Master Data: Are you set up for recording...
Transcript of Master Data: Are you set up for recording...
Master Data: Are you set up for recording failures?John Harrison IBS ChemicalsOctober 23, 2013
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 2
Agenda
• Why should we care?
• What is Master Data?
• Master Data in SAP EAM
• Functional Equipment
• Equipment
• Bills of Material
• Code Lists
• Maintenance Notification: Malfunction Report
• SAP MII – Plant Catalog
• Conclusion
Why should we care?
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 4
Why should we care?
Increasing business support for Reliability for profitability
Changing regulatory environment
Industry Groups are becoming increasing active in this topic
A more graphical view
Social awareness
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 5
Value Case - Using ISA-TR84.00.04 Part 1 Appendix R for Tier 3 & 4 Data
Tier 1 & 2 events are unacceptableISA-TR84.00.04 Part 1 Appendix R for Tier 3 & 4 Data gives us greater event countsMay need to look at BPCS-IPL
How do we set up our systems / master data to facilitate reporting failures?
What is Master Data?
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 7
What is “Master Data”?
No commonly accepted definition:
Definitions include phrases like: • “important to the business”, • “shared by two or more applications”, • “with their associated metadata and attributes”.
For this presentation I would like to use :
Master Data is the data that is essential to the operation or support of one or more specific business process. One essential characteristic of master data
is that it does not change frequently.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 8
Master Data: what is the problem?
Who “owns” the master data?
Are multiple functions responsible for the master data? If so who gets what?
Which “application system” is the system of record?
How do you ensure that all other systems are up-to-date?
Do these systems talk the same “language” semantically?
Can there be an agreed central company wide definition?
Master Data in SAP EAM (for Reporting Failures)
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 10
EAM Master Data
• Functional Locations
• Equipment
• Bills Of Material
• Measurement Points
• Work Centers
• Partners
• Serial Numbers
• Permits
• Warranties
+ Code Lists
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 11
Definitions:
SAP Definition: Functional Location• an organizational unit within logistics that structures the maintenance objects of a
company according to functional, process-related or spatial criteria. A functional location represents the place where a maintenance task is to be performed and an area where equipment can be installed.
• Functional criteria: e.g. pumping station, drive unit
• Process-related criteria: e.g. polymerization, condensing
• Spatial criteria: e.g. hall, location
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 12
Definitions:
SAP Definition: Equipment• an individual, physical object that is to be maintained independently. It can be
installed in a technical system or part of a technical system (functional location). It represents the object on which the technical tasks are performed.
SAP Definition: Maintenance Bill of Material
• a complete, formally structured list of the components making up a technical object or an assembly. The list contains the object numbers of the individual components together with their quantity and unit of measure. The components can be stock or non-stock spares or assemblies, which in turn can be described using maintenance BOMs.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 13
Technical Object Structuring
Choices: There are three different options for representing technical objects:• Functional structuring (only functional locations)• Object-related structuring (only equipment)• Combination (equipment at functional locations)
Structuring From a Technical Perspective• Technical objects of the system are assigned to particular object classes
(equipment, functional location and assembly classes). This type of structuring can be used in addition to structuring from a functional and/or object related perspective.
Structuring From an Accounting Perspective
• The system and its technical objects are assigned to certain cost centers or tangible assets. This type of structuring can be used in addition to structuring from a functional and/or object related perspective.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 14
Maintenance Bills Of Equipment vs. Bill of Material
Equipment BOM’s
• are specific to one piece of equipment (1:1). Equipment BOM’s can contain material specific to that piece of equipment.
Material BOM’s
• can be linked to many equipment / functional locations (n:1) via the construction type. Material BOM’s tend to have more materials assigned as they are linked to more technical objects.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 15
Maintenance Bills Of Material (Uses)
Materials planning (when using maintenance task lists).
• The use of maintenance BOMs is advantageous for material planning, because you can perform material planning when creating a maintenance task list. The link between the task list and the maintenance BOM is created as follows:
• Using the technical object BOM for maintenance task lists for technical objects• Using the assembly in the header for general task lists
Materials/spares planning (when using maintenance orders)
• Support planning of materials or spares by providing an overview of all materials/spare parts that could be required in the maintenance order. This enables you to assign to the order all the materials you require and makes materials/spares planning considerably easier.
Locating malfunctions (when using maintenance notifications)
• Supports locating malfunctions by providing an overview of all components that make up a technical object. From this overview the object for which you want to create a malfunction report can be easily select . This enables the malfunction in the technical object to be located more precisely.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 16
Reporting: How much detail is required?
Where are failures to be reported?• At an piece of equipment• At an assembly• By area• By process, sub process• By Tag
Are failures to be summarized?• By groups of like equipment• By area• By process
How much history is required?• Do you compare failures between equipment?
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 17
Representation: Example: Flow Loop I – PID DiagramFunctional Location Only
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Function Location
Flow Loop 1
Pro / Con
Pro Simple to implement
Con Little detail reporting capabilities
Con No equipment level reporting capabilities
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 18
Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Function Location
Flow Loop 1
Electrical Loop
Pneumatic Loop
Pro/Con
Pro Simple To Implement
Pro Some Additional Detail
Con No reporting at the relevant equipment level
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 19
Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations In Detail
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Function Location Floc 2 Floc 3
Flow Loop 1
Electrical Loop
Flow Transmitter
PLC
Instrument Positioner
Pneumatic Loop
Pro / Con
Pro Detail Reporting Capabilities atfunctional level (representing equipment)
Con Can not replace / move equipment (floc) to another location
Con Complicated to Implement
Con No Installation History Available
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 20
Representation: Example: Flow Loop I – PID DiagramMultiple Functional Locations & Equipment
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Function Location Floc 2 Equipment
Flow Loop 1
Electrical Loop
Flow Transmitter
PLC
Instrument Positioner
Pneumatic Loop
Pro/Con
Pro Installation History Available
Pro Detail Reporting Capabilities at equipment & functional location level
Con Complicated to Implement
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 21
Representation: Example: Flow Loop I – PID DiagramFunctional Location, and Bill of Material
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Function Location Material BOM / Functional Location BOM
Flow Loop 1 Flow Rate Transmitter
PLC
Instrument Positioner
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pro/Con
Pro Simple to Implement
Pro Detail Reporting Capabilities functional location level
Con No implementation history
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 22
Representation: Example: Flow Loop I – PID DiagramFunctional Locations, Equipment, and Bill of Material
PLC
Electrical Signal
Solenoid Valve
Pneumatically Activated Control Flow Rate Valve
Pneumatic Signal
Flow Rate Indicating Transmitter
Flow Rate Control Valve
Flow Rate Sensor
Instrument Positioner
Pro/Con
Pro Detail Reporting Capabilities functional location, equipment & assembly level
Pro Implementation history
Con Complicated to implement
Function Location
Floc 2 Equipment BOM
Flow Loop 1
Electrical Loop PLC Sensor
Flow Rate Transmitter
Instrument Positioner
Solenoid Valve
Pneumatic Loop Control Flow Rate Valve
Functional Locations
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 24
EAM Master Data: Functional Location
Note: Superior Functional Location and Equipment Installation Allowed
If only 1 piece of equipment is allowed to be installed: check Single Installation
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 25
EAM Master Data: Functional Location – Alternate Labels
When different views of functional locations structures are required, use alternate labels. No new structures are generated
E.g. Spatial & Process
Note:
The functional location label is not renamed using this method. The master record of the functional location remains unchanged. Using the alternative label, a reference to this master record in an alternative labeling system has been created
Spatial
Process
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 26
Functional Location – Alternate Labels – Use Example
The user profile defines which labeling system is to be used. Labels are converted to the indicated system
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 27
EAM Master Data: Functional Location – Structure
Note: Construction Type:
• Material number under which functional locations of the same construction are grouped (Links to Bill of Material).
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 28
EAM Master Data: Functional Location – Classification
Classification:
Additional characteristics that further describes the location.
Equipment
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 30
EAM Master Data Equipment
Note: Having a catalog profile associated with the equipment restricts the available entries when reporting failures
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 31
EAM Master Data Equipment
Note: Construction Type:
• Material number under which pieces of equipment of the same construction are grouped (Links to Bill of Material).
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 32
EAM Master Data: Equipment
Classification:
Additional technical characteristics for the equipment
Bills of Material
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 34
EAM Master Data: Functional Location BOM
This Bill of Materials is unique to the Functional Location and can not be used by any other Functional Locations or Equipment
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 35
EAM Master Data: Equipment BOM
This Bill of Materials is unique to the Functional Location and can not be used by any other Functional Locations or Equipment
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 36
EAM Master Data: Material BOM
This Bill of Materials is NOT unique and can be associated with many Functional Locations and Equipment
Catalog Codes
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 38
EAM Data: Code Lists For Reporting
EAM Catalogs• Activities “A”• Object Part “B”• Damage “C”• Cause Code “5”• Tasks “2”
How many codes to use in a code group?• Do not get too fine (7 – 20)• Based on standards? (ISO
14224, PAS 55…)
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 39
EAM Data: Catalog Profiles
Classification and catalogs presented during notification processing
Maintenance Notifications
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 41
Notification: Failure Reporting (Use of Code Groups)
Object Part Code Group (Maintainable Item)
Problem or Damage Code Group (Failure Mechanism)
Cause Code Group (Failure Cause)
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 42
Notification: Failure Reporting (codes at notification & item level
Activity Code Group
Task Code Group
Activity Code Group
Activity, Tasks repeated by Item
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 43
Notification: Failure Reporting (Using Material BOM)
From Material
BOM
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 44
Notification: Failure Reporting (Using Classification)
Classification:
• Allows for additional information to be collected on the Notification
Note: Associated with catalogue profile
SAP MII Plant Catalog
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 46
Information to the People Who Need it (MII 14.0)
SAP MII 14.0 & PCo
Plant Information Catalog
Critical Assets
Shop Floor
SAP MII 14.0
Enterprise
Plant Information Catalog
Region
Plant 1
Func Loc
Work Ctr
Equip
Meas Pt1/Tag
Plant 1
Plant 1
Enterprise
Virtual Group – Points to the hierarchy defined on another
catalog instance
The Plant Information Catalog provides business context to the tags and their data by interfacing to the tag data servers in a generic way. Because of the vendor agnostic system connectivity provided by both the MII and PCo products, levels in this hierarchy can be queried for data using standard MII Queries or Services. This is ideal for the SAP EAM solution to acquire “Measurement Point” exception data to support Condition-Based Maintenance and other various solutions.
Meas Pt2/Tag
Tags have Meta-Data assigned to them from EAM (Equip ID, Cost Center, Work
Center)
PP and PM Assets (Functional Locations, Equipment and Work Centers
ERP
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 47
Information to the People Who Need it Browse of Sensor Network, Map to Business Name
Functional Location
Tags
Conclusion
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 49
Conclusion
• Without the appropriate levels of master data it is impossible to gather and analysis the information to reduce the failure levels.
• The master data must reflect the level of detail that are required to represent the pieces of equipment or assemblies that you are interested in gathering failure data.
• Equipment vs. Functional Locations: choose carefully. There are many options each with their own benefits and challenges
• Accommodate automated data collection capabilities (Tags)
• Consider future requirements / desires when establishing your master data
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 50
Next Steps
November 12 2013• IRN Webinar: Understanding Notifications and Orders in the Failure Data Collection
Process
© 2013 SAP AG or an SAP affiliate company. All rights reserved.
Thank you
Contact information:
John HarrisonSenior Solution Specialist, Industry Business Solutions ChemicalsSAP Labs | 4120 Yonge Street, Suite 600, Toronto, Ontario, Canada, M2P 2B8T +1 (416) 226-7057 I M: +1 (416) 505-5841 E [email protected]
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 52
© 2013 SAP AG or an SAP affiliate company. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of SAP AG. The information contained herein may be changed without prior notice.
Some software products marketed by SAP AG and its distributors contain proprietary software components of other software vendors.
National product specifications may vary.
These materials are provided by SAP AG and its affiliated companies ("SAP Group") for informational purposes only, without representation or warranty of any kind, and SAP Group shall not be liable for errors or omissions with respect to the materials. The only warranties for SAP Group products and services are those that are set forth in the express warranty statements accompanying such products and services, if any. Nothing herein should be construed as constituting an additional warranty.
SAP and other SAP products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of SAP AG in Germany and other countries. Please see http://www.sap.com/corporate-en/legal/copyright/index.epx#trademark for additional trademark information and notices.
© 2013 SAP AG or an SAP affiliate company. All rights reserved. 53
© 2013 SAP AG oder ein SAP-Konzernunternehmen. Alle Rechte vorbehalten.
Weitergabe und Vervielfältigung dieser Publikation oder von Teilen daraus sind, zu welchem Zweck und in welcher Form auch immer, ohne die ausdrückliche schriftliche Genehmigung durch SAP AG nicht gestattet. In dieser Publikation enthaltene Informationen können ohne vorherige Ankündigung geändert werden.
Einige der von der SAP AG und ihren Distributoren vermarkteten Softwareprodukte enthalten proprietäre Softwarekomponenten anderer Softwareanbieter.
Produkte können länderspezifische Unterschiede aufweisen.
Die vorliegenden Unterlagen werden von der SAP AG und ihren Konzernunternehmen („SAP-Konzern“) bereitgestellt und dienen ausschließlich zu Informationszwecken. Der SAP-Konzern übernimmt keinerlei Haftung oder Gewährleistung für Fehler oder Unvollständigkeiten in dieser Publikation. Der SAP-Konzern steht lediglich für Produkte und Dienstleistungen nach der Maßgabe ein, die in der Vereinbarung über die jeweiligen Produkte und Dienstleistungen ausdrücklich geregelt ist. Keine der hierin enthaltenen Informationen ist als zusätzliche Garantie zu interpretieren.
SAP und andere in diesem Dokument erwähnte Produkte und Dienstleistungen von SAP sowie die dazugehörigen Logos sind Marken oder eingetragene Marken der SAP AG in Deutschland und verschiedenen anderen Ländern weltweit. Weitere Hinweise und Informationen zumMarkenrecht finden Sie unter http://www.sap.com/corporate-en/legal/copyright/index.epx#trademark.