Turnaround / Shutdown Management with SAP
Enterprise Asset Management
Dean Fitt
SAP AG
A collaboration of:
What I’ll Cover
 SAP Enterprise Asset Management can be used to manage the whole lifecycle of a
Shutdown.
 Integration and ease of use based on ERP components plant maintenance (PM) and
project system (PS) enabled through the use of Maintenance Event Builder (MEB).
 Portfolio and Project Management (PPM) and Multi Resource Scheduling (MRS) that
support the process.
 Highlight enhancements and new functionality.
 Key points to Take Home
 Questions
Contents
 Introduction & Overview
 SAP Solution for Shutdown Management
 Wrap Up
Why are Shutdowns so important?






Most critical periodical event during the plant life cycle.
Single most influential contributor to the total cost of maintenance.
Safety, Health, and Environment regulations must be adhered to.
Ensures future plant performance and safe-guards the investment.
Compliance with Statutory Regulations
Complex event - time of increased activity, with numerous vendors, contractors, and
heavy equipment engaged in multiple tasks in close quarters.
 Involves strong interaction between Maintenance and Operations.
Typical Phases of a Shutdown
Definition
Planning
Scheduling
 Initial Planning
 EH&S Plan
 Critical Path
 Scoping
 Work Packages
 Resource Leveling
 Work Lists
 Plan Cost
 Pre-shutdown
preparation
 Resource Plan
 Align Capital Work
 High Level Schedule
 Cost Plan (Budget)
 Daily Schedules
Execution
Evaluation
 Execute Work
Packages
 Demobilization
 Time, Material
Confirmations
 Cost Reconciliation
 Manage Break-in
Work
 Post Mortem
 Financial Report
 Progress Reporting
 Equipment Testing
 Work Permits
Timeline
H1
Definition
H2
Planning
H3
H4
Scheduling
Execution
Evaluation
Contents
 Introduction & Overview
 SAP Solution for Shutdown Management
 Wrap Up
SAP Solution for Enterprise Asset Management
Asset
Maintenance
Plan &
Design
MRO
Procurement
& Inventory
Human
Resources
Inspection
& Calibration
Asset
Health
Monitoring
RFID
and
Mobile Devices
Project Management
Materials
Requirements
Planning
Core
Financials
Financial
Optimization
Reliab. Reporting
Procure
& Build
Commission
Operate
Maintain
Decommission
Planning, Building, and
Commissioning Assets
Design &
Specify
Procure
& Build
Enterprise
Asset
Management
Decommission
& Dispose
Asset Visibility
and Performance
Optimized Asset
Operations and Maintenance
Operate &
Maintain
Operational Risk Management
Real Estate Lifecycle Management
SAP supports organizations to efficiently and sustainably manage the whole lifecycle of physical assets in terms of
performance, risks, and expenditures to achieve and maintain the stated business objectives.
 Integrated asset management processes to collaborate across all related activities such as finance, HR, risk, and compliance – easily deployable in
modular implementable steps
 Asset intelligence and a holistic view of performance, risks and expenditures throughout an asset’s lifecycle to ensure efficient utilization of assets
 Continuous and proactive operational risk management to support instant decisions and minimize disruption
 Leverages the SAP Business Suite
* According to PAS 55, the BSI standard for good practice in asset management
SAP Solutions Supporting Shutdown
Definition
Planning
Scheduling
Execution
Evaluation
 Portfolio and
Project
Management (PPM)
 Plant Maintenance
(PM)
 Plant Maintenance
(PM)
 Plant Maintenance
(PM)
 Portfolio and Project
Management (PPM)
 Project System (PS)
 Project System (PS)
 Plant Maintenance
(PM)
 Project System (PS)
 Maintenance Event
Builder (MEB)
 Multi Resource
Scheduling (MRS)
 Project System (PS)
 Cross Application
Time Sheet (CATS)
 Plant Maintenance
(PM)
 Document
Management System
(DMS)
 Enterprise Project
Connection (EPC)
 Mobile EAM Work
Order
 Financial (FI) /
Controlling (CO)
 Materials
Management (MM)
 Materials
Management (MM)
 Multi Resource
Scheduling (MRS)
 Business Intelligence
(BI)
 Maintenance Event
Builder (MEB)
 Materials
Management (MM)
 Maintenance Cost
Budgeting (MCB)
 Project System (PS)
Long Term
Planning &
Monitoring
High Level Architectural View – Shutdown Management
Portfolio / Strategic Buckets
Portfolio Initiative (Program)
Portfolio Item (Project / Proposal)
Asset Planning &
Operations
Project Planning
& Execution
SAP Portfolio and Project Management
optional: Project, Phases, Tasks,
Checklist Items...
Project
Costing
Model
Base Planning
Object
WBS
Network Activities
SAP ERP Project System
Maintenance Cost Budget
PM Order
Notification
Maintenance Plan
Task List
Technical object
PM Order
SAP ERP Plant Maintenance
Maintenance Event
Builder
Multi Resource
Scheduler
Definition
Definition
Planning
Scheduling
Execution
Evaluation
The Planning and Scheduling Life Cycle
Planning
Strategic
Planning
Planning Bucket
Asset Details
Resource
Work details
Quarterly
Plant/ Group
Role level
Project level
Portfolio & Project Management
(PPM)
Tactical
Planning
Scheduling
Execution
Planning
Execution
Detailed
Schedules
Execution
Controlling
Monthly
Daily
Subsection
Floc
Floc/Equip
Equip
Trade
Team
Individual
Individual
Orders
operation
Operation
Operation
Team
Phases
& task
Project System
+ PM Orders
+ Maintenance Event Builder
shift
Evaluation
Multi
Resource
Scheduler
(MRS)
Hours
Planning Granularity
Definition
Time
Job Control and
Analytics
SAP Portfolio and Project Management
SAP Portfolio and Project Management 5.0
Portfolio Planning & Monitoring
Long Term Investment & Portfolio Planning
Risk Assessment, Prioritization
High Level Cost Planning
High Level Resource Planning
SAP Project System (PS)
Capital Pre-Approval
Project Management & Execution
Project Scheduling
Detailed Resource Planning
Detailed Cost Planning & Approval
Scheduling & Dispatching
Regulatory Reporting
Document Management
SAP ERP for Maintenance,
Logistics Financials, HR
Core Processes / Activities
-
Developing Work Lists and Packages
Cost Planning
Processing of work orders
Update of technical assets
Maintenance Event Builder (MEB) – A Workbench for Shutdowns
Prod. Line / Asset 1
Prod. Line / Asset 2
Prod. Line / Asset 3
Prod. Line / Asset 4
t
Maintenance Event Builder
Maintenance Opportunities /
Events
Notifications
Revisions
Orders
General Task Lists
Project
Standard Network / WBS
 Facilitates Maintenance Planning and
Scheduling
 Helps eliminate redundant tasks within a
work package
 Sequences maintenance tasks by assigning
them to appropriate time frames
 Planning project based maintenance events
PS - Project Builder
MEB - Workbench
PM - Developing Work Lists
PM - Maintenance Plans
MCB - Data Flow
Maintenance
Plans
0PM_PRM_PLCS_1
Extractor
Forecast of resources like parts,
service and internal resources
0PM_DS07
0PM_C05
Maintenance Task
list
(Notifications)
Cost planning and
budgeting
0PM_C06
0PM_OPA_1
Maintenance
Maintenance
Orders
Orders
Extractor
0PM_DS04
0PM_C01
Estimated
Unplanned demands
Planning
Definition
Planning
Scheduling
Execution
Evaluation
MEB - Review Backlog

The planner reviews all open maintenance requests that need action.

The planner can group these task based on priority, location and resources needed
MEB - Review Maintenance Opportunity
Planner meets with operations team to plan shutdown
 Planner enters these opportunities as revisions in MEB

MEB – Creating Work Packages for the Shutdown
Based on the dates of the shutdown and priority, the planner assigns maintenance requirements (notification or WO) to the
event.
MEB - Generate Orders for a Revision
Once the work load is evaluated by operations and maintenance, the planner generates orders or assigns
generated orders to the work package
MEB – Optimizing the Work Package
Maintenance Event Builder ensures that all duplicate orders that have the same task list and assigned to same technical
objects are deleted
Revision
Notification
Chk1
SB1
T1
ST1
ST1
ST6
ST2
ST3
ST3
T2
Elimination
ST4
Order
Order
ST5
ST3
ST1
Order
Order
Order
Order
Order
Order
ST1
ST2
ST3
ST4
ST5
ST6
Insert video clip here:
-Overview Radiation Shaft
Scheduling
Definition
Planning
Scheduling
Execution
Evaluation
MEB - Assigning Orders to a Project Automatically
PM/PS - Assigning Orders to a Project Network
Orders can be assigned manually using drag and drop or automatically based on the
Reference PM/PS Element field. Transaction ADPMPS (does not require MEB)
PS - Network and Overall Network Scheduling
• Network Scheduling:
– schedule activities of one network only
• Overall Network Scheduling
(CN24)
– schedule all connected networks/subnetworks (and PM/CS
orders) simultaneously
• Overall Network Scheduling
with Selection Options
(CN24N)
– schedule selected networks/subnetworks simultaneously
– analyze dates of subnetworks (and PM/CS orders) using the
Subnetwork Monitor
PS - Project Editor
•
The Project Editor is enhanced with
•
•
•
•
Additional Data Sets for example PM/CS Order Dates
Date Planning and Scheduling (new)
Advanced Date Overviews and Comparison
Usability Improvements
Date Planning and Scheduling
Overall Dates Overview
Display PM/CS order in
hierarchy
Activity Dates Overview
PS - Project Editor Gantt Chart
In the Gantt Chart, you can:





Display dates of project objects (Tabular area, Graphical area)
Change dates and durations (Drag time bars for WBS elements, Specify dates in tabular area)
Define user-specific settings and manage variants (for example, time bar labels)
Choose different timescales (for example, monthly)
Print and print preview Gantt chart
Multi Resource Scheduling (MRS)
Demand Gantt
Work Center
Gantt
Work Center
Capacity
Alert Monitor
MRS - Scheduler Workplace
SAP Enterprise Project Connection (EPC)
Execution
Definition
Planning
Scheduling
Execution
Evaluation
Time Confirmation Using Cross Application Time Sheets (CATS)
Operations and activities can
automatically be defaulted for
users in CATS
Additional data
such as remaining
work can be
entered via mouse
click.
SAP EAM Work Order Mobile Application
Standard solution for mobilizing SAP Enterprise Asset Management
•
Technical Object Management
Notification Management
■ Create, view, and edit notifications and related
objects (activities, items, tasks)
•
■
■
■
■
Work Order Management
Create, view, and edit work orders
Display related business partners and historical data
Record working time and material consumption
List, calendar, and map view
■
View equipments and functional locations
■
Display technical object on a map
■
Display associated documents
■
Display history and characteristics
Business Partner
■
Display business partner header and contacts
■
List and map view
Inventory Management
Online & Offline
■
Track and manage inventory
■
Material consumption booked on orders updates
inventory
Built on industry leading Sybase Unwired Platform
Work Permit Management (WPM)
 Project with Statoil and ConocoPhillips
to develop an Oil&Gas specific permit to work
solution.
 Existing functionality in SAP Work Clearance Management (WCM) has been
enhanced, so that industry specific work processes for work permits can be
configured in customizing.
WPM - Work Preparation Create Operational Valve & Blind List
Evaluation
Definition
Planning
Scheduling
Execution
Evaluation
Reporting and Analytics Options
KPI Framework
Reports within
BCV
Dashboards
Crystal reports
integrated
Contents
 Introduction & Overview
 SAP Solution for Shutdown Management
 Wrap Up
Long Term
Planning &
Monitoring
High Level Architectural View – Shutdown Management
Portfolio / Strategic Buckets
Portfolio Initiative (Program)
Portfolio Item (Project / Proposal)
Asset Planning &
Operations
Project Planning
& Execution
SAP Portfolio and Project Management
optional: Project, Phases, Tasks,
Checklist Items...
Project
Costing
Model
Base Planning
Object
WBS
Network Activities
SAP ERP Project System
Maintenance Cost Budget
PM Order
Notification
Maintenance Plan
Task List
Technical object
PM Order
SAP ERP Plant Maintenance
Maintenance Event
Builder
Multi Resource
Scheduler
Best Practice
Stage 1 - Developing
 Planning of Effort
 90% of Planned Work
Completed
 Within Budget <5% Over
 All Equipment inspected
Stage 2 - Maturing
 Tight control of scope
 Manage resource
constraints
 Daily status update of
progress
 95% of planned work
completed
 Estimates of work based on
industry norms
 Equipment available for
maintenance
 Delays in equipment startup as a result of integrity
issues
Stage 3 – Best Practice
 Portfolio management
process in place
 Issues rectified early
 Quality of work to ensure
on-time start-up
 Materials and Resources
managed to ensure
availability at right time
 Work Permit process
streamlined
 Early planning
 Shutdown and start-up on
time
Dean Fitt
SAP AG
dean.fitt@sap.com