Maximo_Mini LMM November 2005.ppt

TECHNICAL DEPARTMENT
Maximo Project Implementation Update
(Mini LMM)
November 2005
B. El Medkour & M. Al-Muhaisen

2
Maximo Project/ Mini LMM November 2005
Contents
 Why Maximo Project?
 What is Maximo templates?
 Project preparations in Year 2004
 JCF Vision for the Maximo Project
 Maximo Project Implementation
 Rashadiya Plant Projects ( 2005/2006)
 Equipment data file project
 Fuhais Plant Projects (2005/2006)
 Equipment data file project
 Executable job plan project & inspection/planning Action Plans

3
Why Maximo Project?

4
Maximo Project Objectives
• Maximo will be a tool for improving P.M. practices
• Tool to help maintenance organization to control their activities
( inspection, executions, scheduling, planning,
costing,management, improvement, etc.)
• Improve maintenance efficiency through easy analysis of
historical data, retrieval & traceability of all information
• To unifying both plant best practices & behaviors such as same
reports, procedures, etc.
• Tool for controlling & analyzing the performance of
maintenance organization in both plants
Retune

5
What is Maximo Template?

6
Maximo Template Definition
What is a Template :
The Template is only a tool which formalizes & helps maintenance practices evaluation and
service Lafarge Maintenance policy, it contains
 Validated and documented Best practices
 Key performance indicators
 Pre customized modules
 Interfaces with other Templates or standard tool
 e.g. Interface Maximo and JDE for purchasing
 e.g. Interface Maximo and ADAP
Best Practices
Pre customized Tool

7
 Methodology for roll out
 Training kit (users, tool,etc.)
 Central support for roll out
 Template maintenance and evolution
Material for training & roll out
Support
Why the Maximo Template Project ?
 End 2000, the Division decided to develop a template for Maximo :
 to design and build a pre-configured tool to support Maintenance Best Practices
and to be used as a catalyst for their implementation
 to reduce cost and time of implementation
Associated
service
Retune

8
Project Preparation in Year 2004

9
 Audit & Review all the maintenance activities & best practices
in both plants and the following was noticed & observed:-
1. 1st level inspection is well practiced
2. Some of the Job Plans requires enhancement & improvement in content
3. Specific Job Plans are not fully implemented and not managed through
PMS
4. Inspectors needs a support from execution team in order to perform
specific Job Plans without difficulties as per schedules :
 To provide qualified skills to help inspectors during dismantling & assembling
 To arrange a weekly coordination meeting between Method & Execution Departments
5. There is no inspection job plan for execution team. Most of the executable
prepared Job Plans are having the concept of Replaceable Job Plans
(condition based job plans).
6. All the specific Job Plans that are related to Packing Plant are not
implemented Yet
7. New Job Plans During stoppage need to be created for certain equipment

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• Based on the Audit results an Emergency Action Plan were put
and covered the following actions :-
• Job Plans enhancement & improvement as listed in TD Report
• Implementing of new executable Job Plans for level 5 & some of level
6 equipments
• Packing plant Specific Job Plans implementation & coaching
• Implementing new Job Plans during stoppage for 1st level
• New form creation as listed in TD report
• Selecting Job Plans from 1st & specific Job Plans for routine periodic
inspection for Raw Mills, Kilns & Cement Mills
• Weekly generation of Job Plans in Summary Sheet
• Weekly maintenance coordination meeting for Job Plans
• Work order cycle review & enhancement
• Manage the New created executable Job Plans through PMS

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• Preparation & Activities carried out on the Maximo Project
Level :-
1. Nomination of Both Plant coachers & Rashadiya Plant Project Core team
2. Training both Plant coacher on Maximo 4i Screens & Menus (July 2004)
2. Preparation of JCF main vision for the whole project
3. 1st Draft for Project charter, Budget and schedule was discussed & reviewed with
CTI & BS End of June 2004 at Amman with attendance from both TD & IT
Departments
4. JCF vision for the project was presented and all Maximo project documentations
were distributed in October 2004
5. Investment credit for the whole project was opened on October 2004
6. All the project Hardware was ordered on October 2004 ( all the Servers)
9. Present JCF vision for the project in the Rashadiya Plant( November 2004)
10. A Weekly coordination meeting between TD & IT Dept. Started since November
2004 to review the progress in the project prerequisites & to prepare detailed
schedule for:-
 Hardware installation ( servers)
 Software installation. ( Oracle 9i & standard Maximo)
Retune

12
JCF Vision for Maximo Project

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• We started the implementation with what run P.M.’s
• The implementation will is split into Two Stages and each stage consists of
multi-Phases as follow:
1. Stage one in year 2005 concentrated on ( Rashadiya plant):-
• Equipment codification
• 1st & specific inspection job plans
• Execution Job plans
• Lubrication Job plan
• Safety aspects written in the Job plans
• Equipment Data file (only equipment specifications)
• Work order cycle with workflow
• Basic Planning & scheduling
• Basic reports
Note: Same Stage activities will be repeated in 2006 for Fuhais Plant
2. Live Run implementation was performed in 3 Phases
JCF Maximo Project Methodology & Approach

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3. Stage Two in year 2006 (Rashadiya Plant) and this will cover remaining
activities :-
• All the interfaces (Maximo-JDE, Maximo-MS-project, etc)
• Equipment Data file ( Spare parts)
• Advance Planning & scheduling
• Budget management
• Safety management as per BU-BP-0064
• History files ( if required to customize special screen)
• Other Reports
• On 2nd half of 2006, we will start preparation for all production data (
inspections, house keeping, No load-Start up tests) and these will be test
before End of project
Note: Same stage Two activities will be repeated in 1st Quarter of 2007 for
Fuhais Plant
JCF Maximo Project Methodology & Approach

15
Methodology & Approach
• Start implementation on January 2005 with Rashadiya Plant Followed
after by Fuhais Plant, due to following:
• High number of End users
• Rashadiya plant is more prepared than Fuhais
• It was agreed that 2 coachers at Plant level will be fully dedicated to the
project & working with TD and those will :-
• Learn MAXIMO Template and maintenance BPs
• Participate in analysis and Process Improvement Workshops
• Support the end-users to perform their tasks after the training session
• Train with other trainers the end-users
• Future MAXIMO administrator at plant level
• As agreed with Fuhais Plant Management, implementation will be started
in the plant on beginning of June 2006 & Fuhais plant Coacher will
Participate in Rashadiya Implementation

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Maximo Roll-out Organisation
Regional
Level
Division
Level
BU
Level
Plant
Level
Business Side « IT » Side
IT Competency Centre
Montreal
Business Competency Centre
Lyon (DPC)
Technical Direction
IT Correspondant
Maintenance
Champion
Maintenance Template Coordination
(DPC + Business Systems)
Technical Centre
IT Department
IT Regional
Maintenance
Project

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Project Organization
• Two level of organization is going to be during the project implementation
and mainly that covers the need for Year 2005. In Year 2006 the
organization will be adjusted as per requirements. The levels are as
follow:-
A- Technical Department ( TD) & IT Dept. Level
B- Plant Level
• TD is leading all the project organization at TD & Plant level
• The project progressed in collaboration with Technical Centre (CTI),
Lafarge IT, Maximo competency Centre, Plant personnel and the local
supplier if required

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Project Organization chart
Project Manager
Project Champion
(Start to End)
Rashadiya Plant Maximo Champion
(25% of the Time)
Mech. Inspectors ( 1 Year)
Elect/Inst Inspector(6 Months)
Planners/ Lubrication( 1 Year )
Draft man( As needed)
Data entry ( Start to End)
Maximo Coach/Rashadiya
(100% of the Time)
Maximo Coach/Fuhais
(100% of the Time
Fuhais Plant Maximo Champion
(25% of the Time)
Mech. Inspectors ( 1 Year)
Elect/Inst Inspector(6 Months)
Planners/ Lubrication( 1 Year )
Draft man( As needed)
Data entry ( Start to End)
IT Specialist
(100% of the Time)
IT Coordinator
(30% of the Time)
At BU level during
JED/Maximo interface
stage, Finance &
Purchasing Departments
will be involved in the
project
Note:
Plant Core team members at
Plant level will be adjusted as per
project requirements during Year
2006 ( i.e. Production checklist,
JED interface, Safety, etc.)

19
Project Organization
• Two committees on the Top Management Level is formed in order to Control,
Assist & Evaluate the project progress as follow :-
A- Executive Committee ( Monthly)
To coordinate the day to day activities of the project and derive and manage
project plan . Also to monitor progress against the plan & budget, also identifying
logistics and resources
B- Steering / EXCOM Committee ( Every 4 month)
To provide overall guidance to the project and monitoring the progress, also to
address local requirement issues, project planning and tracking and other site-
specific issues such as logistics and resources

20
Jordan Cement Company Maximo Project Executive committee
Maximo
Project
Manager
IT Manager Fuhais
Maintenance
Manager
Fuhias
Method
Manager
( Plant
Maximo
Champion)
Rashadiya
Plant Deputy
Manager
Rashadiya
Maintenance
Manager
Rashadiya
Method
Manager
( Plant
Maximo
Champion)
Maximo
Project
Champion
Jordan Cement Company Maximo Project Steering committee
Manufacturing
V.P.
Technical V.P. Fuhais Plant
Manager
Rashadiya Plant
Manager
CTI
Relation Director
Financial V.P.

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Roll-Out Organization/Roles & Responsibilities
CTI :
1. Assistance to Project Charter
2. Organization of training sessions specific to Maximo Template
with cement Division resources
3. Assistance for consistency of Maximo Template implementation
according to Cement Division rules and objectives
MCC/ BS (Maximo Competency Center / Business System) :
1. Assistance to Project Charter
2. Recommend/validate hardware, software and network Architecture
3. Provide Maximo Template material and Template for interface to JDE
(including MEA part)
4. Systems expertise and support for IT Template related issues
5. Ensure knowledge transfer for the IT part

22
BU Team ( TD) :
1. Develop and update implementation schedules and plan& monitor and
track budget to actual
2. Communicate high level status of the project
3. Facilitate execution of the project plan & provide 1st level support
4. Learn MAXIMO Template and maintenance BPs
5. Conduct analysis and Process Improvement Workshops
6. Ensure MAXIMO Coach prepare end user training materials
7. Coordinate with Lafarge to train MAXIMO Coach and other relevant
participants
8. Manage implementation team members’ involvement

23
BU (IT) :
1. Facilitate MAXIMO implementation for IT
2. Coordinate with competency center and MRO
3. Prepare IT environment (PC installation, Network adjustment, software
installation and etc …)
4. Provide first IT level support for both hardware and software
5. Assist Project Champion when require
6. Participate in MAXIMO/JDE & Maximo/MS Project Interface
preparation, implementation,testing and lunching
7. Manage the MAXIMO & JDE installation
Local Supplier :
1. Hardware supply, configuration and maintenance
2. Oracle database installation & Basic Maximo installation (if required)
3. Possible developments for localization (data conversion, additional
reports, additional interface with automation systems…)

24
Plant Core Team :-
1. Up-date all the Job plans ( Mech.& Elect. ) 1st, specific, executions, lubrication etc.
2. Build P.M templates as Per Lafarge requirements
3. Implement equipment data files
4. Lead, implement and monitor MAXIMO Best Practices and Maintenance organization
best practices
5. Ensure that all pre-requisites of Maintenance organization & best practices are in
practice for smooth implementation of this project.
6. Ensure all documents (Job Plan, Inspection plan, Preventive Maintenance and etc …)
will be ready at the right time
7. Adopt and practice all pre-requisites of Maintenance organization & best practices
8. Ensure all documents (Job Plan, Inspection plan, Preventive Maintenance and etc …)
captured in MAXIMO contain detail & meaningful information
9. Data Conversion verification for MAXIMO data
10. Prepare all the open date balance for meter base PM’s ( Lubrication Mainly)

25
Rashadiya Plant Roll out Project Activities schedule

26
Training
A) Technical Department (TD) & Coacher level (During Year 2004) :-
• Visit to a plant that has a successful implementation of Maximo.
• Detailed training on Maximo 5.2 Template & Business processes
• Discuss with CTI/BS the latest Lafarge Maximo 5-2 template & Business processes
B) Plant Core Team level :-
• Awareness program for Maximo screens (one day during 2004).
• MRO basic training course on Managing Work with Maximo 5.2
• Training on Maximo 5.2 Template( Data Base Creation ,Jan. 2005)
C) Plant End User level :-
• Awareness program for Maximo screens (one day during April 2005).
• Training on Maximo 5.2 By Profile and as per project stages (2nd half of Year 2005)
Note: Item B & C will be repeated in year of 2006 for Fuhais Plant
Retune

27
Maximo Project implementation

28
Project Progress
• MAXIMO Implementation Project Progress
• Project Preparation: March 2004
• Project start : 1st January 2005
• Project Expected completion date : 31st December 2006
• Project Overall Progress : 46 % up to 17th October 2005

29
BU
Plant
Fuhais
Budget
Return
WBS Start Finsh Progress %
1 17-May-04 31-Dec-06 46%
1-1 17-May-04 31-Dec-06 68%
1-2 24-Nov-04 31-Dec-06 40%
1-2-1 24-Nov-04 28-Dec-05 93%
1-2-1-1 24-Nov-04 28-Dec-05 93%
1-2-1-1.5
Maximo Pilot Shop Rashadiya Plant -
Phase I (Raw Mix)
2-Jan-05 30-Jun-05 100%
1-2-1-1.6
Maximo Roll Out in Rashadiya Plant -
Phase II (Burning, Crushing & Utilities)
22-May-05 13-Oct-05 95%
1-2-1-1.7
Maximo Roll Out in Rashadiya Plant -
Phase III ( CM's, Packing & all remaining
Plant Stages)
26-Sep-05 28-Dec-05 35%
1-2-2 24-Nov-05 31-Dec-06 0%
1-2-2-1 A- Fuhais Plant 2-Jan-06 27-Dec-06 0%
1-2-2-2 B- Interfaces 2-Jan-06 28-Dec-06 0%
1-2-2-3 C- Budget Management 2-Jan-06 31-Dec-06 0%
1-2-2-4 D- Safety Management 24-Nov-05 30-Dec-06 0%
1-2-2-5 E- Production Data 2-Jan-06 31-Dec-06 0%
1-3 Meetings 17-Jan-05 28-Dec-06 30%
Task Name
Stage One - Year 2005
Rashadiya Plant
Stage Two - Year 2006
Maximo at BU level
Maximo at Plant Level
MAXIMO Implementation
Project for Jordan Cement
Company
Project Progress up to October 2005

30
• BU Level (TD & IT)
1. Preparation of Project charter, Budget & detail project schedule
2. Ordering & installation of all Software & hardware
3. Installation of Maximo Template with support from MCC
4. Train all the End users(Around 55 person) on How to utilize Lafarge best
practices through Maximo Software. All training was conduct by Maximo BU
Team for almost 3 weeks (NO Outside consultant)
5. Coach all the End users for around 7 weeks before, during Go live period and
2 days weekly after implementation
6. Preparation of all Maximo database Environments (Test, Train, & Production)
7. Freeze & stop using the existing Work Order System for All Plant Stages ( all
corrective WO’s Running through Maximo since 22nd September 2005) .
8. Discussing with MCC & CTI about all the required enhancements &
modification needed on the Maximo Template
9. Prepare locally all the tables & data for Light interface which launched in
October 2005.
10. BU (TD & IT) overall project progress is 68 %
Maximo Project Progress/ Rashadiya Plant
Return

31
• Plant Level
1. Maximo Minimum coding & location creation
2. Creation of Mechanical Execution Job Plan (119 Job Plan)
3. Creation for Lubrication 1st level inspection for whole plant.
4. Identify the specific Job Plan Measuring points
5. Review the Job plans content & make the required enhancements .
6. Creation of PM routes
7. Prepare the User & Workflow Privileges
8. Prepare linked documents
9. Review & refine all the users privilege on the Maximo Production
Environment database.
10. Review all Maximo Production Environment Mechanical, Electrical &
instrumentation PM’s and fixing the start date for all PM’s .

32
• Plant Level
11. Reviewing & checking all created Routes ( 1st level inspection) on Maximo
Production Environment .
12. Work order generation for all the PM’s on the Maximo Production
Environment
13. Go live for step Phase I &II was launched on July & September 2005
14. Run all corrective WO’s through Maximo
15. Arabic instructions document was prepared by Maximo coacher for End
users to facilitate their navigation
16. Rashadiya Plant overall project progress is around 72%

33
Next Activities
Maximo Project Progress
 Create All asset catalogue templates on Maximo & fill the data on Maximo equipment
module screens
 Link Each Equipment with it’s spare parts through the Spare parts Tab in the
Equipment Module
 Run interface between Maximo-MS-Project in order to be ready before Major
shutdown (waiting to Purchase MS Project version 2003)
 Prepare the schedule for advance training courses:-
 Mainly Planners & inspectors
 IT & Maintenance staff for Actuate Report writer
 Adjust the IT & plant core team Organization based on Year 2006 requirements
 Start Preparing all the Repairable/Replaceable Job Plan
 Start Preparing to create Production Job plans (Shift Production checks, shutdown &
cleaning activities)
The go live for Phase III is Expected to be Mid of November 2005
(one & half Month before Schedule)
(this will complete the stage I of Maximo project Implementation)
 Implement all activities for project Stage II during Year 2006 Return

34
Maximo project at Fuhais plant
 TD and plant are working on the required organization of this project
next, the objective is to nominate Maximo team on December
 The plant team will be built according to the progress of all maintenance
actions followed by TD at Fuhais plant
 Implementation will start beginning of January 2006
Return

35
Maximo Project/ Mechanical Execution Job Plans
Why Mechanical Execution Job Plans??
These are a 1st level Inspection Job plans with a minor repair performed
during equipment stoppage by execution team, and they have a big impact
to improve RF for equipments.
• Creation of (119) New Mechanical Executable Job Plan By Maximo team
• TD team with Maximo Plant coacher,coached the implementation of these
new type of job plans & explained to Execution team How to perform them
& almost around.
• Project progress is around (119/119)= 100%
Return

36
 All the Plant lubrication system was schedule to be Launched with
Maximo 1st phase Implementation for the whole plant and it was
launched completely starting from September 2005
 Work order generation for all Lubrication PM’s on the Maximo
Production Environment:-
 1st Level inspection (make up Lubrication)
 Specific inspection ( Shutdown, Drain )
 The feedback got from Lubrication team is promising & they are happy
with the system ( 1st in Lafarge Group using Maximo 5.2 in managing
Lubrication Activities)
Maximo Project/ Lubrication System
Return

37
Maximo Project Progress/ Hardware Configuration
Return

38
• Total Appropriation Value : 426 KJD
• Total Forecasting Value : 1.5 KJD
• Total Actual Booking Value (Paid) : 179.073 KJD
• Total Appropriation Balance Value : 245.427KJD
Investment Project Cost Control

39
Summary of the Estimated Project Budget/ Based on
Centralized Scenario
Budget Item Cost (KUSD)
Consulting 276
Hardware 100
Software 122
Training 41
Grand Total 544
Grand Total with 10%
Contingency
599
Retune

40
Data File Project Progress/Rashadiya
 The team accomplished a very good progress in Data sheet preparation
compared with last two month progress & they achieved :-
 68 % progress up to 15th September 2005
 In parallel, progress in Spare Part Defining is :
 46 % progress up to 15th September 2005
 Team started up loading all the prepared Data in to Maximo manually &
linking all JDE spare with equipments starting from End of September
2005.
 Target competition date for the project is End of Year 2006.
Retune

41
B- Fuhais Plant Projects

42
1. A presentation that included an examples & explanation on the concept
of these Job Plans was conducted by TD to all Plant Mechanical
Engineers. (January & February 2005)
2. A round 100 Mechanical Execution Job plans examples from Rashadiya
Plant were Provided to Fuhais Maintenance Manager
3. Cement mills already completed and validated by TD, it will be launched
end of October
4. Crusher area completed and validated by TD, it will be launched after
kiln shutdown beginning of November
5. Ram mill area under progress
6. Commitment by team that all executable job plan will be completed
before major shutdown
Mechanical Execution Job Plans

43
Data File Project Progress/Fuhais
 Pilot shop (shop 226) was completed on 20th March 2005 :
 100% in Electrical equipment data sheet specifications ( 38 equipment)
 100% in Mechanical equipment data sheet specifications ( 43 equipment)
 100% Progress in Spare parts
 The new team accomplished a very good progress in Data sheet preparation
(CM 2 shop) compared with last period & they achieved :-
 41 % progress up to 13th October 2005
 A detailed draft schedule for the whole plant will was prepared end of
October 2005
 All the prepared spare part will be sent to Planning Section Head for
validation.
Retune

44
The End

Maximo_Mini LMM November 2005.ppt

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