Work Management and SAP Nuclear
Danilo Spaziani
EBO NPP
18th Annual Nuclear Seminar and Information Meeting
Častá-Papiernička, 28-29th April 2010
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps: corrective and recurring maintenance
5. Conclusions
2
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps: corrective and recurring maintenance
5. Conclusions
3
SAP Nuclear Project: Need for Change
The long term goal for Sloveske Elektrarne Nuclear is to achieve Top Decile
Performance in Safety, Reliability, Production, and Efficiency and become the
World’s Premier Operator Of VVER Technology
An international benchmarking effort to identify Nuclear Industry Best Practice
resulted in recognition of significant gaps in the following programs:
•
Work Management
•
Equipment Reliability
•
Corrective Action
•
Operating Experience
•
Self Assessment& Benchmarking
•
Human Performance Improvement
•
Current Software (ARSOZ) not supporting Best Practice Programs
SE needed to establish a model that
specified appropriate safety and
operational standards including
management, quality assurance,
practices and behaviors
4
SAP Nuclear Project: SNPM
Standard Nuclear Performance Model
Electricity Production
The SAP Nuclear Project is the
Implementation Phase of a 3-years
MAJOR Process and Organizational
Redesign of the Slovenské Elektrárne
Nuclear Organization
Operate Plant
(INPO)
CORE PROCESSES
INPO 01-002 Conduct of Operations
Manage Configuration
(CMBG)
Work Management
(INPO)
Equipment Reliability
(INPO)
(ANSI/NIRMA CM 1.0-2000)
(AP-928)
(AP-913
Materials and Services
(NEI)
(AP-908)
ENABLING PROCESSES
Management
Processes and
Support Services
(NEI)
Loss
Prevention
(NEI)
Training
(INPO)
(AP-921)
Nuclear Fuel
(NEI)
5
SAP Nuclear Project: Benefit
SE Model redesign resulted in new Programs based on Nuclear Industry Best Practice
in the following areas:
•
•
•
•
•
•
Work Management – INPO AP 928
Equipment Reliability – INPO AP 913 (project ongoing)
Corrective Action – WEC functionality based on North American Best Practice
Operating Experience
Self Assessment&Benchmarking
Human Performance Improvement
SAP Software System configured and customized to support Nuclear Industry
Best Practice Programs
Implementation of the SAP Nuclear Project will act as an
accelerant to process, organizational, and behavioral
change leading to significant gains in safety, efficiency,
plant performance, and organizational behavior
6
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps: corrective and recurring maintenance
5. Conclusion
7
SAP Nuclear – Project Objectives and Strategy
Improve EBO and EMO safety and operational performance
Build up SAP Nuclear Competence Centre
Radiation and Radioactive Waste
Management Processes.
ARSOZ is considered as process
standard for new implementation.
Work Management, Equipment
Reliability, and Continuous
Improvement Processes.
INPO Guidelines are standard
AP-928 (Work Management Process
Description)
AP-913 (Equipment Reliability Process
Description)
Strategy:
Replace ARSOZ by SAP functionality.
No Major Process Changes.
Small changes will be made to adapt to EH&S and
to align facilities on single processes
Corrective Action Process - based on
Nuclear Industry best practices as key
inputs in process designs
Strategy:
New processes, new organization structure,
and new software system.
New Integrated system
SAP Nuclear Competence Centre
8
SAP Nuclear Project – SE Approach
2008
7 – 9/08
EAM
Template
10 – 12/08
1 – 3/08
4 – 6/09
7 – 9/09
10 – 12/09
1 – 3/10
4 – 6/10
EAM 80%
Baseline
EH&S
Concept
Implementation
EH&S
Baseline
Training
of Trainers
Development
of RICEFW
Tender
2010
Migration 1
Training
End Users (200)
4 – 6/08
2009
Full production
EMO
Limited Production
(Planning 2010)
EMO/EBO
ARSOZ – running
200-300 End Users
Full production
EBO
Training of end Users
(cca. 2800)
Migration 2
3
Change Management
Sup. 1
Preliminary Go-Live:
Sup. 2
Go-Live:
9
Sup. 3
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps: corrective and recurring maintenance
5. Conclusion
10
Work Management in SE
As defined in the INPO AP-928 the Work Management process is used to Identify,
Plan, Schedule, Execute, and Close work in a manner that helps ensure high levels of
safe and reliable plant operation.
The process encompasses the following steps:
Work Identification
Planned Maintenance – Preventative and Surveillance
On-line
Corrective Maintenance
Modification Activities - Investment
Work Planning
Technician Instructions
Parts, Tools, Blocking, R-Orders, etc.
Work Scheduling
IPSEC
Daily, Weekly, quarterly, cycle online schedules
Outage schedules
Long Term Schedules
Work Execution
Work Close
Outage
11
Work Management: Online Activities
Work management is the process by which maintenance, modifications,
surveillances testing, engineering support, and any work activities that require
plant coordination or schedule integration are implemented
Processes are simple, efficient, incorporate human factors considerations,
and ensure effective performance during all phases of plant operation
Planning and scheduling are applied to activities that impact plant operation or
require detailed work instructions.
The duration of the scheduled work activities are reviewed against technical
specifications and Probabilistic Risk Assessment (PRA). Work is scheduled to
optimize safety system availability and to ensure maintenance can be performed
within allowed regulatory or administrative time limits
13 Weeks Cycle
12
E-6
E-5
Scope Cooling
E-4
Cycle Manager
E-3
E-2
Schedule Cooling
E-1
Work Manager
Planning
Engineering
Parts - Materials – External Resources
Scheduling
Operation - PRA
Operation - Clearance
Work Groups
13
E-0
Review - Feedbacks
E-7
Work Execution
E-8
Work Package Ready
E-9
Schedule Freezing
E-10
Schedule E-4
E-11
Scope Freeze
E-12
Schedule E-10
E-28
Scope E-12
Scope E-28
Post Work
Week Critique
Meeting
Plan of the Day
Meeting
Work Week
Turnover
Technical Rigor
Review
Schedule
Freeze Meeting
Cycle Mg /
Work Week Mg
Turnover
Scope Freeze
Meeting
Coordination
Meeting
Scope
Evaluation
Meeting
Right Work
Meeting
Long ahead
scope meeting
Work Management: On-line 13 Week Cycle
E+1
Work Management: Refueling Outages
The Outage Management process defines a structured approach for the
preparation, the execution and the assessment of refuelling outages by
following the Work Management principles through the IPSEC steps
implementation over a period of 21 months
M-19
Identify
long lead
material
M-18
M-11
M-10
Identify pre- Design
outage
scope
team
freeze
M-9
M-8
Engineering
scope
freeze
Outage
scope
freeze
M-7
M-6
M-4
M-3
Operations
planning for
Wos
Identification Phase
Set outage
golas
M-5
M-2
WCD
preparation
M-1
M-0
M+1
Complete
planning
process
Pre-outage
readiness
assessmen
Outage
activities
execution
Outage
review
process
Execution Evaluation
phase
phase
Preparation Phase
Issue
Schedule
Rev. A
Issue
Schedule
Rev. B
Issue
Schedule
Rev. 0
Perform
ALARA
evaluation
Issue
Schedule
Rev. 1
Each phase is characterized by set of predefined milestones
accurately scheduled in order to optimize the whole
Outage Management process
14
Work
schedule
tracking
Feedback &
lessons
learned
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps: corrective and recurring maintenance
5. Conclusions
15
The IPSEC Steps: Why SAP
Why SAP?
SAP advantages:
• For every management level:
- flexible approach to important information on time
- data reliability
- approach to the same information for every user (limited only by position)
- easier decision process
• For every organization element:
- improvement of the management for operations and transactions
- easier data processing and distribution
- easy maintenance
- used all over the nuclear industry
16
The IPSEC Steps: Why SAP
SD
Modules Description:
FI
MM
CO
AM
SAP
PP
R/3
QM
IM\PS
WF
PM
HR
IS
SD
MM
PP
QM
PM
HR
EH&S
IS
WF
IMPS
AM
CO
FI
PS
Sales and Distribution
Materials Management
Production Planning and Control
Quality Management
Plant Maintenance
Human Resources
Environmental Health and Safety
Industrial Solutions
Work flow
Investment management
Asset Management
Controlling
Financial
Project system
EH&S
Implemented
Modules
in SE, a. s.
The IPSEC steps: Corrective Maintenance
SAP / WEB
Maintenance
work is
Identified
Maintenance
notification is
created in SAP
SAP
Notification is
reviewed and
converted into a
work order
Work is Planned and Scheduled
and the work order is released
SAP
End
Accounting settles the
work order and business
close.
Work order is “Technically Work progress work and
Closed” by the Planner status
(TECO)
Maintenance
work is assigned and
Executed
18
The IPSEC steps: Recurring Maintenance
SAP
Create/ Update Task List/
Maint.Plan
Identify
changes to
the Plan
Work order is auto
generated
(Identified) in SAP
from Maintenance
plans
Work is Planned and Scheduled
and the work order is released
SAP
End
Accounting settles the
work order and business
close.
Work order is “Technically Work progress work and
Closed” by the Planner status
(TECO)
Maintenance
work is assigned and
Executed
19
The IPSEC steps: Identification
AP-928
Identify
-Object
-Symptoms
-When
Create Notif.
Plan
-Object
-When
-What steps
-Resources
-Internal Labor
-Contractors
-Services
-Materials
-Tools
Schedule
-When
-What steps
-Avail. Res.
-Avail. Eqpmt
-Capacity
Close
-Shop papers
-Use resources
-Parts
-Materials
-Tools
-Purchasing
-Work complete
-Time recorded
-What was done
-Labor used
-Parts used
-Materials used
-Return tools
Schedule WO
Print Work Order
Assign WO
Perform Work
Create WO
Release WO
Continuous
Improvement
Execute
Complete WO
Complete Notif.
Analyze
-Usage history
-Performance
-KPIs
AP-913
20
The IPSEC steps: Identification
1. Initial problem discovery
Operator identifies problem during normal rounds / personal identifies issues
Captures data
Tags equipment
2. Problem entered in SAP as a Notification
WHAT
3. Initial Review – Shift Supervisor
Operability review (task generation)
Approval
4. Work Control Team Review – daily SOC meeting
Create work order
Code work order to online or outage
Set priority and preliminary schedule target (5 priorities)
5. Work Order Coding
Assign WO to main Work Management Cycle (online – outage)
Code WO out of Work Management Cycle (FIN team – minor maintenance – recurring activities)
21
The IPSEC steps: Planning
AP-928
Identify
-Object
-Symptoms
-When
Create Notif.
Plan
-Object
-When
-What steps
-Resources
-Internal Labor
-Contractors
-Services
-Materials
-Tools
Schedule
-When
-What steps
-Avail. Res.
-Avail. Eqpmt
-Capacity
Close
-Shop papers
-Use resources
-Parts
-Materials
-Tools
-Purchasing
-Work complete
-Time recorded
-What was done
-Labor used
-Parts used
-Materials used
-Return tools
Schedule WO
Print Work Order
Assign WO
Perform Work
Create WO
Release WO
Continuous
Improvement
Execute
Complete WO
Complete Notif.
Analyze
-Usage history
-Performance
-KPIs
AP-913
22
The IPSEC steps: Planning
1. Review – check history – equipment data
2. Preliminary requirements
Check for duplicity
Safety Classification
Approach grade
3. Define Work Scope
Work Steps / operations relationships
Timing
Resources
Support and permits
Work Clearance requirement
4. Materials/Services
5. Documents/Tools
6. Costs – Plan/Actual
HOW
7. Statusing for WOs
23
The IPSEC steps: Scheduling
AP-928
Identify
-Object
-Symptoms
-When
Create Notif.
Plan
-Object
-When
-What steps
-Resources
-Internal Labor
-Contractors
-Services
-Materials
-Tools
Schedule
-When
-What steps
-Avail. Res.
-Avail. Eqpmt
-Capacity
Close
-Shop papers
-Use resources
-Parts
-Materials
-Tools
-Purchasing
-Work complete
-Time recorded
-What was done
-Labor used
-Parts used
-Materials used
-Return tools
Schedule WO
Print Work Order
Assign WO
Perform Work
Create WO
Release WO
Continuous
Improvement
Execute
Complete WO
Complete Notif.
Analyze
-Usage history
-Performance
-KPIs
AP-913
24
The IPSEC steps: Scheduling
The scheduling is the process necessary to prepare a database containing
all the information needed to model the sequence of work tasks required to
accomplish the approved online/outage scope, minimizing the plant risk
and optimizing duration, cost and resources mobilization
System Window
The main scheduling technique is
based on “System window”
principle where all planned
maintenance, in service inspection
and testing activities on a piece of
equipment or a train of a system
are planned to be performed during
a pre-defined time period
System 1
FEG 1
WCD
FEG 2
WCD
WO 1
WO 2
WO 3
CDF minimization
WO
operations
WHEN
Functional
Equipment Group
WO 4
Work Clearance
Document
time
25
The IPSEC steps: Scheduling
SAP / WEB
Maintenance
work is
identified
End
Maintenance
notification
is created in
SAP
SAP
Notification is
converted into
a work order
Reports run to
identify order for initial
coding (sys cond)
Orders coded
to online or
outage
Maint Plan Maintenance plan
auto generate
orders
Finalize and print
schedule and
SAP WOs
SAP
Run Interface in
reverse and send
operation data
back to SAP
Scheduler to
schedule
operations and
WCD’s in external
software
SAP – Primavera
Run SAP
interface to
external
software
Perform initial
work center
capacity
evaluations
Planning to
perform initial
sequencing of
operations
26
Work is planned
and the work order
is released
The IPSEC steps: Scheduling
Order data:
Order number, type
Short text
Functional Location
Main Work Center
FEG
Due date
Overdue date
Revision code
Basic start / end date & time
System Status / User status
Add / drop field ( custom)
WCA
FEG of WCA
WCD number
SAP
Operations:
Order data:
Primavera
Scheduling
Process
SAP
Work Order number
Revision Code
WCA number (linked to Work Order)
WCD number (linked to Work Order)
Operations:
Restriction start date
Restriction start time
Restriction end date
Restriction end time
Activity ID
Operation #
Project ID
Operation short text
Position on Critical Path
Control key
Duration
Number of persons
Work center of operation
Early start / finish date & Hours
Actual start / finish date and hours
Relationships data
WCD basic data:
WCD #
WCD basic data:
Date & time tags hanging start
Date & time tags hanging end
Date & time tags removal start
Date & time tags removal end
Primavera Project ID
Primavera Activity ID
Position on Critical path
WCD Description
WCD Functional Location
System Status / User Status
Revision code of the WCD
FEG of the WCD
Interface - data synchronization
27
The IPSEC steps: Execute
AP-928
Identify
-Object
-Symptoms
-When
Create Notif.
Plan
-Object
-When
-What steps
-Resources
-Internal Labor
-Contractors
-Services
-Materials
-Tools
Schedule
-When
-What steps
-Avail. Res.
-Avail. Eqpmt
-Capacity
Close
-Shop papers
-Use resources
-Parts
-Materials
-Tools
-Purchasing
-Work complete
-Time recorded
-What was done
-Labor used
-Parts used
-Materials used
-Return tools
Schedule WO
Print Work Order
Assign WO
Perform Work
Create WO
Release WO
Continuous
Improvement
Execute
Complete WO
Complete Notif.
Analyze
-Usage history
-Performance
-KPIs
AP-913
28
The IPSEC steps: Execute
Work Order is Executed
Operations to hang Work Clearance Tags in the field
WCA is approved
Permits are approved
Order is set by Ops to EXEC (Ready to execute)
Maintenance sets Order User status to MWIP (in progress)
Execute the work into the filed
Field operations partially and then finally confirmed
Outage
Outage schedule tracking / adjustment
Work executed
SAP - Primavera
Schedule
tracking
29
The IPSEC steps: Close
AP-928
Identify
-Object
-Symptoms
-When
Create Notif.
Plan
-Object
-When
-What steps
-Resources
-Internal Labor
-Contractors
-Services
-Materials
-Tools
Schedule
-When
-What steps
-Avail. Res.
-Avail. Eqpmt
-Capacity
Close
-Shop papers
-Use resources
-Parts
-Materials
-Tools
-Purchasing
-Work complete
-Time recorded
-What was done
-Labor used
-Parts used
-Materials used
-Return tools
Schedule WO
Print Work Order
Assign WO
Perform Work
Create WO
Release WO
Continuous
Improvement
Execute
Complete WO
Complete Notif.
Analyze
-Usage history
-Performance
-KPIs
AP-913
30
The IPSEC steps: Close
Time sheet
Entry
Work Order and Notification Closed
WO set WOCO status by Maintenance
WCA is completed by Maintenance
WCD set to untag by Plant Operations
Safety tags removed in the field
Work Order
Completion
WCD is closed
Notification has history updated and final
trending completed
All open tasks completed
WO is set to a TECO system status
Notification auto closes
WO archived
Materials
usage
Activity
Reports
Cost
settlement
Notifications
Technical
completion
31
The IPSEC steps: Work Management KPIs
Work Management Process needs a monitoring system that incorporates a systematic review of actual
results and compares these with expectations established by objectives.
As shown by Nuclear industry experience SE adopted an effective way to perform work management
monitoring by using a set of indicators (KPIs) that reflect, in a quantitative manner, the achievements
of the expected results for on-line and outage process.
On-line
Outage
KPIs
KPIs
•Urgent work/High priority
•Scope stability
•On-line executed work
•Weekly executed work
•Not terminated work
•Scope stability from T-6  T-0
•Deviations from planned work man-hours
•WOs operations planned
•WOs planned
•WCD prepared
•WOs added to weekly plan
•Number of NM notifications
•…
•Planned outage duration
•Outage scope
•Scope stability
•Outage cost vs. budget
•Outage total dose vs. dose budget
•Regulatory Body involvement
•WOs operations planned
•WOs planned
•WCD prepared
•Materials and services preparedness
•Outage personnel preparedness
•Timeliness of critical path
•Number of Safety events
•Unplanned work rate
•Not executed work rate
•Number of contaminations events
•Number Human performance error events
•…
Evaluated on
weekly and
monthly basis via
SAP and
interfaced
software
Agenda
1. SAP Nuclear Project
2. Project implementation
3. Work Management Process: on-line and outage maintenance in SE
4. The IPSEC steps in SAP: corrective and recurring maintenance
5. Conclusions
33
Conclusions
7 months after the SAP Nuclear Project Go-live it can be stated that:
 Work Management process is currently implemented at both SE sites (EBO and EMO)
 New way of managing work preparation and execution for on-line and outage
 Organizational structure completely redesigned to support process implementation
 SAP as implemented and customized capable to support the whole Work Management
process (including clearance and permits)
 The usage of Primavera for WOs scheduling safe and reliable also for schedule tracking
 KPIs used on weekly on monthly bases for process monitoring and improvement
 Remarkable increase of operational and safety standards  Work Optimization
 Alignment with Nuclear Industry leader organizations
 Stronger cooperation between SE Facilities and increased capability of international
benchmarking
 SAP Nuclear and Work Management experience as an improvement tool to be exported
inside Enel Group nuclear companies
34
Questions?
35