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SAP Manufacturing Days - Richard Verbeek OpenText

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SAP Manufacturing Days 2013

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SAP Manufacturing Days - Richard Verbeek OpenText

  1. 1. ECM for Excellence in Enterprise Asset Management Richard Verbeek, Principal Solution Consultant September 2013
  2. 2. © 2011 SAP AG. All rights reserved. 2 Agenda Enterprise Asset Management Extended ECM for Enterprise Asset Management Customer Examples Summary
  3. 3. Enterprise Asset Management Keeping Plants Competitive
  4. 4. © 2011 SAP AG. All rights reserved. 4 Enterprise Asset Management is a core Process in the Value Chain Planning / Product Development Procurement Production & Operation Sales & Marketing Customer Service Finance Human Resources Legal IT  Supplier Information Management  Contract Management  Sourcing Strategies  Order Management  Brand Asset Management  Collateral Management  Campaign Management  Account Management  Contract Management  Customer Communications  Multi-channel Customer Service  Case Management  Project Management (E&C, R&D, etc.)  3rd Party Collaboration  IP & Knowledge Mgmt.  Archive Data And Content  Consolidate ECM Systems  Paper Archive Elimination  Legacy Decommissioning  Information Retention  Enterprise Records Management  Automated Compliance  eDiscovery  Contract Management  Vendor Invoice Management  Expense Reimbursement  Collections  Dispute Management  Customer Invoicing  Employee File Management  Talent Sourcing & Acquisition  Reward & Retain  HR Record Retention  Policy Management  Enterprise Asset Mgmt.  Distribution / Logistics  Product Lifecycle Mgmt.  Quality Management
  5. 5. © 2011 SAP AG. All rights reserved. 5 Enterprise Asset Management Key process areas Planning, Building, and Commissioning Assets Asset Visibility and Performance Optimized Asset Operations and Maintenance Asset Safety and Compliance Real Estate Lifecycle Management Asset Lifecycle Plan and Design Procure and Build Commission Operate Maintain Decommission
  6. 6. © 2011 SAP AG. All rights reserved. 6 What matters most? The ability to run highly performing assets  Reduced downtime and shortened repair cycles  Resolve equipment issues more quickly  Deeper insight into the root causes of failures  Reduced regulatory risk
  7. 7. © 2011 SAP AG. All rights reserved. 7 The power to differentiate yourself Note: “Best” = Top 25%, “Worst” = Bottom 25% APQC Benchmark Data 2012, N = 193 SAP Value Engineering, SAP EAM Benchmarking 2011, based on data from over 60 participants (including SAP customers) Unplanned Downtime/ Outages (%) 2.0% Best Best run assets witness >3 times lower unplanned downtime / outages “ ” Annual Service and Maintenance Cost (% of revenue) 1.5% Best Best performers have 5 times lower annual service and maintenance cost “ ” 7 Act. Production Rate / Max. Product Rate (%) 90% Best Best performers have a 3 times less non-productive asset life time “ ”
  8. 8. © 2011 SAP AG. All rights reserved. 8 Key Stakeholders and Objectives in Enterprise Asset Management 8 Engineering Improve Equipment Reliability  Maintenance Effectiveness – MTBF (Mean Time Between Failure)  % Failures Investigated  Extend Asset Life  Up-to-date technical documentation Procurement Cost effective spare part management  Reduce request and order cycle time  % compliant transactions with services contracts  Number of spare part stock outages Production & Operations Maximize productivity  High production rate  Minimize downtime / Maximize wrench time  OEE (Overall Equipment Effectiveness) Maintenance Increase uptime  Maintenance Efficiency - MTTR (Mean Time to Repair)  Schedule compliance  % Rework Time COO  Keep assets profitable  Enforce service levels  Cost of Quality Maximize return on assets  Reduce Penalties & Fines  Worker Safety
  9. 9. ECM for Enterprise Asset Management
  10. 10. © 2011 SAP AG. All rights reserved. 10 The Business Challenge  Inconsistent or incomplete plant information  Long downtimes and outages due to inefficient collaboration in asset-related projects  Complex document handover processes between involved departments and externals  Compliance issues due to lack of secure and long-term storage of asset documentation  Decreased safety due to outdated or non-accessible work procedure or material safety documentation
  11. 11. © 2011 SAP AG. All rights reserved. 11 ECM for Enterprise Asset Management Content Management for key process areas Planning, Building, and Commissioning Assets Asset Visibility and Performance Optimized Asset Operations and Maintenance Asset Safety and Compliance Real Estate Lifecycle Management Asset Lifecycle FLOC + EQUI Workspace Notification Workspace Material Workspace Supplier Workspace Work Order Workspace Project Workspace Facility Workspace Shutdown / TA Workspace Equipment Failure Analysis Plan and Design Procure and Build Commission Operate Maintain Decommission
  12. 12. © 2011 SAP AG. All rights reserved. 12 Functional Location Equipment Materials SupplierProject ECM for Enterprise Asset Management Content Management for key process areas Provide Enterprise Content Management for key SAP Business Objects in Asset Management: Plan and Design Procure and Build Commission Operate Maintain Decommission Asset Lifecycle Maintenance Notification Maintenance Order Task List
  13. 13. © 2011 SAP AG. All rights reserved. 13 Functional Location Equipment Maintenance Notification Materials SupplierProject Task List Maintenance Order ECM in Enterprise Asset Management Content Structure Scope F. LocationDocument Main Function Scope Pos. Document Set Document Type Function Work Order Main Function Equipment Function Main Function Scope Pos. Function Asset Structure and Data
  14. 14. © 2011 SAP AG. All rights reserved. 14 The structure of a vehicle is an hierarchic structure containing all information regarding the composition of a vehicle. Terminology in Functional Location Equipment Example: wheel set, traction engine, compressor group, screw,… Example: Managing Rolling Stock in SAP ERP (Plant Maintenance)
  15. 15. © 2011 SAP AG. All rights reserved. 15 Best practices for achieving excellence in Enterprise Asset Management  360° View on all Plant Information  Access to Content from inside and outside of SAP applications 1 Fast Access to Documentation  Collaboration between involved departments and externals  Effective document control  Efficient handover of documents 3 In-Process Collaboration 2  Quick access to required documentation  Content Workspaces for asset- related projects and maintenance work Efficient Repair and Analysis 4  Up-to date asset documentation  Transparency on SOPs and instructions  Records Management Safety and Compliance
  16. 16. © 2011 SAP AG. All rights reserved. 16 Asset Maintenance Process – The Importance of Documents  Failure Message / Malfunction Report  Notification Documents  Error Files  Photos  Inspection Notes  Checklists & Standard Operating Procedures  Protocols & Other Documentation Maintenance Notification Create Work Orders Shutdown Processing Start-Up Processing Inspection / Repair / Replacement  Material Specification  Contract & Order Documents  Shipment Documents  Vendor Invoices Order Spare Parts  Failure Information (Photos, Reports, Notes)  OEM Supplier Documentation & Correspondence  Failure History  Analysis & Recommendation Documents Failure Analysis  Maintenance Plans  As-built Plant Documentation  Monitoring Records Maintenance Planning and Scheduling Asset Monitoring  Work Package Description  Checklists & Standard Operating Procedures  Equipment Manuals  OEM Recommendations  Technical Documents & Specifications Update Asset Documentation
  17. 17. © 2011 SAP AG. All rights reserved. 17 SAP Extended ECM for Enterprise Asset Management – Example: Equipment Failure Analysis 17 SAPExtendedECMSAPPM Define Scope of Analysis Initiate Analysis Conduct Analysis Recommendations Create Work Orders Completion Records Management Scheduling and Fixing Create Maintenance Notification Conduct Equipment Failure Analysis Notification of Failure Tear Down Repair Start-up  Create Maintenance Notification of type “Malfunction Report”  Maintenance Notification Workspace is created in Extended ECM (including the notification documents)  Create Maintenance Work Order to investigate the problem and provide a remedy  Trigger creation of Failure Analysis Workspace in Extended ECM  Reliability Engineer receives an email with links to Maintenance Notification and Failure Analysis Workspaces  Determine scope (equipment, technician, objective, time frame, etc.)  Collect failure data  Review maintenance / failure history  Upload photographs and any interview notes  Assign responsibilities and roles  Plan tasks and resources (tasks, WFs, follow up)  Create analysis report with findings  Submit report for review/ approval  Conduct predefined analysis (ETA, FTA, RCA)  Record analysis results  Review OEM manuals for op limits and maintenance  Inquire with OEM/supplier on model experience  Control work progress  Printing Shop Papers and assign Technician  Technician repairs the equipment  Everything gets documented in the Maintenance Work Order Workspace  Technician uses an mobile device to access documents in related Workspaces (FLOC, EQUI)  Technician uses mobile device for capturing photos directly into the Workspace  Root Cause Analysis may require revisions to maintenance plan (Inspection, Service, Calibration)
  18. 18. © 2011 SAP AG. All rights reserved. 18 ECM in Plant Maintenance 18 ECM workspaces with folders and documents SAP Plant Maintenance data and structures SAP DMS content
  19. 19. © 2011 SAP AG. All rights reserved. 19 Equipment Workspace in SAP GUI
  20. 20. © 2011 SAP AG. All rights reserved. 20 Equipment Workspace in Extended ECM Web UI – Easy Access for Non-SAP Users Standard Folder Structure for Maintenance Notification automatically created based on a template Related items like FLOC, Maintenance Notifications and Orders are shown in the sidebar of the Equipment SAP PM Data for the Equipment P-3000-N001
  21. 21. © 2011 SAP AG. All rights reserved. 21 Integration in SAP Material Management Material workspace of a pump P-3000 Bill of materials / components of the pump Related Equipment SAP MM Data for the Material P-3000
  22. 22. © 2011 SAP AG. All rights reserved. 22 Related Vendors for selected Materials Vendors for the “Rubber Seal” (SAP MM) Standardized folder structure for “operational supply” materials Material workspace of a pump P-3000
  23. 23. © 2011 SAP AG. All rights reserved. 23 Vendor Workspaces in Extended ECM Related Materials of Vendor Master Data of Vendor and Vendor KPIs
  24. 24. © 2011 SAP AG. All rights reserved. 24 Composite Business Workspaces for Plant Maintenance Task Lists 24
  25. 25. © 2011 SAP AG. All rights reserved. 25 Access to SAP PM documentation from MS Windows® Windows Integration of Extended ECM Complete plant hierarchy (FLOC, EQUI) is automatically available as Windows folder structure Full ECM capabilities with document preview, document edit in MS Office, versioning, audit, metadata, etc.
  26. 26. © 2011 SAP AG. All rights reserved. 26 Access to SAP PM documentation from MS Outlook® Drag & Drop E-Mails from Outlook to Workspaces of Extended ECM Complete plant hierarchy (FLOC, EQUI) is automatically available as email folder structure Full ECM capabilities with document preview, document edit in MS Office, versioning, audit, metadata, available in MS Outlook
  27. 27. © 2011 SAP AG. All rights reserved. 27 Example: Access from Mobile Devices OpenText Tempo – “Dropbox behind the Firewall” OpenText Everywhere – Mobile Access and Filing 27
  28. 28. © 2011 SAP AG. All rights reserved. 28 Access to SAP PM documentation from Mobile Devices Technicians can take pictures and directly file into Extended ECM right from his mobile device.
  29. 29. © 2011 SAP AG. All rights reserved. 29 Viewing & Redlining of technical Drawings (based on Brava! viewer available as add-on for Extended ECM) 29
  30. 30. © 2011 SAP AG. All rights reserved. 30 Access to SAP PM content from MS SharePoint® Extended ECM Documents (also ArchiveLink documents) Extended ECM Sidebar with SAP Data Business Relationships to other Extended ECM Workspaces 30
  31. 31. © 2011 SAP AG. All rights reserved. 31 ECM for Enterprise Asset Management Delivering Measurable Value Business Objectives Value Driver / Key Success Factor (KSF) Key Performance Indicator (KPI) Peer Group Metrics* Improvement with ECM Median Top Performer Conser- vative Most Likely Increase Asset Performance Reduce downtime and shortened repair cycles Actual Production Rate as % of max. Production Rate 80% 90% 3% 6% Unplanned Machine Downtime as % of run time 4% 2% -7% -15% Reduce Maintenance Costs (OPEX) More effective use of available resources % Failures Investigated 60% >80% 20% 40% Scrap and Rework Costs as % of sales 1% 0,28% -10% -20% No Injuries Decrease safety compromise Lost Time Injury Frequency Rate (LTIFR) 5% < 2% -5% -10% *APQC Benchmark Data 2012
  32. 32. Customer Examples
  33. 33. © 2011 SAP AG. All rights reserved. 33 What do the best achieve with ECM? Customer findings after using Extended ECM (Railways, Utilities) 50% Reduced time for Document Handover and Correspondence Mgmt. 30% 50% Reduced time for Asset-related Projects Reduced Costs for Asset Documentation
  34. 34. © 2011 SAP AG. All rights reserved. 34 Improving Enterprise Asset Management with ECM Example in Transportation: NMBS – Belgium Railways (BE) “The benefit of this integration is that you save time finding the right documents, you reduce the cost of manipulating these documents, and you have an accuracy of the information related to specific and critical business processes within your company.” Stephane Haelterman, Project Manager at Belgian Railways Increase Agility Agility to meet evolving customer demands. Compliance with demands for traceability, conformity, and safety certificates. Improve Efficiency All documents integrated to business processes and accessible from multiple user interfaces for operators, technicians, and engineers Reduce Costs Progressive paper cost reduction strategy – estimated EUR 3 million annual savings.
  35. 35. © 2011 SAP AG. All rights reserved. 35 Business Case @ Belgian Railways 35 Cost optimisation Enhanced Customer Services Punctuality of rail services Uncompromising safety New generation of employees European market demands CorporateObjectives OpenTextExtendedECMforSAP Progressive paper cost reduction Faster handling of customer case files, faster information lookup Speed up / avoid breaches in the supply chain Accuracy of technical drawings and valid working procedures Secure historical know-how and offer modern working tools Comply with demands for traceability, conformity, safety certificates
  36. 36. © 2011 SAP AG. All rights reserved. 36 Business case Bridge the gap between business processes and business documents • Technical Drawings • Book of Patterns • Calculation notes • Quality Manuals • Operational Guides • Procedures • Work Instructions • Fact Sheets • Forms • Checklists • Naming Conventions • Technical Catalogue • Pictures Maintenance  Example of solutions Enterprise Asset Management Real Estate Management Employee File Management Invoice Management Travel Receipt Management Intelligent Driver Assistant FI/CO, PLM, SRM, EH&S, HR FI/CO, PS, PM, MM, HR HCM, Non-SAP FI-AP, MM HCM, FI/CO HR, PM, Non-SAP • Lease Agreements • Leasing Contracts • Property Acts • Contract Forms • Contract Account Sheets • Rent Settlements • Customized Emails / Fax • Digital Signatures • Photos Facility Management • Resumes • Learning • Assessments • Appraisals • Medical Attests • Training Attests • Certificates • Function Descriptions HR • Invoices • Taxes • Downpayments • Line Sheets • Brakes Bulletin • Troubleshooting Wizard • Log Book • Time Registration • Incident Handling Driver Procedures Accounts Payable
  37. 37. © 2011 SAP AG. All rights reserved. 37 Close the Gap between ERP and ECM Example in Utilities: IBAarau (CH) “We looked for a solution to integrate Content into the context of our business processes. OpenText has by far the deepest and most stable integration to SAP of all ECM vendors in the market.” Manfred Mengon, ECM Project Manager, IBAarau Increase Agility Change of mindset from the division to the process is driven forward. More efficient cooperation and better customer service. Improve Efficiency Information management optimized throughout the company. Information is quick to find regardless of the user interface. Compliance Legal requirements (compliance) fulfilled. Transparency and consistency across all processes.
  38. 38. © 2011 SAP AG. All rights reserved. 38 Fundamentally change the way to manage content Example in Utilities: HydroOne (CA) “Because of the great integration point with OpenText, Microsoft and SAP, it was a perfect roadmap for us. It was a perfect experience and we've had great success with all three of these companies to date.” Norm Crook, Director, Business IT, Hydro One Increase Agility Integration of business content with business processes in SAP. Knowledge Management to cope with an aging workforce. Improve Efficiency Optimize Damage Claims Process for distributed / linear assets. 360 degree view on all Enterprise Asset information. Compliance Regulatory Compliance and Record Keeping.
  39. 39. © 2011 SAP AG. All rights reserved. 39 HydroOne – SAP Plant Maintenance – Work Order
  40. 40. © 2011 SAP AG. All rights reserved. 40 Adding Context to Information Example in Utilities: REWAG (DE) “OpenText brings more value to our SAP deployment. For instance, all processing steps for house connections now run 30% faster, seamlessly and therefore resource-saving.” Dr. Matthias Dorfner, Director, IT Project Manager, REWAG Increase Agility Easy access to all relevant content for SAP IS-U and non-SAP user. Improve Efficiency Mail room efficiency for incoming mails increased by 100% Speed up filing, processing, and retrieval of documents with OCR and full text search. Reduce Costs Processing costs for house connections decreased by 30%.
  41. 41. Summary
  42. 42. © 2011 SAP AG. All rights reserved. 42 Where do customers see value? Faster access to technical documentation Efficient repairs and failure analysis In-process collaboration with partners and customers Ensuring worker safety + procedural compliance Records Management for all content ECM for Enterprise Asset Management
  43. 43. © 2011 SAP AG. All rights reserved. 43 Roadmap to ECM – following the SAP Business Model ECM for Procurement ECM for Materials Management ECM for Enterprise Asset Mgmt. ECM for Capital Projects Management ECM for Customer Relationship Management ECM for Product Lifecycle Management & Logistics
  44. 44. Questions & Feedback Contact: Richard Verbeek Email: rverbeek@opentext.com Mobile: +31621520205 44

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