the
eventful
group
Premier Partners: Supported by: Produced by:
SAP Plant Maintenance
6-8 June 2011
Mastering SAP Plant Maintenance
2011 | 3
www.masteringsap.co.za/pm
33 Presentations, Case Studies and Sessions in 6 tracks over 3
days covering:
Maintenance Scheduling; Master Data Management;
Training, Change Management & Engaging Your Workforce;
Reporting and Business Intelligence; Budgeting; Maintenance
Planning; Document Management; Enterprise Asset Management
Strategy; Shutdowns & Projects; Rotables; Mobility & Alternative
User Interfaces; Integration to Other Modules; and Permits & Safety
Work Clearance Management
Powerful Keynote Speakers and Thought Leaders:
led by
SAP AG’s (Germany) VP for EAM Solutions, Dr Achim Kruger, the
line-up includes: Vesta Partners (US), Nexen (Canada) and Water
Corporation of WA (Australia)
Three Interactive Workshops:
-
Applying Core SAP Functionality to Support Asset and Reliability
Management
-
User Interface Options for the Maintenance Role
-
Plant Maintenance Blue Print for Master Data
Special JumpStart Session:
Using “Mastering SAP Plant
Maintenance” and the Community to Make the Most Out of Your
SAP Investment
Entire Program Vetted by the Mastering SAP Plant Maintenance
Advisory Team
representing large, medium and small organisations
across many industry sectors
Solutions Showcase
featuring selected partners who understand
the business of organisations using SAP to enable Maintenance and
Reliability and are serious about helping you make the smartest
business and IT investments
Unrivalled Community Networking Activities:
pre-conference
drinks; community networking drinks on Monday evening; direct
access to presenters at Speakers’ Corner; connecting at lunches
and tea breaks in the exhibition area; and utilising complimentary
meeting rooms
Take Home Tools and Resources:
electronic access to all keynotes,
track presentations and sessions
Membership to a Vibrant and Committed SAP Plant
Maintenance Community:
you will receive a contact list of all
conference participants, helping to maintain the momentum created
and keeping the community connected, motivated and informed all
year round
Welcome to the Inaugural
African Mastering SAP Plant
Maintenance Conference.
Thoughtfully designed to encourage
you to look outside of your company
and industry, Mastering SAP Plant
Maintenance is a gathering place where
SAP PM Professionals engage in brave and
important conversations, fi nd answers to common
challenges and inspire one another to explore future
opportunities. This year marks our 15th year of serving
and supporting the Global SAP PM and EAM community.
Hot Topics
The depth and breadth of
the content is a result of 6
months of careful research
and development. SAP
EAM & PM Professionals
from more than 120
organisations across South
Africa have collaborated
with the Mastering SAP PM
Advisory Team in a series
of Round Table Discussions
to create this program
around 13 Hot Topics
Maintenance Scheduling
Effective work scheduling is critical to effective work
management and execution. In recent years graphical
scheduling tools have become available within SAP, joining
the suite of available 3rd party tools. One must embrace
both the system capability and the business processes
fundamental to scheduling. Identifying the scheduling options
in SAP; the standard functional components and most recent
tools; understanding the features and capabilities of Multi
Resource Scheduling (MRS); scheduling through the planning
board, maintaining work centres and HR structure interface;
resource delegation; schedule adjustments, insights into
service requests; demand and resources, including personnel
and tools; optimising schedule and linking of PRT; SAP PM/PS
integration with Primavera, bPortal; integrating the business
processes of project planning and ERP; SAP PM and PS
extended with 3rd party tools to enable better scheduling;
interpret and analyse work order data using a single screen
Maintenance Planning
Driving the reduction in maintenance costs, while increasing plant
reliability, has produced a strong interest in the development
and optimisation of preventive maintenance schedules and the
utilisation of plant measurements as part of this optimisation.
SAP has a powerful but complex suite of capabilities which can be
daunting to understand and apply; features and capabilities; types
of task lists and maintenance plans; structuring maintenance plans
and how to schedule them; simplify planning using the SAP PM
module; how to ensure effective measurements are made and
recorded to form the basis of your maintenance plan; gathering
the readings via interfaces; establishing and delivering the best
maintenance plan for your organisation; ensuring effective
measurements are made and recorded to form the basis of your
maintenance plans
Document Management
Attaching and printing documents such as drawings, work
packs and manuals to SAP is critical and is increasingly becoming
a statutory requirement. It enables organisations to provide
a complete overview of a job, safety information, OEM
documentation, illustrations and a whole array of important
information. Defi ning and managing a document management
system, available DMS functionality within SAP and 3rd party
offerings; standard SAP DMS functionality; business integration
for plant maintenance; managing drawings in SAP DMS, handling
versions of documents, storing and searching for documents;
reporting around documents and their usage/linkage; view PM
notifi cations that are attached to the functional location; feedback
and storing thereof
Enterprise Asset Management Strategy
There has never really been a framework for developing asset
management strategies. PAS55 gives you a framework to work
from. How is SAP aligning with PAS55 - soon to become an ISO
standard?; basic functionality to use in SAP; how to create an
asset management strategy in SAP and it’s alignment with PAS55;
Project and Portfolio Management (PPM); optimise and monitor
portfolios related to asset investments, activities and projects;
create a long and short term asset plan; manage the risk of a project
portfolio related to assets; EAM Audit and Maturity Model; policies,
procedures and processes; data integrity; reporting based on PAS55
standards for analysis and continuous improvement; how using
evolving technologies, such as SCADA can improve the knowledge
cycle; an overview of Asset Condition Assessment (ACA) process
and Asset Risk Assessment (ACA)
Shutdowns & Projects
Integrated and stand-alone tools are available from both SAP
and from 3rd party vendors. Using graphical scheduling tools for
managing shutdown projects; understanding the best procedures
and tools for planning and scheduling a shutdown for success;
journey from isolated tools to integrated bidirectional planning
and scheduling; SAP PM, PS, PI, Primavera Inspire, Primavera
P6; bPortal - the technology to view it all - the SAP revision, the
Primavera schedule, the status and what is to come; integrated and
stand-alone tools are available from both SAP themselves and from
3rd party vendors; using graphical scheduling tools for managing
shutdown projects; understanding the best procedures and tools
for planning and scheduling a successful shutdown
Rotables
Lifecycle management of rotables and repairables is a key
business process for many industries, but is inherently very
labour intensive. While it can be achieved in numerous ways
to meet the varying needs and sophistication of various
businesses, it always requires consideration and integration
of maintenance, stores, purchasing and fi nancials (valuations)
to be successful. This indicates that a successful rotables
and repairables process will be the product of good process
design, selection of appropriate functionality and effective
change management. How well does standard SAP handle
the rotables challenge?; what solution is available in EhP 4?;
deciding what to track; repairables vs. rotables
Mobility & Alternative User Interfaces
Mobile computing brings SAP to the people, placing SAP
solutions in the hands of the workforce at the job location.
This opens tremendous possibilities for the integration of
SAP into real-time business processes, providing
up-to-the-minute updates on work over its lifecycle and tie-ins
to other SAP processes. Users have often struggled to
use standard SAP GUI. What technologies are available to
customers to make the input of transactional data easier?; the
main interfaces that people use; typical work management
scenarios and their management; benefi ts of enhanced user
interfaces; how to set-up the user interfaces; GUI and portal
and how each leverage the pre-defi ned maintenance roles;
learn how standard SAP windows transactions and GuiXT can
be used in the context of the new user interfaces
Integration to Other Modules
PM-PS: the journey from isolated tools to integrated
bidirectional planning and scheduling: projects and budgeting;
bPortal; the interface between plant maintenance and stores/
purchasing is inherently very close and the functionality
is tightly integrated in SAP; getting the most from BoMs;
reporting and analysis of consumptions; available DMS
functionality within SAP and 3rd party offerings; integrating
reports to support the overall business process and
integration between different modules; successfully use SAP
MII together with Modular Mining (Powerview) and SAP ERP
and output reports in BOBJ Xcelcius
Permits & Safety Work Clearance Management
What is SAP’s offering in this space? Should one use 3rd
party tools instead? Integrating Audit Management Cross
Application as part of core SAP in order mitigate the risk
of operations; avoid errors and inconsistency; capture
inspection feedback and audit fi ndings; reports for analysis
and continuous improvement; progress tracking on corrective
actions and highlighting of major risk areas; detail instructions
to personnel and 3rd parties on what and how often to
inspect and perform audits; how to integrate the systems
process with the practical application of permits and work
clearance; maintenance and operations should follow the
same processes for safety; managing the safety
of contractors on site
Master Data Management
Getting the Master Data right and keeping it right over time is
recognised as one of the keys to effective maintenance system design
and is the only way to ensure integrity and accuracy. Identifying
processes for Master Data creation; the basic blueprint available in SAP
PM; journey of sustainable EAM Master Data and tools; foundational
building blocks; clean-up and data governance; Master Data design;
defi ning and maintaining Master Data standards and consistency;
assigning accountability and performance recognition; going beyond
the foundation stage; making use of 3rd party independent auditors
to show compliance; application of an ISO standard in SAP; loading
data using standard SAP migration tools; effective root cause analysis;
the importance of equipment name plate data; improve change
management control; organisational challenges; data capturing
responsibilities; using the masterkey tool and SAP workfl ow to enforce
Master Data integrity; functional locations and equipment Master Data
Training, Change Management & Engaging Your Workforce
While the need for training has always been recognised as part of the
go-live process, there is now a strong recognition that training is an
ongoing need, whether to maintain engagement, handle new people
coming into roles, or as part of upgrades or system changes. The
methods to achieve this are usually quite different to handling the initial
training requirements; direct training interventions; developing training
packages; staff involvement and identifying training needs; transfer of
knowledge (turnover and promotion); training techniques and tools;
continuous training as users evolve and mature; management buy-in
and drive; SAP quick training wins and tips; change management
techniques used; embedding change; being the leader; techniques to
overcome resistance; creating an enabling environment between the
vision and the execution
Reporting
Growing business sophistication and data volumes are driving the need
for analytical tools to report and control works and asset management
outcomes. The standard SAP tools available in Business Warehouse and
SAP BusinessObjects are increasingly being considered for this purpose
and their use in the plant maintenance area. Why use BI?; BI reports
for managing notifi cations in BI and custom SAP PM notifi cations;
SAP BusinessObjects PM specifi c reports; SAP strategy management
as a KPI for PM customer complaint notifi cations; Maintenance Cost
Budgeting (MCB) in BI; integrating reports to support the overall
business process and integration between different modules; learn how
to successfully use SAP MII together with Modular Mining (Powerview)
and SAP ERP and output reports in BOBJ Xcelcius; asset performance
reporting
Budgeting
The fundamental principal underpinning the budgeting process is a
philosophical discussion within an organisation as to who “owns” the
budget. Once that is understood, do you understand the process of
budgeting in SAP? Re-forecasting and revising budgets; available
technologies; what forms the basis of Maintenance Cost Budgeting
(MCB) in DPO; understanding the capabilities and limitations of
MCB; working out your budget based on a maintenance plan;
consider the complete asset life cycle process starting with strategic
planning; capital project and planning over the life cycle of the asset;
maintenance operational budgets that include preventive maintenance
www.masteringsap.co.za/pm
Keynote and
International Speakers
John has specialised for the last 17 years in architecting, designing, delivering and supporting SAP PM and EAM
solutions across Australia, New Zealand and SE Asia. Over this time he has worked across a wide range of industries
from processing and manufacturing through to government and military environments, with a consistent focus
on matching SAP functionality and capability to specifi c required business outcomes. John has had a key role in
the development of the Australian Mastering SAP PM conference since its inception 15 years ago and continues
to chair the steering committee, facilitate the conference round table discussions and present in various roles at
the conferences. Prior to SAP, John worked as a chemical engineer for 17 years in plant start-ups, operations and
maintenance in the petrochemical and mining industries.
John Dwyer - National Solution Leader (EAM), Oxygen Business Solutions (Australia)
Using “Mastering SAP Plant Maintenance” and the Community to Make
the Most Out of Your SAP Investment
Tips and Tricks with Maintenance Plans
Len is Vice President of the EAM Energy and Utility Practice for Vesta Partners. His responsibilities include
business development and identifying new business opportunities in the Utility Market. He has 25 years of
industry experience as a Project Manager, Logistics and Maintenance Manager. Prior to joining Vesta, Len spent
10 years with SAP as an Executive Solution Engineer for Utilities and was a Solution Manager for Enterprise
Asset Management. As a recognised expert in SAP EAM, he is a frequent featured speaker at industry events
and seminars. He focuses on showing organisations how the SAP solution can be used to support their business
requirements. Len is committed to building long term relationships with customers by helping them maximise
their investment in SAP for maintenance and reliability.
Len Harms - Vice President, Energy and Utility Practice, Vesta Partners
The Art of the Possible - Scheduling Options in SAP
“The Next Big Thing” or Just Another Thing? Asset Management
Strategy and Standards
Norm specialises in SAP PM along with integration to engineering and plant process systems. For the past 13 years he has
been involved in continuous improvement, best practices, plant turnarounds, re-engineering, process improvements, process
safety development and implementation projects. Norm has held technical and functional roles with Agrium, NOVA Chemicals,
DuPont, Canexus and Nexen Inc. and Marathon Oil. Today, Norm focuses on knowledge execution management and asset
information management systems and the enabling of standardisation, consistency and productivity through better use of
grass root technologies like SAP.
Norm Poynter - Business Analyst, Nexen, Inc. (Canada)
Change Management - Moving the Organisation an Inch
Process Safety Information - Integrating to SAP
Dean is a Solution Manager specialising in SAP Enterprise Asset Management (EAM) for the energy and natural
resources industries. Dean is based at SAP HQ in Walldorf, Germany. Dean joined SAP in 1998 as a Plant Maintenance
(PM) Consultant with SAP Africa, before moving to Germany in 2001. Dean started his career as Mechanical Engineer
and joined SAP from a competitor ERP vendor where he worked as a Maintenance Consultant implementing their
maintenance management system.
Dean Fitt - Solution Manager, SAP AG (Germany)
Nuggets of Gold - Unearthing the New EAM Functionality in SAP ERP 6.0
Linear Asset Management and Operation Account Assignment with SAP EAM
Greg started his career as a motor mechanic before completing a degree in mechanical engineering from the University of
Western Australia in 1981. Greg gained extensive experience in operations and maintenance of the Water Corporation’s
assets in WA. He was the team leader during the implementation of the SAP PM in 1997 and has been continuously
involved in improvements in business processes for the corporation’s asset management and maintenance systems
since that time. Greg has a detailed knowledge of SAP PM and integrated systems as they apply in the Corporation.
Over the past 10 years he has had extensive involvement in major enhancements to how the Corporation manages all
maintenance information systems. The most signifi cant in recent years has been the move to mobile computing for fi eld
workers, completed in 2004 and signifi cantly improved in 2009. Greg was one of the people responsible for designing and
implementing the system and working to deliver the education and the cultural changes required for this to succeed.
Greg Rimmer - Process Manager, Plant Maintenance & Mobile Computing, Water Corporation of WA (Australia)
Basic Fundamentals of Asset Management at the Water Corporation - Is it Really
All That Complex?
Getting SAP PM to Work for Your Users - The Story of Our User Interface Journey
Achim started his career as an offi cer with the German Air Force where he held several positions in helicopter and
transport aircraft maintenance as well as systems engineering. Joining SAP Germany in 2002, Achim fi rst served as a
consultant before establishing the SAP Defense & Security Industry Portfolio at SAP AG. After several other duties in
Solution Management and Development, Achim is now a Vice President for SAP’s solutions in the area of Enterprise
Asset Management. Achim obtained a Diploma in Aerospace Engineering from the University of the Federal Armed
Forces in Munich as well as a Diploma in Economics from the University of Hagen.
Achim Krüger - Vice President, EAM Solutions, SAP AG (Germany)
SAP’s Roadmap for EAM - From Supporting Maintenance to Linking Assets
to the Business
Bob is one of the most recognisable faces in world rugby, having played 42 times for the Springboks and played Super 10,
12 and 14 rugby for three franchise teams - the Stormers, Cats and Sharks. He played Currie Cup for Western Province,
who won the title three times on his watch. After a stint in the UK that involved more work than play, Bob capped off a
successful comeback to rugby in South Africa with victory at the 2007 RWC. Bob is now an entrepreneur with various
interests. He is a sports broadcaster for the Supersport team, owns a country pub in Noordhoek Cape Town, hosts a
weekly sports lifestyle show on South African radio, hosts the annual Cape Town Tens Tournament with Rob Fleck and
he is actively involved in his Bobs for Good Foundation since its inception in 2009. In his spare time Bob likes to relax by
fi shing, surfi ng and importantly raising his family.
Bob Skinstad - ex-Springbok Captain & Rugby World Cup Winner
Guest Keynote Presentation: Bob Skinstad
Conference Overview
Wednesday Workshops
Workshop 1: Applying Core SAP Functionality to Support Asset and Reliability Management
Led by: John Dwyer - National Solution Leader (EAM), Oxygen Business Solutions (Australia)
Workshop 2: User Interface Options for the Maintenance Role
Led by: Len Harms - Vice President, Energy and Utility Practice, Vesta Partners (USA)
Workshop 3: Plant Maintenance Blue Print for Master Data
Led by: Norm Poynter - Business Analyst, Nexen Inc. (Canada)
08.30
Sunday Evening JumpStart
Using “Mastering SAP Plant Maintenance” and the Community to Make the Most Out of Your SAP Investment
John Dwyer - Australian Conference Advisory Committee Chair for Mastering SAP Plant Maintenance & National Solution Leader (EAM),
Oxygen Business Solutions (Australia)
18.00
Tuesday Conference Day Two
Tea & Coffee/Exhibition Viewing
08.00
“The Next Big Thing” or Just Another
Thing? Asset Management Strategy and
Standards
Len Harms - Vice President, Energy and
Utility Practice, Vesta Partners (USA)
10.40
Morning Tea & Coffee/Exhibition Viewing
Navigating an Ocean of Master Data -
Staying Afloat in a Distributed Electricity
Asset Environment
Martin Aldrich - SAP PM Integration Specialist,
City of Cape Town
10.00
11.35
SAP PM Maintenance Cost Budgeting -
From Zero to Hero
Hendrik du Plessis - Senior Solution Specialist,
Physical Asset Management, Exxaro Coal
(Pty) Ltd
Integrating SAP with Reliability Assurance
Methods - Putting Research Into Practice
Steve Turner - Founder and Director, OMCS
International (Australia)
Keynote Presentation: SAP’s Roadmap for EAM - From Supporting Maintenance to Linking Assets to the Business
Dr. Achim Krüger - Vice President, EAM Solutions, SAP AG (Germany)
09.00
Lunch/Exhibition Viewing
Process Safety Information -
Integrating to SAP
Norm Poynter - Business Analyst, Nexen
Inc. (Canada)
12.25
13.25
Using SAP Plant Maintenance to Define
Maintenance Processes and Help
Embed Systemic Change
Riaan Blignaut - Business Process Owner,
Lonmin Mines
Linear Asset Management and Operation
Account Assignment with SAP EAM
Dean Fitt - SAP Solution Manager, SAP AG
(Germany)
Stick to Your Blueprint - Sustaining SAP
PM Over a Decade at Samancor Chrome
Donald Grant - Engineering Manager,
Samancor Chrome
14.20
Principles for Effective Shutdown
Management: Minimising Complexity
and the Role of SAP
Peet van Rensburg - Superintendent
Maintenance Planning, Phalabora Mining
Company
Driving Integrated Business Performance
Reporting
Ernest Stonestreet - Principle Engineer Asset
Management, Anglo American Group Mining
and Technology
Afternoon Tea & Coffee/Exhibition Viewing
Mastering SAP Plant Maintenance Conference Close
Closing Keynote Presentation: Getting SAP PM to Work for Your Users - The Story of Our User Interface Journey
Greg Rimmer - Process Manager, Plant Maintenance & Mobile Computing, Water Corporation of WA (Australia)
15.10
17.00
15.50
TRACK A
TRACK B
TRACK C
Execute Shutdown Activities in SAP PM
From the Outside Without Losing Any
Data
Leon van der Merwe - Planning Officer &
SAP PM Super User, TSB Sugar
Sweating Your Existing SAP
Investments - SAP Document
Management for Plant Maintenance
Dolf Engels - Solution Analyst for Anglo
American, Sishen Mine, Kumba Iron Ore
& Warren Buss - ECM Solution Manager,
Nokusa Engineering Informatics
Monday Conference Day One
Registration/Arrival Tea & Coffee/Exhibition Viewing
Conference Opening and Chairperson’s Welcome
08.00
08.35
09.00
10.00
Opening Keynote Presentation: The Art of the Possible - Scheduling Options in SAP
Len Harms - Vice President, Energy and Utility Practice, Vesta Partners (USA)
Keynote Presentation: Change Management - Moving the Organisation an Inch
Norm Poynter - Business Analyst, Nexen, Inc. (Canada)
11.40
TRACK A
TRACK B
TRACK C
Ensuring Shutdown Project Execution
As It Was Always Intended - SAP PM/PS
Integration with Primavera
Rubin Boer - Business Analyst, PetroSA
Training and Documentation Basics -
SAP Training and Development
Tim Swain - Operations Manager,
Maintenance Systems Solutions Pty Ltd
(Australia)
Tips and Tricks with Maintenance Plans
John Dwyer - National Solution Leader (EAM),
Oxygen Business Solutions (Australia)
11.00
Morning Tea & Coffee/Exhibition Viewing
Using Smart Business Intelligence
Tools for Plant Maintenance to Provide
Transparency
Shaun van der Merwe - Principal Business
Analyst, SAP Solution Centre - Logistics &
PM, City of Cape Town
12.35
Delivering One Version of the Truth with
SAP Document Management - a Massive
Time Saver
Gary Ruttledge - Regional Plant Maintenance
Systems Manager, Sappi South Africa
Managing Engineering Risk with SAP
Audit Management for Regulatory
Compliance
Jannie Potgieter - Director Enterprise Asset
Management, Collaborit
Lunch/Exhibition Viewing
13.25
Basic Fundamentals of Asset
Management at the Water Corporation -
Is it Really All That Complex?
Greg Rimmer - Process Manager, Plant
Maintenance & Mobile Computing, Water
Corporation of WA (Australia)
15.20
SAP PM Master Data - Physical Asset
Management’s Friend or Foe?
Paul J Grobler - Senior Engineer, Physical
Asset Management, Exxaro Coal (Pty) Ltd
Simplifying Planning and Scheduling
Within SAP
Dana Jordaan - Senior Project Manager,
Prometheus Group
Nuggets of Gold - Unearthing the New
EAM Functionality in SAP ERP 6.0
Dean Fitt - SAP Solution Manager, SAP AG
(Germany)
14.25
From Office to Shop Floor - SAP PM
Scheduling on the Planning Board to
Increase Maintenance Productivity for
Artisans
Bob Govender - Specialist: Maintenance
Support, Richards Bay Minerals
Enterprise Asset Management - Defining
the Way Forward for a New Generation
Andrew Fisher - Program Manager and
Strategic Account Manager, Britehouse
Guest Keynote Presentation: Bob Skinstad
16.40
Afternoon Tea & Coffee/Exhibition Viewing
16.10
Mastering SAP Plant Maintenance Community Networking Drinks Sponsored by
Mastering SAP Plant Maintenance
2011 | 11
www.masteringsap.co.za/pm
Sunday 5 June 2011
TRACK B 10.00Monday 6 June 2011
Registration/Arrival Tea & Coffee/Exhibition Viewing Conference Opening and Chairperson’s Welcome
08.00 08.35 09.00 18.00
Opening Keynote Presentation: The Art of the Possible - Scheduling Options in SAP
Scheduling continues to be one of the hottest topics in SAP Plant Maintenance. Many planners struggle to aggregate demand related and resource related data from numerous sources into a single scheduling tool. Not only is the process time consuming and tedious, but the result is woefully inadequate for your task: matching demand with your best suited resources. In 2005 SAP released an add-on scheduling tool called Multi-Resource Scheduling (MRS). Since that time the solution has seen a number of enhancements. It is a highly configurable solution that provides a comprehensive, real-time, up-to-date planning overview in an intuitive graphical planning board.
This presentation will cover a review of the standard foundational components required to do scheduling in SAP and an overview of the most used scheduling tools. Foundation topics will include, work centre capacity, schedule dates, capacity evaluation and capacity levelling. Three different scheduling tools will be reviewed with particular emphasis on SAP MRS including a live demonstration of the solution.
Supported business processes include:
• Planning oversight - gain comprehensive insights into service requests, demand and resources, including personnel and tools • Resource delegation - promptly assign the right people and tools to the right location at the right time
• Schedule adjustment - quickly respond to changing requirements based on real-time understanding of availability, location and suitability of available resources • Dispatching processes - cost-effectively coordinate activities and resources while optimising resource utilisation
Len Harms - Vice President, Energy and Utility Practice, Vesta Partners (USA) Keynote Presentation: Change Management - Moving the Organisation an Inch
Organisations today are faced with a multitude of issues ranging from aging workforces to societal shifts in employee expectations. Woven into the fabric of the organisation experiencing these issues is the matter of change. Increasingly we need to recognise it’s not the technology or the process which dictate the challenges to change. It’s the people and their collective ability or inability to collaborate and create ground swells of enthusiasm for the change from the “middle out”.
With over 15 years of history of the Mastering SAP PM program in Australia and the SAP-Centric EAM program in North America there is plenty of intellectual property at your fingertips to draw on and leverage from in support of improving and making change within your organisation.
• Types of change • Management vs. leadership
• What’s the hardest SAP functionality to implement? • The stickiness factor
• Communities of practice and special interest groups • Perseverance to sustain the change
• Your tribe is awaiting a leader, could you be the one?
Norm Poynter - Business Analyst, Nexen, Inc. (Canada)
Current SAP release: ECC 6.0 Original go-live date: June 2002
Using “Mastering SAP Plant Maintenance” and the Community to Make the Most Out of Your SAP Investment
Mastering SAP Plant Maintenance is not just a conference. It is access to a vibrant and knowledgeable community of Maintenance, Support and IT and people who rely on SAP as a critical enabler in their organisations.
This session is designed to introduce you to the conference and its associated community. It will provide you with guidelines, tips and tricks about how best to utilise your three days to get the best possible return on your conference investment. Led by John Dwyer, the Chairman of the Australian SAP PM Conference Advisory Team who has been involved with the conference over its 15 years, the session will give you an overview to SAP PM and then point you towards specifics in the program so that you can:
• Leave with real solutions to business and technical problems • Hear what to do (and what not to do!) from other customers • Identify implementation tips and tricks
• Review and select solutions and services from SAP PM Partners • Get access to local and global SAP product experts
• Become part of a long lasting network for ongoing advice and knowledge
John Dwyer - Australian Conference Advisory Committee Chair for Mastering SAP Plant Maintenance & National Solution Leader (EAM), Oxygen Business Solutions (Australia)
Using Smart Business Intelligence Tools for Plant Maintenance to Provide Transparency
The City of Cape Town implemented SAP ERP in 2003 with the first line of reporting being via SAP standard reports. These reports work well for those transacting every day in the SAP PM module. However this is where the transparency ended for those not living in the system. The service delivery levels within the organisation could not be truly appreciated and understood. A cloud existed between what was happening in PM and what management, executive management and the politicians could see with regards to their ‘actual’ service delivery across the whole organisation. With the introduction of SAP’s BW solution, SAP’s BusinessObjects and SAP’s Strategy Management, the team was able to provide transparency across the organisation through to the highest level of management.
• Why we used BW - what advantages did we gain? • Using BW for PM where standard PM reports can’t
deliver
• BI reports for managing notifications in BW and custom SAP PM notification (ZPM08) reports • SAP’s BusinessObjects PM specific reports - ‘a
picture says a thousand words’
• SSM - SAP strategy management as a KPI for PM customer complaint notifications
• Future initiatives - MCB (Maintenance Cost Budgeting) in BW
Shaun van der Merwe - Principal Business Analyst, SAP Solution Centre - Logistics & PM, City of Cape Town
Current SAP release: ECC 6.0 Original go-live date: January 2003
12.35 Delivering One Version of the Truth with SAP Document Management - a Massive Time Saver
For years managing documents within the Sappi South Africa mills has had its challenges. Although the mills make use of their planning libraries, documents are often filed incorrectly. Indexing for “easy” retrieval is not updated and often looking for documents like pressure test certificates, crane load test certificates, fan performance curves, RCA documents, troubleshooting guides and quick fix routines among others proved to be challenging.
In 2007, we decided to explore the possibilities of implementing the SAP Document Management System (DMS) and at the same time, upgrade to ECC 6. Subsequent to the successful implementation at the Ngodwana Mill, DMS has been rolled out and implemented in the other six mills.
Implementing DMS meant that when a maintenance person is called out to a mill, he or she is able to open the PM notification and attached to the functional location, equipment or assembly, is a document icon, by clicking on the icon, the system will open up showing the Document Info Records (DIR) assigned to that specific functional location, equipment or assembly for easy retrieval. These documents were previously available but they first had to be found, costing time and money. The system worked so well for maintenance that it is now being used by other departments. Firstly, it was extended to procurement and is being used for storing contracts and procurement records and more recently to HR who are now uploading personal and medical records of every employee for the past 40 years.
Gary Ruttledge - Regional Plant Maintenance Systems Manager, Sappi South Africa
Current SAP release: ECC 6.0 Original go-live date: June 1996
TRACK A TRACK B TRACK C
Managing Engineering Risk with SAP Audit Management for Regulatory Compliance
One of the major focus areas and concerns for all legally appointed engineers is safety and compliance to regulatory prescriptions. In order to mitigate the risk of operating outside of the law and safety concerns in general, it is required to have structured processes and supporting systems in place. Few people are aware of the Audit Management Cross Application that is part of core SAP and how this module can be integrated with your existing SAP PM functionality to great effect. This tool integrates with PM Notifications where your existing work management process kicks in to complete the loop.
In order to effectively manage this process the following needs to be in place:
• Inspection schedules and audit programs which in some cases have long cycle times spanning months and years
• Detail instructions to personnel and 3rd parties on what and how often to inspect and perform audits
• Capture inspection feedback and audit findings • Generate corrective actions from feedback and
findings
• Reports for analysis and continuous improvement, progress tracking on corrective actions and highlighting of major risk areas You can learn how SAP Audit Management provides a complete solution for the engineer to manage risk and regulatory compliance. The solution can be used for all types of audits including PAS55 and System Integrity Audits.
Jannie Potgieter - Director Enterprise Asset Management, Collaborit
Tips and Tricks with Maintenance Plans
Maintenance plans have some of the most powerful and complex functionality in SAP Plant Maintenance. We tend to use them just to “pop out a work order to do a check every three months”, but they are capable of so much more. They can adjust the actual date of performing previous tasks, suppress minor checks when major checks are due, be triggered from measurements rather than just time, produce shutdown worklists, plan one-off post-commissioning inspections, reflect irregular operations in seasonal industries and so on. This presentation provides a solid overview of the functionality of maintenance plans and tips and tricks for the usage of that functionality in real world situations.
• Types of task lists and maintenance plans • Structuring maintenance plans and task lists • Scheduling of maintenance plans • What do those scheduling parameters do? • Some interesting things that can be done with
maintenance plans
• Reporting and analysis against task lists and maintenance plans
John Dwyer - National Solution Leader (EAM), Oxygen Business Solutions (Australia)
11.40
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Morning Tea & Coffee/Exhibition Viewing
11.00
Training and Documentation Basics - SAP Training and Development
With the rude awakening we have just had within our market (Global Financial Crisis), the first thing that companies downsize is their support services. Within a company that runs a CMMS, this usually means the training and documentation department. Now we are getting back on our feet and need to start looking to the future.
This presentation will help beginners or people new to training, by providing workable simple solutions and help on identifying training needs, developing training packages and integrating SAP training and business activities.
• Staff involvement and identifying training needs • Developing training packages
• Commitment to training
• Techniques and tools within one course • SAP quick wins and tips
Tim Swain - Operations Manager, Maintenance Systems Solutions Pty Ltd (Australia) Ensuring Shutdown Project Execution As It Was
Always Intended - SAP PM/PS Integration with Primavera
PetroSA required a solution to ensure the plant shutdown was executed within the allocated time, cost and resources. They were challenged to keep the mechanical completion of the shutdown within these constraints. The solution was not to replace SAP PM/PS functionality but to find a perfect fit to extend the work done in SAP to the scheduling tool. Primavera P6 and Inspire were chosen to provide the solution and the result.
• The journey from isolated tools to integrated bidirectional planning and scheduling
• Actual implementation of the solution (SAP PM, PS, PI, Primavera Inspire, Primavera P6)
• High level overview of the actual process that was implemented (SAP PM/PS > Interface > Primavera P6 > Interface > SAP PM/PS)
• bPortal - the technology to view it all (the SAP revision, the Primavera schedule, the status and what to do next)
• It worked for the shutdown - now for turnarounds and routine maintenance
This presentation will show you how SAP PM and PS can be extended with 3rd party tools to enable better scheduling and management of these activities. It will highlight how technology is used to provide planners, engineers and management with the different views they require.
Rubin Boer - Business Analyst, PetroSA
Current SAP release: R/3 4.7 Enterprise Original go-live date: June 1992
Tuesday 7 June 2011
Tea & Coffee/Exhibition Viewing
08.00
09.00 Keynote Presentation: SAP’s Roadmap for EAM - From Supporting Maintenance to Linking Assets to the Business
Best practice in doing asset management spans the whole lifecycle of a physical asset from cradle to grave. Challenges today lie in the accuracy of how your system represents what is going on in the enterprise, linking asset management policies and execution to the overall business goals. Still the efficiency of the maintenance worker is the other subject that requires attention. Based on the capabilities that have been delivered with Innovations 2010 the presentation will cover topics like:
• What is the next generation mobile offering from SAP?
• How does SAP Enterprise Asset Management support the implementation of PAS55? • What is the vision for integrating EAM with geospatial and technical information? • Why is asset data governance so important for workers safety and managing risk? • How can analytics support asset performance management?
Dr. Achim Krüger - Vice President, EAM Solutions, SAP AG (Germany)
10.00 Morning Tea & Coffee/Exhibition Viewing
“The Next Big Thing” or Just Another Thing? Asset Management Strategy and Standards
Aging infrastructure, need to improve reliability, increased demand for limited capital to meet these ever growing challenges, organisations need to create long term asset strategies with increased visibility to their portfolio of asset work, the resource requirements and the decision making process. Along with these challenges there is an increasing international consensus about required good practices in the management of physical assets and the creation of PAS55, the Publicly Available Specification reflects this trend. PAS55 is a published standard and is applicable to any organisation where physical assets are a key or a critical factor in achieving its business goals.
SAP Enterprise Asset Management has long been used to implement an asset strategy, this presentation will cover how you can create an asset management strategy in SAP and its alignment with PAS55, Section 4.3 “asset management strategy, objectives and plans”. One of the key solutions is Project and Portfolio Management (PPM). It is a comprehensive solution designed to improve the definition, balancing, approval and monitoring of activities, projects, programs and portfolios. Organisations use PPM to optimise and monitor portfolios related to asset investments, activities and projects.
• Create long and short term asset plans • Align the plans to corporate goals and strategies • Plan financial and human resources
• Manage the risk of a project portfolio related to assets
• EAM Audit and Maturity Model • What forms the basis of MCB in DPO • Requirements for analysis and continuous
improvement
Len Harms - Vice President, Energy and Utility Practice, Vesta Partners (USA)
10.40 Execute Shutdown Activities in SAP PM From the Outside Without Losing Any Data
Since implementing SAP R/3, scheduling constraints within SAP forced TSB Sugar to look for an alternative “tool” to manage large scale projects and shutdowns involving thousands of activities. Business requirements dictated that no historical data and information be jeopardised and for all analysis to be accessible in SAP PM. Using standard SAP we have tried various potential solutions with mixed success.
The chosen solution - remote installation of the pipeline transporter for MS Projects 2010 - provides high performance, enterprise-class SAP integration, making it quicker, easier and more effective as well as being very cost effective. The application integrates the business processes of project planning and ERP. The solution has since been implemented at all three of the TSB sugar mills.
• Previous potential options - tried with mixed success • The solution: remote installation of the Pipeline
Transporter for MS Projects 2010 • Comprehensive out of the box solution (SAP
compliant)
• MS Project for scheduling and reporting • End user feedback and the way forward
Leon van der Merwe - Planning Officer & SAP PM Super User, TSB Sugar
Current SAP release: ECC 6.0 Original go-live date: April 1996
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Sweating Your Existing SAP Investments - SAP Document Management for Plant Maintenance
Since inception, SAP R/3 has had a SAP DMS solution that is a world-class, fully functional and modern content management system that delivers all the necessary controls. The biggest advantage of using SAP DMS is significant business productivity and operational improvements. The implementation of a SAP DMS solution will also mean that there will be further entrenchment of the SAP ERP solution within the existing business processes.
Effective plant maintenance requires access to information in documents - drawings, specifications, photos, work instructions etc. Getting hold of the right documents is often a painful and time consuming challenge for the maintenance planner. However, not being able to give the right documents to the artisans can lead to a huge increase in operational and safety risks and cost. So, how does your organisation address this issue? Integrating SAP’s Plant Maintenance and Document Management systems with a document printing facility solves this problem elegantly and delivers real business value.
The presentation will highlight the standard functionality of SAP DMS, how customised enhancements can be implemented, business integration into the PM environment, the commercial advantages of utilising the SAP DMS and how 3rd party applications can be integrated into SAP DMS. • Standard SAP DMS functionality
• Business integration for plant maintenance • Managing drawings in SAP DMS
• Implementation of Cideon Document Output Management at Kumba
• Managing drawings for quality inspections during receiving items from a vendor
• Managing output of job cards
Dolf Engels - Solution Analyst for Anglo American, Sishen Mine, Kumba Iron Ore & Warren Buss - ECM Solution Manager, Nokusa Engineering Informatics
Current SAP release: R/3 4.7 Enterprise Original go-live date: June 2007
16.10 Afternoon Tea & Coffee/Exhibition Viewing
Guest Keynote Presentation: Bob Skinstad
16.40
Mastering SAP Plant Maintenance Community Networking Drinks Sponsored by
17.40
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Basic Fundamentals of Asset Management at the Water Corporation - Is it Really All That Complex?
At the Water Corporation SAP PM is their primary asset management software tool. The ability to store and retrieve data from SAP has been a continual focus for the organisation and is still evolving. Since implementing SAP they have been constantly improving and enhancing the processes and the data quality required for good asset management. This has been done in order to minimise the whole of life costing of assets while at the same time maximising the service levels of all assets.
This presentation will discuss some of the lesser known tools that the Water Corporation use to improve the asset life cycle management process.
• Typical asset management questions that a utility is faced with and role of traditional asset management methodologies
• A discussion of the basic functionality in SAP. What has worked and what has not?
• An overview of Asset Condition Assessment (ACA) processes and Asset Risk Assessment (ARA) • How using evolving technologies, such as SCADA can
improve the knowledge cycle
• Data integrity - the never ending journey! • Reporting - a discussion of their evolving reporting
capability
• The people side of the story - issues faced along the way and what they are currently working towards • Where to next for the Water Corporation - what are
the next steps in the journey?
Greg Rimmer - Process Manager, Plant Maintenance & Mobile Computing, Water Corporation of WA (Australia)
Current SAP release: ECC 6.0 Original go-live date: November 1998
15.20 SAP PM Master Data - Physical Asset Management’s Friend or Foe?
Since implementing SAP R/3 in 1998, system and business process showed varying degrees of integration success. In early 2000, Exxaro Resources Limited (then Iscor Ltd) was on a learning curve with respect to SAP R/3 and physical asset management process. In 2006, it was clear that physical asset management could only reach its full potential by ensuring that master data formed the foundational building blocks.
During this same time Grootegeluk Coal (subsidiary from Exxaro) took the lead and drafted a master data game plan by involving SAP power users and maintenance senior planners. Since 2009 we have adopted the SAP PM Master Data standard at 13 business units known as the “Exxaro Way”.
• How to go about formulating a master data standard • Insight into managing master data to enhance
sustainability
• Assigning the correct accountability and performance recognition
• Use of 3rd party independent auditors to show compliance
• Further enhancements - improvement of change management control
The presentation will highlight the success experienced with the physical asset management process
environment with SAP PM Master Data as the back bone, such as planning and scheduling, shutdown management, tactics and materials management forecasting.
Paul J Grobler - Senior Engineer, Physical Asset Management, Exxaro Coal (Pty) Ltd
Current SAP release: R/3 4.7 Enterprise Original go-live date: August 1998
Simplifying Planning and Scheduling Within SAP
Improve your scheduling capabilities and learn new ways to simplify planning using the SAP PM module. Discover how to organise and assign tasks quickly and accurately, interpret and analyse large amounts of work order data using a single screen and complete all SAP scheduling tasks using the drag and drop functionality. • Create turnarounds and weekly schedules graphically • Level workload based on work centre or individual
capacity
• Prepare schedules and work packages in PDF format to easily print and/or distribute
• Update order and operation status and masse vs. one at a time
• Create task lists from existing orders
• Chart weekly schedule compliance without a spread sheet
An on-line demonstration will show the available functionality within the SAP Plant Maintenance module.
Dana Jordaan - Senior Project Manager, Prometheus Group
Nuggets of Gold - Unearthing the New EAM Functionality in SAP ERP 6.0
SAP introduced the concept of enhancement packages with the release of SAP ERP 6.0. This presentation will give a summarised overview of the new functionality in the enhancement packages (EhP) and focus on 3 “nuggets”.
• Overview of new functionality in the enhancement packages
• Operator and Inspection Rounds (EhP4) • Shift Notes and Shift Reports (EhP3/5) • Rotables Management (EhP4)
The presentation will highlight the new functionality including tips on how to get further detailed information.
Dean Fitt - SAP Solution Manager, SAP AG (Germany)
14.25 From Office to Shop Floor - SAP PM Scheduling on the Planning Board to Increase Maintenance Productivity for Artisans
It is a standard requirement by Rio Tinto that scheduled tasks must be executed through the planning board in SAP. The planning board is a tool that highlights resource loading, providing the scheduler with the visibility to view over and under allocations of hours.
• Maintaining work centres and HR structure interface
• Scheduling using the planning board • Optimising scheduling and linking of PRT • Measuring scheduling compliance • Learning and outcomes
Bob Govender - Specialist: Maintenance Support, Richards Bay Minerals
Current SAP release: R/3 4.6C Original go-live date: January 2003
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Enterprise Asset Management - Defining the Way Forward for a New Generation
The traditional paradigm of plant maintenance has changed to Enterprise Asset Management and there are many new buzz words around like asset care, PAS55 and Overall Equipment Effectiveness (OEE). During this presentation Britehouse will shed some light on some of the technologies including mobility, MII, BI and cloud. Challenge your traditional thoughts and views around this age old topic and define the new ‘awesome’.
• Traditional thinking • Modern talk • Equipment to BI
• Integrating traditional SAP modules, MII, BI and mobility
• Jump the maturity curve
Andrew Fisher - Program Manager and Strategic Account Manager, Britehouse
Mastering SAP Plant Maintenance
2011 | 15
www.masteringsap.co.za/pm
Navigating an Ocean of Master Data - Staying Afloat in a Distributed Electricity Asset Environment
Enterprise Asset Management (EAM) has been identified as a strategic initiative for service delivery in the City of Cape Town. Historically, very little time was spent on proper master data structuring and cleansing, with a knock-on effect on the system. This presentation shows the journey and lessons learnt on the way to a sustainable EAM master data foundation and in particular takes a hard look at master data tools, data capturing responsibilities and trade-offs during master data design stages. • The business case for master data restructuring,
clean-up and data governance
• Master data design and agreeing on standards, including classification
• Organisational challenges
• Masterkey tool and SAP workflow to enforce master data integrity
• Beyond the foundation stage
Martin Aldrich - SAP PM Integration Specialist, City of Cape Town
Current SAP release: ECC 6.0 Original go-live date: January 2003
11.35 SAP PM Maintenance Cost Budgeting - From Zero to Hero
Before the implementation of SAP R/3 in 1998, Exxaro (then Kumba Resources) did maintenance cost budgeting based on activity and history. This meant gathering information from several sources to enter into a specially written Visual Basic program. The calculations of the activities and remaining life had to be done in the MES (My Excel Spreadsheet) and due to manual intervention, it was always prone to mistakes. The process used to budget on this legacy system, however, was well defined and that gave them the necessary direction in developing MCB in SAP. During the original SAP implementation phase the team realised the opportunity in SAP to budget from history and activities. This fitted in with what Exxaro tried to achieve in the old legacy system and for the first time a budget could be realised based on a maintenance plan. Grootegeluk Coal (subsidiary of Exxaro Resources) took the lead to start developing DPO (Dynamic Planning and Optimisation) in SAP R/3 3.1. DPO is not only a maintenance cost budget development, but also includes HR and PP. Other business units were also used extensively to help define the solution and processes. • What forms the basis of MCB in DPO?
• Insight into managing MCB to enhance sustainability • Advantages of implementing DPO
• Enhancements of DPO
• Further enhancements - in SAP ECC 6 • Why not SAP standard MCB?
The presentation will highlight the development of DPO, the successes, the shortcomings (which we believe can be addressed in SAP ECC 6 and BPC) and our vision for DPO in the SAP ECC 6 environment.
Hendrik du Plessis - Senior Solution Specialist, Physical Asset Management, Exxaro Coal (Pty) Ltd
Current SAP release: R/3 4.7 Enterprise Original go-live date: August 1998
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Process Safety Information - Integrating to SAP
The secret is out; we’ve all become information managers! There was no fighting the integration - a simple maintenance work order could create all flavours of chaos in FI/CO if not done properly!
And just think about the reporting aftermath! Where does it start? From the first idea, concept, or Design Basis Memorandum (DBM) and we all know it becomes increasingly complicated.
Not recognising the magnitude and complexity of the data, the documents and drawings in your organisation being generated, allows risk to creep in. If they are not woven together by common denominators (addresses) information management becomes an even greater challenge.
Data errors and inconsistencies become most apparent during handover and operations readiness as owners load SAP Master Data and deploy operations and maintenance systems.
At this phase though it’s too late! Your Process Safety Information is at risk and going back is an arduous if not impossible task. Process Safety Information is inherently necessary during all phases of a facility lifecycle. This presentation will explore approaches to better utilising SAP and 3rd party tools to ensure a single access point for Process Safety Information.
• Improved asset data integrity
• Enabling operations integrity management • Improving plant safety and reliability and ensuring
regulatory compliance
Norm Poynter - Business Analyst, Nexen Inc. (Canada)
Current SAP release: ECC 6.0 Original go-live date: June 2002
13.25 Using SAP Plant Maintenance to Define Maintenance Processes and Help Embed Systemic Change
Prior to 2005, planned maintenance was very fragmented at Lonmin and only a small part of the business even used a CMMS at all or actively practiced proactive maintenance activities. Lonmin then rolled out SAP, including the PM module. In order to derive the benefits of having SAP PM offered and to establish a stable PM platform, a fundamental organisational, cultural and resource shift was required.
This presentation will show how SAP PM became the agent of change and helped to create and shape the planned maintenance landscape at Lonmin, especially at a process division level. SAP PM on its own will not create sustainable change in any business unless it is supported by a clear vision, charter, plan, organisation and appropriate resources. Five years on, the value of SAP PM and its interaction with the SAP Materials Management (MM) module has started to bear fruit and show the promise envisioned in 2005. SAP PM provides a very structured landscape within which a maintenance intensive business can ensure the running of proper asset management programs for the full life cycle of the business.
• Engineering leadership to embed change • Creating an enabling environment between the
vision and the execution • Direct training interventions • Technical aspects • Planner competency
Riaan Blignaut - Business Process Owner, Lonmin Mines
Current SAP release: ECC 6.0 Original go-live date: October 2005
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12.25 Lunch/Exhibition Viewing
Linear Asset Management and Operation Account Assignment with SAP EAM
This presentation will focus on the new and enhanced functionality for Linear Asset Management (LAM) and Operation Account Assignment (OAA) that were shipped with SAP ERP 6.0 Enhancement Package 5. The new LAM functionality will allow users to define an asset e.g. roads, pipelines and rail tracks, in terms of linear attributes like start point, end point, length, unit of measure and to assign perpendicular and vertical offsets. These attributes will also be part of orders, notifications, maintenance items and measurement documents so that when work is performed on a linear asset, like repairing a section of pipeline, the work and cost involved in that repair is attributed to the specific segment of the asset rather than the entire asset. With the OAA functionality, the costs associated with orders can be assigned and reported at the operation level of the order.
• Linear asset modeling
• Inspection and work management for linear assets • Reporting for linear assets
• Operation account assignment
Dean Fitt - SAP Solution Manager, SAP AG (Germany)
Integrating SAP with Reliability Assurance Methods - Putting Research Into Practice
Research (Ledet, 1994) shows that to be effective in asset management, capital intensive organisations need to be good at planning and scheduling and should have a good and focused PM program. Companies that are good at data collection excel and use this information for their benefit. This fast pace presentation will explore SAP in this regard and discuss its strengths and weaknesses.
• Explore the four quadrants of reliability assurance and the research done in this area
• Understand how SAP can be used to apply these four quadrants
• Learn from experience about what works and where the traps lie
• Examine some case studies that illustrate the benefits
This presentation is full of tips and simple approaches that can be implemented the day you return to work. The benefits of simplicity cannot be overstated in this endeavour.
Steve Turner - Founder and Director, OMCS International (Australia)
Stick to Your Blueprint - Sustaining SAP PM Over a Decade at Samancor Chrome
Middelburg Ferrochrome has successfully run SAP PM since going live in November 2001. The SAP PM system is well entrenched in the way that the maintenance teams do their work in the plants. The current work management flow diagram is still the original that was drawn up at the implementation stage, with only minor changes since then.
Bet you’re wondering how we achieved this!!! Discover how we created an understanding of the SAP PM tool and the development of the work management flow diagram. We will explore the change management process that we went through before and after ‘go live’. By applying the common agreed method of structuring the maintenance management through SAP PM, both the mines and smelters in Samancor Chrome, have been able to gather the cost to operate per functional location, improve budgeting and measure labour or external service effectiveness.
• Sustaining our SAP PM discipline and working at this discipline for over a decade
• Providing artisans with the tools to close the loop - through directly feeding back via PC’s placed in the workshops (and alternative methods of achieving the same outcome)
• Changing and entrenching our culture with strong leadership and sticking to our guns
• Constant discussion and review of the business processes by system specialists
• Picking up on planned maintenance reports and having expert persons driving the understanding of the relationships between the measures.
Donald Grant - Engineering Manager, Samancor Chrome
Current SAP release: ECC 6.0 Original go-live date: Dec 2002
14.20 Principles for Effective Shutdown Management: Minimising Complexity and the Role of SAP
One of the questions often encountered when looking at shutdown management is when does the shutdown management process apply? There is no definitive answer to this question, however in general the process applies to events where the site management team deems that the event is not part of the normal routine, weekly or monthly maintenance and should be managed using the process.
One of the key principles for effective shutdown management is to minimise complexity. In many operations there is a tendency to defer maintenance work for the next shutdown and then try and include as much activity into the shutdown event as possible. This often results in failure to meet cost and duration goals, poor health safety and environmental performance and significant waste.
In theory all the identified work should already be captured in the CMMS and this step is simply grouping together all relevant work orders into a shutdown event. This is usually done using a revision in SAP. Often the Shutdown Manager will also need to actively seek information from condition monitoring reports, engineers, operators and maintainers. The Shutdown Manager should also arrange a pre-shutdown inspection of all shutdown items. When this inspection is carried out it should be done with representation from both maintenance and operations teams. The methodology described in this presentation focuses on identifying the critical work that must be done during the shutdown and managing that work well. • Identifying the critical work
• SAP work packages integration in flowed critical path gantt charts
• Manage the shutdown schedule • History in the CMMS
• Post shutdown reviews and capturing key learnings
Peet van Rensburg - Superintendent Maintenance Planning, Phalabora Mining Company
Current SAP release: R/3 4.6C Original go-live date: June 2002
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Driving Integrated Business Performance Reporting
A primary challenge facing Anglo American was the need to improve reporting and particularly the need to have greater visibility of composite performance indicators in SAP. One of the issues was around standardised definitions, as many of the metrics were based in different systems. In addition, organisational silo’s with their own definitions of performance exacerbated the problem.
A proof of concept project was initiated to enable Overall Equipment Effectiveness (OEE) reporting for the Mogalakwena Mine, Open Pit Area. The concept project was successful and is being rolled out to other Anglo American business units using SAP. From a technical perspective SAP MII was used together with Modular Mining (Powerview) and SAP ERP and the output was reports in BOBJ Xcelcius.
• Project implementation experiences • Demonstration of the system • Lessons learnt
• Future implementation considerations
Ernest Stonestreet - Principle Engineer Asset Management, Anglo American Group Mining and Technology
Current SAP release: ECC 6.0 Original go-live date: April 1999
15.10 Afternoon Tea & Coffee/Exhibition Viewing
15.50
Mastering SAP Plant Maintenance Conference Close
17.00
Closing Keynote Presentation: Getting SAP PM to Work for Your Users - The Story of Our User Interface Journey
The Water Corporation of WA implemented SAP in 1998 and quickly recognised that the system interfaces for basic functionality like creating and managing work orders and notifications had to be streamlined. An important issue was to make this system easy to use right from day one.
How do you manage 1200 work orders/notifications on a daily basis in SAP PM without a lot of people to drive it? How do you ensure that your most important work is being done? See one way that this can be done in the SAP PM environment.
• An overview of the Water Corporation and the PM work management problem
• The journey - a description of each of the phases that the Water Corporation went through as the solution evolved into the current process and tool sets • An overview of the main interfaces that people use
• Typical work management scenarios and their management • The benefits of enhanced user interfaces
Greg Rimmer - Process Manager, Plant Maintenance & Mobile Computing, Water Corporation of WA (Australia)
Current SAP release: ECC 6.0 Original go-live date: November 1998
