest technology

Uniform interface for various


applications

Simple access and high usability Simple adaptability and thereby


simple re-design of business processes

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 47

Individual Page Construction: Example

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 48

Business Package for Assets: Contents

Information on technical objects as well as


corresponding notifications and orders

Simple creation and tracking of notifications Installation and dismantling of equipments Time completion confirmation Material availability check Creation, changing and display of document

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 49

Mobile Asset Management

Suite of tools tailored to the needs


of the field service & field maintenance personnel

Extends Plant Maintenance and


Customer Service functionality

Offline processing using mobile engine

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 50

Mobile Asset Management - Functional Overview


Data creation and assignment

SAP Backend

Data update in backend

Order Management

Measurement & Counter Readings

Contract Management

Inventory Management

Business Partner Management

Notification Management

Technical Object Management

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 51

Advantages of Mobile Asset Management

Extended mobility through locationindependent work

Immediate on-site data entry Improved data quality Direct access to up-to-date data Lower process costs

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 52

Integration to mySAP SRM


Catalog
OCI Compliant Catalog e.g. BugsEye

R/3 System
PM / CS

SRM
Enterprise Buyer

Maintenance Order
Select spare parts / services

Sourcing
Requirement

Purchase Requisition
Replication of purchase order

Purchase Order (Copy)

Purchase Order

Goods Receipt / Service Entry

Invoice

Follow-on documents can be created in backend or in EBP

Confirmation / Service Entry

Invoice

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 53

Component Planning with Enterprise Buyer


SAP R/3 4.6C and below
Order 4711
Operation 10 Operation 20 Select order

Enterprise Buyer
Order 4711
Operation 10 Operation 20 Go to catalog

External parts catalog

Order 4711
Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10

Transfer components

Order 4711
Operation 10 Pump P1000 Gears Gx01 Operation 20 Washer 10-10

Transfer to shopping cart Pump P1000 Gears Gx01 Washer 10-10

Reservation Purchase requisition

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 54

Integration into Investment Management

Asset under Construction

Depreciation Simulation

Fixed Assets

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 55

Project Oriented Shutdown Planning


mySAP PLM Program Management

Project Information System


Costs/Revenues Budget Project Structure Procurement Payments Claims Status Schedule

Project Management
Workforce Progress

Documents

Shutdown Project Life-Cycle


Idea & Concept Planning & Approval Project Execution Closing

mySAP PLM Project Management


SAP AG 2003, Asset Life-Cycle Management, Speaker Name 56

Shutdown Planning with Project-Oriented Maintenance (POM)


mySAP PLM Asset Life-Cycle Management offers an interface to Primavera P3, which you can use to plan shutdowns with reduced costs and downtimes. This includes:
Shutdowns (Processing industry) Revisions (Utilities) Checks/Overhauls (Aerospace)

POM supports the following core processes:


Identification and selection of the work Planning/Budgeting Optimization/Simulation Performance and support of unplanned work Evaluations/Reporting

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 57

cFolders for Enterprise Asset Management

Defined partners receive controlled access to documents and


materials as well as material BOMs outside of the R/3 system

Simple call-up using Internet Explorer and user ID Own status management allows "Mini-Workflow"
and version concept

Documents and notes can


be edited and selected

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 58

Example: Info Exchange with Service Providers


Operator

Ordering of services

Service provider

Construction of the cFolders structure Info call up of updated data

Call up of the cFolders structure

Technical confirmation, completion of documents, for example, on handheld devices

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 59

Example: Information Exchange with Customers


Service Provider Customer

Provision of services

Construction of the cFolders structure Notification recording

Call up of cFolders structure

Notifications for cFolders objects

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 60

Integration and Platforms: Advantages

User-friendly interface in Enterprise


Portal

Realtime documentation of maintenance


work through Mobile Asset Management

Tailored shutdown planning Company-wide exhange of information


with cFolders

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 61

Contents

Enterprise Asset Management Technical Assets Management Preventive and Predictive Maintenance Breakdown Maintenance Refurbishment Process Integration and Platforms Work Clearance Management
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 62

Work Clearance Management

Adhere to health and safety requirements in the workplace Maintain plant safety and high system availability Observe additional company-specific guidelines Follow environmental protection regulations Comply with legal safety standards
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 63

Work Clearance Management: Basic

Isolation of technical objects to ensure safe and secure working conditions for personnel during maintenance work or controlled tests

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 64

Architecture

Work Approval
Order

Applications
Work Clearance Application (WCA) Application for Fire Protection ...

Work Approval Work Clearance Application Operational WCD

Further Applications

Enhanced Model
Order
Work Clearance Application

Work Clearance Documents


Work Clearance Document Template Operational Work Clearance Document

Operational WCD

Standard Model

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 65

Maintenance Process

Maintenance plan

Work Clearance Management

Notification

Create Order

Plan Order

Release Order

Confirm Order

Complete Order

Analyze Histories
SCADA Work Clearance Management

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 66

Objects
Status processing and audit trail: system status and user status

General data Reference object

Assignment of partners: different roles possible


Long text processing: several internal remarks

Areas of responsibility
Location data Planning data
Assignment of documents: link to document management system Assignment of permits: process relevant, interactive, ...

Use of catalog technique: code groups and codes


SAP AG 2003, Asset Life-Cycle Management, Speaker Name 67

Work Clearance Management: Advantages

Maximize your employee's safety Improve work efficiency Enhance your assets'
productivity

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 68

Summary

Enterprise Asset Management: Your Benefits

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 69

Advantages for Asset Operators

Increased asset efficiency and lower


TCO

Sustained optimization of asset usage Reduced expenditure for service


providers and materials

Higher production capacities

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 70

Key Customers

SAP AG 2003, Asset Life-Cycle Management, Speaker Name 72

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