Jeremy carson nz oracle user group presentation an overview of enterprise asset management
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This document provides an overview and summary of Solid Energy's implementation of Oracle eAM for enterprise asset management. Some key points: - Solid Energy is a large New Zealand coal mining and energy company with over 1,200 employees and 600 contractors managing many production assets. - They implemented Oracle eAM in 2003 and have since configured it for 6 sites to manage over 15,000 work orders, 2,000 assets, and 4,000 preventative maintenance activities annually. - Critical aspects of the implementation included developing a taxonomy document, detailed solution design, asset model configuration, and extensive maintenance staff involvement to ensure adoption. - Key benefits have been a single maintenance system, better integration with stores, comprehensive asset
Jeremy carson nz oracle user group presentation an overview of enterprise asset management
- 1. Introduction to Oracle eAM (Enterprise Asset Management) and our implementation experiences Jeremy Carson Applications Manager
- 2. CMMS - Computerised Maintenance Management System Point Solution e.g. Maximo, Mexx or ERP Integrated Solution e.g Oracle E-Business Suite, JDE, Peoplesoft or Other e.g. Excel
- 3. What do you have ? ?
- 4. Agenda • Solid Energy Overview • Key Configuration Steps • Asset Model • Maintenance Tasks • Work Management • Preventative Maintenance • Cost Management • Key experiences • Questions ?
- 6. Solid Energy Overview – Energy Business • Coal - Steel Production (Export / NZ Steel) Electricity Generation (Genesis) - Domestic Industries (Fonterra / Holcim / Alliance / Silver Fern) • Renewables – Wood pellets / Biodiesel / Solar • New Energy – Coal Seam Gas, Coal to Fertiliser
- 7. Solid Energy Overview - People • Approx 1200 employees nationwide, predominately in the Waikato, South Island West Coast and Southland • Approx 600 directly employed contractors
- 8. Solid Energy Overview - Assets • An asset intensive business • High focus on Health and Safety • High focus on availability and utilisation of assets • Predominately Mobile and Fixed Plant assets
- 9. Solid Energy Assets - Trucks
- 10. Solid Energy Assets - Excavators
- 11. Solid Energy Assets – Conveyors
- 12. Solid Energy Assets – Underground Miners
- 13. Solid Energy Assets – Water Treatment Plants
- 14. Solid Energy Assets – Train Loadouts
- 15. Solid Energy Overview – Our eAM Install • Have used Oracle eAM since 2003 as an early adopter on Oracle EBusiness Suite 11.5.7 • Now using Oracle E-Business Suite 12.0.6 • Currently have 6 live Oracle eAM sites/organisations • System Statistics - 15,000+ work orders per annum 2000+ maintained assets 4000+ preventative maintenance activities 5000+ maintenance purchase requisitions per annum 10000+ maintenance inventory issues per annum
- 17. Configuration Steps – Taxonomy document • As part of solution design create a Taxonomy document, which defines; • eAM organization parameters e.g. default WIP Accounting Class • Key lookups e.g. Areas, Departments, Categories • Define standards and naming conventions for key setup areas - Asset Model e.g. Asset Number/Groups/Hierarchy/Categories - Maintenance Tasks e.g. Activities, Activity Type/Source/Cause - Work Management e.g. Work Order Type/Status/Priority - Preventative Maintenance e.g. Meters, Schedules • Taxonomy must understand system limitations e.g. Asset Number must be unique • Taxonomy is a living document…refine with subsequent implementations • Successful taxonomy makes system intuitive for users
- 18. Configuration Steps – Solution Design document • Document how Oracle eAM will deliver each business process e.g. Asset Breakdown to Work Order creation • Swim lane the business process across business roles e.g. maintenance, procurement, stores • Detailed application mapping to requirements for each process step • Review regularly and iteratively with key maintenance personnel • Develop Proof of Concepts to assist with design validation and acceptance
- 19. Asset Model
- 20. Asset Model - Asset Numbers • • • • Asset Numbers are the key entity in eAM Mostly represent physical assets Can be virtual assets in asset hierarchy for roll-up/grouping Assets are setup either as a; - Capital Asset or - Rebuildable Inventory Components which rotate on/off Capital Assets and are repaired/refurbished in between. • Asset Numbers exist in separate register (using Oracle Install Base) than the Fixed Asset register • Asset Numbers can be linked to a single Fixed Asset Number TIP: Asset Numbers must be unique through the system Consider physical asset naming and common sites names
- 21. Asset Model - Asset Number screen
- 22. Asset Model - Asset Number screen
- 23. Asset Model - Asset Groups • Each Asset belongs to an Asset Group • Many key configurations driven by Asset Group - Asset Bills of Materials – Typical materials used for maintenance - Templates – Provides automatic creation of Preventative Maintenance configuration e.g. Activities, Meters, Schedules - Asset Attributes – Storage of additional asset information - Failure Analysis – Failure, Cause and Resolution • Define groups to represent virtually identical assets, in terms of materials and preventative maintenance e.g. Make and Model combination. TIP: Asset Groups must be unique through the system
- 24. Asset Model - Asset Groups screen
- 25. Asset Model - Asset Hierarchy • Assets belong in a hierarchy • Each Asset has a Parent Asset • Establishes a roll-up mechanism for; - Cost reporting Preventative Maintenance forecasting Searches Maintenance and failure history • Virtual assets at top of hierarchy to deliver meaningful rollups; - Production or process affinity - Geographical or physical location
- 26. Asset Model - Asset Hierarchy screen
- 27. Asset Model - Summary
- 29. Maintenance Tasks - Activities • Activities are predefined Maintenance work to be completed • Generally routine work e.g. exchange pump, replace tyres or preventative maintenance work e.g. services / inspections • Activities define the following - Tasks – More detailed tasks of the predefined work - Bills of Materials – Required materials - Routings – Required labour or equipment - File attachments – Such as service sheet, diagrams, safety procedures • Create Activity Association Template to associate to an Asset Group or associate to an individual Asset
- 30. Maintenance Tasks – Activity Association screen
- 31. Work Management
- 32. Work Management – Work Requests • Simple interface to capture reactive Maintenance work • Can go through approval process, then be assigned to Work Orders
- 33. Work Management – Work Requests
- 34. Work Management – Work Orders • Work Orders represent specific instances of Maintenance work for an asset • Created in the following ways; - Manually i.e. unplanned / corrective work - Automatically by Preventative Maintenance forecast - Automatically from Condition Based monitoring (via Oracle Quality) • Work Orders record maintenance history and planned and actual costs • Work Orders must have; - Asset associated - One or more Tasks i.e. Operations - Scheduled Start / End Time • Work Orders can have; - Predefined Work assigned i.e. Activity - Material requirements i.e. Stock, Non Stock, Requisitions - Labour requirements i.e. Trade resource
- 35. Work Management – Work Orders screen
- 36. Work Management – Work Orders screen
- 37. Work Management – Completion • Completion updates Last Service information e.g. 250hr service completed at 12,500 hrs on 01-Feb-2010 • Prevents further costs being coded to the Work Order • Captures the following information; - Actual Start and End time - Job Notes - Failure Analysis
- 38. Work Management –Completion screen
- 40. Preventative Maintenance - Schedules • Define when activities should occur for an Asset or Asset Group • Defined to occur by; - Date Rules – every 7 days - Meter Rules – every 50 hours, 10000 km’s - List Dates – on 01-Jan-2011 • Work forecasts from Last Service Information i.e. when activity was last completed for the asset - Date Rules – on 01-Jan-2010 - Meter Rules – at 2000 hours - Combinations of the above • Single definition can schedule multiple activities which share a common base interval • Schedules can include suppression e.g. 250hr service suppresses 50hr service if its forecast within 20 hours of it
- 41. Preventative Maintenance – Schedules screen
- 42. Preventative Maintenance - Meters • Meters used to schedule activities • Ascending meters e.g. kilometres, hours • Fluctuating meters e.g. temperature, pressure, vibration • Meter hierarchies allowing parent meter to increment children e.g. truck hours increments rim hours
- 43. Preventative Maintenance – Meters screen
- 44. Preventative Maintenance - Forecasting • Forecasting generates Work Orders as per schedules • Forecasts for a specified maintenance window e.g. next 14 days • Can perform online or as a concurrent program • Can selectively forecasts groups of assets
- 45. Preventative Maintenance - Forecasting
- 46. Preventative Maintenance - Summary
- 47. Cost Management
- 48. Cost Management – WIP Accounting Class (WAC) • WIP Accounting Classes (WAC) define accounting rules • Single GL accounts defined for Material and Resource transactions • Limited capability for complex accounting requirements • Default WAC for Organisation • Can be superseded by WAC configured against the at Asset, Activity or Work Order
- 49. Cost Management – Actual to Planned Costs • Planned Costs built up on Work Order using - Materials – Defaulted from Activity BOM or manually requested - Labour – Defaulted from Activity Routing or manually requested • Actual Costs accumulate on Work Order from - Stores inventory issues to Work Order - Purchase requisition (Direct Item) receipts - Maintenance Resource transactions - Invoice Price Variances (PO Matching) • Cost Analysis can then be performed in multiple ways, such as; - Asset using Hierarchy - Work Order - By Activity
- 50. Cost Management – Work Order costs
- 51. Key experiences
- 52. Key Experiences – What we have achieved • A single maintenance system throughout the organization • Better integration between stores and maintenance • Comprehensive asset and component history • Focus on preventative maintenance, driving better asset reliability • Better management of maintenance workload • Standardised asset information and maintenance procedures • Ability to analyse asset and maintenance department performance
- 53. Key experiences – Maintenance Staff Involvement • Maintenance staff involvement essential throughout implementation lifecycle • Creates required buy-in for successful business transition and adoption • Select “right” person carefully - Positive / Seeks improvement i.e. this is something new, but we should use - Resilient / Can do attitude i.e. that not ideal but we can make it work - Well Respected i.e. will lead others to accept solution and advocate it • Ensure the maintenance team is well trained and supported once live
- 54. Key experiences – Data load • Data load is manual, complicated and time consuming • Limited open interfaces - Items (Asset Group, Activities) / Asset Number / Meter Reading • Now several more APIs in R12 - Maintenance Object (Asset Number) / Activity / Preventative Maintenance • We have built custom Excel templates and used DataLoad utility • Have final dataset loaded for UAT, you will get many useful “corrections”
- 55. Key experiences – Reporting • Standard reports are “limited” • Develop a custom Work Order, probably in BI Publisher now • Develop suite of reports to meet user requirements • We developed Discoverer reports, some examples; - Asset Hierarchy / History / Availability Asset / Work Order costing – by Hierarchy Asset / Work Order Material Requirements Asset Failure Analysis Key Performance e.g. Planned Versus Unplanned, Maintenance backlog Configuration reports e.g. BOMS, Activities, Schedules • Other off the shelf options worth investigating - Oracle eAM Daily Business Intelligence - Vizaya WorkAlign® Analytics - Signum EAM Analytics™
- 56. Key experiences – Reporting
- 57. Key experiences – Subledger Accounting • “Get around” limitation of single material and labour GL accounts • We use Subledger Accounting to re-code; - Expense Account – Based on Item/PO Category - Asset Account – Based on Flexfield held against Asset Number • Not too complicated once you have a working prototype • Use some consulting initially to get initial setup working
- 58. Key experiences – Usability • Release 12 Self Service is a dramatic improvement • Maintenance Supervisors can work solely in Self Service • Personalisation can de-clutter Self Service • Consider customisation for “pain points”
- 59. Questions ? • Ask now if we have time • Come see me afterwards • Email me after the conference jeremy.carson@solidenergy.co.nz