Martin Butler presented a solution to improve routine work management (RWM) at Kumba Iron Ore. The current SAP PM module was ineffective for planning and scheduling tasks or allocating resources. The solution was to develop an add-on system to calculate available man-hours and allocate resources to scheduled tasks. This would provide visibility into resource utilization and allow for optimal allocation. However, future upgrades may not include the add-on and it cannot integrate with other SAP functions for reporting. Considerations for future projects include involving ERP specialists, ensuring upgrades and a BI system for accurate reporting.

1. ROUTINE WORK MANAGEMENT
IMPLEMENTATION – KUMBA IRON ORE
Group 3
Martin Butler
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2. CONTENTS
• Physical Asset Management
• Planning Problem
• Resources Allocation Problem
• Routine work management process
• Solution
• Pros and cons
• Consideration for future projects
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3. PHYSICAL ASSET MANAGEMENT
Maintenance Strategy
100%
Maintenance Process Reengineering Organization / Human Resources
80%
60%
Reliability Analysis Information Technology
40%
20%
Performance Measures /
Autonomous Maintenance and TPM 0%
Benchmarking
Routine Work Management (Planning
Maintenance Tactics
& Scheduling)
Shutdown (SD) & Turnaround (TA)
Contractor Management
Management
Materials Management
Overall Team Assessment Pwc Benchmark
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4. PLANNING PROBLEM
SAP PM module ineffective with regards to planning and scheduling
Difficult to plan a task in detail with different operations on one work
order
Unrealistic controls and measure that need to be completed for routine
tasks
Feedback received from maintenance personnel will be manipulated
due to unrealistic work process
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5. RESOURCES ALLOCATION PROBLEM
SAP PM Function not able to calculate available man hours for a
specific period
Therefore not able to allocate available resources to planned tasks
Managers therefore not able to optimize available resources
Difficult to determine the optimal FTE per equipment
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6. ROUTINE WORK MANAGEMENT PROCESS 1 Identifying
2 Planning
3 Scheduling
4 Allocation
5 Executing
6 Analysis
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7. THE SOLUTION
Develop a add-on system to calculate and allocate resources
Maintenance Managers must be able to calculate man hours available
Available hours need to be allocated to scheduled tasks
Measure planned vs unplanned task execution
Improve on maintenance processes continuously
Improve the OEE
Assist Management to evaluate the utilization of resources
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8. ADDITIONAL SYSTEM
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9. PROS
Visibility on effectiveness of maintenance resource utilization
Resources could be allocated to different areas
Best practice with regards to planning and scheduling of resources
CONS
Future upgrades on SAP will not include RWM add on
SAP cannot utilize info for reporting on other functions
Back-up and support needed from IT department and not from SAP
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10. CONSIDERATION FOR FUTURE PROJECTS
Rather include ERP system specialist during development
Ensure further development and upgrades
BI system to be considered to ensure accurate reporting
More focus on continuous improvement with regards to planning of
tasks
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11. THANK YOU
ANY QUESTIONS? 11