Shutdown Scheduling

Draft

BASIC PRINCIPLES OF SHUTDOWN
SCHEDULING IN SAP

______________________________________________________________________

Printed: February 5, 2011
/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.doc
Last Modified: 2/3/2011 01:07:00 AM Draft

Gentile Consulting Inc.

Table of Contents
1.0Purpose 2

2.0Scope 2

3.0Discussion 3

4.0Summary/Conclusions 12

1.0 Purpose
The purpose of this document is to introduce the concepts and techniques required to
effectively schedule shutdown work entirely within SAP. It is not intended to be a step by
step instruction manual. Specific business processes are developed in detail for each
organization however, it is important for everyone to understand the concepts involved and
how their everyday activities affect the schedule. Using SAP will allow live real-time
schedule reports and status to be available to everyone with access to SAP.
2.0 Scope

This document will cover the following topics:

• Why it is necessary to schedule work in SAP
• Introduction to the “WINDOWS” concept of scheduling.
• Introduction to SAP “Networks”
• Integration of SAP Networks and Work Orders to create a schedule.
• Introduction to on-line reports for all levels of the organization.

Printed: February 5, 2011 2

Last Modified: 2/3/2011 01:07:00 AM


3.0 Discussion

Why schedule in SAP

SAP is a fully integrated software system in which various modules share a common
database. This means that the information that a planner puts on a work order provides
data that is used by all modules of the program. The system will automatically order parts
and services, make demands on work groups resources, provide input to the financial
planning groups, all based on the dates of the work order operations.

If the dates on the work order are incorrect, the basic functionality of SAP is diminished
and the company cannot realize the improvements and benefits it expected when it made
the investment in SAP. Incorrect dates on the work order will supply incorrect data to all
the modules seen below.




The “WINDOWS” concept of scheduling

Window scheduling is a technique that is used by many industries regardless of the
scheduling tool being used. Consider the following sequence of events.

Reduce Steam Demand to Secure Boiler Feed Pump Reduce Steam Demand to
50% #1 10%

Boiler Feed
Pump #1 Work
Window

Secure Main Steam Header Hydro Main Steam Header Increase Steam Demand to
Start Boiler Feed Pump #1
#1 #1 50%

The scenario in the above illustration describes reducing the output of a boiler to facilitate
the hydrostatic testing of a steam header. The “Work Window” depicted in red is that
period in time when #1 Boiler Feed Pump is available for maintenance without effecting
the overall duration of the hydrostatic testing evolution.




Project Systems Networks

A network is a structure the Project Systems module that contains specific work
instructions similar to the work order in the Plant Maintenance module. These work
instructions are referred to as activities. The network activities may be logic tied and
scheduled. A simple network is illustrated graphically below.




Subnetworks

It is possible to add more details to your network by creating subnetworks to
network activities. In the example below a project network was created with the
high level network consisting of design, installation and closeout activities. More
detail was added by adding a subnetwork to the installation activity.

You can use subnetworks to refine and detail your networks as planning
progresses. You create subnetworks by breaking down a network activity into one
or more subnetworks. The system treats subnetworks and networks the same, that
is, you can plan dates, capacities, costs, materials and production resource/tools
also with a subnetwork.




Network Activities

Network Activities are discrete tasks similar to work order operations with the following
characteristics:

• They have duration.
• They have a defined start and a defined finish.
• Resources are needed to execute them.
• They incur costs.
• They are worked without interruption.

There are the following types of activities in Project Systems:

• Internal processed activities (work performed by internal employees)
• Externally processed activities (work performed by external employees)
• Primary costs activities (activity costs that are expected to arise through the
consumption of goods and services that originate from outside the company




Integration of SAP Networks and Work Orders

PM work orders can be linked to any network or subnetwork activity. When they are
linked the dates on the work order will be derived from the activity date. When the
network is scheduled all work orders attached will also be scheduled. This allows
scheduling personnel to maintain the dates of many orders at once by using a single
transaction.

Operative Network
Operative Network

Sub Networks
Sub Networks

PM Orders
PM Orders




Project Systems Reporting

Now that the PS and PM modules are linked through the networks reports
can be generated through the PS module that can be used by all levels and
departments in the organization via a single source. Illustrated below are
some reports generated by the system.

Gant Charts




Work Center Schedules

Material Reports




Real Time Cost Reports




Hundreds of reports involving all work groups can be generated from a
single transaction in the PS module. Any report generated by external
scheduling software can be duplicated in SAP.

4.0 Summary/Conclusions

The integration of the PS and PM modules will provide a scheduling capability
previously impossible in the company. This scheduling capability will require little or
no input from the individuals performing the work since all schedule updates occur
through the already implemented conformation process.

The critical success factors involved in this process are:




• All work planned and managed within SAP (Capital, Maintenance,
Operations)
• Work orders must contain detailed planning
• Accurate and timely confirmations of all operations



Shutdown Scheduling

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