Shutdown Scheduling


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Shutdown Scheduling

  1. 1. Draft BASIC PRINCIPLES OF SHUTDOWN SCHEDULING IN SAP ______________________________________________________________________Printed: February 5, 2011/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM Draft
  2. 2. Gentile Consulting Inc.Table of Contents1.0Purpose 22.0Scope 23.0Discussion 34.0Summary/Conclusions 121.0 PurposeThe purpose of this document is to introduce the concepts and techniques required toeffectively schedule shutdown work entirely within SAP. It is not intended to be a step bystep instruction manual. Specific business processes are developed in detail for eachorganization however, it is important for everyone to understand the concepts involved andhow their everyday activities affect the schedule. Using SAP will allow live real-timeschedule reports and status to be available to everyone with access to SAP.2.0 ScopeThis 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/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  3. 3. Gentile Consulting Inc.3.0 DiscussionWhy schedule in SAPSAP is a fully integrated software system in which various modules share a commondatabase. This means that the information that a planner puts on a work order providesdata that is used by all modules of the program. The system will automatically order partsand services, make demands on work groups resources, provide input to the financialplanning 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 diminishedand the company cannot realize the improvements and benefits it expected when it madethe investment in SAP. Incorrect dates on the work order will supply incorrect data to allthe modules seen below.Printed: February 5, 2011 3/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  4. 4. Gentile Consulting Inc.The “WINDOWS” concept of schedulingWindow scheduling is a technique that is used by many industries regardless of thescheduling 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 facilitatethe hydrostatic testing of a steam header. The “Work Window” depicted in red is thatperiod in time when #1 Boiler Feed Pump is available for maintenance without effectingthe overall duration of the hydrostatic testing evolution.Printed: February 5, 2011 4/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  5. 5. Gentile Consulting Inc.Project Systems NetworksA network is a structure the Project Systems module that contains specific workinstructions similar to the work order in the Plant Maintenance module. These workinstructions are referred to as activities. The network activities may be logic tied andscheduled. A simple network is illustrated graphically below.Printed: February 5, 2011 5/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  6. 6. Gentile Consulting Inc.SubnetworksIt is possible to add more details to your network by creating subnetworks tonetwork activities. In the example below a project network was created with thehigh level network consisting of design, installation and closeout activities. Moredetail was added by adding a subnetwork to the installation activity.You can use subnetworks to refine and detail your networks as planningprogresses. You create subnetworks by breaking down a network activity into oneor more subnetworks. The system treats subnetworks and networks the same, thatis, you can plan dates, capacities, costs, materials and production resource/toolsalso with a subnetwork.Printed: February 5, 2011 6/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  7. 7. Gentile Consulting Inc.Network ActivitiesNetwork Activities are discrete tasks similar to work order operations with the followingcharacteristics:• 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 companyPrinted: February 5, 2011 7/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  8. 8. Gentile Consulting Inc. 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 NetworkOperative NetworkSub NetworksSub NetworksPM OrdersPM OrdersPrinted: February 5, 2011 8/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  9. 9. Gentile Consulting Inc. 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 ChartsPrinted: February 5, 2011 9/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  10. 10. Gentile Consulting Inc. Work Center Schedules Material ReportsPrinted: February 5, 2011 10/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  11. 11. Gentile Consulting Inc. Real Time Cost ReportsPrinted: February 5, 2011 11/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  12. 12. Gentile Consulting Inc. 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/ConclusionsThe integration of the PS and PM modules will provide a scheduling capabilitypreviously impossible in the company. This scheduling capability will require little orno input from the individuals performing the work since all schedule updates occurthrough the already implemented conformation process.The critical success factors involved in this process are:Printed: February 5, 2011 12/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM
  13. 13. Gentile Consulting Inc. • All work planned and managed within SAP (Capital, Maintenance, Operations) • Work orders must contain detailed planning • Accurate and timely confirmations of all operationsPrinted: February 5, 2011 13/home/pptfactory/temp/20110205194001/shutdownscheduling-12969347797599-phpapp02.docLast Modified: 2/3/2011 01:07:00 AM