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Transcript of BRD- MAINTENANCE
NBCL PLANT MAINTENANCE MODULE
COMPILED BY: ICST /16.07.15
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
NYANZA BOTTLING CO .LTD
Business Requirements Document
(BRD)
Prepared by: ICST- NBCL
Prepared for: Management -NBCL
Date Submitted:
Document Number: 1/ PLANT MAINTENANCE /BRD
Version: 0.1
Last Updated: July 16, 2015
Creation Date: July 16, 2015
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
VERSION
Version Number
Prepared
By
0.1 SANGAM BADAJENA
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
VERSION UPDATED
Submitted
Date
Approved
By
Approval
Date
Description ofChange
Description of Change
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
TABLE OF CONTENTS
INTRODUCTION ................................
Purpose of a Requirements Analysis
Audience ................................
Stakeholder Identification ................................
Purpose of BRD ................................
Business Goal ................................
Benefits of BRD ................................
BUSINESS OVERVIEW ................................
Flow Chart ................................
Suggested ERP flow......................................................................
OEE Report Calculation...........................................................................
APPENDIX A: REQUIREMENTS ANALYSIS APPROV
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
TABLE OF CONTENTS
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Purpose of a Requirements Analysis ..................................................................................
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flow...................................................................................................
OEE Report Calculation.............................................................................................
ENTS ANALYSIS APPROVAL .................................................
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NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
1 INTRODUCTION
1.1 PURPOSE OF A REQUIREMENT
A requirement analysis document
for a new or altered PLANT MAINTENANCE
is the process of gathering information about business and technical requirements supporting a request,
consolidating this information into a cohesive document.
1.2 AUDIENCE
The audience for this document includes:
1. NBCL Management
2. Maintenance Department.
3. ICST-NBCL
4. ESS- Service Provider [i.e., developers who may participate in the requirements
Implementation of ERP Module]
1.3 STAKEHOLDER IDENTIFICATION
Stakeholder Name
Number of Individuals
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
REQUIREMENT ANALYSIS
encompasses activities conducted to determine the needs or conditions
PLANT MAINTENANCE process. It commonly takes place after a request is received. It
is the process of gathering information about business and technical requirements supporting a request,
consolidating this information into a cohesive document.
includes:-
developers who may participate in the requirements
CATION
Number of Individuals
Critical Success Factors
encompasses activities conducted to determine the needs or conditions
. It commonly takes place after a request is received. It
is the process of gathering information about business and technical requirements supporting a request,
developers who may participate in the requirements at later stage for
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
1.4 PURPOSE OF BUSINESS REQUIREMENT
The main purpose of the BRD is to Implement ERP
current process in System.
1.5 BUSINESS GOALS / OBJECTIVES TO BE ACH
• Planned / preventive, repair, emergency and other user
• Ensure all materials, supplies and parts are available and accessible to maintain and service
equipment.
• Access existing or create new maintenance work orders from
and reporting
• Complete maintenance history and audit trail
• Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg
Spare inventory are consum
• Generate work orders and schedule
level) for planned maintenance
1.6 BENEFITS OF BRD
Through this BRD, one can analyze all process
ICST & Maintenance Team to switch all system in ERP with required Reports.
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
USINESS REQUIREMENT DOCUMENT
The main purpose of the BRD is to Implement ERP for PLANT MAINTENANCE
OBJECTIVES TO BE ACHEIVED
preventive, repair, emergency and other user-defined maintenance tasks
Ensure all materials, supplies and parts are available and accessible to maintain and service
create new maintenance work orders from system to enhance communication
Complete maintenance history and audit trail
Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg
Spare inventory are consumed
Generate work orders and schedule material inventory and required labor (with associated skill
level) for planned maintenance
BRD, one can analyze all process. This document will help Management,
m to switch all system in ERP with required Reports.
PLANT MAINTENANCE & to incorporate all
defined maintenance tasks details.
Ensure all materials, supplies and parts are available and accessible to maintain and service
to enhance communication
Maintain an accurate picture of all cost activity against equipment maintenance as hours and Engg
material inventory and required labor (with associated skill
anagement,
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
2. BUSINESS OVERVIEW
In NBCL & NDL Maintenance team is following 4 kinds of maintenance process
1. Annual Maintenance (Through OEM)
equipments & will submit a report to Management with complete details of service need to be done
(Spare part details, Time to resolve
reports to Management and after required approvals maintenance team will make Purchase request for
spare parts if it is not available in Stores. After receiving Spare parts ,OEM person will come and resolve
the issue.
2. Preventive Maintenance- In this type of maintenance maintenance time /Date is fixed. Team will plan
accordingly.
3. Predictive Maintenance- In this type of maintenance ,team have to plan
machines.
4. Break Down Maintenance- This is a situation where team have to give support (Maintenance ) on
immediately.
All the above maintenance process are captured in manual sheets and then goes to management
preparing different reports. Only if OEM service person is comi
being raised. Rest all are in manual sheets.
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
In NBCL & NDL Maintenance team is following 4 kinds of maintenance process-
1. Annual Maintenance (Through OEM)- In this process a service person will come to analyze the
equipments & will submit a report to Management with complete details of service need to be done
(Spare part details, Time to resolve problem, Cost for resolving issue's). Maintenance team will send this
reports to Management and after required approvals maintenance team will make Purchase request for
spare parts if it is not available in Stores. After receiving Spare parts ,OEM person will come and resolve
In this type of maintenance maintenance time /Date is fixed. Team will plan
In this type of maintenance ,team have to plan as per
This is a situation where team have to give support (Maintenance ) on
All the above maintenance process are captured in manual sheets and then goes to management
preparing different reports. Only if OEM service person is coming for service then only a service PO is
being raised. Rest all are in manual sheets.
-
In this process a service person will come to analyze the
equipments & will submit a report to Management with complete details of service need to be done
issue's). Maintenance team will send this
reports to Management and after required approvals maintenance team will make Purchase request for
spare parts if it is not available in Stores. After receiving Spare parts ,OEM person will come and resolve
In this type of maintenance maintenance time /Date is fixed. Team will plan
as per to working condition of
This is a situation where team have to give support (Maintenance ) on
All the above maintenance process are captured in manual sheets and then goes to management for
ng for service then only a service PO is
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
2.3 FLOW CHART OF PLANT MAINTENANCE
MAINTENANCE
ANNUAL
MAINTENANCE
PREVENTIVE
MAINTENANCE
PREDECTIVE
MAINTENANCE
BREAK DOWN
MAINTENANCE
In
Annual Maintenance process
service PO need to close after
Work Order close.
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
PLANT MAINTENANCE-NBCL
STORE
WORK ORDER
PURCHASE
REQUEST
PO
MATERIAL
REVEIVED / GRN
Work Order In
Process
WORK ORDER
CLOSE
SERVICE PO TO
OEM
SERVICE PO
CLOSE
Spare part
availability
check at store
If
Yes If No
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
SUGGESTED FLOW IN ERP
STEP 1. ISSUE LOG (ANNUAL / PREVENTIVE
Whenever there will be some maintenance required , Maintenance team will have to
in system. This may be Annual maintenance / Preventive Maintenance / Predective Maintenance /
Breakdown Maintenance. This is a sample format to log problem
Abbreviations
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
(ANNUAL / PREVENTIVE / PREDECTIVE / BREAKDOWN
Whenever there will be some maintenance required , Maintenance team will have to
in system. This may be Annual maintenance / Preventive Maintenance / Predective Maintenance /
Breakdown Maintenance. This is a sample format to log problem details with Machine.
DOWN - MAINTENANCE)
Whenever there will be some maintenance required , Maintenance team will have to create an Issue Log
in system. This may be Annual maintenance / Preventive Maintenance / Predective Maintenance /
details with Machine.
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
COMMON PROCESS FOR APPLICATION
User can perform following task.
a. Add: It is used to add new record.
b. Edit: It is used to modify existing record.
c. View: It is used to view in details.
d. Close: It is used to close the screen/form
e. Delete: It is used to delete existing record.
f. Save: This button updates the modified entries.
g. Cancel: It helps in cancelling the ongoing process.
h. Print: It prints the report.
CANCELLING THE EXISTING ISSUE
There may be some scenario where modification required on
to login from their id & can make changes as per to requirement ( Approval Required
Mandatory). To make any changes department have to take approval from Management ( Auto alert to
Supervisor login / request for change ) through ERP Only . This process will capture all history of making
Plan , Editing , Cancelling & Closing details.
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
Add: It is used to add new record.
Edit: It is used to modify existing record.
View: It is used to view in details.
close the screen/form
Delete: It is used to delete existing record.
Save: This button updates the modified entries.
Cancel: It helps in cancelling the ongoing process.
SSUE LOG FROM SYSTEM / EDITING DETAILS FROM
There may be some scenario where modification required on loged data or cancelling the
to login from their id & can make changes as per to requirement ( Approval Required
atory). To make any changes department have to take approval from Management ( Auto alert to
Supervisor login / request for change ) through ERP Only . This process will capture all history of making
Plan , Editing , Cancelling & Closing details.
ETAILS FROM SAVED LOG DATA
data or cancelling the log , user need
to login from their id & can make changes as per to requirement ( Approval Required- Management -
atory). To make any changes department have to take approval from Management ( Auto alert to
Supervisor login / request for change ) through ERP Only . This process will capture all history of making
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
STEP 2: JOB ORDER/ CLOSING JO
After Making Maintenance Log
allocate the work in actual. User need to fill all details of
complete the Order.
*Once the JO is assigned to a supervisor through Work Order, System will show JO status as WIP &
Once Work order is completed , system will show JO status as Completed.
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
JO
for Machines , User need to make JO ( Job order) where they will
allocate the work in actual. User need to fill all details of Shift / Machine / Spare Part
*Once the JO is assigned to a supervisor through Work Order, System will show JO status as WIP &
Once Work order is completed , system will show JO status as Completed.
, User need to make JO ( Job order) where they will
Spare Part Required Qty to
*Once the JO is assigned to a supervisor through Work Order, System will show JO status as WIP &
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
STEP 3: (MRS) MATERIAL REQUISITION
In this form User can request for materials required for
after Maintenance / Repairing the balance materials will be issued
user need to select codes for the same
Abbreviations
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
EQUISITION SLIP
can request for materials required for Maintenance process. Material will be received &
the balance materials will be issued back to warehouse. For
the same.
. Material will be received &
to warehouse. For all Spare parts
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
STEP 4: MATERIAL RECEIVE NOTE
After getting materials from stores , user need to make " stock in" in
Maintenance team have to count all materials &
raised. Here they can enter the details like short fall in Qty while receiving materials from Stores
warehouse. This is very important for recording movements of each item through system.
mandatory here.
STEP 5: WORK ORDER / CLOSING
Here user need to allocate the work to respective supervisor along with the shift / Time required to
complete the JO. All spare parts will be handed over to supervisor to complete this work.
After completing Work Order , User need to change the status of WO to Close. This format will also be
used for closing Work Order in system.
all will be recorded in Machine Repair Logs. One can see in re
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
OTE
After getting materials from stores , user need to make " stock in" in Maintenance
team have to count all materials & cross check before making inward entry against MRS
raised. Here they can enter the details like short fall in Qty while receiving materials from Stores
. This is very important for recording movements of each item through system.
LOSING WORK ORDER
Here user need to allocate the work to respective supervisor along with the shift / Time required to
complete the JO. All spare parts will be handed over to supervisor to complete this work.
leting Work Order , User need to change the status of WO to Close. This format will also be
used for closing Work Order in system. When User will close the WO , the linked JO will be closed and
all will be recorded in Machine Repair Logs. One can see in reports - All history of the machines like No .
Maintenance warehouse .
cross check before making inward entry against MRS
raised. Here they can enter the details like short fall in Qty while receiving materials from Stores /
. This is very important for recording movements of each item through system. QC is
Here user need to allocate the work to respective supervisor along with the shift / Time required to
complete the JO. All spare parts will be handed over to supervisor to complete this work.
leting Work Order , User need to change the status of WO to Close. This format will also be
When User will close the WO , the linked JO will be closed and
All history of the machines like No .
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
of time it has been repaired / Day Wise / Supervisor Allocated / Time taken to repair / Type of
maintenance etc.
Over All Equipment Efficiency Report
There will be a report to calculate OEE (Over all Equipment
The table below contains hypothetical shift data, to be used for a complete OEE calculation, starting with
the calculation of the OEE Factors of
of measurement (in this case minutes and
Example-
Calculation steps-
As per to above example , system will calculate Planned Production Time, Good Bottles
Availability & finally Quality. Below formula defined for each steps.
Result-
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
of time it has been repaired / Day Wise / Supervisor Allocated / Time taken to repair / Type of
Over All Equipment Efficiency Report
There will be a report to calculate OEE (Over all Equipment efficiency ) during a shift.
The table below contains hypothetical shift data, to be used for a complete OEE calculation, starting with
the calculation of the OEE Factors of Availability, Performance and Quality. Note that the same units
of measurement (in this case minutes and Bottles) are consistently used throughout the calculations.
As per to above example , system will calculate Planned Production Time, Good Bottles
Availability & finally Quality. Below formula defined for each steps.
of time it has been repaired / Day Wise / Supervisor Allocated / Time taken to repair / Type of
efficiency ) during a shift.
The table below contains hypothetical shift data, to be used for a complete OEE calculation, starting with
. Note that the same units
) are consistently used throughout the calculations.
As per to above example , system will calculate Planned Production Time, Good Bottles, Operating Time,
NBCL PLANT MAINTENANCE
COMPILED BY: ICST /17.06.14
DOCUMENT No. NBCL/1/ PLANT MAINTENANCE
APPENDIX A: REQUIREMENTS ANALYSI
The undersigned acknowledge that they have reviewed this requirements analysis document and agree
with its information. Changes to this version will be coordinated with, and approved by, the undersigned,
or their designated representatives.
Signature:
Print Name:
Title:
Role:
Signature:
Print Name:
Title:
Role:
Signature:
Print Name:
Title:
Role:
PLANT MAINTENANCE MODULE
PLANT MAINTENANCE
REQUIREMENTS ANALYSIS APPROVAL
acknowledge that they have reviewed this requirements analysis document and agree
with its information. Changes to this version will be coordinated with, and approved by, the undersigned,
or their designated representatives.
Date:
Date:
Date:
acknowledge that they have reviewed this requirements analysis document and agree
with its information. Changes to this version will be coordinated with, and approved by, the undersigned,