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Enterprise Asset Management_Training PPT.pptx
- 2. Ramco ERP SuiteEnterprise Edition Enterprise Asset Management
- 3. Asset Intensive Segment Transportation Aviation, Rail,Road High-capital, 24 x7 process plants - Petrochem, Cement Utilities - Electric generation, T & D, Waterworks Infrastructure support - pipelines, facilities Vertical Segments addressed
- 4. • Maximize AssetAvailability • Optimize Asset Utilization • Meet Safety and Compliance Requirements • Improve Return on Capital • Reduce Surplus Inventory • Increase Workforce Productivity • Integrate Asset Management with Enterprise Systems • Effective Control of Total Asset Life Cycle Key Benefits
- 5. Asset Induction &Work Management
- 6. • Work Elements •Work Groups • Employee • Other Key Masters • Location Structure • Equipment Profile • Equipment Registry Key Benefits
- 7. • User DefinedType, Categories etc. • Facility to copy content from one task / procedure to another Sequence No. Description Sequence No. Description Sequence No. Description Type : PM, BD, Inspection etc. Category : Electrical, Mechanical etc. Duration : Hours, etc. Requirements: Spares, Tools, Resources etc. Type : PM, BD, Inspection etc. Category : Electrical, Mechanical etc. Duration : Hours, etc. Requirements: Spares, Tools, Resources etc. Type : PM, BD, Inspection etc. Category : Electrical, Mechanical etc. Duration : Hours, etc. Requirements: Spares, Tools, Resources etc. Procedure level requirements + Aggregation of all task requirements Tasks Activities Procedures Key Benefits
- 8. Tools & other resources Workgroup WorkgroupLeader Equipment Planning Group Workgroup Equipment Work Groups
- 9. Workgroup Primary Skills Hourly RateAttendance types Secondary Skills Employee
- 10. Other Resources E.g. :Material Handling Tools Skills Assign Number available Hourly Rates Usage Type Availability Assign Serial Number Number Available Hourly Rates Usage Type Availability Hourly Rate Attendance Type Other Key Masters
- 11. Child Location Level 1Turbine 500 MW Unit 1 Boiler 500 MW Unit 1 500 MW Unit 1 Apex Location Child Location Level 2 • Build hierarchy of location structure to mimic organization structure • Cost views and roll-ups • Build location profile by attaching attributes such as planning groups, trouble shooting guides, inspection point Coal Mill 500 MW Unit 1 Location Structure
- 12. Installation date Life parameter Dailyrun hours Location Work group Purchase information Calendar Financial Information Equipment life Place holder details Operational date Spares structure Inspection points Parameters Off line details Calibration details Equipment Equipment Registry
- 13. Parent equipment Conveyer Child equipment Gearbox Runhours Oil Color Temperature Range Attribute Placeholder Conveyor motor Rotable Parameters Technical – HP Consumption – Run Hours Range - Current Parameters Technical – HP Consumption – Run Hours Range - Current Equipment Profile
- 14. Rotables Track MovementHistory Inherit run hours / other parameters from parent Remove a defective one Attach a good one Rotables
- 15. Work Logs Add toHistory Add to Pending Jobs lists Generate Work Request/ Work order Process Work Log entries Transfer to other Work Log Specify Type and Category Configure as many of Work Logs as needed Record Observations on Equipment/ Locations Work Log Work Management
- 16. Reject request Work requestForward request Approve request Refer in another Work order Generate Work order Stage 1 – Work Request Work Order Cycle
- 17. Work order Work order Approval SchedulingExecution Closure Problems Tasks Skills Resources Tools References Services Resource Loading Spares availability Skills Employees Resources Tools Report Actuals Return unconsumed parts Stage 1 – Work Order Work Order Cycle
- 18. • Match JobRequirements and Skill assignments • Plan and Ensure Spares availability • Control Costs • Provide Right Solutions for the Maintenance Problems • Reduce Search Time and Increase Wrench Time • Maintain Comprehensive Asset Information Key Benefits Asset Induction and Work Management
- 19. Work order Maintenance Strategy Scheduling Location/ Equipment Services Task / Procedure Resources, Spares, Tools Calendar / Usage-based Clearance Permit Internal / External Rule-based Forecast Preventive Maintenance
- 20. • Reduce PrematureFailures/ Unplanned Down Time • Forecast Spares/ Resources Requirements & Plan • Achieve Balance between Internal effort and Out Sourced effort • Ensure Assets Operation as per design parameters Key Benefits Preventive Maintenance
- 21.
- 22. Calendar / Usage-based Clearance Permit Workorder Rule-based Forecast Inspection orders Condition Monitoring Strategy Inspection Task / Procedure Scheduling Location / Equipment Predictive Maintenance
- 23. Parameter updation through Inspection orders Parameterupdation Real Time Integration with DCS/ SCADA Direct Parameter Updation Work Request/ Work Order Location / Equipment Parameters Updated Predictive Triggers Predictive Maintenance Action Triggering
- 24. • Preempt impendingfailures • Greater Maintenance cost effectiveness • Bring Focus on Critical Equipment • Longer useful life of assets Key Benefits Predictive Maintenance
- 25.
- 26. Failure Group Equipment 1 Equipment2 Equipment Trouble shooting guide Trouble shooting guide Failure modes & description Hierarchy of failure modes Resolutions Tasks Standard Procedures Trouble Shooting Guide
- 27. Failure Mode 1 FailureMode 2 Failure Mode 3 Failure Mode 4 Failure Mode 5 Failure Mode 6 Failure Mode 7 Resolution 1 Task / Procedure Resolution 2 Task / Procedure Resolution 3 Task / Procedure Resolution 5 Task / Procedure Resolution 4 Task / Procedure Trouble Shooting Guide
- 28. • Severity basedon weighted average of - Production Down Hours - Maintenance Expenses - Safety Rating • Occurrence of Failures • Detectability (chances of detecting failure) Risk Factor = Severity Rating * Occurrence Rating * Detectability Rating Can be done at Equipment Level Equipment - Problem level Failure Analysis
- 29. • Analyze Failuresand provide Right Maintenance • Greater safety and environmental integrity • Greater Maintenance cost effectiveness • Better teamwork • Improved operating performance (output, product quality, customer service) Key Benefits
- 30.
- 31. Equipment (Also Down /Ganged Groups) Plan Type Plan Category Cost Type Plan Priority Shut Down List Pending Task Basket Work Requests Task Library PM Tasks Tasks & Services Plan for spares View / Reserve Raise service/ Purchase requests Work Orders / Inspection & Calibration Orders Create Shut Down Plan Select Location / Equipment Create Work Orders Planning Shut Down Plan
- 32. Export Import Execute Close plan ReportActuals Return Unconsumed Parts Scheduling Activity based Scheduling Resource Based Leveling Shut Down Plan Shut Down Plan Scheduling / Execution
- 33. • Ensure Availabilityof Men and Materials • Monitor effectively the Progress of Shut Down Jobs • Complete Shutdown Activities with in budgeted Time and Cost • Plan and Schedule effectively Key Benefits
- 34.
- 35. Sequence No. Description Sequence No. Description Description Status Type: PM, BD, Inspection etc. Category : Electrical, Mechanical etc. Duration : Hours, etc. Requirements: Spares, Tools, Resources etc. Type : PM, BD, Inspection etc. Category : Electrical, Mechanical etc. Duration : Hours, etc. Requirements: Spares, Tools, Resources etc. Type : Hot, Cold, etc.. Category : Electrical, Mechanical etc. Activity on : Equipment / Location Activity Type : Lock Out/ Tag Out Clearance Procedures Activities Sequence No. Description Sequence No. Description Description Type Status Type : Hot, Cold, etc.. Category : Electrical, Mechanical etc. Safety Procedures Hazards Clearance Permit Key Benefits
- 36. Issue Permit Request for Clearance Permit Reject request Create Permit Secure Clearance(s) SecureApproval(s) Clearance Permit Request / Issue
- 37. Clearance Permit open Maintenance Jobs Completed Not completed Request for Extension Reject Extension Approve Extension Return Permit ClosePermit Clearance Permit Closure / Extension
- 38. • Achieve Coordinationbetween Operations and Maintenance • Ensure Safety and Statutory Compliance Key Benefits
- 39.
- 40. Calendar / Usage-based Clearance Permit Workorder Rule-based Internal / external Calibration Schedule Equipment Forecast Calibration orders Calibration Task / Procedure Calibration requirements of equipment Calibration
- 41. Calibration order Record pre- calibration values Calibrate Recordpost calibration values Master Instrument used Person calibrating Calibration Certificate Passed Calibration
- 42. • Ensure properfunctioning of Equipment • Maintain Equipment health and Quality Output • Perform Calibration Tasks on time Key Benefits
- 43.
- 44. Approve proposal Propose Budget for Location Resources,Skills, Spares, Tools, miscellaneous Create plan Approve plan Allocate for Critical equipment • Propose Budgets for - Functions - Types of Work E.g. Mechanical - Preventive Proposals Budgets
- 45. Approved plan Allocate for location Apportion across periods Reviewbudget against Actuals Allocate for critical equipment Resources, Skills, Spares, Tools, miscellaneous • Monthly, quarterly, half-yearly, yearly allocation of budgets for - Functions - Types of Work E.g. Mechanical - Preventive Allocation Budgets
- 46. • Cater forSpares/ Resources/ Miscellaneous Costs • Ensure that the actual cost is within the Budgets • Control Overall Maintenance Costs • Propose Fund Requirements at Location/ Equipment level Key Benefits
- 47.
- 48. Maintenance plan PM Schedule Service Items Bills of materials Standard Rate Service Request Work order Contracts
- 49. Process service requests Createcontracts Receipt of Services Create blanket contracts Issue Release Slip Against a Work Order Against Multiple Work Orders in a Service Receipt Issue items, if necessary Pay Reconcile issue and return of items • Rate Contracts • Lump Sum Contracts • Annual Maintenance Contracts Contracts
- 50. • Achieve aBalance between Internal and External mix • Ensure Coordination • Reduce Total Maintenance Costs • Leverage Maintenance Task Outsourcing Key Benefits
- 51. MRO and AfterSales Service
- 52. • Customer locations •Customer units • Maintenance Crew Unit Location Crew Unit Induction
- 53. • Customer centricservice levels • Multi Unit-Service level agreement • Types of Service level • Auto –Renewal • Escalation for Agreement • Multiple Payment plans • PM Visits->SWO Service Level Agreement
- 54. Report WO Actual Spare Part Actual LaborActual Service Actual Allocate Spares Reserve Spares Raise PR Skills/Employees Assignment SCR for Service Service Level Agreement Create Work order FRESH WO Scheduling SCHEDULED Customer Complaint WO Execution INPROGRESS/COMPLETED WO Closure CLOSED Units Sale Order Customer Problems Spares Skills Services References COBI Generation Service Work Order
- 55. • Billing basedon either reported parameter value or reported hours • Supports both Parameter and Skill reporting • Consolidation of the reported value for billing Service Level Agreement Reporting for Billing
- 56. • Improves CustomerSatisfaction • Supports both Service and Sales & Service Industry • Supports Repair, Preventive Maintenance, Installation and Movement of Customers Units • Minimal data capture through simplified User interface screens Key Benefits
- 57.
- 58. Ramco ERM -Offerings SITE Inspection Eqp. Allocation
- 59. Types of Rentals •Equipment Rented for Fixed Price per Day/Week/Month • Equipment Time Sheet optional (No billing based on it) • Employee assignment is optional & expenses can be Invoiced based on employee timesheet actuals. Fixed • Equipment Rented for a specific price per Hour • Invoiced based on time sheet hours reported against Equipment • Employee assignment is optional & expenses can be Invoiced based on employee timesheet actuals. Time Sheet Based • Equipment Rented based on Usage . Like Run Hours, Tones Lifted etc. • Invoiced based on the Reported consumption against Equipment • Employee assignment is optional & expenses can be Invoiced based on employee timesheet. Usage Based
- 60. Pre Requisites Rental Calendar 1.Classify as Working, non working days, exceptions 2. Captured it in Quotation and Rental Agreement. 3. Generate Invoice accordingly for holidays and OT hours Equipment Master 1. Create Equipment or Vehicle 2. Map spares and usage parameters Rental Pricing 1. Price at Model or Eqp. Category 2. Time based & Consumption based pricing
- 61. RFQ 1. Record Customerrequests on equipment hire 2. Capture RFQ by Eqp. Desc or Eqp. Category Site Inspection 1. Record Customer site data 2. Feed Input given by each Emp. (Inspectors) Quotation 1. Facility to raise Quotation against RFQ & with out any reference 2. Specify the mode of rental billing (Fixed/ Time/ Usage based) 3. Specify Equipment OT rates & Skill OT Rates Rental Process
- 62. RFQ to Agreement(Fixed Rental) Custom erRFQ Equipm ent Available? Equipm ent PriceEngine EN D Proce ss N o Re ntalQ uotati on (Fixe dRental) Specify Re ntalPeriod Approve Q uotation G enerateR ental Agreem ent Yes SpecifySpares &Accy.
- 63. RFQ to Agreement(Time Based Rental) Custom erRFQ Equipm ent Available? Equipm ent PriceEngine EN D Proce ss N o Re ntalQ uotati on (Tim eBasedRental) Specify Re ntalPeriod Approve Q uotation G enerateRental Agreem ent Yes SpecifySkill &OTRates Specify Spares& Accy.
- 64. RFQ to Agreement(Usage Based Rental) Custom erRFQ Equipm ent Available? Equipm ent PriceEngine EN D Pr oce ss N o Re ntalQ uotati on (Tim eBasedRental) Specify UsageParam eters Approve Q uotation G enerateRental Agreem ent Yes Specify Spare s& Accy.
- 65. Agreement 1. Create Agreementagainst Lease Quotation 2. Assign Billing Frequency 3. Assign Mobilization & Assembly rates 4. Specify Additional Lease Details Lease Details 1. Assign Equipments 2. Assign Skills 3. Assign OT & Holiday Rates for Equipment & Labour Rental Process
- 66. Agreement to Dispatch RentalAgreem ent Skills M appe dIn SLA? AssignEm ploye es Equipm ent&Accy. Assignm ent N o Equipm ent allocatedin SLA? DispatchEquipm ent &Accessorie s Yes N o Yes
- 67. Equipment Allocation 1. Equipment& Accessory Allocation 2. Equipment & Accessory Replacement 3. Equipment & Accessory Deallocation
- 68. Dispatch 1. Track Equipment& Accessories & Dispatches 2. Maintain Dispatch, Cust. Receipt & Ack. Details 3. One unique tracking no. for all dispatches Receipt 1. Track Equipment & Accessories & Receipts 2. Maintain Cust Dispatch & Depot Receipt Details 3. One unique tracking no. for all Receipts Dispatch & Receipt
- 69. Time Sheet Booking 1.Book Equipment & Employee timesheets 2. OT Hours, Holiday Hours Auto computed & no manual entry 2. Supports Timesheet booking for fixed rental billing Usage Booking 1. Record Equipment Usage against Agreement 2. Updates Equipment Usage log on Approval Actuals Reporting
- 70. Actuals Booking &Billing - Fixed Rental GenerateBillingW O (Asp erBillingFreq.) G enerate Invoice ReceiveEquipm ent &Accessories LeaseExpired? No AssignN ew Equipm ent StartEquipm ent OperationsOnsite Yes Equipm ent Down Deallocate Equipm ent Equipm en t Receipt
- 71. Agreement to Invoicing- Timesheet Based Rental GenerateBillingW O (AsperBillingFreq.) Generate Invoice ReceiveEquipment &Accessories LeaseExpired? No AssignNew Equipm ent StartEquipm ent OperationsOnsite Yes Equipm ent Down Deallocate Equipm ent ReportEm p. Tim esheet Em ployee Assigned? Yes Standard Rental? Report Equipm entTime Sheet Yes No No Equipm ent Receipt
- 72. Agreement to Invoicing- Usage Based Rental GenerateBillingW O (Asp erBillingFreq.) Generate Invoice ReceiveEquipment &Accessories LeaseExpired? No AssignN ew Equipm ent StartEquipm ent OperationsOnsite Yes Equipm ent Down Deallocate Equipm ent ReportEm p. Tim esheet Em ployee Assigned? Yes Standard Rental? Report Equipm entUsage Yes No No Equipm ent Receipt
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