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: [Link]
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
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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
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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
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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
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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
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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
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Summary
Enterprise Asset Management: Your Benefits
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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
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Key Customers
SAP AG 2003, Asset Life-Cycle Management, Speaker Name 72
